JP6984611B2 - Laminated body and its manufacturing method - Google Patents

Description

The present invention relates to a laminate having a thermoplastic resin layer, a backing member made of a non-woven fabric, and a foamed polyurethane layer, and a method for producing the laminate.

Laminates made of a skin made of a thermoplastic resin layer and lined with a foam of a polyurethane layer are widely used as an automobile interior material used for automobile interior parts such as automobile instrument panels and door trims, for example. Then, a stitch pattern by sewing may be applied to the skin of such a laminated body in order to enhance the design and commerciality.

Here, when the foam of the polyurethane layer is lined with the thermoplastic resin layer having the stitch pattern by sewing, there is a problem that the component of the polyurethane layer leaks onto the skin made of the thermoplastic resin layer through the seams.

To solve such a problem, for example, in Patent Document 1, when sewing a thermoplastic resin material, sewn portions set in advance at predetermined intervals on the thermoplastic resin material are melted by a heating device and are in a molten state. It is sewn along the sewn area. Then, in Patent Document 1, the sewing thread and the thermoplastic resin material are integrated by spraying a refrigerant on the sewn portion of the thermoplastic resin material or by transporting the thermoplastic resin material to a cooling device to cure the sewn portion. To prevent resin leakage.
Further, in Patent Document 2, after the thread is sewn on the skin material, a sealing tape is attached from the back side along the seam, an adhesive is applied and dried to perform cross-linking curing treatment, or the seam is formed from the back side. The foaming agent and the like are prevented from leaking from the seams of the threads by heating and melting the resin threads to close the joints.
Further, in Patent Document 3, by laminating the tape on the sewn portion of the epidermis, it is possible to prevent the raw material of the polyurethane foam layer from entering through the hole in the sewn portion.

Japanese Unexamined Patent Publication No. 2014-19060 Japanese Unexamined Patent Publication No. 3-1938 International Publication No. 2016/147637

However, the conventional methods described in Patent Documents 1 and 2 that perform heat treatment, cross-linking and curing treatment, etc. are inferior in workability. Further, as a result of repeated studies by the present inventor, in the conventional method described in Patent Documents 2 to 3 in which the tape is attached from the back of the sewn skin, foaming is performed on the surface of the sewn thermoplastic resin layer. The components of the polyurethane layer may leak out, leaving room for further improvement.

Therefore, an object of the present invention is to provide a laminate in which the components of the foamed polyurethane layer are suppressed from leaking onto the surface of the thermoplastic resin layer even if the thermoplastic resin layer is sewn.
Further, according to the present invention, even if the thermoplastic resin layer is sewn, it is possible to satisfactorily suppress the leakage of the components of the foamed polyurethane layer onto the surface of the thermoplastic resin layer by a simple method. The purpose is to provide a method.

The present inventor has made diligent studies for the purpose of solving the above problems. Then, the present inventor can integrally sew the thermoplastic resin layer together with the backing member made of the non-woven fabric backed to the thermoplastic resin layer, and the surface of the thermoplastic resin layer sewn when the foamed polyurethane is lined. The present invention has been completed by finding that a laminated body in which the components of the foamed polyurethane layer do not easily leak can be obtained.

That is, the present invention is intended to advantageously solve the above problems, and the laminate of the present invention is a laminate having a thermoplastic resin layer, a backing member made of a non-woven fabric, and a foamed polyurethane layer. The thermoplastic resin layer is the outermost surface layer, and the thermoplastic resin layer and the backing member are integrally sewn. If the thermoplastic resin layer and the backing member made of a non-woven fabric are integrally sewn, even if the laminate is sewn with the thermoplastic resin layer, the component of the foamed polyurethane layer is on the surface of the thermoplastic resin layer. Can be satisfactorily suppressed from leaking.

Here, in the laminated body of the present invention, it is preferable that the backing member contains a polyester resin. This is because if the backing member made of a non-woven fabric contains a polyester resin, a laminated body in which the backing member and the foamed polyurethane layer are in good contact with each other can be obtained. Further, if the backing member made of a non-woven fabric contains a polyester resin, the component of the foamed polyurethane layer leaks onto the surface of the thermoplastic resin layer in the laminated body in which the thermoplastic resin layer is sewn. This is because it can be suppressed more.

Further, in the laminated body of the present invention, it is preferable that the mass (weight) per unit area of the backing member is 50 g / m ^{2 or more.} If the basis weight of the backing member made of the non-woven fabric is not less than the above lower limit, the component of the foamed polyurethane layer leaks onto the surface of the thermoplastic resin layer even in the laminated body in which the thermoplastic resin layer is sewn. This is because it can be further suppressed.

Further, the laminate of the present invention is preferably for automobile interior parts. This is because if the laminate of the present invention is used for manufacturing an automobile interior part such as an automobile instrument panel and a door trim, an automobile interior part having excellent design and commerciality can be obtained.

In the laminate of the present invention, the thermoplastic resin layer is preferably a vinyl chloride resin layer. This is because if the thermoplastic resin layer is a vinyl chloride resin layer, the laminate of the present invention can be more preferably used in manufacturing automobile interior parts such as automobile instrument panels and door trims. ..

The present invention also aims to advantageously solve the above problems, and the method for producing a laminate of the present invention is a laminate having a backing member made of a thermoplastic resin, a non-woven fabric, and a foamed polyurethane layer. The process of integrally sewing the thermoplastic resin layer and the backing member to obtain the thermoplastic resin layer with the backing member, and the backing member side of the thermoplastic resin layer with the backing member. It is characterized by having a step of lining the foamed polyurethane layer from the above to obtain a laminate. In this way, first, the thermoplastic resin layer and the backing member made of a non-woven fabric are integrally sewn, and then the foamed polyurethane layer is lined. It is possible to satisfactorily suppress the leakage of components.

According to the present invention, even if the thermoplastic resin layer is sewn, it is possible to provide a laminated body in which the components of the foamed polyurethane layer are suppressed from leaking onto the surface of the thermoplastic resin layer.
Further, according to the present invention, even if the thermoplastic resin layer is sewn, it is possible to satisfactorily suppress the leakage of the components of the foamed polyurethane layer onto the surface of the thermoplastic resin layer by a simple method. Production method can be provided.

FIG. 1 is a plan view of a laminated body according to the present invention. FIG. 2 is a bottom view of the thermoplastic resin layer with a backing member used in the manufacturing method of the present invention. FIG. 3 is a partially enlarged cross-sectional view of the sewn portion of the laminated body according to the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In each figure, those with the same symbol indicate the same component. Further, the present invention is not limited to the embodiments shown below.

(Laminated body)
The laminate of the present invention is a laminate having a thermoplastic resin layer, a backing member made of a non-woven fabric, and a foamed polyurethane layer, in which the thermoplastic resin layer is the outermost layer and the thermoplastic resin layer and the backing. It is necessary that the member is integrally sewn. Unless the thermoplastic resin layer and the backing member are integrally sewn, it is not possible to sufficiently suppress the leakage of the components of the foamed polyurethane layer onto the surface of the sewn thermoplastic resin layer. In the laminated body of the present invention, by adopting the above configuration, the surface of the thermoplastic resin layer is sewn, and the components of the foamed polyurethane layer are prevented from leaking onto the surface. Therefore, the laminate of the present invention is used for automobile interior parts, for example, for automobile interior parts, for manufacturing automobile interior parts such as automobile instrument panels and door trims, which are stitch-decorated to enhance the design and commercial value. It can be suitably used as a member.

<Thermoplastic resin layer>
The thermoplastic resin layer is the outermost surface layer in the laminated body of the present invention, and needs to be integrally sewn with the backing member. The thermoplastic resin layer can be suitably used as the skin of automobile interior parts such as automobile instrument panels and door trims, for example.

The thermoplastic resin layer usually contains a thermoplastic resin, and may further contain a plasticizer and an additive. Above all, from the viewpoint of imparting good flexibility to the thermoplastic resin layer, it is preferable that the thermoplastic resin layer uses a thermoplastic resin and a plasticizer in combination.
In the present invention, the thermoplastic resin layer is usually a thermoplastic resin molded sheet having a sheet-like structure, preferably a non-foamed thermoplastic resin molded sheet. Here, in the present specification, the "sheet-like structure" is a structure formed into a sheet shape having no special processed structure such as a woven structure and a non-woven structure described later.

<< Thermoplastic resin >>
Here, the thermoplastic resin is not particularly limited, and the acrylic resin, silicone resin, fluororesin, vinyl chloride resin, polyvinylidene chloride, polyethylene, polypropylene, ethylene-propylene copolymer, polyvinyl acetate, ethylene- Vinyl acetate copolymer, polyvinyl alcohol, polyacetal, polystyrene, polyurethane, polyacrylonitrile, styrene-acrylonitrile copolymer, acrylonitrile-butadiene copolymer (nitrile rubber), acrylonitrile-butadiene-styrene copolymer (ABS resin), styrene -Butadiene block copolymer or its hydrogen additive, styrene-isoprene block copolymer or its hydrogen additive, polyphenylene ether, modified polyphenylene ether, aliphatic polyamides, aromatic polyamides, polyamideimide, polycarbonate, polyphenylene sulfide, Examples thereof include polysulfone, polyether sulfone, polyether nitrile, polyether ketone, polyketone, liquid crystal polymer, ionomer, and the like. These may be used alone or in combination of two or more.

[Vinyl chloride resin]
Among the above, vinyl chloride resin is preferable as the thermoplastic resin. In general, since vinyl chloride resin is excellent in processability, if the thermoplastic resin layer contains vinyl chloride resin, for example, it is easy to obtain a thermoplastic resin layer that can be suitably used as a skin of automobile interior parts having excellent decorativeness. Because.

[Content ratio]
The content ratio of the thermoplastic resin contained in the thermoplastic resin layer is not particularly limited, and can be, for example, 30% by mass or more and 70% by mass or less.

<< Plasticizer >>
The plasticizer that can be contained in the thermoplastic resin layer is not particularly limited, and is phthalic acid-based, trimellitic acid-based, pyromellitic acid-based, adipic acid-based, azelaic acid-based, sebacic acid-based, and maleic acid-based. , Fumaric acid-based, citric acid-based, itaconic acid-based, oleic acid-based, ricinolic acid-based, stearic acid-based, phosphoric acid-based, glycol-based, glycerin-based, epoxy-based plasticizers and the like. Among them, the plasticizer is preferably, for example, a trimellitic acid-based such as trimellitic acid ester and a pyromellitic acid-based such as pyromellitic acid ester, and the trimellitic acid trialkyl ester (here, trimellitic acid trialkyl). It is more preferable that the number of carbon atoms of the alkyl group contained in the ester is the same or different from each other in one molecule.) By using the trimellitic acid-based and pyromellitic acid-based plasticizers, the flexibility and processability of the thermoplastic resin composition that can be used for forming the thermoplastic resin layer and the thermoplastic resin layer can be further enhanced. Therefore, for example, it is possible to better obtain a thermoplastic resin layer that can be suitably used as a skin of automobile interior parts having excellent decorativeness.

[Content ratio]
Here, the content ratio of the plasticizer that can be contained in the thermoplastic resin layer is not particularly limited, and can be, for example, 30% by mass or more and 70% by mass or less.

<< Additives >>
The additive that can be further contained in the thermoplastic resin layer is not particularly limited, and for example, a surface modifier such as silicone oil; an additive similar to the component described in Patent Document 3; has a similar content ratio. Can be used in.

<< Formation method >>
The thermoplastic resin layer can be formed, for example, by molding a thermoplastic resin composition containing the above-mentioned components by any method, preferably by powder molding, and more preferably by powder slush molding.

Here, the above-mentioned thermoplastic resin composition may be prepared by mixing the above-mentioned components by any method, or a commercially available product may be used.
The mixing method is not particularly limited, and examples thereof include a method in which components other than the dusting agent are mixed by a dry blend, and then the dusting agent is added and mixed. Here, it is preferable to use a Henschel mixer for the dry blend. The temperature at the time of dry blending is not particularly limited, and is preferably 50 ° C. or higher, more preferably 70 ° C. or higher, and preferably 200 ° C. or lower.

Further, for example, in powder slash molding, the following methods can be used without particular limitation. That is, the thermoplastic resin composition is sprinkled on a mold heated to an arbitrary temperature range, left for 5 seconds or more and 30 seconds or less, then the excess thermoplastic resin composition is shaken off, and further, under an arbitrary temperature. , Leave it for 30 seconds or more and 3 minutes or less. Then, the mold is cooled to 10 ° C. or higher and 60 ° C. or lower, and the obtained thermoplastic resin layer is removed from the mold. Then, the demolded thermoplastic resin layer is obtained, for example, as a sheet-shaped molded body in the shape and pattern of a mold.
Here, the mold temperature to be heated at the time of molding is not particularly limited, and is preferably 200 ° C. or higher, more preferably 220 ° C. or higher, preferably 300 ° C. or lower, and 280 ° C. or lower. Is more preferable.

<Backing member>
The backing member of the laminate of the present invention is composed of only a non-woven fabric, and is usually arranged on the back side of the thermoplastic resin layer in the laminate of the present invention. Therefore, in the laminated body of the present invention, the thermoplastic resin layer and the backing member are sewn in direct contact with each other without any adhesive or the like intervening between the thermoplastic resin layer and the backing member. Further, the backing member needs to be integrally sewn with the above-mentioned thermoplastic resin layer in the laminated body of the present invention. Since the thermoplastic resin layer and the backing member made of a non-woven fabric are integrally sewn, the backing member leaks the component of the foamed polyurethane layer onto the surface of the thermoplastic resin layer in the laminate of the present invention. Plays a role in preventing.

<< Non-woven fabric >>
The non-woven fabric constituting the backing member may be composed of only a single non-woven fabric, or may be a laminated structure of a plurality of non-woven fabrics.
Here, in the present invention, the "nonwoven fabric" has a non-woven structure in which fibers are bonded to each other in an arbitrary direction or in a random direction.

[Fiber composition]
Here, the fiber constituting the non-woven fabric is not particularly limited as long as it is a fiber capable of forming the above-mentioned non-woven structure, and includes a fiber containing a polyamide-based resin, a fiber containing a polyaramid-based resin, and a polyester-based resin. Organic fibers such as fiber, cellulose, cotton, linen, wool and silk; inorganic fibers such as glass fiber, carbon fiber, alumina fiber, tungsten fiber, molybdenum fiber, titanium fiber, steel fiber, boron fiber, silicon carbide fiber and silica fiber. ; And so on. Further, one kind or two or more kinds of fibers may be used as the fibers constituting the non-woven fabric. Among the above, as the fiber constituting the non-woven fabric, an organic fiber is preferable, a fiber containing a polyester resin is more preferable, and a fiber composed of only a polyester resin is further preferable. Generally, a polyester resin which is a polycondensate of a polyvalent carboxylic acid and polyalcohol has a polar group. Therefore, if the nonwoven fabric is made of a fiber containing a polyester resin and the backing member contains the polyester resin, in the laminated body, both the nonwoven fabric and the above-mentioned thermoplastic resin layer, and both the nonwoven fabric and the foamed polyurethane layer described later can be used. This is because they can be brought into close contact with each other and delamination can be suppressed satisfactorily.
Further, polyester-based resins preferably mentioned as the composition of the fibers constituting the nonwoven fabric are, for example, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and polybutylene naphthalate.

<< Metsuke amount >>
Further, the mass (grain amount) per unit area of the backing member ^{is preferably 25 g / m 2} or more, more preferably 35 g / m ² or more, and further preferably 50 g / m ² or more. It is more preferably 55 g / m ² or more, further preferably 60 g / m ² or more, particularly preferably 80 g / m ² or more, and preferably 300 g / m ² or less. More preferably, it is 200 g / m ^{2 or less.} In the backing member having a basis weight of the lower limit or more, the fibers of the non-woven fabric constituting the backing member are more densely bonded. Therefore, when the basis weight of the backing member is not less than the above lower limit, it is more difficult for the component of the foamed polyurethane layer in contact with the backing member to penetrate into the backing member. In addition, when the amount of the backing member is equal to or more than the above lower limit, the backing member is formed in the sewing hole in the thermoplastic resin layer when the thermoplastic resin layer and the backing member made of a non-woven fabric are integrally sewn. This is because the fibers of the non-woven fabric can easily enter and the components of the polyurethane foam layer can be more prevented from leaking onto the surface of the thermoplastic resin layer. Further, when the basis weight of the backing member is not more than the above upper limit, the workability of the sewing process can be well maintained and the cost can be reduced.

<< Thickness >>
The thickness of the backing member is preferably 0.18 mm or more, more preferably 0.22 mm or more, further preferably 0.25 mm or more, and further preferably 0.29 mm or more. It is more preferably 0.30 mm or more, particularly preferably 0.35 mm or more, preferably 5 mm or less, more preferably 3 mm or less, still more preferably 1 mm or less. .. This is because if the thickness of the backing member is at least the above lower limit, it is possible to further prevent the components of the foamed polyurethane layer from leaking onto the surface of the thermoplastic resin layer. Further, when the thickness of the backing member is not more than the above upper limit, the workability of the sewing process can be further improved and the cost can be further reduced.

<< Tear strength >>
The tear strength of the backing member is preferably 7N or more, more preferably 11N or more, further preferably 14N or more, further preferably 18N or more, and even more preferably 28N or more. It is particularly preferable, and it is preferably 60 N or less. When the tear strength of the backing member is equal to or higher than the above lower limit, the backing member has sufficient physical strength against the sewing hole, so that the nonwoven fabric constituting the backing member is not damaged and the thermoplastic resin layer is formed. This is because the backing member made of the non-woven fabric and the non-woven fabric can be sewn together better. Further, if the tear strength of the backing member is not more than the above upper limit, the workability of the sewing process can be further improved.
In the present invention, the "tear strength" can be measured according to JIS L 1913: 2010.

<< Formation method >>
The backing member is, for example, a dry method in which relatively short fibers are formed thinly; a wet method in which shorter fibers are mixed with water and formed by straining like paper; the above-mentioned resin or the like is dissolved to form a thread. A method of binding the fibers to each other and spreading them thinly (spunbond method); a method of making the fibers finer in a higher temperature environment than the above spunbond method (melt blow method); further, the above spunbond method and the melt blow method. It can be formed by obtaining a non-woven fabric by a combination of the above;
Here, the bonds between the fibers are, for example, (a) chemical adhesion by a resin as an adhesive (chemical bond or resin bond), (b) fusion by heating (thermal bond), and (c) hooked needle. Mechanical entanglement (needle punch), (d) entanglement by jetting high-pressure water flow (water flow entanglement or spunlace), (e) stitching of fibers spread in the plane (stitch bond), etc. Can be done.

<Polyurethane foam layer>
Further, the foamed polyurethane layer of the laminated body of the present invention is a foamed molded product made of polyurethane, and usually serves to support the above-mentioned thermoplastic resin layer by being laminated on the above-mentioned backing member side.
Here, the foamed polyurethane layer is not particularly limited, and can be obtained, for example, according to the method for forming a laminate described later.

For example, when the polyurethane foam layer is ^{lined with a relatively high density of 0.2 g / cm 3} or more, the strength of the laminated body can be improved, but when the polyurethane foam layer is lined, the thermoplastic resin layer is used. There is a risk that the components of the polyurethane foam layer will easily leak onto the surface. However, in the laminate of the present invention, since the thermoplastic resin layer and the predetermined backing member are integrally sewn, even if polyurethane is foamed at a relatively high density, the component of the foamed polyurethane layer is the thermoplastic resin layer. Leakage on the surface can be satisfactorily suppressed.

<Method of forming a laminated body>
The laminating method of the laminated body is not particularly limited, and for example, as shown in FIGS. 1 to 3, the following methods can be used.
That is, first, the backing member 4 made of the above-mentioned non-woven fabric is laminated (backing) from the back surface of the portion of the thermoplastic resin layer 2 to be sewn. Next, the thermoplastic resin layer 2 and the backing member 4 are integrally sewn using an arbitrary sewing method to obtain the thermoplastic resin layer 11 with the backing member. At this time, although the thermoplastic resin layer 2 and the backing member 4 are in close contact with each other through the sewn thread, there is usually a gap between the thermoplastic resin layer 2 and the backing member 4 where the thread does not pass. Can occur. Subsequently, on the backing member 4 side of the thermoplastic resin layer 11 with a backing member, isocyanates and polyols, which are raw materials for foamed polyurethane, are reacted to carry out polymerization, and polyurethane is foamed by a known method. By doing so, the foamed polyurethane layer 5 is directly formed on the back surface (the backing member 4 side) of the thermoplastic resin layer 11 with the backing member. In this way, the laminate 1 having the thermoplastic resin layer 2, the backing member 4 made of a non-woven fabric, and the foamed polyurethane layer 5 is formed. Then, usually, the thermoplastic resin layer 2 becomes the skin 2.
The foamed polyurethane layer 5 may be formed by an open type that is open to the atmosphere or a closed type in a closed space.

Here, when the gap is generated between the thermoplastic resin layer and the backing member, polyurethane may enter between the thermoplastic resin layer and the backing member when the foamed polyurethane layer is formed. However, in the present invention, since the thermoplastic resin layer and the backing member made of the non-woven fabric are integrally sewn, it is possible to satisfactorily suppress the leakage of the components of the foamed polyurethane layer onto the surface of the thermoplastic resin layer. can.
Further, when the foamed polyurethane layer is formed in the closed type, or when the polyurethane is foamed with a high density even in the open type, a relatively high foaming pressure is generally applied, so that the component of the foamed polyurethane layer is thermoplastic. The risk of leakage onto the surface of the resin layer increases. However, in the laminate of the present invention, since the thermoplastic resin layer and the backing member made of a non-woven fabric are integrally sewn, the thermoplastic resin is formed even when the foamed polyurethane layer is formed in a relatively high pressure environment. It is considered that the leakage of the components of the polyurethane foam layer onto the surface of the layer can be satisfactorily suppressed.

<< Sewing method >>
The sewing method is not particularly limited as long as the thermoplastic resin layer and the backing member made of a non-woven fabric can be integrally sewn in the laminated body, but is usually performed prior to the formation of the foamed polyurethane layer described above. Further, as a sewing method, any thread may be used to sew in one direction. For example, as shown in FIGS. 1 to 3, the upper thread 31 and the lower thread 32 are used for thermoplasticity with a backing member. You may sew from both the front surface and the back surface of the resin layer 11. Further, sewing may be performed manually (or hand sewing), but from the viewpoint that various sewing methods can be easily selected, it is preferable to use a sewing machine or the like.
In the present specification, when a sewing machine is used, the "upper thread" usually refers to a thread that is passed through a sewing machine needle, and the "bobbin thread" is usually used by winding it around a bobbin. Refers to a thread that is threaded through a loop made in step 1 or hooked on a needle thread to form a seam.

Then, for example, when a sewing machine is used, sewing may be lock stitch (the needle thread and the bobbin thread are entangled to form a seam) according to JIS B 9003: 1999, or single chain stitch (one chain stitch). The threads may be entangled in a chain to form a seam). Further, when the sewing machine is used, sewing may be performed by other sewing methods such as double chain stitching and pinpoint sewing. Further, the stitch may be appropriately selected from straight stitch, zigzag stitch, dotted line pattern stitch, double needle stitch, triple stitch, cycle stitch, satin stitch, blind stitch, scallop stitch and the like according to a desired design.

Here, from the viewpoint of further preventing the components of the foamed polyurethane layer 5 from leaking onto the surface of the thermoplastic resin layer 2 through the sewing holes generated in the thermoplastic resin layer 2, the integral sewing is shown in FIGS. 1 to 3. As shown, it is preferable to use the needle thread 31 and the bobbin thread 32. Further, as shown in FIG. 1, the needle thread 31 appears on the surface of the thermoplastic resin layer 2, and the bobbin thread 32 does not appear on the surface of the thermoplastic resin layer 2 (as shown in FIG. 2). It may appear on the back surface of the thermoplastic resin layer 11 with a backing member). In particular, for example, as shown in FIG. 3, if the bobbin thread 32 is pulled up by the needle thread 31 and integrally sewn, the fibers of the backing member 4 made of a non-woven fabric are sewn in the thermoplastic resin layer 2 for each stitch. This is because the component of the foamed polyurethane layer 5 can be further suppressed from leaking from the seam because the sewing hole can be closed by pulling into the hole.

[thread]
The thread used for integral sewing is not particularly limited as long as the thermoplastic resin layer and the backing member made of non-woven fabric can be integrally sewn. Threads made of long fibers; Among them, synthetic fiber yarn is preferable, and yarn made of polyester resin is more preferable. This is because the yarn made of polyester resin is generally highly durable and versatile, and the thermoplastic resin layer and the backing member can be sewn together better.
Further, the diameter (thickness) of the thread may be appropriately selected according to a desired design.

[needle]
Further, the needle used for integral sewing may be a general needle such as a sewing machine needle, but the gap that may occur around the seam in the thermoplastic resin layer by sewing is reduced to further suppress the leakage of the components of the foamed polyurethane layer. From this point of view, it is preferable that the diameter (thickness) of the needle is close to the diameter of the thread.

(Manufacturing method of laminated body)
The method for manufacturing a laminate of the present invention is a method for manufacturing a laminate having a backing member made of a thermoplastic resin and a non-woven fabric and a foamed polyurethane layer, the step of obtaining a thermoplastic resin layer with a backing member, and the backing. It is characterized by having a step of lining a foamed polyurethane layer on a thermoplastic resin layer with a backing member to obtain a laminate. Further, in the method for manufacturing a laminated body of the present invention, in addition to the above-mentioned steps of obtaining a thermoplastic resin layer with a backing member and a step of obtaining a laminated body, for example, a backing member made of a thermoplastic resin layer and a non-woven fabric is prepared. It may further have other steps such as steps. In the manufacturing method of the present invention, the thermoplastic resin layer and the backing member made of a non-woven fabric are integrally sewn to manufacture a laminated body. Therefore, for example, when the foamed polyurethane layer is lined, it is sewn. It is possible to sufficiently suppress the leakage of the components of the polyurethane foam layer onto the surface of the thermoplastic resin layer. Therefore, the laminate obtained according to the manufacturing method of the present invention is used for, for example, for manufacturing automobile interior parts, in particular, automobile instrument panels and door trims which are stitch-decorated to enhance the design and commerciality. It can be suitably used as an automobile interior member.

<Step to obtain a thermoplastic resin layer with a backing member>
The process of obtaining the thermoplastic resin layer with the backing member will be illustrated and described with reference to FIGS. In the step of obtaining the thermoplastic resin layer with the backing member, the thermoplastic resin layer 2 and the backing member 4 made of a non-woven fabric are integrally sewn to obtain the thermoplastic resin layer 11 with the backing member. Here, as the backing member 4 made of the thermoplastic resin layer 2 and the non-woven fabric, the same composition, properties, and content ratio as described above can be adopted for the laminated body. Further, as the method of integral sewing, the same sewing method as described above for the laminated body can be adopted.
Then, the obtained thermoplastic resin layer with a backing member is used in the step of obtaining a laminate to be described in detail later.

<Process to obtain a laminate>
In the step of obtaining the laminate, the foamed polyurethane layer 5 is lined from the backing member 4 side of the thermoplastic resin layer 11 with the backing member obtained in the above step to obtain the laminate 1. Here, as a method for forming the foamed polyurethane layer 5 and a method for forming the laminated body 1, the same method as described above for the laminated body can be adopted.

<Other processes>
Further, the method for manufacturing a laminated body of the present invention is, for example, a step of preparing a thermoplastic resin layer, a step of preparing a backing member made of a non-woven fabric, etc. prior to the above-mentioned step of obtaining a thermoplastic resin layer with a backing member. It may further have other steps of.

<< Process of preparing the thermoplastic resin layer >>
Here, in the step of preparing the thermoplastic resin layer, for example, a commercially available thermoplastic resin layer may be used, or the thermoplastic resin composition is used by the same forming method as described above for the laminated body. A thermoplastic resin layer may be formed.

As an example, as the vinyl chloride resin that can be contained in the thermoplastic resin composition used for forming the thermoplastic resin layer, for example, one kind or two or more kinds of vinyl chloride resin particles can be contained, and optionally one kind. Alternatively, two or more kinds of vinyl chloride resin fine particles can be further contained. Above all, the vinyl chloride resin preferably contains at least vinyl chloride resin particles, and more preferably contains vinyl chloride resin particles and vinyl chloride resin fine particles. Here, the vinyl chloride resin particles usually function as a base material of the thermoplastic resin layer, and the vinyl chloride resin fine particles function as a dusting agent (powder fluidity improving agent).
In the present specification, the "resin particles" refer to particles having a particle diameter of 30 μm or more, and the “resin fine particles” refer to particles having a particle diameter of less than 30 μm.

<< Process of preparing the backing member >>
Further, in the step of preparing the backing member made of the nonwoven fabric, a commercially available nonwoven fabric may be used, or the nonwoven fabric may be formed by the same forming method as described above for the laminated body.

Hereinafter, the present invention will be specifically described based on examples, but the present invention is not limited to these examples. In the following description, "%" and "part" representing quantities are based on mass unless otherwise specified.
The leakage rate of the components of the foamed polyurethane layer onto the surface of the thermoplastic resin layer was measured by the following method.

<Leakage rate of components of polyurethane foam layer>
The state of the thermoplastic resin layer (skin) in the obtained laminate was visually observed. Specifically, among the total number of stitches S _T = 60 or applied to the surface of the thermoplastic resin layer, it was counted the number stitching portion where components of the polyurethane foam layer has leaked S _L (the number). Then, the degree to which the component of the foamed polyurethane layer leaked onto the surface of the thermoplastic resin layer was calculated according to the leakage rate (%) = ( _SL / _{ST) × 100 of the component of the foamed polyurethane layer.}

(Example 1)
<Preparation of thermoplastic resin composition>
Among the components of the thermoplastic resin layer shown in Table 1, the components excluding the plasticizer and the dusting agent were placed in a Henschel mixer and mixed. Then, when the temperature of the mixture rises to 80 ° C., all the plasticizer is added, and the temperature is further raised to dry up (the plasticizer is absorbed by the particulate thermoplastic resin, and the mixture becomes even more smooth. It means the state of plasticity.) Then, when the dried-up mixture was cooled to a temperature of 100 ° C. or lower, a dusting agent was added to prepare a vinyl chloride resin composition for powder molding as a thermoplastic resin composition.

<Formation of thermoplastic resin layer>
The thermoplastic resin composition obtained above is sprinkled on a textured mold heated to a temperature of 250 ° C., left to stand for an arbitrary time of about 8 to 20 seconds to melt, and then a surplus thermoplastic resin composition is prepared. Was shaken off. Then, the textured mold sprinkled with the thermoplastic resin composition was allowed to stand in an oven set at a temperature of 200 ° C., and 60 seconds after the standing, the textured mold was cooled with water. When the mold temperature was cooled to 40 ° C., a vinyl chloride resin sheet having a size of 150 mm in length × 200 mm in width × 1 mm in thickness as a thermoplastic resin layer was removed from the mold.

<Formation of thermoplastic resin layer with backing member>
As shown in FIG. 2, a non-woven fabric (non-woven fabric) cut to a width of 25 mm as a backing member on the back surface of the thermoplastic resin layer obtained above (the surface without the grain pattern without direct contact with the mold). A thermoplastic resin layer with a backing member was obtained by integrally sewing a thermoplastic resin layer and a backing member made of a non-woven fabric in a state where (manufactured by Toyobo Co., Ltd., product number "3301A", polyester resin) was stacked. Here, for sewing, a sewing machine (manufactured by JUKI, product number "LU-2860-7"), a sewing machine needle (manufactured by Organ Needle, product number "DPx17S") and a thread (manufactured by Onuki Textile Co., Ltd., trade name "Ace Crown Vehicle"). , Polyester resin, product number: needle thread "# 5", bobbin thread "# 8") was used. In addition, the stitches were made by applying two 30 stitches in substantially parallel at a distance of about 8 mm at an interval of 3 stitches / cm and a speed of 3.3 stitches / sec (that is, the total number of stitches = 30). × 2 = 60 pieces.). Here, the stitching direction is aligned with the vertical direction according to the product specifications of the above-mentioned non-woven fabric.
The properties of the non-woven fabric used are as follows, and these values are the commercial property values according to JIS L 1913: 2010.
Metsuke amount: 30 g / m ²
Thickness: 0.20 mm
Tear strength: 8N-9N
Tensile strength: 36N / 5cm ~ 121N / 5cm
Growth rate: 31% -33%
Dry heat shrinkage rate: 0.3% to 1.4%

<Formation of laminated body>
The thermoplastic resin layer with a backing member obtained above is placed in a mold having a length of 200 mm, a width of 300 mm, and a thickness of 10 mm with the surface of the thermoplastic resin layer (the surface of the skin having a grain pattern) facing down. I laid it down.
Separately, 50 parts of PO (propylene oxide) / EO (ethylene oxide) block adduct of propylene glycol (hydroxyl value 28, content of terminal EO unit = 10%, content of internal EO unit 4%), PO of glycerin 50 parts of EO block adduct (hydroxyl value 21, content of terminal EO unit = 14%), 2.5 parts of water, ethylene glycol solution of triethylene diamine (manufactured by Toso Co., Ltd., trade name "TEDA-L33") 0.2 parts, triethanolamine 1.2 parts, triethylamine 0.5 parts, and a foam stabilizer (manufactured by Shinetsu Chemical Industry Co., Ltd., trade name "F-122") 0.5 parts, and the polyol is mixed. A mixture was obtained. Moreover, the obtained polyol mixture and polymethylene polyphenylene polyisocyanate (polymeric MDI) were mixed at a ratio of an index of 98 to prepare a mixed solution. Then, the prepared mixed liquid was poured from above the backing member side of the thermoplastic resin layer with the backing member laid in the mold as described above. Then, the mold was covered with an aluminum plate having a size of 348 mm × 255 mm × 10 mm, and the mold was sealed. By leaving the mold to be sealed for 5 minutes, a laminated body in which a polyurethane foam layer (thickness: 9 mm, density: 0.2 g / cm ^{3) is lined with a thermoplastic resin layer with a backing member is formed in the mold.} Formed within.
Then, the formed laminate was taken out from the mold, and the leakage rate of the components of the foamed polyurethane layer was calculated according to the above method. The results are shown in Table 1.

(Example 2)
In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition is the same as in Example 1 except that the non-woven fabric is replaced with another product number (manufactured by Toyo Spinning Co., Ltd., product number "3401A", polyester resin). A thermoplastic resin layer, a thermoplastic resin layer with a backing member, and a laminate were manufactured. The properties of the non-woven fabric used are as follows, and these values are the commercial property values according to JIS L 1913: 2010.
Metsuke amount: 40 g / m ²
Thickness: 0.24 mm
Tear strength: 12N to 13N
Tensile strength: 54N / 5cm ~ 159N / 5cm
Growth rate: 26% -34%
Dry heat shrinkage rate: 0.2% to 1.0%
Then, it was observed and calculated by the same method as in Example 1. The results are shown in Table 1.

(Example 3)
In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition is the same as in Example 1 except that the non-woven fabric is replaced with another product number (manufactured by Toyo Spinning Co., Ltd., product number "3501A", polyester resin). A thermoplastic resin layer, a thermoplastic resin layer with a backing member, and a laminate were manufactured. The properties of the non-woven fabric used are as follows, and these values are the commercial property values according to JIS L 1913: 2010.
Metsuke amount: 50 g / m ²
Thickness: 0.27 mm
Tear strength: 15N
Tensile strength: 70N / 5cm ~ 183N / 5cm
Growth rate: 25% -34%
Dry heat shrinkage rate: 0.3% to 1.0%
Then, it was observed and calculated by the same method as in Example 1. The results are shown in Table 1.

(Example 4)
In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition is the same as in Example 1 except that the non-woven fabric is replaced with another product number (manufactured by Toyo Spinning Co., Ltd., product number "3601A", polyester resin). A thermoplastic resin layer, a thermoplastic resin layer with a backing member, and a laminate were manufactured. The properties of the non-woven fabric used are as follows, and these values are the commercial property values according to JIS L 1913: 2010.
Metsuke amount: 60 g / m ²
Thickness: 0.30 mm
Tear strength: 20N
Tensile strength: 90N / 5cm ~ 223N / 5cm
Growth rate: 29% to 32%
Dry heat shrinkage: 0.2% -0.8%
Then, it was observed and calculated by the same method as in Example 1. The results are shown in Table 1.

(Example 5)
In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition is the same as in Example 1 except that the non-woven fabric is replaced with another product number (manufactured by Toyo Spinning Co., Ltd., product number "3701A", polyester resin). A thermoplastic resin layer, a thermoplastic resin layer with a backing member, and a laminate were manufactured. The properties of the non-woven fabric used are as follows, and these values are the commercial property values according to JIS L 1913: 2010.
Metsuke amount: 70 g / m ²
Thickness: 0.31 mm
Tear strength: 23N to 24N
Tensile strength: 104N / 5cm ~ 269N / 5cm
Growth rate: 27% -33%
Dry heat shrinkage rate: 0.4% to 0.8%
Then, it was observed and calculated by the same method as in Example 1. The results are shown in Table 1.

(Example 6)
In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition is the same as in Example 1 except that the non-woven fabric is replaced with another product number (manufactured by Toyo Spinning Co., Ltd., product number "3A01A", polyester resin). A thermoplastic resin layer, a thermoplastic resin layer with a backing member, and a laminate were manufactured. The properties of the non-woven fabric used are as follows, and these values are the commercial property values according to JIS L 1913: 2010.
Metsuke amount: 100 g / m ²
Thickness: 0.39 mm
Tear strength: 32N-45N
Tensile strength: 132N / 5cm ~ 324N / 5cm
Growth rate: 23% to 30%
Dry heat shrinkage rate: 0.3% to 1.2%
Then, it was observed and calculated by the same method as in Example 1. The results are shown in Table 1.

(Comparative Example 1)
In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition and the thermoplastic resin layer were formed in the same manner as in Example 1 except that the non-woven fabric was not used (that is, the backing member was not used). And the laminate was manufactured.
Then, it was observed and calculated by the same method as in Example 1. The results are shown in Table 1.

1) Product name "ZEST (registered trademark) 2500Z" manufactured by Shin-Daiichi PVC Co., Ltd.
2) Product name "ZEST PQLTX" manufactured by Shin Daiichi PVC Co., Ltd.
3) Made by Kao Corporation, product name "Trimex N-08"
4) Product name "ADEKA SIZER O-130S" manufactured by ADEKA
5) Product name "Alchemizer (registered trademark) 5" manufactured by Kyowa Chemical Industry Co., Ltd.
6) Product name "MIZUKALIZER DS" manufactured by Mizusawa Industrial Chemicals, Inc.
7) Showa Denko, product name "Karenzu DK-1"
8) Product name "SAKAI SZ2000" manufactured by Sakai Chemical Industry Co., Ltd.
9) Product name "DAPX 1720 (A) Black" manufactured by Dainichiseika Co., Ltd.
10) Made by Toyobo Co., Ltd., product name "Ecre (registered trademark)" various product numbers

From Table 1, the laminates of Examples 1 to 6 in which the thermoplastic resin layer and the backing member made of the non-woven fabric are integrally sewn do not have the backing member made of the non-woven fabric, and the thermoplastic resin layer and the backing member are backed. It was found that the leakage of the components of the foamed polyurethane layer was remarkably suppressed as compared with the laminated body of Comparative Example 1 in which the integral sewing with the member was not performed (the thermoplastic resin layer was sewn independently).

According to the present invention, even if the thermoplastic resin layer is sewn, it is possible to provide a laminate in which the components of the foamed polyurethane layer are suppressed from leaking onto the surface of the thermoplastic resin layer.
Further, according to the present invention, even if the thermoplastic resin layer is sewn, it is possible to satisfactorily suppress the leakage of the components of the foamed polyurethane layer onto the surface of the thermoplastic resin layer by a simple method. Production method can be provided.

1 Laminated body 11 Thermoplastic resin layer with backing member 2 Thermoplastic resin layer (skin)
31 thread (upper thread)
32 thread (bobbin thread)
4 Backing member made of non-woven fabric 5 Polyurethane foam layer

Claims (6)

A laminate having a thermoplastic resin layer, a backing member made of a non-woven fabric, and a polyurethane foam layer.
The thermoplastic resin layer is the outermost layer, and
Using the needle thread and the bobbin thread from both directions of the thermoplastic resin layer side and the backing member side, the thermoplastic resin layer and the backing member are integrated while pulling up the bobbin thread with the needle thread. Ri Na is sewing,
The needle thread appeared on the surface of the thermoplastic resin layer and did not appear on the surface of the backing member.
Said lower thread, not appear on the surface of the thermoplastic resin layer, Ru appear on the surface of said backing member, laminate. The laminate according to claim 1, wherein the backing member contains a polyester resin. The laminated body according to claim 1 or 2, wherein the mass per unit area of the backing member is 50 g / m ^{2 or more.} The laminate according to any one of claims 1 to 3, which is used for automobile interior parts. The laminate according to any one of claims 1 to 4, wherein the thermoplastic resin layer is a vinyl chloride resin layer. A method for manufacturing a laminate having a thermoplastic resin layer , a backing member made of a non-woven fabric, and a foamed polyurethane layer.
Using the needle thread and the bobbin thread from both directions of the thermoplastic resin layer side and the backing member side, the thermoplastic resin layer and the backing member are integrated while pulling up the bobbin thread with the needle thread. The process of sewing to obtain a thermoplastic resin layer with a backing member,
A step of lining the foamed polyurethane layer from the backing member side of the thermoplastic resin layer with a backing member to obtain a laminate.
Have a,
The needle thread appeared on the surface of the thermoplastic resin layer and did not appear on the surface of the backing member.
Said lower thread, not appear on the surface of the thermoplastic resin layer, Ru appear on the surface of the backing member, the manufacturing method of the laminate.

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