JPS59187844A - Manufacture of laminate - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a laminate in which a face material is laminated and integrated on one or both sides of a flexible polyurethane foam by heat pressing, and particularly relates to a method for suitably manufacturing a laminate having an uneven shape. .

Conventionally, flexible polyurethane foam is coated with thermoplastic resin film, leather, or woven fabric on one or both sides.

Non-woven fabric etc. are fused and integrated to give an uneven pattern 2
J@ to three-layer laminated products are used as vehicle interior materials, baggage materials, walls, floor coverings, etc. Currently, such laminates are mainly produced by the high-frequency welding method, but this method relies on very expensive special foams, requires expensive welding machines, and also requires chlorinated surface materials. It has the disadvantage of being limited to vinyl and the like. On the other hand, in addition to the high-frequency well-glue method, a method has been proposed in which a special foamable hardened resin is applied to the foam surface and then heated to form a shadow. In addition to requiring a complicated process of foaming and curing the cured resin, there are also restrictions in that the coating process and the shaping process must be performed consecutively.

In view of the above circumstances, the present inventors used a cost-effective heat press method to easily and reliably form uneven patterns on flexible polyurethane foam and face material without requiring any special form or process. As a result of conducting various studies on methods for laminating and integrating the face material, we found that a thermoplastic resin composition was coated in advance on the surface (one or both sides) of the soft urethane foam on which the face material was to be laminated, and then a thermoplastic resin composition was applied by heat pressing. The present invention was made based on the finding that the above object can be achieved by locally fusing the two.

That is, in the present application, a thermoplastic resin composition is coated on a flexible polyurethane foam in advance, and the flexible polyurethane foam and a face material are hot-pressed using, for example, a mold having uneven parts, thereby forming a molten thermoplastic resin composition. The material penetrates into the foam, greatly improving the thermoformability of the mold, especially the pressed foam part (welm part) by the convex part, and in this case, this also goes hand in hand with the high thermoformability of polyurethane foam. Therefore, even immediately after the mold is removed at high temperature, the molded shape is prevented from collapsing due to the restoring force of the foam, and a clear weld line can be obtained.

The present invention will be explained in detail below.

The method for producing a laminate according to the present invention includes locally fusing a flexible polyurethane foam and a face material by heat pressing, and laminating and integrating the face material on one or both sides of the flexible polyurethane foam. A thermoplastic resin composition is applied in advance to the surface of the flexible polyurethane foam to be laminated.

Here, as the flexible polyurethane foam, ether-based flexible polyurethane foam or ester-based polyurethane foam is used. In this case, the flexible polyurethane foam has excellent breathability according to JIS, Li2
Based on the cotton fabric testing method of O2-1972, the amount of air passed by the testing machine ((7)/cm/%) was 40.
Above, it is more desirable to use a foam of 80 or more, and by using this kind of foam, when applying a thermoplastic resin composition, the composition can easily penetrate not only the surface of the foam but also the inside of the foam. , the adhesive strength is further improved.

In addition, in order to improve heat fusion properties, foam raw materials are foamed by adding vinyl chloride resin or plasticizers as heat fusion properties improving ingredients, and flexible polyurethane foams are made by adding vinyl chloride resin paste or vinylidene chloride resin latex. It is also possible to use a material impregnated with a heat fusion improver such as .

As the flexible polyurethane foam, a normal polyurethane foam with a cell membrane can be used, but a reticulated foam without a cellular membrane can be particularly preferably used, and by using this reticulated foam, thermoplastic resins can be The composition easily penetrates into the foam, further improving adhesive strength.

Further, a flexible polyurethane foam having an apparent density of 0.014 to 0.05 is preferably used.

In addition, as a flexible polyurethane foam, heat 7'L/
flexibility (20m thick urethane foam is 4wII)
The minimum pressing temperature at which the foam is compressed to I+ and held for 120 seconds, and the thickness of the foam is 4.5 mm or less 24 hours after release of the press, is called the heat-pressable temperature for that foam)
A material having a temperature of 200° C. or lower, particularly 180° C. or lower can be suitably used, thereby making it possible to perform hot pressing at a lower temperature.

The thermoplastic resin composition should have a softening point of 60 to 180°C, particularly 80 to 150°C, in order to improve the heat resistance of the stack and to perform hot pressing at a lower temperature.
For example, hot melt adhesives such as &lJ7 mid resin type and polyester resin type can be used.
Specifically, Evergrip (Sail Chirney (Ja
(manufactured by Yan) Limited).

In addition, when implementing the present invention, the amount of the thermoplastic resin composition applied to the flexible polyurethane foam is 1 laminated side (single side).
30-4009/m % especially 40-150,! 9
/m2, and if the coating amount is less than 30g/m2, sufficient thermal adhesion may not be obtained.
Moreover, using more than 400 g/m is disadvantageous in terms of cost, and the foam may become hard.

Furthermore, it is preferable that the thermoplastic resin composition penetrates into the interior of the polyurethane foam by at least 1+ mn, particularly by at least 2 mn, thereby ensuring reliable thermal bonding. In this case, it is preferable that the thickness of the non-permeable part of the thermoplastic resin composition of the polyurethane foam is 30 mm or less, especially 20 mm or less, and this will ensure the inconvenience that a part of the welder may lift up after hot press molding. Defends by 1.

Thermoplastic resin composition □The proboscis may be coated on the entire surface of the urethane foam, or may be coated only on the portion where it meets the surface ISj.

It is convenient to uniformly apply the thermoplastic resin composition using a roll coater, one-way roller coater, one-way curtain flow coater, or spot-coat using a one-way gravure coater. By applying a post-heat roller, the penetration into the foam can be further enhanced.

After application, the thermoplastic resin composition may be solidified by adhering the face material before solidifying, or it may be solidified without contacting the curved material.

Furthermore, in the present invention, immediately after coating the thermoplastic resin composition, while maintaining adhesion, vinyl chloride resin powder,
Thermoplastic resin powder such as vinylidene chloride resin powder, acrylic resin powder, vinyl chloride-vinyl acetate copolymer, etc. can also be sprinkled onto the thermoplastic resin composition and fixed.
In addition to this, it is possible to further improve the thermal fusion properties.

Indeed, in the present invention, instead of the thermoplastic resin powder, or by sprinkling, a thin film of 100 ml of heat may be laminated onto the thermoplastic resin composition.

However, in the present invention, a thermoplastic resin composition can also be applied to the surface of the curved material that comes into contact with the urethane foam in order to further improve the heat fusion properties. The thermoplastic resin composition may be applied to the entire surface of the curved material that comes into contact with the urethane foam, or may be applied only to the portion that will be fused to the urethane foam. Note that the same thermoplastic resin IJy products as mentioned above can be used.

Furthermore, while the thermoplastic resin composition coated on the face material maintains its adhesive properties, heat-j'J plastic 4ff-1 fat powder such as vinyl chloride resin powder or vinylidene chloride resin powder is sprinkled to fix the adhesive. It is also possible to further improve the thermal fusion properties. Note that instead of coating the face material with a thermoplastic resin, a solution tie 70 or an emulsion type adhesive may be applied, and instead of spraying thermoplastic resin powder, a thermoplastic resin thin film of the type 74 described above may be applied. can also be laminated.

As described above, the surface of the flexible polyurethane foam on which the face material is to be laminated is coated with a thermoplastic resin composition in advance, and the flexible polyurethane foam and the face material are heat-pressed using a mold having an uneven shape. There are no particular restrictions on the type of surface material, but in the present invention, natural fiber woven fabric or non-woven fabric, soft vinyl chloride resin, polyamide resin, acrylic resin are used as the surface material. , synthetic resin films such as hnylidene chloride resin, leather,
Woven fabric or non-woven fabric is the same as the front side material as the back side surface material, or is it similar to the front side material? 1. A self-supporting board material such as a plywood, a wooden board, a cardboard board, a metal board 2 and a synthetic resin board is preferably used.

In this case, the surface material should have a diameter of 50 mm in one or both axial directions.
It is preferable to use a material with an elongation rate of 100 LI or higher, especially 100 LI or higher, which provides excellent cushioning properties.
Moreover, a laminate with clear welder lines can be obtained. Note that the surface material having a melting temperature of 160 to 240°C is preferably used. Further, as the surface material, a material whose surface is brushed or flocked may be used.

When using film, leather, woven fabric, or non-woven fabric as the back surface material, 10 lbs.
It is preferable to use a material having an elongation rate of less than 2 cycles, especially less than 2 cycles, thereby making it possible to obtain a laminate with excellent processing suitability.

In the present invention, only the above-mentioned front surface material or both the front surface material and the back surface material are used, and heat pressing is applied from the front surface material side. In particular, both the front surface material and the back surface material are When used, it is possible to obtain a sandwich-structured laminate that can be suitably used as an interior material for automobiles.

In this way, when manufacturing a laminate with a sandwich structure, the amount of the thermoplastic resin composition applied to the back side phase is greater than the amount applied to the front side, so that the back side phase and the soft polyurethane The fusion properties with the foam can be improved.

In the present invention, the heat press material, equipment, etc. are not particularly limited and may be selected as appropriate, but if the thickness of the welder part is 20CI) or less than the original polyurethane foam thickness,
It is preferable to hot press the welding material so that a clear weld line can be obtained. In addition, the hot press temperature is 10% higher than the softening point of the thermoplastic resin composition.
℃ or more, especially 20℃ or more higher, and 10℃ or more, especially 20℃ or more lower than the melting temperature of the surface material (most preferably,
is 10 to 70 degrees Celsius lower than the melting temperature of the surface material, especially 20 to 50 degrees Celsius), and is 40 to +50 degrees Celsius below the heat-pressable temperature of the polyurethane foam used, especially -20 to +30 degrees Celsius. It is preferable to set it as temperature.

'fx O, the heat pressing may be carried out continuously using a roll or a conveyor, or may be carried out in a patch manner using a heat press machine.

Furthermore, in the present invention, after the hot press mold is removed, the thermoplastic resin composition can be further pressed by a mold having a temperature lower than the softening point of the thermoplastic resin composition before it is cured, and thereby the welder It is possible to reliably prevent the pattern from losing its shape.

As described above, according to the method for producing a laminate according to the present invention, the flexible polyurethane foam and the facing material are heat-pressed using a mold having an uneven shape to laminate the facing material on one or both sides of the flexible polyurethane foam. In the method of
By previously coating the surface of the flexible polyurethane foam on which the above-mentioned face material is laminated with a thermoplastic resin composition, a laminate having clear weld lines can be obtained simply, reliably, and inexpensively.

Furthermore, according to the method of the present invention, molding can be performed at a lower temperature and in a shorter time than when the urethane foam and face material are integrated by the conventional heat press method, and as a result, the urethane foam and the fabric, etc. It is possible to prevent melting, expansion and contraction of fabrics etc. due to heat, which is the biggest problem in integrated heat press.

Furthermore, according to the present invention, after the thermoplastic resin is applied, the shaping can be performed immediately on the same line, or when the thermoplastic resin is applied, the face materials are laminated to form two or three layers. This method has various advantages, such as the ability to create a laminated product and then shape it with shadows at any time (only a device is required for shaping).

EXAMPLES The present invention will be specifically explained below with reference to Examples.

[Examples 1 to 5] Using the apparatus shown in Fig. 1 and Fig. 2, # Each of the laminates of Examples 1 to 5 shown in Table 1 was manufactured, and the thickness (tl) of the welded part and the thickness (t2) of the non-welded part of this laminate were measured, and the original thickness of the form (t,) was measured. compared with. The results are shown in Table 2. In Table 2, the level difference refers to the difference in thickness between the welded part and the non-welded part, and is related to the float and the hardness of the form. The larger the float and step, the clearer the welter line.

DESCRIPTION OF THE APPARATUS FIG. 1 shows an apparatus for producing the laminate of this example. In this apparatus, a hot melt coating applicator 2. Immediately after, the front side material 6 and the back side material 7 are respectively laminated on the front and rear surfaces of the form 1 using pressure rolls 4 and 5, and then the movement of the form is stopped. , a laminate is produced by hot pressing using a hot press device 8. This heat press device 8 performs heat pressing using a flat press table 8a and a template 8b having an uneven shape, and the template 8b has a letter-shaped protrusion as shown in FIG. be. Also, in the figure, a has 5 wins, b has 20 ken, C has 70 wins, d has 50 m+n, and e and f each have 5 wins.

In Example 4, EVA was applied only to the surface, and only the surface material was laminated.

Table 2 From the results shown in Table 2, it was confirmed that the method of the present invention produced a laminate with clear weld lines. That is,
In Examples 1 to 3 with a three-layer structure using ordinary flexible polyurethane foam, a laminate having a step difference of 6 to 10 m was obtained, and in Example 4 with a two-layer structure, a laminate having a step difference of 3 m or more was obtained,
In particular, in Example 5, which had a three-layer structure using a net-like foam without a cell membrane, a laminate having a step height of 15 or more was obtained.

[Brief explanation of drawings]

FIG. 1 is a partially cross-sectional schematic diagram showing the apparatus used for manufacturing the laminate of the example, and FIG. 2 is a back view showing a template of the hot press apparatus of the same apparatus.

Claims (1)

[Scope of Claims] 1. A method of laminating and integrating a flexible polyurethane foam and a facing material on one or both sides of the flexible polyurethane foam by heat-pressing the flexible polyurethane foam and the facing material using a mold having an uneven shape,
A method for producing a laminate, which comprises previously applying a 5M thermoplastic resin composition to the surface of the soft d IJ urethane foam on which the above-mentioned face material is to be laminated. 2. Air permeability as a flexible polyurethane foam is JIS-
The manufacturing method according to claim 1, wherein the flow rate of air is 40 m3/sec or more using a Frazier type tester based on the Li2O2-1972 cotton fabric test method. 3. The manufacturing method according to claim 1 or 2, using a mesh-like flexible polyurethane foam without a cell membrane. 4. Temperature at which a soft polyurethane foam can be hot-pressed (minimum press for a soft polyurethane foam with a thickness of 20 mm to be compressed on 4 sides and held for 120 seconds, and the foam thickness 24 hours after the press is released to be 45 mm or less) temperature) is 2
The manufacturing method according to any one of claims 1 to 3, using a material having a temperature of 00°C or lower. 5. As a thermoplastic resin composition, the softening point is 60 to 180°C
The manufacturing method according to any one of claims 1 to 4, using a material falling within the range of . 6. The coating amount of the thermoplastic resin composition is 30 to 30 per laminated surface.
4'OOji/m The manufacturing method according to claim 5. 7. The manufacturing method according to claim 5 or 6, in which the thermoplastic resin composition is allowed to penetrate from the surface of the flexible polyurethane foam to the inside by at least one inch. 8. The method of manufacturing the flexible polyurethane foam according to claim 7, wherein the non-permeable portion of the thermoplastic resin composition has a thickness of 30 lines or less. 9. Using natural fiber woven or non-woven fabric, synthetic resin film, leather, woven fabric or non-woven fabric as the front side material, heat press from the front side material side to form a soft column. 9. The manufacturing method according to any one of claims 1 to 8, wherein a face material is laminated on one side of the urethane foam. 10 A woven fabric or non-woven fabric made of natural fibers or a synthetic resin film, leather, woven fabric or non-woven fabric is used as the front side material, and a woven fabric or non-woven fabric made of natural fibers is used as the back side material 1 A synthetic resin film or leather. Any one of claims 1 to 8, in which a woven fabric, a non-woven fabric, or a self-supporting plate material is used, and the face material is laminated on both sides of the flexible polyurethane foam by hot pressing from the front side material side. Manufacturing method described. 11. The manufacturing method according to claim 9 or 10, wherein the surface material has an elongation coefficient of 50 or more in at least one axial direction. 12 As a surface material, the elongation rate is 50 in both axial directions.
% or more of the manufacturing method according to claim 11. 13. The manufacturing method according to any one of claims 9 to 12, using a surface material having a melting temperature of 160 to 240°C. 14. The manufacturing method according to any one of claims 9 to 13, in which the surface layer has a raised or flocked surface. 15. The manufacturing method according to claim 10, wherein a film, leather, or woven fabric with an elongation rate of 10 inches or less in both axial directions is used as the back side material. 16, 811 parts of Werther's body 7]? Claim 1: The thickness of the polyurethane foam is 20 times or less of the thickness of the original flexible polyurethane foam.
16. The manufacturing method according to any one of items 1 to 15. 17. The thermosoles temperature is 10°C or more higher than the softening point of the thermoplastic resin composition and 10°C or more lower than the melting temperature of the surface material, and 1-40 is the hot-pressable temperature of the soft 7J urethane foam. The manufacturing method according to any one of claims 1 to 16, wherein the temperature is in the range of ~+50°C. 18. Set the heat press temperature to 10~10% higher than the melting temperature of the surface material.
Claims 1 to 16 set the temperature to be 70°C lower.
The manufacturing method described in any of the paragraphs. 19. After removing the heat press mold, the thermoplastic resin composition is further pressed by a mold having a temperature lower than the softening point of the thermoplastic resin composition before it hardens. 18. The manufacturing method described in any one of 18.