JPS63135206A - Manufacture of surfacing material - Google Patents

Abstract

PURPOSE:To make it possible to use sharp groove shape in a decorative design and at the same time contrive to improve the bonding strength between a skin material and a foam by a method wherein polyurethane foaming stock liquid is applied in the form of a flat plate and the foaming of the stock liquid and the integration of the skin material and the foam are done simultaneously and, in addition, the shaping is done also during the integration. CONSTITUTION:There is no special limitation as a skin material 1. However the preferable skin material is a synthetic resin sheet such as polyvinyl chloride sheet or the like. When necessary, on the surface of said sheet, thermoplastic synthetic resin fiber is flocked or decorative pattern is applied by embossing. The preferable thickness of polyurethane foamed layer 2 is about 2-30mm. The preferable depth of the groove is about 1-15mm. The preferable density of the foamed layer is in the range of 0.04-0.12g/cm<2>. The shape relieving is done simultaneously with the integration of a surfacing material and a foam. As the method for the shape relieving, the method such as to press the skin material with a pressing jig having a shape conforming to the shape of the surface of a product is exampled.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for manufacturing cladding materials for various interior products used in transportation vehicles such as automobiles, railway vehicles, aircraft, and ships, and other household items. Regarding.

(Prior art) Conventionally, for example, as a surface material for automobile interior materials, the mainstream has been a composite material made by slicing polyurethane foam, melting and softening the surface with flame, and laminating a surface material such as 7-laminated 7-laminated foam. It is used as a surface material for door trims, pillars, headrests, seat cushions, etc.

In addition, as a method for creating an uneven shape on the surface of the epidermis, the methods listed below are used.

■Method by sewing A gate shape is created by covering a foam wadding with a groove shape in advance and sewing it at the bottom of the groove. Sewing marks appear, and both ends of the convex part are easy to sag, making it unsatisfactory in terms of design, and the work is labor-intensive, resulting in a lot of waste in terms of cost and time 6 ■Method using adhesive On the surface of the sprouted foam wadding, a skin formed in advance into a desired uneven shape by pressing is adhered using an adhesive (eg, Utility Model Publication No. 61-79997).

This method requires groove formation and press molding, which is wasteful in terms of cost and time.

■ Method using high-frequency welding A groove shape is formed by welding a pattern-forming electrode on a skin member consisting of a laminate of a skin, foam wadding, and a 7-day cover (e.g., JP-A-6L-82778).
. This method leaves welding marks on the surface of the skin, and both ends of the convex portion are likely to be curved, making it unsatisfactory in terms of design. In addition, the machines are expensive and consume a lot of power, resulting in a lot of waste in terms of cost.

■ Method using a hot press A pattern forming press is used to heat-weld a skin member consisting of a skin, foam wadding, and a laminate with a wadding force of 1 < - to form a groove shape (e.g., Utility Model No. 61-63
996). This method also leaves welding marks on the surface of the skin, and both ends of the convex portion tend to sag, making it unsatisfactory in terms of design. In addition, the power consumption of the machine is large, resulting in a lot of waste in terms of cost.

■Integrated foaming method 7 Abric & 4 In order to prevent the skin material from being impregnated with the foaming solution, a resin film or closed cell foam backing is attached to the back of the skin material according to the shape of the foam mold. A foaming stock solution is poured directly onto the back surface of the inner and outer skin material to form an integral mold (eg, Japanese Patent Publication No. 61-17654). This method requires a backing on the back side of the skin material, which is wasteful in terms of cost and time. If there is no backing, the foaming solution comes into direct contact with the skin material, so it easily impregnates and seeps out onto the surface, resulting in a hard texture and an unsatisfactory design.

(Problems to be Solved by the Invention) The purpose of the present invention is to easily form uneven shapes on the skin material without wasting time and cost by introducing special machines or special work, and furthermore, It is an object of the present invention to provide a method for producing a surface material which has excellent design and texture, has no blurring or processing marks, has little impregnation because there is no direct contact between the surface skin and a reaction liquid.

Another object of the present invention is to provide a method for producing a surface material that improves the adhesive interface strength between the surface material and polyurethane foam and the adhesion to other materials compared to conventional products, and solves problems such as skin peeling. It is in.

(Means for Solving the Problems) The present invention is characterized in that a polyurethane foaming stock solution is applied in a flat plate shape, and is integrated with the skin material at the same time as foaming, and shaping is also performed at the time of integration. The present invention relates to a method for manufacturing a facing material comprising a two-layer laminated structure having a thickness and shape of .

In the present invention, there are no particular restrictions on the skin material, but 77
In addition to plastic, polyvinyl chloride, polyvinylidene chloride,
Synthetic resin sheets such as polyester, polyacrylonitrile, nylon, polyolefin, and polyurethane are preferred. If necessary, short thermoplastic synthetic resin fibers may be flocked to the surface of these sheets, or a decorative pattern may be applied by embossing or the like. Furthermore, it may be made of suede or suede-like material. The thickness of the polyurethane foam layer is preferably about 2 to 30IIIl, and the groove depth is preferably about 1 to 15+sfi. It can be made to have an appropriate thickness depending on the application. Density is about 0.04~
A range of 0.12 g/am' is preferred.

In the present invention, when integrating the facing material and the foam, shaping is also performed. Examples of the shaping method include a method of pressing the skin material with a presser having a shape that matches the shape of the product surface. At this time, by using a frame together with the presser jig, it is possible to manufacture a covering material in which a foam layer is formed only in a limited and specific part of the covering material that corresponds to the area within the frame. Furthermore, by using jigs of various shapes instead of a flat one as a holding jig, it is also possible to partially change the thickness of the foam layer to give it a curved shape, a stepped shape, etc. Furthermore, a frame with a foaming liquid return plate on the upper side can be used as the frame, and by folding the skin material on the board and foaming it so that it does not come into contact with the foaming liquid, the end surface of the skin material becomes polyurethane. It is possible to create a facing material that does not adhere to the foam. The return plate may be formed integrally with the frame, or may be separate from the frame.

Further, in the present invention, a 04 resin film layer can be provided at the lowest part of the facing material. 04 As the fat film, acrylic film is preferable due to its adhesiveness with other materials, but other synthetic materials such as urethane film and latex (fat film can also be used depending on the application. The thickness of the film is about 0. The thickness is preferably in the range of 0.02 to 0.06 mm, and the weight is preferably in the range of about 0.0 to 60 g per 1w12, but it may be better to make it somewhat thicker depending on the purpose.

(Effects of the Invention) According to the present invention, it is possible to easily create an uneven shape without R blur on the surface of the covering material, so that a sharp groove shape can be used in the design.

In addition, in the present invention, since a somewhat impregnated layer is formed at the adhesive interface between the polyurethane foam and the skin material, considerable adhesive strength can be obtained6.Furthermore, by providing a resin film layer on the bottom surface of the foam layer, it is possible to bond to other materials. This changes from 7α adhesion to surface adhesion, improving adhesion to other materials.Furthermore, since this film layer is impermeable, integral foaming with RIM using this surface material is possible without impregnation with reaction liquid. It's easy to do.

Furthermore, by using a specially shaped frame and holding jig, the shape of the product surface can be freely changed according to the purpose.

(Example) A detailed explanation will be given below with reference to examples.

Example 1 A polyurethane foaming stock solution was applied to a constant thickness on a Teflon-treated glass belt, and the glass belt was transferred to a hot plate heated to about 60°C, and a presser with a shape shown in Fig. 1 (a) was pressed with 77 bricks. Temporarily bond the surface to match the shape of the jig [The cross-sectional view of the temporary bonded state is shown in Figure 1 (b), and place it on top of the polyurethane foam stock solution, and foam while applying a load of approximately 201 per square meter. When this is done, the thickness of the polyurethane foam layer is 20 mm, and the depth of the groove is 10 fII.
A facing material for a two-layer laminated structure shown in FIG. 2 of I11 was obtained.

Example 2 Acrylic film scraps with a thickness of 0.05 mm are prepared by applying acrylic film noyon onto a Teflon-treated glass belt. Apply polyurethane foaming solution to a certain thickness on top of this, transfer the glass belt to a hot plate heated to about 60℃, and place a frame (c) that matches the shape you want to foam on the glass belt, as shown in Figure 3. . Then, the surface of the 77 brick is temporarily bonded together with the presser foot shown in FIG. 3(d) [a cross-sectional view of the temporarily bonded state is shown in FIG. The foaming process is performed while applying a load of approximately 20 kg per square meter, and both i edges of the skin material are cut to produce a facing material with the configuration shown in Figure 4 and the shape shown in Figure 5. I was able to do something.

Example 3 Using the frame shown in Fig. 6, in which a foaming liquid return plate was provided on the upper side of the frame shown in Fig. 3(e), the skin material was folded back on the plate as shown in Fig. 7. A covering material in which the end surface of the covering material does not adhere to the polyurethane foam as shown in FIG. 8 was produced in the same manner as in Example 2, except that it did not come into contact with the foaming liquid.

[Brief explanation of the drawing]

Figure 1 (,) and Figure 3 (d) are the presser jig, Figure 1 (b)
) and FIG. 3(e) show the state in which the covering material is temporarily attached to the presser foot, FIG. 3(e) shows the frame, FIG. 2 and FIG. 4 show the cross section of the covering material of the present invention, and The figure is a perspective view of a facing material of the present invention obtained by cutting both end edges of a double laminated structure formed using the frame and holding jig shown in FIG. 3. f! Figure IJ6 is a frame equipped with a return plate for the foaming liquid, Figure 7 is a schematic diagram explaining how to create a facing material using the frame in Figure 6, and Figure 8 is a frame with a return plate for the foaming liquid. FIG. 2 is a perspective view of a facing material of the present invention obtained using a frame equipped with a return plate and a pressing jig. (1) is a skin material, (2) is a polyurethane foam layer, (3) is a resin film layer, (4) is a return plate, (5) is a frame, and (6) is a holding jig. (Above) Applicant Toyo Rubber Industries Co., Ltd. Agent Patent Attorney 1) Iwao Mura Figure 1 (a) (b) Figure 2 Figure 4 Figure 3 (d) (C)

Claims (4)

[Claims] (1) A two-layer laminated structure with a predetermined thickness and shape, characterized by applying a polyurethane foaming solution in a flat plate, foaming and integrating with the skin material, and shaping at the same time as the integration. A method of manufacturing a facing material made of objects. (2) The method for manufacturing a facing material according to claim 1, wherein a resin film layer is provided at the lowest part of the facing material. (3) The method for manufacturing a facing material according to claim 1, wherein shaping is performed using a frame together with a pressing jig, and a foam layer is formed in a limited and specific range of the facing material. (4) A method for manufacturing a facing material according to claim 3, in which a frame provided with a return plate is used as the frame.