JPH0788260A - Skin-consolidated chip urethane member and its manufacture - Google Patents

Abstract

PURPOSE:To offer a skin consolidated chip urethane member at a low-cost associate with its manufacturing method by using chips obtained by crushing fine the waste or splinters of urethane products including skin laminate urethane. CONSTITUTION:Chips 4 are prepared by crushing fine the waste or splinters of urethane products, and thereto a binder is mixed to present hybrid chips. These chips are put in dies 8, 9 or in a sack. A compressive force and a high temp. are applied to the chips so that they are bonded together through the action of the binder so that an internal material 1 having an appropriate solidness (density) is formed, when a skin should be bonded simultaneously.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is a skin that makes it possible to recycle urethane products by using waste or scraps of urethane products used for seats of automobiles and railway cars, interior parts of houses, furniture, etc. The present invention relates to an integrated chip urethane member and a method for manufacturing the same.

[0002]

Urethane is widely used for seat cushions of automobiles and railroad vehicles, but it is extremely difficult to recycle scraps generated as wastes due to its thermosetting property or in the manufacturing process. It is a material. Therefore, for example, scraps such as scrapped polyurethane foam (including skin laminated urethane) used for seat cushions of automobiles are finely crushed into crushed chips, and various products are manufactured using the crushed chips. This has been done for the purpose of recycling as well.
However, there is an inconvenience that the member made of urethane can be used only in a place where it cannot be seen from the outside. However, such a problem has been solved by forming an inner member by pressing and heating a crushed urethane tip, and adhering a skin to the inner member. For example, Japanese Patent Publication No. 64-239
According to the invention disclosed in Japanese Patent Publication No. 5, a skin material is set in a mold, and a crushed chip obtained by crushing scraps such as polyurethane foam is impregnated with a foaming stock solution of polyurethane. This impregnated mixture is filled in the molding die, and by pressing and heating it, the foaming stock solution foams while binding the crushed chips to each other to form a cushion layer, and at the same time, the cushion layer and the skin are integrally molded. The present invention relates to a method for manufacturing a cushion sheet.

[0003]

In the above invention, when integrally molding the inner member manufactured from the skin material and the crushed chips, the cushion layer which is the inner member is formed by using the expensive foaming undiluted solution, so that the cost is high. Becomes It is no exaggeration to say that manufacturing costs are a major factor that hinders the spread of recycling, and whether or not recycling is successful depends on cost reduction issues. Therefore, the conventional invention is not always satisfactory in this respect. further,
When manufacturing, put the material between the upper mold and the lower mold,
Since the material is heated and pressure-molded, it is necessary to perform a complicated deburring process. An object of the present invention is to provide a skin-integrated chip urethane member that is inexpensive and easy to manufacture, and a method for manufacturing the same.

[0004]

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and the first aspect of the present invention is that a crushing chip formed by finely crushing wastes and scraps of urethane products is bound by a binder. The present invention relates to a skin-integrated chip urethane member material, which comprises a bonded inner member and a skin adhered to the surface of the inner member via an adhesive and has a desired outer shape and density. According to a second aspect of the present invention, there is provided a mixed chip obtained by setting a skin material on a molding die via an adhesive, and then finely crushing wastes and scraps of a urethane product and mixing a binder as a binder with a crushed chip. The mixture is charged into a molding die, and the mixing chips are subjected to compressive force and high temperature to bond the crushing chips with a binder to form an inner member having an appropriate hardness (density), and at the same time, a skin is formed on the inner member. The present invention relates to a method for manufacturing a surface-integrated chip urethane member to be bonded. Further, a third invention is to form a mixed chip by mixing a binder as an adhesive with a crushed chip obtained by finely crushing waste or scraps of a urethane product, and applying a predetermined amount of the mixed chip to the inner surface of the adhesive. It is housed in a bag-shaped body made of the existing skin material, then the bag-shaped body is closed to form a flat body, and the flat body is further housed in a molding die to apply a predetermined compressive force and high temperature. The present invention relates to a method for producing a skin-integrated chip urethane member in which crushed chips are bonded together by a binder to simultaneously bond a skin to an inner member having an appropriate hardness (density).

[0005]

The product of the present invention is extremely inexpensive because the crushed chips obtained by finely crushing wastes and scraps of urethane products containing skin-laminated urethane are bonded with an inexpensive binder, and the inner member and the skin are integrated. Since it is possible to manufacture it, the recycling of urethane, which was a material that is extremely difficult to recycle, will make great progress. Further, when the crushed chips are enclosed in the bag-like body in the production, burrs are prevented from being generated, post-processing is not required, and burrs are prevented from becoming new waste.

[0006]

Embodiments of the present invention will now be described with reference to the drawings. Since the skin-integrated chip urethane member according to the present invention shown in FIG. 1a can be formed in any manner depending on the shape of the mold, it is used for a door trim T of an automobile having an uneven design as shown in FIG. A partial cross-section of the one is shown. This skin-integrated chip urethane member is composed of an inner member 1 joined by a binder mixed in a crushing chip formed by finely crushing wastes and scraps of a urethane product containing a skin laminated urethane, and a moquette on the surface of the inner member 1. The outer skin 2 is integrally formed from an appropriate material such as fabric, synthetic leather and mat. The one shown in FIG. 2 is a skin-integrated chip urethane member in which a laminated product made of slab urethane 3 is interposed between the inner member 1 and the skin 2. The skin-integrated chip urethane member having such a structure is manufactured at an extremely low cost because a polyurethane foaming stock solution is not used unlike a conventional product.

Further, the skin-integrated chip urethane member of the present invention shown in FIG. 1a is, as shown in a partially enlarged schematic diagram in FIG. 1b, a crushed chip obtained by finely crushing waste or scraps of urethane products. 4,4. ． ． They are bound to each other by a binder 5 and are compressed to an appropriate hardness (density) and given a desired shape. However, since a polyurethane foaming undiluted solution is not used in the production, a new foamed layer is formed. Is not formed.

Next, a first manufacturing method according to the present invention will be described. In this method, a skin selected from appropriate materials such as moquette, fabric, synthetic leather, and mat is placed on a molding die (not shown) having a desired shape, and a film-like adhesive is further added. Set on the epidermis. Next, a crushed chip obtained by finely crushing urethane including the skin laminated urethane is mixed with a binder to obtain a mixed chip, and the mixed chip is filled on the skin. Further, while compressing to a suitable hardness (density), the inside of the mold is heated to a high temperature by, for example, introducing steam into the mold, and the crushing chips are bonded through a binder to obtain a desired product. A shaped inner member is formed. At the same time, the high temperature caused by steam or the like also dissolves the film adhesive, so that the skin is simultaneously adhered to the surface of the inner member. In addition, as shown in FIG. 2, a laminate of the skin 2 and the slab urethane 3 can also be manufactured. It goes without saying that the outer member can be bonded by a general bonding method after the inner member is molded independently.

Further, the second method according to the present invention will be described with reference to the process schematic diagram shown in FIG. Grinding chips 4 in which binder is mixed with grinding chips obtained by grinding waste products of urethane products such as skin scraps, urethane scraps, and laminate cutting scraps are used for moquette, fabric, synthetic leather,
A bag-shaped body 6 formed by sewing an adhesive material (for example, a film-shaped adhesive material) attached to the inside of a surface skin selected from an appropriate material such as a mat is provided, and the bag-shaped body 7 is provided with the above-mentioned bag-shaped opening 7. The crushed chips 4 are put in (step A). Next, the bag-shaped inlet 7 is closed to form the flat body 6a (step B).
Then, the flat body 6a with the guide 8a is placed on the lower molding die 8 provided with the two protrusions 11 (step C).

Next, steam is fed into the mold from the air supply passage 8b formed below the lower molding die 8, and at the same time, the upper molding die 9 is lowered to apply a predetermined pressure to the flat body 6a. For this reason, the chip urethane is bound to each other by the action of the binder and at the same time given a predetermined shape by the pressing action, and is hardened to an appropriate hardness (density). 2) is molded. At the same time, an adhesive material (film adhesive) existing inside the bag-shaped body 6
Is melted and the outer skin and the inner member are simultaneously adhered, and in the present embodiment, the outer skin integrated chip urethane having the two groove portions 12 corresponding to the two protrusions 11 of the lower molding die 8 is formed ( Step D). Then, the skin-integrated chip urethane molded body 10 is taken out from the lower molding die 8 and dried to complete the operation (step E).

No expensive foaming stock solution is used in any of the above methods, so that not only manufacturing at low cost is possible, but also the bag-shaped body 6 is filled with a required amount of chip urethane and a binder. No burrs are generated after processing, no post-processing such as deburring is required, and no new waste is generated due to burrs. Incidentally, FIG. 5 shows a cross section of the chip urethane member manufactured in the above-mentioned embodiment, and FIG. 5A shows an inner member 1 obtained by heating and press-molding a chip urethane strip. The outer skin 2 is adhered, and the one shown in FIG. B is a laminate in which a slab urethane 3 is interposed between the outer skin 2 and the inner member 1.

Any shape of the chip urethane member can be manufactured according to the mold used for manufacturing, and various products such as the floor mat M shown in FIG. 5 can be manufactured. Note that the imaginary line in FIG. 5 indicates the seat installed on the floor mat M.

[0013]

As described above, the skin-integrated chip urethane member according to the present invention comprises an inner member formed by finely crushing waste and scraps of a polyurethane product, and an inner member in which crushed chips are bonded to each other by a binder. It is composed of a skin that is adhered to the surface of the inner member via the inner surface of the inner member, and has a desired outer shape and density. It is extremely important in contributing to the progress of recycling. Moreover, regardless of the material or shape of the fabric such as woven fabric, knitted fabric, leather, mat, etc., any skin can be selected and used according to the applied product. In addition, a laminate of slab urethane can also be used, and since the characteristics of chip urethane such as soundproofing effect, heat insulating effect and cushioning performance can be fully utilized, its application range is large. Moreover, the design shape can be freely selected by selecting the press die.

Further, according to the first method for manufacturing a skin-integrated chip urethane member according to the present invention, the skin is set on a mold having a desired shape via an adhesive, and then wastes and scraps of polyurethane products are collected. The mixed chips, which are made by finely crushing the crushed chips and the binder as the binder, are loaded into the outer skin set in the molding die, and then the compressive force and high temperature are applied to the urethane chips to obtain an appropriate hardness. Since an inner member having (density) and a shape is molded, and at the same time a skin is adhered to the inner member to form a chip urethane member, an expensive urethane foam foam material is not used. In addition, it is possible to manufacture a skin urethane integrated chip urethane member at an extremely low cost, which will enhance the recycling of waste urethane.

The second method for manufacturing a skin-integrated chip urethane member according to the present invention is a mixed chip in which a binder as an adhesive is mixed with a crushed chip obtained by finely crushing waste or scraps of a urethane product. Since a predetermined amount of this mixed chip is contained in a bag-shaped body made of a skin material having an adhesive on the inner surface, an expensive foaming stock solution is not used. It has become possible to manufacture in. Further, since burr does not occur after processing, not only is post-processing such as deburring processing unnecessary, and no new waste is generated due to burr generation.

[Brief description of drawings]

FIG. 1a is a sectional view of a skin-integrated chip urethane member of the present invention.

FIG. 1b is an enlarged schematic view of the skin-integrated chip urethane member of FIG.

FIG. 2 is a sectional view of another embodiment of the skin-integrated chip urethane member of the present invention.

FIG. 3 is a schematic diagram showing a case where the skin-integrated chip urethane member of the present invention is applied to an automobile door trim.

FIG. 4 is a schematic process diagram of an embodiment of a manufacturing method according to the present invention.

FIG. 5a is a cross-sectional view of a skin-integrated chip urethane member manufactured by the manufacturing method shown in FIG.

FIG. 5b is a cross-sectional view of another skin-integrated chip urethane member manufactured by the manufacturing method shown in FIG.

FIG. 6 is a perspective view showing a case where the skin-integrated chip urethane member according to the present invention is applied to a floor mat of an automobile.

[Explanation of symbols]

 1 Inner member 2 Skin 4 Grinding chip 5 Binder 6 Bag-shaped body 8 Molding lower mold 9 Molding upper mold 10 Skin-integrated chip urethane member

Claims (3)

[Claims] 1. An inner member having crushed chips obtained by finely crushing wastes and scraps of urethane products, which are bonded together by a binder, and a skin adhered to the surface of the inner member via an adhesive, In addition, a skin-integrated chip urethane member characterized by having a desired outer shape and density. 2. A mixed chip obtained by setting a skin on a molding die via an adhesive and then finely crushing wastes and scraps of urethane products and mixing a binder serving as a binder into the crushed chips. It is charged in a mold, and further, a compressive force and a high temperature are applied to the mixed chips to bond the crushed chips to each other with a binder to form an inner member having an appropriate hardness, and at the same time, to adhere a skin to the inner member. A method of manufacturing a surface-integrated chip urethane member. 3. A mixed chip is formed by mixing a crushed chip obtained by finely crushing wastes and scraps of urethane products with a binder as an adhesive, and a predetermined amount of the mixed chip is made to have the adhesive present on the inner surface. It is housed in a bag-shaped body made of a skin material, and then the bag-shaped body is closed to form a flat body. The flat body is further housed in a molding die and a predetermined compressive force and high temperature are applied to the ground chips. A method for producing a skin urethane-integrated chip urethane member, characterized in that the skins are simultaneously bonded to an inner member having an appropriate hardness by binding each other with a binder.