JPS6362369B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing an integrally foamed sheet. More specifically, the present invention relates to a method for manufacturing an integrally foamed sheet having an embossed pattern with a good texture.

Conventionally, as a manufacturing method for cushion sheets, particularly sheets with embossed patterns for seats in transportation vehicles such as automobiles, railway vehicles, and aircraft, and furniture such as chairs and sofas, a skin is coated on the inner surface of a mold with a predetermined embossed pattern. After the bodies are brought into close contact using the suction method,
A method is known in which a foaming solution such as polyurethane is injected into the foam, heated, and foam-molded integrally with the skin body. However, from the point of view of sewing after foaming, in current sheets that use a laminate having a fabric such as woven fabric, knitted fabric, or non-woven fabric on the inner surface (as the lining) as the skin body, this method does not allow injection of foaming stock solution. Sometimes, the fabric is impregnated with the foaming stock solution, which has the disadvantage that it becomes hard after foaming and makes the surface feel uncomfortable.

The present invention was made in order to eliminate the various drawbacks of the conventional method as described above, and the present invention was made in order to eliminate the various drawbacks of the conventional method. A polyurethane integrally foamed sheet characterized by placing a polyurethane foam pad so as to cover only the concave portions, then injecting a polyurethane foaming solution into the pad, and further foaming the foaming solution integrally with the skin body and pad. This is a manufacturing method.

Next, one embodiment of the present invention will be described with reference to the drawings. That is, as shown in FIG. 1, a skin body 2 is placed on a lower mold 1 having an uneven pattern on its inner surface corresponding to the embossed pattern to be produced, after being heated with a heater (not shown) if necessary. Place it on. This skin body 2 is made of polyvinyl chloride, nylon, polyurethane, etc. on a base fabric such as knitted fabric, woven fabric, or nonwoven fabric.
Leather coated with synthetic resin such as polyamino acid, synthetic leather, etc. are used. Therefore, a fabric (not shown) such as a woven fabric, a nonwoven fabric, or a knitted fabric is laminated on the back surface of this skin body (the side opposite to the surface in contact with the mold).

After this skin body 2 is placed on the lower mold 1, it is brought into close contact with the inner surface of the lower mold 1 and is pre-molded into the same pattern as the inner surface. As a molding method, for example, as shown in FIG. After placing the skin body 2 on the lower mold 1,
When the suction device 4 is actuated, the skin body 2 closes the suction hole 5
As a result, the skin body 2 comes into close contact with the inner surface of the lower mold 1 and forms the same pattern as the unevenness on the inner surface of the lower mold 1.

The skin body 2 that is in close contact with the lower mold 1 in this way
A polyurethane foam pad 8 is placed in the recess 6 so as to cover only the recess 6 excluding the projection 7. In this case, the pad 8 may simply be placed on the skin body 2, but it is desirable that the two be fully or partially adhered or adhered to each other with an adhesive, adhesive, or the like. As the polyurethane foam pad, a polyurethane foam slab is usually used, but other sheet-like materials may also be used. Next, when a predetermined amount of polyurethane foaming solution is injected into the lower mold 1, a portion of the foaming solution impregnates the surface of the polyurethane foam slab 8 to form an impregnated layer 9, as shown in FIG. form 10. Further, in the convex portions 7, the foaming stock solution is impregnated into the skin body 2, but in the concave portions 6, the entire surface of the skin body 2 is covered with the pad 8, so that impregnation of the foaming stock solution into the skin body 2 is blocked. be done.

Then, as shown in FIG. 3, when the upper mold 11 is closed and heated to a predetermined temperature to cause foaming, the polyurethane foam 12 is formed in the space formed between the lower mold 1 and the upper mold 11, and the pad 8 and the convex portion 7 of the skin body 2
It is formed integrally with. After the foaming is cured, the upper mold 11 is removed and removed from the lower mold 1 to obtain an integrally foamed sheet 13 having an embossed pattern as shown in FIGS. 4 and 5.

As described above, in the method of the present invention, a polyurethane foam pad is placed in the recesses of a skin body that has been previously formed into the pattern in a mold having a predetermined uneven pattern on the inner surface so as to cover only the recesses. Then, a polyurethane foaming stock solution is injected into this, and the foaming stock solution is foamed integrally with the skin body and pad to produce a polyurethane integrally foamed sheet. Therefore, the injected foaming stock solution is Since the concave portions, that is, the convex surfaces of the sheet as a product, come into contact only through the pad, the foaming stock solution is not impregnated into the fabric layer on the back side of the skin body, but only into the pad. Therefore, when the foaming solution foams and forms a foam, the skin does not become hard, and the foaming solution does not reach the parts of the pad that come into contact with the skin, so the cushion texture of the product sheet is affected. It won't hurt anything. on the other hand,
The convex parts of the skin body during preforming come into contact with the foaming stock solution, so these parts are impregnated with the foaming stock solution to some extent;
This area not only has nothing to do with the texture of the sheet as it becomes a concave part of the product, but in fact, as mentioned above, the foaming solution impregnates this area and foams, so the integrity of the foam and the skin body is good. As a result, the peeling of the epidermis from the cushion part after long-term use is reduced. Furthermore, since it is manufactured as described above, productivity is extremely high.

[Brief explanation of drawings]

1 to 3 are sectional views showing each step of an embodiment of the method of the present invention, and FIGS. 4 to 5 are perspective views showing an example of an integrally foamed sheet produced by the method of the present invention. 1... lower mold, 2... epidermal body, 4... suction device,
5... Suction hole, 6... Concave portion, 7... Convex portion, 8...
Polyurethane foam pad, 9... Foaming stock solution impregnated part, 10... Foaming stock solution layer, 11... Upper mold, 12
...Polyurethane foam, 13...Integrated foam sheet.

Claims (1)

[Claims] 1. A polyurethane foam pad is placed in the recessed part of the skin body on which the pattern has been previously formed in a mold having a predetermined uneven pattern on the inner surface so as to cover only the recessed part, and then a polyurethane foam stock solution is placed on this. 1. A method for producing an integrally foamed polyurethane sheet, which comprises: injecting a foaming stock solution into the foam, and then foaming the foaming stock solution integrally with the skin and the pad.