JPS5995134A - Manufacture of ornamental laminated material with three-dimensional ornamental section - 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 This invention relates to decorative laminate materials used for vehicle seat covers, interior materials such as door linings, sofas, beds, etc., particularly decorations having three-dimensional decorative parts. The present invention relates to a method for manufacturing a laminated material.

For example, in the case of automobile seats, three-dimensional raised shapes, patterns, etc. are provided on the surface of the seats from the viewpoints of usability, decorativeness, and the like.

Various methods have been proposed and implemented to give this raised shape and pattern, but one method is to sew a plastic sheet that regulates the groove pattern onto the surface of the seat surface material using a sewing machine to create a predetermined groove pattern. It has been attempted to create a concavo-convex shape with However, this method requires a large number of man-hours because the plastic sheets are sewn together using a sewing machine, and at the same time, the stitching tends to impair the unevenness and three-dimensional appearance of the surface of the sheet member.

In view of these points, the present invention provides a three-dimensional uneven shape to the surface of this type of surface material, and creates a plastic welded part of a predetermined shape at the inner bottom of the recess in an extremely simple and beautiful manner. This paper proposes a novel method for manufacturing decorative laminate materials.

That is, the present invention provides a method of interposing powdered thermoplastic plastic on the surface of the surface material of a surface material in which a surface material such as fabric, a cushion layer such as a foamed plastic sheet, and a reinforcing lining fabric are integrally laminated. This is then compressed using a mold having a predetermined shape, and sufficient heat is applied to melt the powdered thermoplastic, thereby forming a compressed material having a plastic welded portion having a predetermined mold shape on the inner bottom of the surface layer material. The gist is to form four parts, and examples will be described below.

Figure 1 of the attached drawings is an overall old perspective view of an automobile seat seat (S) shown as an embodiment of the present invention, and Figure 2 is a view of 2-2 in Figure 1.
FIG. As shown in the figure, this seat S has a cushion core 9 made of, for example, soft polyurethane foam, which defines the basic shape of the seat.
The sheet cover unit 10 made of the decorative laminate material of the present invention molded into a predetermined shape is covered and wrapped.

The seat cover unit 10 is provided with a decorative portion as shown in the figure. This decorative part is composed of a compressed recess 15 formed in a predetermined shape such as a design line or a letter as shown in the figure, and a plastic welded part 20 clearly formed at the inner bottom 15a of the compressed recess 15.

FIG. 3 is a partially cutaway perspective view of the surface material 11 constituting the seat cover integral 10. A cushion layer 13 made of a foamed plastic sheet such as the above, and a reinforcing backing cloth 14 made of a non-woven fabric are bonded and laminated together by, for example, known flame lamination (flame bonding). The cushion layer 13 of the surface material 11 can have a desired thickness depending on the depth of the compressed recess 15 to be formed, but in the example, a flexible polyurethane foam having a thickness of about 10 mm was used.

Next, the process of forming the above-mentioned seat cover integral 10 will be explained according to the drawings in FIGS. 4 and 5. The figure shows that the above-mentioned surface layer material 11 is placed on the lower die 30 of a high-frequency welder, and the surface layer material 11 is Powdered thermoplastics in position 2
1 (FIG. 4), the inside of the compressed recess 15 is compressed by an upper mold 31 having mold blades 35 of a predetermined shape, and heat sufficient to melt the powdered thermoplastic is applied. This figure shows a state (FIG. 5) in which a plastic welded part 2o of a predetermined shape is formed on the bottom part 16a. The thermoplastic powder 21 used in the examples is a color powder of a polyvinyl chloride resin compound, and in addition to this polyvinyl chloride resin #1, polyethylene resin paratar, polypropylene resin powder, etc. are often used.

The surface material 11 is compressed by the mold blade 35 by pinching pressure by the mold blade 35 and by applying a high frequency voltage from both molds 30 and 31 which also serve as electrodes.
The powdered thermoplastic plastic 21 located at the pinched portion 5 is melted and thermally welded to the surface of the outer cloth 12. Only the portion corresponding to the surface 35a of the mold blade 35 is thermally welded, and the other powdered plastics 21 remain as a residue on the surface of the outer fabric. Therefore, after the high-frequency welder molding is completed, the remaining powdered plastics 21 is collected and used again.

Another molding method is shown in FIGS. 6-8. Here, as in the above embodiment, a mold blade 36 is provided on the lower mold 30 in order to simplify and facilitate collection of excess powdered plastic, X, 21 remaining after molding or cleaning of the surface. Form the tip into a square 37 shape,
The powdered plastic 21 is housed in the square portion 37 and is to be subjected to high frequency welder molding. In this example, the powdered plastic 21 is stored in the square part 37 at the tip of the mold blade 36, so that no excess powder remains around or is scattered during molding, and the finish after molding is Work becomes simple and easy. In this embodiment, since the mold blade 36 for storing the powdered plastics 21 is provided in the lower mold 3OK, the mold is set so that the outer fabric 12 of the surface layer material 11 is on the lower surface side. A welter" molding similar to the example described is made.

Although the above embodiment uses a high frequency welder, it is also effective to use an ultrasonic welder that welds powdered thermoplastics by ultrasonic vibration.

The mold or molding method for the ultrasonic welder can be almost the same as for the high-frequency welter described above.

As described above, according to the present invention, a powdered thermoplastic is interposed on the outer fabric surface of the outer layer material including a cushion layer made of a foamed plastic sheet, and this is compressed by a mold having a predetermined shape. Sufficient heat is applied to melt the powdered thermoplastic, and a compressed four part having a predetermined mold-shaped plastic welded part at the inner bottom is formed on the surface of the surface material. A design decoration part made of a plastic welded part in a line shape or a shape specified by the company can appear extremely three-dimensionally and clearly within the compression recess. In particular, since this invention involves welding powdered plastics, it is possible to very beautifully apply decorative parts to the surface of outer fabrics such as Noahbrick, which is generally considered difficult to adhere. The degree of freedom in the design of the decorative part is also greatly expanded, making it possible to bring out a high level of design.

Furthermore, in the method of this invention, by using a high frequency or ultrasonic welter mold as in the embodiment, a three-dimensional pattern of a desired shape can be created extremely simply and easily, and it is possible to create a three-dimensional pattern of a desired shape using conventional sewing processing or plastic sheet processing. Compared to using
Great advantages can also be enjoyed in terms of quality.

[Brief explanation of the drawing]

Fig. 1 is a perspective view of an automobile seat equipped with an integrated seat cover showing an example of the decorative laminate material according to the present invention, Fig. 2 is a partially enlarged cross-sectional view taken along line 2-2 in Fig. 1, and Fig. 3 is a cover FIG. 4 is a cross-sectional view of a mold showing an embodiment of the present invention, FIG. 5 is a cross-sectional view of the molded state, and FIG. 6 is a perspective view of another embodiment. FIG. 7 is a partial perspective view of the mold, and FIG. 8 is a cross-sectional view showing the molding state. 10...Seat cover integrated, 11...Surface material, 1
2.=front cloth, 13.. cushion layer. 15... Compression recessed part, 20... Plastic welded part, 21... Powdered thermoplastic plastic,
30...Lower mold, 31...Upper mold, 35.36
...Mold blade, 37...Masu part. Figure 1 Figure 4 Figure 6 Figure 4 Figure 7 Figure 8

Claims (1)

[Scope of Claims] 1. Powdered thermoplastic glass is applied to the surface of the surface material of a surface material in which a surface fabric such as fabric, a cushion layer such as a foamed plastic sheet, and a reinforcing lining fabric are integrally layered. This is compressed by a mold having a predetermined shape, and sufficient heat is applied to melt the thermoplastic powder to form a welded part of the plastic in a predetermined mold shape on the inner bottom of the surface layer material. 1. A method for producing a decorative laminate having a three-dimensional decorative part, the method comprising forming a compressed recess having a three-dimensional decorative part. 2. A method for producing a decorative laminate having a three-dimensional decorative portion according to claim 1, wherein the thermoplastic powder is melted by applying a high frequency voltage. & A method for producing a decorative laminate having a three-dimensional decorative portion according to claim 1, wherein the powdered thermoplastic is melted by ultrasonic vibration.