WO2017141972A1 - 表皮一体発泡品及びその製造方法 - Google Patents

表皮一体発泡品及びその製造方法 Download PDF

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Publication number
WO2017141972A1
WO2017141972A1 PCT/JP2017/005541 JP2017005541W WO2017141972A1 WO 2017141972 A1 WO2017141972 A1 WO 2017141972A1 JP 2017005541 W JP2017005541 W JP 2017005541W WO 2017141972 A1 WO2017141972 A1 WO 2017141972A1
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WO
WIPO (PCT)
Prior art keywords
pad
layer
skin
outer material
foam
Prior art date
Application number
PCT/JP2017/005541
Other languages
English (en)
French (fr)
Inventor
隆介 横田
Original Assignee
株式会社イノアックコーポレーション
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 株式会社イノアックコーポレーション filed Critical 株式会社イノアックコーポレーション
Priority to JP2018500160A priority Critical patent/JP6824240B2/ja
Priority to US15/998,650 priority patent/US11633937B2/en
Priority to CN201780012752.1A priority patent/CN108698267B/zh
Publication of WO2017141972A1 publication Critical patent/WO2017141972A1/ja

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Definitions

  • the present invention relates to a foam integrated with a skin and a method for producing the same.
  • a pad by forming a pad by foaming liquid polyurethane into a bag-shaped outer material having a surface layer and a backing layer of a polyurethane sheet to obtain a foam integrated with a skin such as a headrest.
  • liquid polyurethane may permeate the polyurethane sheet. If a part of the liquid polyurethane is solidified inside the polyurethane sheet and a plurality of resin pieces are formed inside the outer material, the feeling of touch is impaired.
  • a polyurethane film was stuck inside the polyurethane sheet to prevent liquid polyurethane from entering the polyurethane sheet. Furthermore, in order to prevent liquid polyurethane from leaking out from the seam obtained by stitching the polyurethane sheets into a bag shape, a polyurethane film seal was applied to the seam. However, such a method is costly.
  • the present inventor has previously proposed to use a polyethylene sheet having a closed cell structure instead of a polyurethane sheet having an open cell structure (see Patent Document 1). Since the polyethylene sheet has a closed cell structure, liquid polyurethane does not enter the polyethylene sheet, and liquid urethane does not leak from the seam.
  • the present inventor considered that after forming a large block-like polyethylene foam, slicing the foam to obtain a plurality of foamed polyethylene sheets and forming a backing layer with the foamed polyethylene sheets was. This is because when the foamed polyethylene sheet is cut out from a large polyethylene foam, the cut surface is moderately roughened, so that it is expected that the bond strength between the foamed polyethylene sheet and the polyurethane used as the pad is increased.
  • the present inventor has found that such a method does not increase the bonding strength between the foam sheet and the polyurethane as the pad.
  • a corona treatment is performed to perform a surface modification treatment to increase the bond strength between the foam sheet and the polyurethane used as the pad.
  • a corona treatment is applied to such a foam sheet, a through-hole is generated in the bulk layer due to the streamer corona generated during the corona treatment. Therefore, when foaming polyurethane as a pad, the foaming gas easily escapes from the polyethylene sheet to the outside, making it difficult to obtain a good foam.
  • the present invention has an object to provide a skin-integrated foam having a good hand feeling, a good foamed state of the pad, and a good bonding strength between the backing layer and the pad, and a method for producing the same.
  • a pad made of foam resin A bag-like outer material integrated with the pad and covering the pad;
  • the outer material has a top layer, and a foamed resin liner layer integrated with the surface layer.
  • the backing layer made of the foamed resin has a closed cell structure,
  • the backing layer made of the foamed resin is provided with a pad-side skin layer having a higher density than the bulk layer on the pad side,
  • a skin-integrated foam product is provided in which the skin layer is subjected to corona treatment.
  • a method for producing a foam integrated with a skin comprising a foamed resin pad and a bag-like outer material integrated with the pad and covering the pad, Forming a sheet-like backing layer in which a skin layer having a higher density than the bulk layer is formed on the front surface and the back surface with a foamed resin having a closed cell structure; Applying corona treatment to the skin layer located on the back surface; Binding the surface layer to the surface of the backing layer to obtain the outer material; Processing the outer material into a bag shape so that the backing layer is on the inside; There is provided a method for producing a skin-integrated foamed product, in which a liquid foamed resin raw material is injected into the bag-shaped outer material and the foamed resin raw material is foam-cured to obtain the pad.
  • a skin-integrated foam having a good hand feeling, a good foamed state of the pad, and a good bonding strength between the backing layer and the pad, and a method for producing the same.
  • the headrest 10 (an example of an integrated skin foam product) of the present embodiment includes a headrest body 10 ⁇ / b> H and a gate-shaped stay 12.
  • the top of the stay 12 is embedded in the headrest body 10H.
  • the leg 12A of the stay 12 protrudes from the bottom of the headrest body 10H.
  • the leg portion 12 ⁇ / b> A of the stay 12 can be fixed to the upper portion of the vehicle seat 90.
  • the headrest body 10H has a urethane foam pad 15 and an outer member 20.
  • the outer material 20 is provided outside the pad 15.
  • the outer material 20 is integrated with the pad 15.
  • the outer material 20 has a bag shape that covers the pad 15.
  • the top of the stay 12 is embedded in the pad 15.
  • the outer material 20 has a surface layer 21 and a lining layer 22.
  • the lining layer 22 is integrated with the surface layer 21 via an adhesive layer 23.
  • the backing layer 22 is bonded to the pad 15.
  • the surface layer 21 is formed of, for example, a fabric sheet, a synthetic leather sheet, a genuine leather sheet, or the like.
  • the backing layer 22 is formed of a foamed sheet 25 made of foamed polyethylene having a closed cell structure. The expansion ratio of the foam sheet 25 is preferably 10 to 50 times.
  • the adhesive layer 23 can be formed by, for example, an adhesive or hot melt.
  • the backing layer 22 is integrally provided with a bulk layer 26, a pad side skin layer 27a, and a front side skin layer 27b.
  • the bulk layer 26 is provided between the pad side skin layer 27a and the front side skin layer 27b.
  • the pad-side skin layer 27a is provided on the surface of the bulk layer 26 on the pad 15 side.
  • the front skin layer 27 b is provided on the surface layer 21 side of the bulk layer 26.
  • the pad-side skin layer 27a and the front-side skin layer 27b may be referred to as the skin layer 27 when called without distinction.
  • the skin layer 27 is a layer having a higher density than the bulk layer 26.
  • the skin layer 27 is formed by a film in which bubbles smaller than the closed cells formed in the bulk layer 26 are collected or formed as a resin during foam molding of the foam sheet 25.
  • the closed cell structure means a structure in which the bubbles in the foamed resin are not continuous with the adjacent bubbles.
  • the pad-side skin layer 27a is subjected to corona treatment, and the wettability of the outermost surface 28a on the pad 15 side is set to 45 [dyn / cm] or more. Preferably, the wettability is 60 [dyn / cm] or more.
  • the pad side skin layer 27a is coupled to the pad 15 at the outermost surface 28a.
  • the outermost surface 28a of the pad side skin layer 27a is directly bonded to the urethane resin of the pad 15 without using an adhesive or the like.
  • the front skin layer 27b is also subjected to corona treatment, and the wettability of the outermost surface 28b on the surface layer 21 side is 45 [dyn / cm] or more.
  • the front skin layer 27b is bonded to the surface layer 21 at the outermost surface 28b.
  • the outermost surface 28b of the front side skin layer 27b is bonded to the surface layer 21 via the adhesive layer 23 as described above.
  • the foam sheet 25 can be continuously formed by, for example, extrusion molding.
  • the foamed sheet 25 is formed by foaming and curing the polyethylene resin raw material, the front and back surfaces of the foamed sheet 25 in contact with the mold and the roller are cooled by the resin on the mold surface and solidified in a fine bubble state, The polyethylene resin foam raw material is cured into a film.
  • the skin layer 27 can be formed on the front surface and the back surface of the foam sheet 25.
  • the skin layer 27 having a thickness of 50 ⁇ m to 500 ⁇ m can be formed when the thickness of the foam sheet 25 is 1.5 mm to 3 mm.
  • the foam sheet 25 becomes the backing layer 22 in a later step.
  • the skin layer formed on the surface of the foamed sheet 25 becomes the front side skin layer 27b. Therefore, the skin layer formed on the surface is referred to as the front side skin layer 27b.
  • the skin layer formed on the back surface of the foam sheet 25 becomes the pad-side skin layer 27a. Therefore, the skin layer formed on the back surface is referred to as the pad-side skin layer 27a.
  • the foam sheet 25 is subjected to corona treatment so that the wettability of the pad-side skin layer 27a and the front-side skin layer 27b is 45 [dyn / cm] or more.
  • the appearance changes little even if corona treatment is performed the outermost surfaces of the skin layers 27a and 27b that have been subjected to corona treatment and improved wettability are shown in FIG. 3B as 28a and 28b. As shown.
  • Corona treatment is a kind of surface modification treatment.
  • a streamer corona is generated between the two electrodes via the foam sheet 25.
  • the high-energy electrons generated thereby cut the main chain and side chain of the polymer bond of the foam sheet 25 to generate a polar functional group.
  • the wettability can be evaluated by a test method defined in JIS K6768.
  • the wettability of the surface of general foamed polyethylene not subjected to corona treatment is about 36 [dyn / cm]. Further, the wettability of the surface of general foamed polypropylene not subjected to corona treatment is also about 36 [dyn / cm].
  • the wettability can be increased to an arbitrary value by adjusting the corona treatment time, the voltage applied between the electrodes, and the like.
  • the outer material 20 is obtained by bonding the surface layer 21 to the surface side skin layer 27b of the foam sheet 25 using an adhesive, hot melt, or the like.
  • the foam sheet 25 becomes the backing layer 22. Since the front-side skin layer 27 b with improved wettability is formed on the surface of the foam sheet 25, the adhesive and the molten resin are well bonded to the foam sheet 25. For this reason, the bonding strength between the backing layer 22 and the adhesive layer 23 is increased, and the outer material 20 in which the backing layer 22 and the surface layer 21 are bonded with high strength is obtained.
  • the outer material 20 is processed into a bag shape so that the backing layer 22 is inside.
  • the outer material 20 may be cut into a plurality of small pieces 20H as necessary, and the small pieces 20H may be sewn into a bag shape (see FIG. 1B). More specifically, it is first sewn in a bag shape so that the lining layer 22 is on the outside. At this time, a part of the joint is left as an opening 20A without sewing together. Next, when the bag is turned upside down using the opening 20A, the outer member 20 positioned inside the seam can be obtained. In addition, if this opening 20A is formed so as to be disposed in a portion covering the lower surface of the pad 15 (see FIG. 1B), the appearance design of the headrest 10 is not impaired.
  • the outer material 20 and the stay 12 are set in the mold 30 (see FIG. 4).
  • the outer material 20 is disposed so that the opening 20A faces upward.
  • the stay 12 is arranged so that the leg portion 12A faces upward, and the top portion is positioned inside the bag-shaped outer member 20.
  • the mold 30 a known mold used for skin integral foam molding can be used.
  • the mold 30 includes a movable mold 32 that can rotate with respect to the fixed mold 31. Cover molds 33 and 34 are rotatably provided on the fixed mold 31 and the movable mold 32.
  • the nozzle 36 is caused to enter the outer material 20 from the opening 20A, and the foamed urethane raw material 35 is injected from the nozzle 36 (see FIG. 4).
  • the foamed urethane raw material 35 is foam-cured in the outer material 20 to form the pad 15 (see FIG. 5). Since the wettability of the outermost surface 28 a of the pad side skin layer 27 a of the outer material 20 is enhanced, the pad 15 adheres well to the backing layer 22. At this time, since the through hole due to the influence of the corona treatment is not opened in the backing layer 22, the foaming gas hardly passes through the backing layer 22, and the pad 15 can be foamed well. When the molded product is removed from the mold 30, the headrest 10 in which the outer material 20 is integrated with the pad 15 is obtained.
  • the backing layer 22 has a closed cell structure, and the pad-side skin layer 27a is provided on the pad side. Further, the pad-side skin layer 27 a has a higher density than the bulk layer 26. Since the skin layer prevents the formation of through holes in the bulk layer that occurs during the corona treatment, gas or liquid is unlikely to pass through the pad-side skin layer 27a.
  • the pad-side skin layer 27a provided on the pad side has a high density in this way, the liquid foamed resin material penetrates into the pad-side skin layer 27a and further into the bulk layer 26 located inside the pad-side skin layer 27a. It is difficult to expect an anchor effect. For this reason, there was a concern that the bonding strength between the pad 15 and the backing layer 22 would decrease. Further, as described above, since the surface of the pad-side skin layer 27a is smooth, the anchor effect does not occur, and there is a concern that the bonding strength between the pad 15 and the backing layer 22 is lowered.
  • a foam sheet having no skin layer is obtained.
  • a through-hole is formed in the bulk layer due to the streamer corona generated during the corona treatment. Then, it becomes easy for liquid and gas to pass through the skin layer.
  • the foamed sheet 25 can be used in a subsequent process without being cut in the thickness direction after the foamed sheet 25 is continuously formed, thereby reducing the manufacturing cost of the headrest 10. It's easy to do.
  • the backing layer 22 has a higher density than the bulk layer 26, and the front skin layer 27b having a wettability of 45 [dyn / cm] or more by corona treatment. It may be provided integrally on the surface on the surface layer 21 side.
  • the corona treatment may be performed so that the wettability of the skin layer (front skin layer 27b) located on the surface is 45 [dyn / cm] or more.
  • the front-side skin layer 27b can also prevent the formation of through holes during corona treatment on the front side and make it difficult for gas and liquid to pass through the backing layer 22.
  • the liquid foamed resin raw material used as the pad 15 is inject
  • the foamed resin raw material to be the pad 15 is foam-cured inside the outer material 20, the gas is less likely to escape to the outside, and it is easy to obtain a pad 15 in a better foamed state.
  • the wettability of the pad-side skin layer 27a may be 60 [dyn] or more. The wettability is further increased, and the bonding strength between the backing layer 22 and the pad 15 is more likely to be increased.
  • FIGS. 6A and 6B in the headrest 10 ⁇ / b> V of the present embodiment, the point that the surface layer 21 and the lining layer 22 are bonded with the urethane slab 24 is the first embodiment described above. And different.
  • the other structure of the headrest 10V since it is the same as that of the headrest 10 of the said 1st Embodiment, description is abbreviate
  • a method for manufacturing the headrest 10V will be described.
  • a sheet-like foam sheet 25 in which a skin layer 27 having a higher density than the bulk layer 26 is formed on the front surface and the back surface is formed of a foamed resin having a closed cell structure.
  • corona treatment is applied to the foam sheet 25 so that the wettability of the skin layers on the front and back surfaces is 45 [dyn / cm].
  • the outermost surfaces of the corona-treated skin layers 27a and 27b are indicated by 28a and 28b in FIGS. 6B, 7B, and 7C.
  • the urethane slab 24 is sandwiched between the surface layer 21 and the foamed sheet 25 by a frame lamination method (flame lamination method), and is integrally bonded to form the outer material 120H (see FIG. 7C).
  • a frame lamination method flame lamination method
  • the surface of the urethane slab 24 is fired to melt its surface, and the melted portion is solidified in a state of being pressed against the surface of the surface layer 21 and the foamed sheet 25, and the urethane slab 24 and the surface layer 21 or This is a method of integrating with the backing layer 22.
  • the wettability of the front side skin layer 27b of the lining layer 22 is high, the bondability between the surface layer 21 and the lining layer 22 can be enhanced.
  • the foamed sheet 25 thus obtained is processed into a bag shape to obtain the outer material 20.
  • the headrest 10V is obtained by injecting the foamed urethane raw material 35 into the bag-shaped interior and foaming and curing the foamed urethane raw material 35 (see FIGS. 4 and 5 of the first embodiment). Also according to the present embodiment, the same effects as those of the first embodiment can be obtained.
  • the skin layer 27 is formed on both the front surface and the back surface of the foam sheet 25 has been described.
  • the skin layer 27 may be formed at least on the back surface of the foam sheet 25. If the pad-side skin layer 27a is formed on the back surface of the foam sheet 25, the pad-side skin layer 27a is subjected to corona treatment to increase the bonding strength with the pad 15, and the gas and liquid are not easily passed. A foamed pad can be obtained.
  • the foamed resin that forms the backing layer and the foamed resin that forms the pad may be the same, but the foamed resin that forms the pad is composed of an open-celled resin, and the foamed resin that forms the backing layer is composed of a closed-celled resin. It is preferable to do. In general, it may be difficult to obtain good bond strength between different resins. However, according to the skin-integrated foamed product of the present embodiment, because the wettability of the pad side skin layer is high, even if the foamed resin forming the backing layer and the foamed resin forming the pad are different resins, good bond strength Is obtained.
  • the foam sheet 25 was comprised with the foamed polyethylene, as long as it was comprised with the foamed resin of the closed cell structure, you may be comprised with olefin type foamed resins, such as a foamed polypropylene, for example.
  • the “skin-integrated foam” of the present invention is the headrest 10, 10V, but may be an armrest, a seat cushion, a seat back, or the like.
  • the outer material 120H is formed by the frame laminating method.
  • the outer material 120H may be formed by adhesion such as an adhesive or hot melt.
  • Sample No. 11 Corona treatment was performed on both sides of a polyethylene foam sheet having a density of 33 [kg / m 3 ] and having a skin layer on both sides. The corona treatment was performed under the conditions of a discharge amount of 0.8 kW and a feed speed of 5 m / min. An outer material having the foamed sheet as a backing layer was prepared, a foamed resin raw material serving as a pad was injected into the bag-shaped outer material, and the foamed resin raw material was foamed and cured. Eleven headrests were produced. The outer layer of the outer material is a fabric (polyester fabric). This sample No. The pad foaming state of 11 headrests was evaluated.
  • Sample No. 12 Corona treatment under the same conditions as Sample 1 was performed on the pad side of a polyethylene foam sheet having a density of 33 [kg / m 3 ] and having a skin layer only on the pad side.
  • Sample No. 12 In the same manner as in No. 11, an outer material having this foamed sheet as a backing layer was produced, and a foamed resin material serving as a pad was injected into the bag-shaped outer material. Twelve headrests were produced. The outer layer of the outer material is a fabric (polyester fabric). This sample No. The foaming state of the pad was evaluated for 12 headrests.
  • Sample No. 13 Sample No. 2 was formed on both sides of a polyethylene foam sheet having a density of 33 [kg / m 3 ] and no skin layer. Corona treatment under the same conditions as in No. 11 was performed. Sample No. In the same manner as in No. 11, an outer material having this foamed sheet as a backing layer was produced, and a foamed resin material serving as a pad was injected into the bag-shaped outer material. Thirteen headrests were produced. The outer layer of the outer material is a fabric (polyester fabric). This sample No. The foaming state of the pad was evaluated for 13 headrests.
  • Sample No. 21 is Sample No. 11 is the same headrest.
  • the surface tension on the pad side surface of the outer material was 45 [dyn / cm].
  • the pad and the outer material were not easily peeled off. Further, when the peeled surface is observed, the interface between the pad and the outer material is partially broken, but there is also a portion where the pad is broken because the bond strength of the interface is high and the interface is not broken. confirmed. In this way, sample no. It was confirmed that the 21 headrests had a bonding strength that could withstand practical use.
  • Sample No. 22 An outer material is formed by corona treatment on both sides of a polyethylene foam sheet having a density of 32 [kg / m 3 ] and having a skin layer on both sides. 22 headrests were produced. The corona treatment was performed under the conditions of a discharge amount of 0.8 kW and a feed speed of 5 m / min. The surface tension on the pad side surface of the outer material was 48 [dyn / cm]. As a result of the peeling test, the outer material was not peeled off from the pad with the applied peeling force. It was confirmed that the 22 headrests had a bonding strength that could withstand practical use. When the peeling force was further increased, the pad portion was almost destroyed and the outer material was peeled off. In other words, since the bonding strength at the interface between the pad and the outer material is high, the interface is hardly broken, and the pad is almost broken.
  • Sample No. 23 An outer material is formed by corona treatment on both sides of a polyethylene foam sheet having a density of 42 [kg / m 3 ] and having a skin layer on both sides. 23 headrests were produced. The corona treatment was performed under the conditions of a discharge amount of 0.8 kW and a feed speed of 5 m / min. The surface tension of the outer material pad side surface was 65 [dyn / cm]. As a result of the peeling test, the outer material was not peeled off from the pad with the applied peeling force. It was confirmed that 23 headrests had a bonding strength that could withstand practical use. When the peeling force was further increased, only the pad portion was destroyed and the outer material was peeled off. That is, since the bonding strength at the interface between the pad and the outer material is high, the interface does not break, and only the pad breaks.
  • Sample No. 24 An outer material was formed on a polyethylene foam sheet having a density of 33 [kg / m 3 ] and having a skin layer on both sides without being subjected to corona treatment. 24 headrests were produced. The surface tension of the outer material pad side surface was 36 [dyn / cm]. As a result of the peel test, the outer material backing layer was easily peeled off from the pad. It was confirmed that the 24 headrests had a bonding strength that could not withstand practical use. When the peeled surface was observed, it was confirmed that the interface between the pad and the backing layer of the outer material was broken, and the interface was broken because the bonding strength at the interface was low. This is presumably because the surface tension was insufficient because the corona treatment was not applied to the pad side skin layer, and the bonding strength was lowered.

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Abstract

パッド（１５）と、パッド（１５）を覆う袋状のアウタ材（２０）とを有する表皮一体発泡品が提供される。アウタ材（２０）は、表地層（２１）と、発泡樹脂製の裏地層（２２）とを有する。裏地層（２２）は独立気泡構造である。裏地層（２２）には、バルク層（２６）より高密度なパッド側スキン層（２７ａ）がパッド（１５）側に設けられている。パッド側スキン層（２７ａ）にはコロナ処理が施されている。

Description

表皮一体発泡品及びその製造方法
　本発明は、表皮一体発泡品及びその製造方法に関する。
　表地層と、ポリウレタンシートの裏地層とを有する袋状のアウタ材に、液状のポリウレタンをいれてポリウレタンを発泡させてパッドを形成し、ヘッドレストなどの表皮一体発泡体を得ることが知られている。しかし、このような製造方法では、ポリウレタンシートは連続気泡構造なので、液状のポリウレタンがポリウレタンシートに浸透してしまうことがあった。液状のポリウレタンの一部がポリウレタンシートの内部で固化してしまい、アウタ材の内部に複数の樹脂の小片が形成されてしまうと、手触り感を損ねてしまう。
　そこで、ポリウレタンシートの内側にポリウレタンフィルムを貼り付けて液状ポリウレタンのポリウレタンシートへの浸入を阻止していた。さらに、ポリウレタンシートを袋状に縫い合わせた縫い目から液状のポリウレタンが漏れ出てしまうことを防ぐために、縫い目にポリウレタンフィルムのシールを貼り付けていた。しかし、このような方法はコストが嵩んでしまう。
日本国特開２００２－２１０２７１号公報
　そこで、連続気泡構造のポリウレタンシートのかわりに、独立気泡構造のポリエチレンシートを用いることを本発明者は先に提案している（特許文献１参照）。ポリエチレンシートは独立気泡構造なのでポリエチレンシートの内部に液状ポリウレタンが進入せず、また、縫い目からの液体ウレタンの漏れだしが生じにくい。
　当初、本発明者は、大きなブロック状のポリエチレンの発泡体を形成した後に、この発泡体をスライスして複数枚の発泡ポリエチレンシートを得て、この発泡ポリエチレンシートで裏地層を形成することを検討していた。大きなポリエチレンの発泡体から発泡ポリエチレンシートを切り出す際に、その切断面が適度に荒らされるので、発泡ポリエチレンシートとパッドとなるポリウレタンとの結合強度が高まることが期待されるためである。しかし、本発明者は鋭意研究の結果、このような方法によっては、発泡シートとパッドとなるポリウレタンとの結合強度が高まらないことを見出した。
　さらに、コロナ処理を施して表面改質処理をし、発泡シートとパッドとなるポリウレタンとの結合強度を増すことが考えられる。しかし、このような発泡シートにコロナ処理を施してしまうと、コロナ処理中に生じるストリーマコロナによりバルク層に貫通孔が生じてしまう。そのため、パッドとなるポリウレタンを発泡させる際にその発泡ガスがポリエチレンシートから外部に抜け出しやすく、良好な発泡体を得ることが難しかった。
　そこで本発明は、良好な手触り感を有し、かつ、パッドの発泡状態が良好で、かつ、裏地層とパッドとの結合強度が良好な表皮一体発泡体およびその製造方法を提供することを目的とする。
　本発明の一側面によれば、
　発泡樹脂製のパッドと、
　前記パッドと一体化されており前記パッドを覆う袋状のアウタ材(outer material)とを有し、
　前記アウタ材は、表地層(top layer)と、前記表地層と一体化された発泡樹脂製の裏地層（liner layer）とを有し、
　前記発泡樹脂製の前記裏地層は独立気泡構造であり、
　前記発泡樹脂製の前記裏地層にはバルク層より高密度なパッド側スキン層（pad-side skin layer）が前記パッド側に設けられており、
　前記スキン層にはコロナ処理が施されている、表皮一体発泡品が提供される。
　また、本発明の一側面によれば、
　発泡樹脂製のパッドと、前記パッドと一体化されており前記パッドを覆う袋状のアウタ材とを有する表皮一体発泡品の製造方法であって、
　表面と裏面とにバルク層より高密度のスキン層が形成されたシート状の裏地層を、独立気泡構造の発泡樹脂で形成する工程と、
　前記裏面に位置する前記スキン層にコロナ処理を施す工程と、
　前記裏地層の前記表面に表地層を結合させて前記アウタ材を得る工程と、
　前記裏地層が内側となるように前記アウタ材を袋状に加工する工程と、
　袋状の前記アウタ材の内部に液状の発泡樹脂原料を注入し、前記発泡樹脂原料を発泡硬化させて前記パッドを得る工程と、をこの順に行う表皮一体発泡品の製造方法が提供される。
　本発明によれば、良好な手触り感を有し、かつ、パッドの発泡状態が良好で、かつ、裏地層とパッドとの結合強度が良好な表皮一体発泡体およびその製造方法が提供される。
本発明の第１実施形態に係るヘッドレストの斜視図である。 本発明の第１実施形態に係るヘッドレストの断面図である。 ヘッドレストの部分断面図である。 発泡シートの断面図である。 コロナ処理後の発泡シートの断面図である。 アウタ材の断面図である。 発泡ウレタン原料をアウタ材の内部に注入しているときの金型の内部を示す断面図である。 発泡ウレタン原料が発泡硬化した後の金型の内部を示す断面図である。 第２実施形態に係るヘッドレストの断面図である。 第２実施形態に係るヘッドレストの部分断面図である。 ヘッドレストの製造工程を示す図である。 ヘッドレストの製造工程を示す図である。 ヘッドレストの製造工程を示す図である。
　［第１実施形態］
　以下、本発明を車両用シートのヘッドレストに適用した第１実施形態を図１Ａ～図５に基づいて説明する。
　図１Ａに示すように、本実施形態のヘッドレスト１０（表皮一体発泡品の一例）は、ヘッドレスト本体１０Ｈと門型のステー１２とを備えている。ヘッドレスト本体１０Ｈの内部にステー１２の頂部が埋め込まれている。ステー１２の脚部１２Ａは、ヘッドレスト本体１０Ｈの底部から突出されている。ステー１２の脚部１２Ａは、車両用シート９０の上部に固定可能とされている。
　図１Ｂに示すように、ヘッドレスト本体１０Ｈは、発泡ウレタン製のパッド１５と、アウタ材２０とを有している。アウタ材２０は、パッド１５の外側に設けられている。アウタ材２０はパッド１５と一体化されている。アウタ材２０はパッド１５を覆う袋状とされている。ステー１２の頂部はパッド１５内に埋設されている。
　図２に示すように、アウタ材２０は、表地層２１と裏地層２２とを有している。裏地層２２は、表地層２１に接着層２３を介して一体化されている。裏地層２２はパッド１５と結合されている。表地層２１は、例えば、ファブリックシート、合成皮革シート、本革シート等で形成される。裏地層２２は、独立気泡構造の発泡ポリエチレン製の発泡シート２５で形成されている。発泡シート２５の発泡倍率は、１０倍～５０倍が好ましい。接着層２３は、例えば接着剤やホットメルトで形成することができる。
　裏地層２２はバルク層２６と、パッド側スキン層２７ａと、表側スキン層２７ｂとを一体的に備えている。バルク層２６はパッド側スキン層２７ａと表側スキン層２７ｂとの間に設けられている。パッド側スキン層２７ａは、バルク層２６のパッド１５側の表面に設けられている。表側スキン層２７ｂは、バルク層２６の表地層２１側に設けられている。以降の説明において、パッド側スキン層２７ａと表側スキン層２７ｂとを区別せずに呼ぶ場合に、スキン層２７と表記する場合がある。
　スキン層２７は、バルク層２６よりも密度の高い層である。スキン層２７は、バルク層２６に形成されている独立気泡よりも小さい気泡が集まっていたり、発泡シート２５の発泡成形時に樹脂化した皮膜によって形成されている。なお、独立気泡構造とは、発泡樹脂中の気泡が隣接する気泡と連続していない構造を意味する。
　パッド側スキン層２７ａにはコロナ処理が施されており、そのパッド１５側の最表面２８ａの濡れ性が４５［ｄｙｎ／ｃｍ］以上とされている。好ましくは、濡れ性が６０［ｄｙｎ／ｃｍ］以上とされている。
　パッド側スキン層２７ａは、その最表面２８ａでパッド１５と結合されている。パッド側スキン層２７ａの最表面２８ａは、接着剤などを介さずに、パッド１５のウレタン樹脂と直接結合されている。
　表側スキン層２７ｂにもコロナ処理が施されており、その表地層２１側の最表面２８ｂの濡れ性が４５［ｄｙｎ／ｃｍ］以上とされている。表側スキン層２７ｂは、その最表面２８ｂで表地層２１に接着されている。表側スキン層２７ｂの最表面２８ｂは、上述したように接着層２３を介して表地層２１と接着されている。
　次に、ヘッドレスト１０の製造方法について図３Ａから図５を用いて説明する。
　まず、図３Ａに示すように、表面と裏面とにバルク層２６より高密度のスキン層２７が形成されたシート状の発泡シート２５を、独立気泡構造の発泡ポリエチレンで形成する。発泡シート２５は、例えば押し出し成形などで連続的に形成することができる。
　ポリエチレン樹脂原料を発泡硬化させて発泡シート２５を形成する際に、金型やローラに接触する発泡シート２５の表面や裏面は金型表面などで樹脂が冷やされて微細な気泡状態で固まったり、ポリエチレン樹脂発泡原料が皮膜状に硬化する。このようにして発泡シート２５の表面と裏面とにスキン層２７を形成することができる。このようにスキン層２７を形成する場合には、発泡シート２５の厚みが１．５ｍｍ～３ｍｍである場合に、５０μｍ～５００μｍの厚みのスキン層２７を形成することができる。
　なお、発泡シート２５は後の工程で裏地層２２となる。後の工程で、発泡シート２５の表面に形成されたスキン層は表側スキン層２７ｂとなるため、表面に形成されたスキン層を表側スキン層２７ｂと呼ぶ。後の工程で、発泡シート２５の裏面に形成されたスキン層はパッド側スキン層２７ａとなるため、裏面に形成されたスキン層をパッド側スキン層２７ａと呼ぶ。
　次に、パッド側スキン層２７ａおよび表側スキン層２７ｂの濡れ性が４５［ｄｙｎ／ｃｍ］以上となるように発泡シート２５にコロナ処理を施す。なお、コロナ処理を施しても外観の変化は少ないが、図３Ｂにおいては理解を容易にするためにコロナ処理が施されて濡れ性が改善されたスキン層２７ａ，２７ｂの最表面を２８ａ，２８ｂとして示している。
　コロナ処理自体は公知の技術を用いることができる。コロナ処理とは、表面改質処理の一種である。例えば、発泡シート２５を２つの板状の電極の間に配置し、電極間に高電圧を印加すると、発泡シート２５を介して２つの電極間にストリーマコロナが生じる。これにより生じた高エネルギーの電子が発泡シート２５の高分子結合の主鎖や側鎖を切断し、極性官能基を生成させる。これにより、発泡シート２５の面が活性化されて濡れ性が高まる。なお、濡れ性は、ＪＩＳ　Ｋ６７６８に定められる試験方法にて評価することができる。
　例えば、コロナ処理をしていない一般的な発泡ポリエチレンの表面の濡れ性は、約３６［ｄｙｎ／ｃｍ］である。また、コロナ処理をしていない一般的な発泡ポリプロピレンの表面の濡れ性も約３６［ｄｙｎ／ｃｍ］である。コロナ処理する時間、電極間に印加する電圧などを調整することにより、濡れ性を任意の値まで高めることができる。
　次いで、図３Ｃに示すように、接着剤やホットメルト等を用いて発泡シート２５の表側スキン層２７ｂに表地層２１を結合させてアウタ材２０を得る。この工程により発泡シート２５は裏地層２２となる。発泡シート２５の表面に濡れ性が高められた表側スキン層２７ｂが形成されているため、接着剤や溶融した樹脂が発泡シート２５に良好に結合する。このため、裏地層２２と接着層２３との結合強度が高められ、裏地層２２と表地層２１とが高い強度で結合されたアウタ材２０が得られる。
　次いで、裏地層２２が内側となるようにアウタ材２０を袋状に加工する。なお、袋状に加工する前に、必要に応じてアウタ材２０を複数枚の小片２０Ｈに切り出して、小片２０Ｈを袋状に縫製してもよい（図１Ｂ参照）。
　より詳しくは、初めに裏地層２２が外側となるように袋状に縫製しておく。このときには、つなぎ目の一部は互いに縫い合わせずに開口２０Ａとしておく。次に、この開口２０Ａを使って袋を裏返すと、縫い目を内側に位置されたアウタ材２０を得ることができる。なお、この開口２０Ａは、パッド１５（図１Ｂ参照）の下面を覆う部分に配置するように形成するとヘッドレスト１０の外観意匠性を損ねない。
　次に、アウタ材２０とステー１２を金型３０（図４参照）にセットする。アウタ材２０は、開口２０Ａが上側を向くように配置する。ステー１２は、脚部１２Ａが上側を向くように配置し、頂部を袋状のアウタ材２０の内部に位置させる。金型３０は、表皮一体発泡成形に用いられる公知の金型を用いることができる。例えば金型３０は、固定型３１に対して回動可能な可動型３２を有する。固定型３１と可動型３２の上部に、蓋型３３，３４が回動可能に設けられている。
　次いで、開口２０Ａからアウタ材２０内にノズル３６を進入させ、ノズル３６から発泡ウレタン原料３５を注入する（図４参照）。
　次いで、発泡ウレタン原料３５をアウタ材２０内で発泡硬化させ、パッド１５を形成する（図５参照）。アウタ材２０のパッド側スキン層２７ａの最表面２８ａの濡れ性が高められているため、パッド１５は裏地層２２に良好に付着する。このとき、裏地層２２には、コロナ処理の影響による貫通孔がバルク層に開いていないので、発泡ガスが裏地層２２を通過しにくく、パッド１５を良好に発泡させることができる。そして、金型３０から成形品を脱型すると、アウタ材２０がパッド１５と一体となったヘッドレスト１０が得られる。
　ここで、発泡ウレタン原料３５が発泡硬化したパッド１５は、発泡密度が０．０２５ｇ／ｃｍ３～０．１００ｇ／ｃｍ３に成形されている。発泡密度が０．０２５ｇ／ｃｍ３より小さいとクッション性が損なわれ、荷重をかけてその後にその荷重を取り除いたときのパッド１５の戻りが悪くなる。また、発泡密度が０．１００ｇ／ｃｍ３より大きくなるとパッド１５が重くなってしまう。
　次に、本実施形態のヘッドレスト１０及びその製造方法の作用効果について説明する。
　本実施形態のヘッドレスト１０（表皮一体発泡品の一例）およびその製造方法によれば、裏地層２２が独立気泡構造で、パッド側にパッド側スキン層２７ａが設けられている。また、パッド側スキン層２７ａはバルク層２６に比べて密度が高くされている。そして、このスキン層によりコロナ処理時に起こるバルク層における貫通孔の形成が防がれているので、ガスや液体がパッド側スキン層２７ａを通過しにくい。このため、パッド１５となる液状の発泡樹脂原料を袋状のアウタ材２０に注入した際に、液状の発泡樹脂原料がパッド側スキン層２７ａを介してバルク層２６や表地層２１に漏れ出しにくい。これにより、良好な手触り感を有する表皮一体発泡品が得られやすい。また、液状の発泡樹脂原料を発泡硬化させてパッド１５を形成する際に、発泡ガスがパッド側スキン層２７ａを介してバルク層２６や表地層２１に漏れ出しにくい。これにより、良好な発泡状態のパッド１５が得られる。
　なお、このようにパッド側に設けられたパッド側スキン層２７ａが高密度であると、液状の発泡樹脂原料がパッド側スキン層２７ａの内部やさらにその内方に位置するバルク層２６に浸透しにくくアンカー効果が期待できない。このため、パッド１５と裏地層２２との結合強度が低下することが懸念された。また、上述したようにパッド側スキン層２７ａの表面は滑らかなので、やはりアンカー効果が生じず、パッド１５と裏地層２２との結合強度が低下することが懸念された。
　しかし、コロナ処理によってパッド側スキン層２７ａの濡れ性を高めることができるとともに、コロナ処理による貫通孔の形成を防いで、パッド１５と裏地層２２との良好な結合強度が得られることを本発明者は実験的に見出した。これにより、パッド１５とアウタ材２０との良好な結合強度も確保される。
　通常、厚みをもつブロック状の発泡材を得てから、これを厚さ方向に複数枚にスライスすると、スキン層を持たない発泡シートが得られる。このような発泡シートにコロナ処理を施してしまうと、コロナ処理中に生じるストリーマコロナによりバルク層に貫通孔が生じてしまう。すると、液体やガスがスキン層を通過しやすくなってしまう。
　また、本実施形態に係る製造方法によれば、連続的に発泡シート２５を形成した後にそれを厚さ方向で切断することなく後の工程で用いることができるため、ヘッドレスト１０の製造コストを低減しやすい。
　また、上述した実施形態の表皮一体発泡品において、裏地層２２は、バルク層２６より高密度であり、かつ、コロナ処理により濡れ性が４５［ｄｙｎ／ｃｍ］以上とされた表側スキン層２７ｂを表地層２１側の面に一体的に備えていてもよい。
　また、上述した実施形態の表皮一体発泡品の製造方法において、裏地層２２となる発泡シート２５を形成する工程より後で発泡シート２５を表地層２１に結合させてアウタ材２０を得る工程より前に、表面に位置するスキン層（表側スキン層２７ｂ）の濡れ性が４５［ｄｙｎ／ｃｍ］以上となるようにコロナ処理を施してもよい。
　パッド側スキン層２７ａに加えて表側スキン層２７ｂによっても、表側のコロナ処理時の貫通孔の形成を防ぎ、ガスや液体が裏地層２２を通過することを難しくすることができる。これにより、パッド１５となる液体の発泡樹脂原料をアウタ材２０の内部に注入した際に、発泡樹脂原料が表地層２１へ浸入することを確実に防止できる。また、パッド１５となる発泡樹脂原料をアウタ材２０の内部で発泡硬化する際にガスが外部により逃げにくくなり、さらに良好な発泡状態のパッド１５を得られやすい。
　また、上述した実施形態の表皮一体発泡品において、パッド側スキン層２７ａの濡れ性が６０［ｄｙｎ］以上とされていてもよい。より濡れ性が高まり、裏地層２２とパッド１５との結合強度がより高まりやすい。
　［第２実施形態］
　以下、本発明の第２実施形態を図６～図７に基づいて説明する。本実施形態は、上記第１実施形態を変形したものであり、アウタ材における表地層の構造が上記第１実施形態と異なっている。具体的には、図６Ａ及び図６Ｂに示すように、本実施形態のヘッドレスト１０Ｖでは、表地層２１と裏地層２２とがウレタンスラブ２４で貼り合されている点が、上述した第一実施形態と異なる。ヘッドレスト１０Ｖのその他の構成については、上記第１実施形態のヘッドレスト１０と同様になっているので、同一符号を付すことで説明を省略する。
　次に、ヘッドレスト１０Ｖの製造方法について説明する。
　まず、上記第１実施形態と同様に、表面と裏面とにバルク層２６より高密度のスキン層２７が形成されたシート状の発泡シート２５を、独立気泡構造の発泡樹脂で形成する。
　次に、表面と裏面のスキン層の濡れ性が４５［ｄｙｎ／ｃｍ］となるように、発泡シート２５にコロナ処理を施す。図６Ｂおよび図７Ｂ、図７Ｃにコロナ処理されたスキン層２７ａ，２７ｂの最表面を２８ａ，２８ｂで示した。
　次いで、フレームラミネート法（flame laminate method）により、ウレタンスラブ２４を表地層２１と発泡シート２５で挟んで一体結合し、アウタ材１２０Ｈを形成する（図７Ｃ参照）。フレームラミネート法とは、ウレタンスラブ２４を火であぶってその表面を溶融させ、溶融した部分を表地層２１と発泡シート２５の表面に押し付けた状態で固化させて、ウレタンスラブ２４と表地層２１や裏地層２２と一体化させる方法である。このとき、裏地層２２の表側スキン層２７ｂの濡れ性が高いので、表地層２１と裏地層２２との結合性を高めることができる。
　このようにして得られた発泡シート２５を袋状に加工してアウタ材２０を得る。袋状の内部に発泡ウレタン原料３５を注入し、その発泡ウレタン原料３５を発泡硬化させることで、ヘッドレスト１０Ｖが得られる（上記第１実施形態の図４及び図５を参照）。
　本実施形態によっても、上記第１実施形態と同様の効果を奏することが可能となる。
　［他の実施形態］
　本発明は、上記実施形態に限定されるものではなく、例えば、以下に説明するような実施形態も本発明の技術的範囲に含まれ、さらに、下記以外にも要旨を逸脱しない範囲内で種々変更して実施することができる。
　なお、上述した説明では発泡シート２５の表面と裏面の両方にスキン層２７を形成する例を説明したが、少なくとも発泡シート２５の裏面にスキン層２７を形成すればよい。発泡シート２５の裏面にパッド側スキン層２７ａが形成されていれば、パッド側スキン層２７ａにコロナ処理を行ってパッド１５との結合強度を高めながら、ガスや液体を通過させにくくして良好な発泡状態のパッドを得ることができる。
　裏地層をなす発泡樹脂とパッドをなす発泡樹脂は同一であってもよいが、パッドをなす発泡樹脂は連続気泡構造の樹脂で構成し、裏地層をなす発泡樹脂は独立気泡構造の樹脂で構造することが好ましい。一般的には、異なる樹脂間では良好な結合強度を得ることが難しいことがある。しかし、本実施形態の表皮一体発泡品によれば、パッド側スキン層の濡れ性が高いため、裏地層をなす発泡樹脂とパッドをなす発泡樹脂とが異なる樹脂であっても、良好な結合強度が得られる。
　上記実施形態では、発泡シート２５が発泡ポリエチレンで構成されていたが、独立気泡構造の発泡樹脂で構成されていれば、例えば、発泡ポリプロピレン等のオレフィン系の発泡樹脂で構成されていてもよい。
　上記実施形態では、本発明の「表皮一体発泡品」がヘッドレスト１０，１０Ｖであったが、例えば、アームレスト、シートクッション、シートバック等であってもよい。
　上記第２実施形態では、アウタ材１２０Ｈの形成は、フレームラミネート法により行われていたが、接着剤やホットメルト等の接着により行われてもよい。
［実施例］
　試料Ｎｏ．１１～１３のヘッドレストを作製し、スキン層の有無によるパッドの発泡状態を評価した。その結果を表１に示す。
　試料Ｎｏ．１１：
　密度が３３［ｋｇ／ｍ３］で両面にスキン層を有するポリエチレン製の発泡シートの両面にコロナ処理を施した。コロナ処理は、放電量０．８ｋＷ、送りスピード５ｍ／ｍｉｎという条件で行った。この発泡シートを裏地層とするアウタ材を作製し、袋状のアウタ材の内部にパッドとなる発泡樹脂原料を注入し、該発泡樹脂原料を発泡硬化させて試料Ｎｏ．１１のヘッドレストを作製した。アウタ材の表地層はファブリック（ポリエステルの織物生地）である。この試料Ｎｏ．１１のヘッドレストについてパッドの発泡状態を評価した。
　試料Ｎｏ．１２：
　密度が３３［ｋｇ／ｍ３］でパッド側にのみスキン層を有するポリエチレン製の発泡シートのパッド側に試料１と同条件のコロナ処理を行った。試料Ｎｏ．１１と同様に、この発泡シートを裏地層とするアウタ材を作製し、袋状のアウタ材の内部にパッドとなる発泡樹脂原料を注入し、該発泡樹脂原料を発泡硬化させて試料Ｎｏ．１２のヘッドレストを作製した。アウタ材の表地層はファブリック（ポリエステルの織物生地）である。この試料Ｎｏ．１２のヘッドレストについてパッドの発泡状態を評価した。
　試料Ｎｏ．１３：
　密度が３３［ｋｇ／ｍ３］でスキン層の無いポリエチレン製の発泡シートの両面に試料Ｎｏ．１１と同条件のコロナ処理を行った。試料Ｎｏ．１１と同様に、この発泡シートを裏地層とするアウタ材を作製し、袋状のアウタ材の内部にパッドとなる発泡樹脂原料を注入し、該発泡樹脂原料を発泡硬化させて試料Ｎｏ．１３のヘッドレストを作製した。アウタ材の表地層はファブリック（ポリエステルの織物生地）である。この試料Ｎｏ．１３のヘッドレストについてパッドの発泡状態を評価した。
　得られた結果を表１に示す。
　試料Ｎｏ．１１，１２ともにパッドの発泡状態は良好であった。また、発泡原料などの漏れや表地層への染み出しも確認されなかった。
　試料Ｎｏ．１３は、パッドの発泡状態が不良であった。発泡原料の表地層への染み出しが見られた。また、発泡原料の表地層への染み出しによりアウタ材が部分的に硬化してしまった。
　以上の結果より、少なくともパッド側スキン層がアウタ材に設けられていれば良好な発泡状態のパッドが得られることが確認できた。
Figure JPOXMLDOC01-appb-T000001
　次に、試料Ｎｏ．２１～２４のヘッドレストを作製し、所定の大きさの力をかけてパッドからアウタ材を剥がしてアウタ材とパッドとの接合強度を評価した。その結果を表２に示す。
試料Ｎｏ．２１：
　試料Ｎｏ．２１は、試料Ｎｏ．１１と同じヘッドレストである。アウタ材のパッド側の表面の表面張力は４５［ｄｙｎ／ｃｍ］であった。
　剥離試験の結果、パッドとアウタ材は簡単には剥離しなかった。また、剥離した面を観察すると、パッドとアウタ材との界面が部分的に破壊されたものの、該界面の接合強度が高いために該界面の破壊が生じずにパッドで破壊が生じた部位も確認された。このように、試料Ｎｏ．２１のヘッドレストは実用に耐える接合強度を有することが確認された。
試料Ｎｏ．２２：
　密度が３２［ｋｇ／ｍ３］で両面にスキン層を有するポリエチレン製の発泡シートの両面にコロナ処理を施してアウタ材を形成し、得られたアウタ材を用いて試料Ｎｏ．２２のヘッドレストを作製した。コロナ処理は、放電量０．８ｋＷ、送りスピード５ｍ／ｍｉｎという条件で行った。アウタ材のパッド側の表面の表面張力は、４８［ｄｙｎ／ｃｍ］であった。
　剥離試験の結果、付与した剥離力ではアウタ材がパッドから剥がれず、試料Ｎｏ．２２のヘッドレストは実用に耐える接合強度を有することが確認された。なお、剥離力を更に大きくしたところ、ほぼパッド部分が破壊されてアウタ材が剥がれた。つまり、パッドとアウタ材との界面の接合強度が高いために該界面の破壊が生じにくく、ほぼパッドで破壊が生じていた。
試料Ｎｏ．２３：
　密度が４２［ｋｇ／ｍ３］で両面にスキン層を有するポリエチレン製の発泡シートの両面にコロナ処理を施してアウタ材を形成し、得られたアウタ材を用いて試料Ｎｏ．２３のヘッドレストを作製した。コロナ処理は、放電量０．８ｋＷ、送りスピード５ｍ／ｍｉｎという条件で行った。アウタ材のパッド側の表面の表面張力は、６５［ｄｙｎ／ｃｍ］であった。
　剥離試験の結果、付与した剥離力ではアウタ材がパッドから剥がれず、試料Ｎｏ．２３のヘッドレストは実用に耐える接合強度を有することが確認された。なお、剥離力を更に大きくしたところ、パッド部分のみが破壊されてアウタ材が剥がれた。つまり、パッドとアウタ材との界面の接合強度が高いために該界面の破壊が生じず、パッドのみに破壊が生じていた。
試料Ｎｏ．２４：
　密度が３３［ｋｇ／ｍ３］で両面にスキン層を有するポリエチレン製の発泡シートにコロナ処理を施さずにアウタ材を形成し、得られたアウタ材を用いて試料Ｎｏ．２４のヘッドレストを作製した。アウタ材のパッド側の表面の表面張力は、３６［ｄｙｎ／ｃｍ］であった。
　剥離試験の結果、アウタ材の裏地層がパッドから簡単に剥がれてしまい、試料Ｎｏ．２４のヘッドレストは実用に耐えない接合強度であることが確認された。剥離した面を観察すると、パッドとアウタ材の裏地層との界面が破壊されており、該界面の接合強度が低いために該界面の破壊が生じていることが確認された。これは、パッド側スキン層にコロナ処理が施されなかったために表面張力が不十分となり、接合強度が低下してしまったものと考えられる。
　以上の結果より、パッド側スキン層の表面張力が４５［ｄｙｎ／ｃｍ］以上となるようにコロナ処理が施されていれば、十分な接合強度が得られることが確認できた。また、パッド側スキン層の表面張力が６０［ｄｙｎ／ｃｍ］以上となるようにコロナ処理が施されていれば、より好ましい接合強度が得られることが確認できた。
Figure JPOXMLDOC01-appb-T000002
　１０，１０Ｖ　　ヘッドレスト（表皮一体発泡品）
　１５　　パッド
　２０　　アウタ材
　２１　　表地層
　２２　　裏地層
　２５　　発泡シート
　２７ａ　　パッド側スキン層
　２７ｂ　　表側スキン層
　３５　　発泡ウレタン原料（発泡樹脂）

Claims (8)

  1. 　発泡樹脂製のパッドと、
    　前記パッドと一体化されており前記パッドを覆う袋状のアウタ材とを有し、
    　前記アウタ材は、表地層と、前記表地層と一体化された発泡樹脂製の裏地層とを有し、
    　前記発泡樹脂製の前記裏地層は独立気泡構造であり、
    　前記発泡樹脂製の前記裏地層にはバルク層より高密度のパッド側スキン層が前記パッド側に設けられており、
    　前記パッド側スキン層にはコロナ処理が施されている、表皮一体発泡品。
  2. 　前記パッド側スキン層は、コロナ処理により濡れ性が４５［ｄｙｎ／ｃｍ］以上とされ、前記裏地層の前記パッド側の面に一体的に設けられている、請求項１に記載の表皮一体発泡品。
  3. 　前記裏地層は、前記バルク層より高密度であり、かつ、コロナ処理により濡れ性が４５［ｄｙｎ／ｃｍ］以上とされた表側スキン層を前記表地層側の面に一体的に備えている、請求項１または２に記載の表皮一体発泡品。
  4. 　前記パッド側スキン層および前記表側スキン層の濡れ性が６０［ｄｙｎ／ｃｍ］以上とされている、請求項１～３のいずれか一項に記載の表皮一体発泡品。
  5. 　発泡樹脂製のパッドと、前記パッドと一体化されており前記パッドを覆う袋状のアウタ材とを有する表皮一体発泡品の製造方法であって、
    　表面と裏面とにバルク層より高密度のスキン層が形成されたシート状の裏地層を、独立気泡構造の発泡樹脂で形成する工程と、
    　前記裏面に位置する前記スキン層にコロナ処理を施す工程と、
    　前記裏地層の前記表面に表地層を結合させて前記アウタ材を得る工程と、
    　前記裏地層が内側となるように前記アウタ材を袋状に加工する工程と、
    　袋状の前記アウタ材の内部に液状の発泡樹脂原料を注入し、前記発泡樹脂原料を発泡硬化させて前記パッドを得る工程と、をこの順に行う表皮一体発泡品の製造方法。
  6. 　前記コロナ処理は、前記裏面に位置する前記スキン層の濡れ性が４５［ｄｙｎ／ｃｍ］以上となるように施す、請求項５に記載の表皮一体発泡品の製造方法。
  7. 　前記裏地層を形成する工程より後で前記アウタ材を得る工程より前に、前記表面に位置する前記スキン層の濡れ性が４５［ｄｙｎ／ｃｍ］以上となるようにコロナ処理を施す工程を有する、請求項６に記載の表皮一体発泡品の製造方法。
  8. 　前記裏面および表面に位置する前記スキン層の濡れ性が６０［ｄｙｎ／ｃｍ］以上となるようにコロナ処理が施される、請求項７に記載の表皮一体発泡品の製造方法。
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