WO2018105535A1

WO2018105535A1 - Laminate and manufacturing method thereof

Info

Publication number: WO2018105535A1
Application number: PCT/JP2017/043370
Authority: WO
Inventors: 崇倫藤原
Original assignee: 日本ゼオン株式会社
Priority date: 2016-12-07
Filing date: 2017-12-01
Publication date: 2018-06-14
Also published as: JPWO2018105535A1; JP6984611B2

Abstract

The purpose of the present invention is to provide a laminate in which components of a foamed polyurethane layer are suppressed from leaking out on the surface of a thermoplastic resin layer even if the thermoplastic resin layer is sewn. This laminate comprises a thermoplastic resin layer, a backing member comprising a nonwoven fabric, and a foamed polyurethane layer, wherein the thermoplastic resin layer is the outermost surface layer, and the thermoplastic resin layer and the backing member are sewn together into a single body.

Description

Laminated body and method for producing the same

The present invention relates to a laminate having a thermoplastic resin layer, a backing member made of a nonwoven fabric and a foamed polyurethane layer, and a method for producing the laminate.

A laminate formed by lining a polyurethane layer foam on a skin made of a thermoplastic resin layer is widely used as an automobile interior material used for automobile interior parts such as an automobile instrument panel and a door trim. And in order to improve the designability and commerciality, the stitch pattern by sewing may be given to the skin of such a laminated body.

Here, when a polyurethane layer foam is lined on a thermoplastic resin layer having a stitch pattern formed by sewing, there is a problem that components of the polyurethane layer leak onto the skin made of the thermoplastic resin layer through the seam.

To solve such a problem, for example, in Patent Document 1, when sewing a thermoplastic resin material, a sewing portion previously set at a predetermined interval on the thermoplastic resin material is melted with a heating device, Sewing along the sewing point. And in patent document 1, a sewing thread and a thermoplastic resin material are integrated by spraying a refrigerant | coolant on the sewing location of a thermoplastic resin material, or conveying a thermoplastic resin material to a cooling device and hardening a sewing location. And prevents leakage of resin.
Moreover, in patent document 2, after a thread | yarn is sewed on a skin material, a sealing tape is affixed along a seam from a back side, an adhesive is applied and dried, and a bridge | crosslinking hardening process is performed, or a seam from a back side. The foaming agent and the like are prevented from leaking from the seam of the yarn by a method such as heating and melting the resin-based yarn to close the joint.
Furthermore, in patent document 3, the raw material of a foaming polyurethane layer, etc. are prevented from entering from the hole of a sewing part by laminating | stacking a tape on the sewing part of an outer skin.

Japanese Patent Laid-Open No. 2014-19060 Japanese Patent Laid-Open No. 3-1938 International Publication No. 2016/147737

However, the conventional methods described in Patent Documents 1 and 2 in which the heat treatment and the cross-linking curing treatment are performed are inferior in workability. Also, as a result of repeated studies by the present inventors, in the conventional methods described in Patent Documents 2 to 3 in which tape is applied from the back of the sewn skin, foaming is performed on the surface of the sewn thermoplastic resin layer. The components of the polyurethane layer may leak out, leaving room for further improvement.

Then, even if the thermoplastic resin layer is sewed, this invention aims at providing the laminated body by which the component of the foaming polyurethane layer was suppressed on the surface of the said thermoplastic resin layer.
In addition, the present invention provides a laminate that can satisfactorily suppress leakage of the components of the polyurethane foam layer on the surface of the thermoplastic resin layer by a simple method even when the thermoplastic resin layer is sewn. It aims to provide a method.

The present inventor has intensively studied for the purpose of solving the above problems. And if this inventor sews a thermoplastic resin layer integrally with the backing member which consists of a nonwoven fabric which backed the said thermoplastic resin layer, when the foaming polyurethane is lined, the surface of the thermoplastic resin layer sewn The present inventors have found that a laminate in which the components of the foamed polyurethane layer hardly leak out can be obtained, and the present invention has been completed.

That is, the present invention aims to advantageously solve the above-mentioned problems, and the laminate of the present invention is a laminate having a thermoplastic resin layer, a backing member composed of a nonwoven fabric, and a foamed polyurethane layer. The thermoplastic resin layer is the outermost surface layer, and the thermoplastic resin layer and the backing member are integrally sewn. If the thermoplastic resin layer and the backing member made of non-woven fabric are sewn together, the foamed polyurethane layer component is formed on the surface of the thermoplastic resin layer, even in a laminate in which the thermoplastic resin layer is sewn. Can be suppressed satisfactorily.

Here, in the laminate of the present invention, the backing member preferably contains a polyester resin. This is because if the backing member made of a nonwoven fabric contains a polyester-based resin, a laminate in which the backing member and the polyurethane foam layer are in good contact can be obtained. In addition, if the backing member made of a nonwoven fabric contains a polyester-based resin, in the laminate in which the thermoplastic resin layer is sewn, the foamed polyurethane layer component leaks onto the surface of the thermoplastic resin layer. It is because it can suppress more.

In the laminate of the present invention, the backing member preferably has a mass (unit weight) per unit area of 50 g / m ² or more. If the basis weight of the backing member made of non-woven fabric is equal to or more than the above lower limit, the foamed polyurethane layer component leaks onto the surface of the thermoplastic resin layer even in a laminate in which the thermoplastic resin layer is sewn. This is because this can be further suppressed.

Further, the laminate of the present invention is preferably used for automobile interior parts. This is because, when the laminate of the present invention is used for the production of automobile interior parts such as automobile instrument panels and door trims, automobile interior parts excellent in design and merchantability can be obtained.

In the laminate of the present invention, the thermoplastic resin layer is preferably a vinyl chloride resin layer. This is because, if the thermoplastic resin layer is a vinyl chloride resin layer, the laminate of the present invention can be more suitably used when, for example, automobile interior parts such as automobile instrument panels and door trims are manufactured. .

Moreover, this invention aims at solving the said subject advantageously, and the manufacturing method of the laminated body of this invention is a laminated body which has a backing member which consists of a thermoplastic resin, a nonwoven fabric, and a polyurethane foam layer. A method of integrally sewing the thermoplastic resin layer and the backing member to obtain a thermoplastic resin layer with a backing member, and a backing member side of the thermoplastic resin layer with the backing member And a step of backing the foamed polyurethane layer to obtain a laminate. Thus, first, if the thermoplastic resin layer and the backing member made of nonwoven fabric are integrally sewn, and then the foamed polyurethane layer is lined, the foamed polyurethane layer is formed on the surface of the thermoplastic resin layer by a simple method. It is possible to satisfactorily suppress the leakage of components.

ADVANTAGE OF THE INVENTION According to this invention, even if the thermoplastic resin layer is sewn, the laminated body by which the component of the foaming polyurethane layer was suppressed from leaking on the surface of the said thermoplastic resin layer can be provided.
In addition, according to the present invention, even if the thermoplastic resin layer is sewn, a laminate that can satisfactorily suppress the leakage of the component of the polyurethane foam layer on the surface of the thermoplastic resin layer by a simple method. The manufacturing method of can be provided.

FIG. 1 is a plan view of a laminate according to the present invention. FIG. 2 is a bottom view of a thermoplastic resin layer with a backing member used in the production method of the present invention. FIG. 3 is a partially enlarged cross-sectional view at a sewing location of the laminate according to the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In addition, what attached | subjected the same symbol in each figure shall show the same component. Further, the present invention is not limited to the embodiments shown below.

(Laminate)
The laminate of the present invention is a laminate having a thermoplastic resin layer, a backing member made of nonwoven fabric and a foamed polyurethane layer, the thermoplastic resin layer being the outermost surface layer, and the thermoplastic resin layer and backing The member needs to be integrally sewn. If the thermoplastic resin layer and the backing member are not integrally sewn, it is not possible to sufficiently prevent the components of the foamed polyurethane layer from leaking onto the surface of the sewn thermoplastic resin layer. And in the laminated body of this invention, the component of a foaming polyurethane layer is prevented from leaking out on the said surface, by sewing the surface of a thermoplastic resin layer by employ | adopting the said structure. Therefore, the laminated body of the present invention is used for, for example, automobile interior parts, particularly automobile interior parts for producing automobile interior parts such as automobile instrument panels and door trims which have been stitched to improve design and merchandise. It can be suitably used as a member.

<Thermoplastic resin layer>
The thermoplastic resin layer is the outermost surface layer in the laminate of the present invention, and needs to be integrally sewn with the backing member. And a thermoplastic resin layer can be used conveniently as a skin of automotive interior parts, such as a vehicle instrument panel and a door trim, for example.

The thermoplastic resin layer usually contains a thermoplastic resin, and may further contain a plasticizer and an additive. Among these, from the viewpoint of imparting good flexibility to the thermoplastic resin layer, the thermoplastic resin layer preferably uses a thermoplastic resin and a plasticizer in combination.
In the present invention, the thermoplastic resin layer is usually a thermoplastic resin molded sheet having a sheet-like structure, preferably a non-foamed thermoplastic resin molded sheet. Here, in this specification, the “sheet-like structure” is a structure formed into a sheet shape that does not have a special processing structure such as a woven structure and a non-woven structure described later.

<< Thermoplastic resin >>
Here, the thermoplastic resin is not particularly limited, and is not limited to acrylic resin, silicone resin, fluorine resin, vinyl chloride resin, polyvinylidene chloride, polyethylene, polypropylene, ethylene-propylene copolymer, polyvinyl acetate, ethylene- Vinyl acetate copolymer, polyvinyl alcohol, polyacetal, polystyrene, polyurethane, polyacrylonitrile, styrene-acrylonitrile copolymer, acrylonitrile-butadiene copolymer (nitrile rubber), acrylonitrile-butadiene-styrene copolymer (ABS resin), styrene Butadiene block copolymer or hydrogenated product thereof, styrene-isoprene block copolymer or hydrogenated product thereof, polyphenylene ether, modified polyphenylene ether, aliphatic polyamides, Aromatic polyamides, polyamide-imide, polycarbonate, polyphenylene sulfide, polysulfone, polyether sulfone, polyether nitrile, polyether ketone, polyketone, liquid crystal polymers, ionomers, and the like. These may be used individually by 1 type and may use 2 or more types together.

[Vinyl chloride resin]
Among the above-mentioned, a vinyl chloride resin is preferable as the thermoplastic resin. In general, since vinyl chloride resin is excellent in processability, if the thermoplastic resin layer includes vinyl chloride resin, for example, a thermoplastic resin layer that can be suitably used as the skin of automobile interior parts having excellent decorativeness can be easily obtained. Because.

[Content ratio]
The content rate of the thermoplastic resin contained in the thermoplastic resin layer is not particularly limited, and can be, for example, 30% by mass or more and 70% by mass or less.

<< Plasticizer >>
The plasticizer that can be contained in the thermoplastic resin layer is not particularly limited, and is not limited to phthalic acid, trimellitic acid, pyromellitic acid, adipic acid, azelaic acid, sebacic acid, maleic acid. And fumaric acid-based, citric acid-based, itaconic acid-based, oleic acid-based, ricinoleic acid-based, stearic acid-based, phosphoric acid-based, glycol-based, glycerin-based, and epoxy-based plasticizers. Among them, the plasticizer is preferably a trimellitic acid type such as trimellitic acid ester or a pyromellitic acid type such as pyromellitic acid ester, and trimellitic acid trialkyl ester (here, trimellitic acid trialkyl ester). The number of carbon atoms of the alkyl group of the ester may be the same or different in one molecule. If a trimellitic acid-based and pyromellitic acid-based plasticizer is used, the flexibility and workability of the thermoplastic resin composition that can be used for forming the thermoplastic resin layer and the thermoplastic resin layer can be further enhanced. Therefore, for example, a thermoplastic resin layer that can be suitably used as the skin of automobile interior parts having excellent decorativeness can be obtained more favorably.

[Content ratio]
Here, the content ratio of the plasticizer that can be included in the thermoplastic resin layer is not particularly limited, and can be, for example, 30% by mass or more and 70% by mass or less.

<< Additives >>
Additives that the thermoplastic resin layer may further contain are not particularly limited, and include, for example, surface modifiers such as silicone oil; additives similar to the components described in Patent Document 3; Can be used.

<< Formation Method >>
And a thermoplastic resin layer can be formed by shape | molding the thermoplastic resin composition containing the component mentioned above by arbitrary methods, Preferably powder molding, More preferably, powder slush molding.

Here, the said thermoplastic resin composition may mix and prepare the component mentioned above by arbitrary methods, and may use a commercial item.
The mixing method is not particularly limited, and examples thereof include a method in which components other than the dusting agent are mixed by dry blending, and then the dusting agent is added and mixed. Here, it is preferable to use a Henschel mixer for the dry blending. Moreover, the temperature at the time of dry blending is not specifically limited, 50 degreeC or more is preferable, 70 degreeC or more is more preferable, and 200 degreeC or less is preferable.

For example, in powder slush molding, the following method can be used without any particular limitation. That is, the thermoplastic resin composition is sprinkled on a mold heated to an arbitrary temperature range, left for 5 seconds or more and 30 seconds or less, and then the excess thermoplastic resin composition is shaken off. Leave for 30 seconds to 3 minutes. Thereafter, the mold is cooled to 10 ° C. or more and 60 ° C. or less, and the obtained thermoplastic resin layer is removed from the mold. The demolded thermoplastic resin layer is obtained, for example, as a sheet-like molded body shaped like a mold and a pattern.
Here, the mold temperature to be heated at the time of molding is not particularly limited and is preferably 200 ° C. or higher, more preferably 220 ° C. or higher, and preferably 300 ° C. or lower, and 280 ° C. or lower. More preferably.

<Backing member>
The backing member of the laminate of the present invention is composed of only a non-woven fabric, and is usually disposed on the back side of the thermoplastic resin layer in the laminate of the present invention. Therefore, in the laminate of the present invention, the thermoplastic resin layer and the backing member are sewn in direct contact with no adhesive or the like interposed between the thermoplastic resin layer and the backing member. Further, the backing member needs to be integrally sewn with the above-described thermoplastic resin layer in the laminate of the present invention. When the thermoplastic resin layer and the backing member made of non-woven fabric are integrally sewn, the backing member has a component of the polyurethane foam layer leaking out on the surface of the thermoplastic resin layer in the laminate of the present invention. Play a role to prevent.

<< Nonwoven fabric >>
The nonwoven fabric constituting the backing member may consist of only a single nonwoven fabric, or may be a laminate of a plurality of nonwoven structures.
Here, in the present invention, the “nonwoven fabric” has a non-woven structure formed by bonding fibers with an arbitrary directionality or in a random direction.

[Fiber composition]
Here, the fiber constituting the nonwoven fabric is not particularly limited as long as it is a fiber that can form the above-described nonwoven structure, and includes a fiber including a polyamide-based resin, a fiber including a polyaramid-based resin, and a polyester-based resin. Organic fibers such as fiber, cellulose, cotton, hemp, wool and silk; inorganic fibers such as glass fiber, carbon fiber, alumina fiber, tungsten fiber, molybdenum fiber, titanium fiber, steel fiber, boron fiber, silicon carbide fiber and silica fiber And the like. Moreover, 1 type, or 2 or more types of fibers may be used for the fiber which comprises a nonwoven fabric. Among the above, as a fiber which comprises a nonwoven fabric, an organic fiber is preferable, the fiber containing polyester-type resin is more preferable, and the fiber which consists only of polyester-type resin is still more preferable. In general, a polyester resin which is a polycondensate of a polyvalent carboxylic acid and a polyalcohol has a polar group. Therefore, if the backing member contains a polyester-based resin because the nonwoven fabric is made of a fiber containing a polyester-based resin, in the laminate, both the nonwoven fabric and the above-described thermoplastic resin layer, and the nonwoven fabric and the foamed polyurethane layer described later are provided. It is because it can adhere | attach well and can suppress delamination favorably.
Furthermore, the polyester-type resin suitably mentioned as a composition of the fiber which comprises a nonwoven fabric is a polyethylene terephthalate, a polytrimethylene terephthalate, a polybutylene terephthalate, a polyethylene naphthalate, a polybutylene naphthalate, for example.

<< Weight weight >>
Further, the mass per unit area (weight per unit area) of the backing member is preferably 25 g / m ² or more, more preferably 35 g / m ² or more, and further preferably 50 g / m ² or more. Preferably, it is more preferably 55 g / m ² or more, still more preferably 60 g / m ² or more, particularly preferably 80 g / m ² or more, and preferably 300 g / m ² or less. More preferably, it is 200 g / m ² or less. In the backing member having a basis weight of not less than the above lower limit, the fibers of the nonwoven fabric constituting the backing member are more closely coupled. Therefore, if the weight per unit area of the backing member is equal to or more than the above lower limit, the component of the polyurethane foam layer in contact with the backing member is less likely to penetrate into the backing member. In addition, if the basis weight of the backing member is equal to or greater than the above lower limit, the backing member is formed in the sewing hole in the thermoplastic resin layer when the thermoplastic resin layer and the backing member made of nonwoven fabric are integrally sewn. This is because the non-woven fabric fibers are more likely to enter, and the foamed polyurethane layer components can be further prevented from leaking onto the surface of the thermoplastic resin layer. Further, if the basis weight of the backing member is equal to or less than the above upper limit, the workability of the sewing process can be maintained well and the cost can be reduced.

<< Thickness >>
Further, the thickness of the backing member is preferably 0.18 mm or more, more preferably 0.22 mm or more, further preferably 0.25 mm or more, and further preferably 0.29 mm or more. Preferably, it is more preferably 0.30 mm or more, particularly preferably 0.35 mm or more, preferably 5 mm or less, more preferably 3 mm or less, still more preferably 1 mm or less. . This is because if the thickness of the backing member is equal to or more than the above lower limit, it is possible to further prevent components of the foamed polyurethane layer from leaking onto the surface of the thermoplastic resin layer. Moreover, if the thickness of the backing member is less than or equal to the above upper limit, the workability of the sewing process can be further improved and the cost can be further reduced.

<< Tear Strength >>
Further, the tear strength of the backing member is preferably 7N or more, more preferably 11N or more, further preferably 14N or more, still more preferably 18N or more, and 28N or more. Is particularly preferable, and 60 N or less is preferable. If the tear strength of the backing member is greater than or equal to the above lower limit, the backing member has sufficient physical strength against the stitching hole, so that the thermoplastic resin layer does not damage the nonwoven fabric constituting the backing member. This is because the backing member made of nonwoven fabric and the nonwoven fabric can be sewn together better. Further, if the tear strength of the backing member is not more than the above upper limit, the workability of the sewing process can be further improved.
In the present invention, “tear strength” can be measured according to JIS L 1913: 2010.

<< Formation Method >>
The backing member is, for example, a dry method in which relatively short fibers are thinly formed; a wet method in which short fibers are further mixed with water and then sprinkled like paper; A method of bonding and spreading thin fibers together (spun bond method); a method of making fibers finer in a higher temperature environment than the above spun bond method (melt blow method); and the above spun bond method and melt blow method It can form by obtaining a nonwoven fabric by the combination of these.
Here, the bonds between the fibers are, for example, (a) chemical bonding (chemical bond or resin bond) with a resin as an adhesive, (b) fusion by heating (thermal bond), (c) with a hooked needle. Perform mechanical entanglement (needle punch), (d) entanglement by jetting high-pressure water flow (water entanglement or span lace), (e) stitching fibers spread in the surface (stitch bond), etc. Can do.

<Foamed polyurethane layer>
The foamed polyurethane layer of the laminate of the present invention is a foamed molded product made of polyurethane, and is usually laminated on the backing member side described above and plays a role of backing the thermoplastic resin layer described above.
Here, the polyurethane foam layer is not particularly limited, and can be obtained, for example, according to a method for forming a laminate described later.

For example, when the foamed polyurethane layer is lined with a relatively high density of 0.2 g / cm ³ or more, the strength of the laminate can be improved, but when the foamed polyurethane layer is lined, the thermoplastic resin layer There exists a possibility that the component of a foaming polyurethane layer may leak on the surface easily. However, in the laminate of the present invention, since the thermoplastic resin layer and the predetermined backing member are integrally sewn, even if polyurethane is foamed at a relatively high density, the component of the foamed polyurethane layer is that of the thermoplastic resin layer. Leakage on the surface can be well suppressed.

<Method for forming laminate>
The method for laminating the laminate is not particularly limited. For example, as shown in FIGS. 1 to 3, the following method can be used.
That is, first, the backing member 4 made of the above-mentioned nonwoven fabric is laminated (backed) from the back surface of the portion where the thermoplastic resin layer 2 is subjected to the sewing process. Next, the thermoplastic resin layer 11 with the backing member is obtained by integrally sewing the thermoplastic resin layer 2 and the backing member 4 using an arbitrary sewing method. At this time, although the thermoplastic resin layer 2 and the backing member 4 are in close contact with each other through the sewn thread, the gap between the thermoplastic resin layer 2 and the backing member 4 where the thread does not pass is usually a gap. Can occur. Subsequently, on the backing member 4 side of the thermoplastic resin layer 11 with the backing member, polymerization is performed by reacting isocyanates, which are raw materials of the polyurethane foam, with polyols and the like, and foaming of the polyurethane by a known method. By performing, the foaming polyurethane layer 5 is directly formed on the back surface (backing member 4 side) of the thermoplastic resin layer 11 with the backing member. Thus, the laminated body 1 which has the thermoplastic resin layer 2, the backing member 4 which consists of a nonwoven fabric, and the foaming polyurethane layer 5 is formed. Usually, the thermoplastic resin layer 2 becomes the skin 2.
The formation of the polyurethane foam layer 5 may be performed by an open type that opens to the atmosphere or by a closed type in a sealed space.

Here, in the case where the gap is generated between the thermoplastic resin layer and the backing member, polyurethane may enter between the thermoplastic resin layer and the backing member when forming the foamed polyurethane layer. However, in the present invention, since the thermoplastic resin layer and the backing member made of nonwoven fabric are integrally sewn, it is possible to satisfactorily suppress the leakage of the foamed polyurethane layer component on the surface of the thermoplastic resin layer. it can.
In addition, when the foamed polyurethane layer is formed in a closed type, or in the case of an open type foaming with a higher density of polyurethane, in general, a relatively high foaming pressure is applied, so the component of the foamed polyurethane layer is thermoplastic. The risk of leaking onto the surface of the resin layer increases. However, since the laminate of the present invention is formed by integrally sewing a thermoplastic resin layer and a backing member made of a nonwoven fabric, the thermoplastic resin can be used even when a polyurethane foam layer is formed in a relatively high pressure environment. It is thought that it can suppress well that the component of a foaming polyurethane layer leaks on the surface of a layer.

<< Sewing method >>
The sewing method is not particularly limited as long as the thermoplastic resin layer and the backing member made of a nonwoven fabric can be integrally stitched in the laminate, but is usually performed prior to the formation of the above-described polyurethane foam layer. As a sewing method, an arbitrary thread may be used to sew in one direction. For example, as shown in FIGS. 1 to 3, an upper thread 31 and a lower thread 32 are used to provide thermoplastic with a backing member. The resin layer 11 may be sewn from both the front and back sides. Sewing may be performed manually (or hand-sewn), but it is preferable to use a sewing machine such as a sewing machine from the viewpoint of easily selecting various sewing methods.
In this specification, when using a sewing machine, the “upper thread” usually refers to a thread that is passed through a sewing needle, and the “lower thread” is usually used by being wound around a bobbin. The thread that forms the seam through the loop made in or hooked on the upper thread.

And, for example, when using a sewing machine, according to JIS B 9003: 1999, it may be a main stitch (upper thread and lower thread are intertwined to form a seam), or a single ring stitch (one sewing) The thread may be intertwined in a chain shape to form a seam). Furthermore, the sewing in the case of using the sewing machine may be other sewing methods such as double chain stitching and pinpoint sewing. Further, stitches may be appropriately selected according to a desired design from linear stitching, zigzag stitching, dotted line stitching, double needle stitching, triple stitching, cycle stitching, satin stitching, blind stitching, scallop stitching, and the like.

Here, from the viewpoint of further preventing the components of the foamed polyurethane layer 5 from leaking onto the surface of the thermoplastic resin layer 2 through the sewing holes generated in the thermoplastic resin layer 2, the integral sewing is illustrated in FIGS. As shown, it is preferable to use an upper thread 31 and a lower thread 32. Further, as shown in FIG. 1, the upper thread 31 appears on the surface of the thermoplastic resin layer 2, and the lower thread 32 does not appear on the surface of the thermoplastic resin layer 2 (as shown in FIG. More preferably, it may appear on the back surface of the thermoplastic resin layer 11 with the backing member). In particular, for example, as shown in FIG. 3, if the upper thread 31 and the lower thread 32 are pulled up and integrally sewn, the fibers of the backing member 4 made of nonwoven fabric are sewn in the thermoplastic resin layer 2 at each seam. This is because the components of the polyurethane foam layer 5 can be further prevented from leaking out from the seams because the seams can be closed by pulling the holes.

[yarn]
The thread used for the integral sewing is not particularly limited as long as the thermoplastic resin layer and the backing member made of a nonwoven fabric can be integrally sewn. For example, a thread obtained by spinning a short fiber such as cotton thread or wool; a raw thread or a synthetic fiber thread And yarn made of long fibers. Among these, a synthetic fiber yarn is preferable, and a yarn made of a polyester resin is more preferable. This is because a yarn made of a polyester resin generally has high durability and versatility, and can integrally sew the thermoplastic resin layer and the backing member better.
Further, the diameter (thickness) of the yarn may be appropriately selected according to the desired design.

[needle]
The needle used for integral sewing may be a general needle such as a sewing needle, but the gap that may occur around the seam in the thermoplastic resin layer by sewing is reduced to further prevent leakage of the foamed polyurethane layer components. From this point of view, the diameter (thickness) of the needle is preferably a size close to the diameter of the yarn.

(Laminate manufacturing method)
The method for producing a laminate of the present invention is a method for producing a laminate comprising a thermoplastic resin, a backing member comprising a nonwoven fabric, and a foamed polyurethane layer, the step of obtaining a thermoplastic resin layer with a backing member, And a step of backing a foamed polyurethane layer on a thermoplastic resin layer with a contact member to obtain a laminate. Moreover, the manufacturing method of the laminated body of this invention prepares the backing member which consists of a thermoplastic resin layer and a nonwoven fabric, for example in addition to the process of obtaining the thermoplastic resin layer with a backing member mentioned above, and the process of obtaining a laminated body. You may have other processes, such as a process, further. And in the manufacturing method of this invention, since the laminated body is manufactured by integrally sewing the thermoplastic resin layer and the backing member made of the nonwoven fabric, for example, when the polyurethane foam layer is lined, it is sewn. It can fully suppress that the component of a foaming polyurethane layer leaks out on the surface of a thermoplastic resin layer. Therefore, the laminate obtained according to the production method of the present invention is used, for example, for automobile interior parts, especially for producing automobile instrument panels and door trims, etc., which have been decorated with stitches to improve design and merchantability. It can be suitably used as an automobile interior member.

<Process for obtaining thermoplastic resin layer with backing member>
A process of obtaining the thermoplastic resin layer with the backing member will be described with reference to FIGS. In the step of obtaining the thermoplastic resin layer with the backing member, the thermoplastic resin layer 2 and the backing member 4 made of a nonwoven fabric are integrally sewn to obtain the thermoplastic resin layer 11 with the backing member. Here, as the backing member 4 made of the thermoplastic resin layer 2 and the nonwoven fabric, the same composition, properties, content ratio, and the like as described above for the laminate can be adopted. Moreover, the sewing method similar to what was mentioned above about the laminated body can also be employ | adopted for the method of integral sewing.
And the obtained thermoplastic resin layer with a backing member is used in the process of obtaining the laminated body explained in full detail behind.

<Step of obtaining a laminate>
In the step of obtaining the laminated body, the foamed polyurethane layer 5 is lined from the backing member 4 side of the thermoplastic resin layer 11 with the backing member obtained in the above step to obtain the laminated body 1. Here, as the formation method of the polyurethane foam layer 5 and the formation method of the laminate 1, the same methods as described above for the laminate can be employed.

<Other processes>
Moreover, the manufacturing method of the laminated body of this invention is the process of preparing the backing member which consists of a process of preparing a thermoplastic resin layer prior to the process of obtaining the thermoplastic resin layer with a backing member mentioned above, for example, etc. The other steps may be further included.

<< Step of preparing a thermoplastic resin layer >>
Here, in the step of preparing the thermoplastic resin layer, for example, a commercially available thermoplastic resin layer may be used, or by using the thermoplastic resin composition in the same formation method as described above for the laminate. A thermoplastic resin layer may be formed.

As an example, as the vinyl chloride resin that the thermoplastic resin composition used for forming the thermoplastic resin layer can contain, for example, one kind or two or more kinds of vinyl chloride resin particles can be contained, and optionally one kind. Alternatively, two or more kinds of vinyl chloride resin fine particles can be further contained. Among these, the vinyl chloride resin preferably contains at least vinyl chloride resin particles, and more preferably contains vinyl chloride resin particles and vinyl chloride resin fine particles. Here, the vinyl chloride resin particles usually function as a base material for the thermoplastic resin layer, and the vinyl chloride resin fine particles function as a dusting agent (powder fluidity improver).
In the present specification, “resin particles” refers to particles having a particle size of 30 μm or more, and “resin particles” refers to particles having a particle size of less than 30 μm.

<< Process for preparing backing member >>
In the step of preparing a backing member made of a nonwoven fabric, a commercially available nonwoven fabric may be used, or the nonwoven fabric may be formed by the same formation method as described above for the laminate.

EXAMPLES Hereinafter, although this invention is demonstrated concretely based on an Example, this invention is not limited to these Examples. In the following description, “%” and “part” representing amounts are based on mass unless otherwise specified.
And the leak rate of the component of the foaming polyurethane layer on the surface of a thermoplastic resin layer was measured with the following method.

<Leakage rate of components of polyurethane foam layer>
The state of the thermoplastic resin layer (skin) in the obtained laminate was visually observed. Specifically, among the total number of stitches S _T = 60 or applied to the surface of the thermoplastic resin layer, was counted the number stitching portion where components of the polyurethane foam layer has leaked S _L (the number). Then, the degree of leakage of the foamed polyurethane layer component onto the surface of the thermoplastic resin layer was calculated according to the leakage rate (%) of the foamed polyurethane layer component = (S _L / S _T ) × 100.

Example 1
<Preparation of thermoplastic resin composition>
Among the blended components of the thermoplastic resin layer shown in Table 1, the components excluding the plasticizer and the dusting agent were placed in a Henschel mixer and mixed. Then, when the temperature of the mixture rises to 80 ° C., all the plasticizer is added, and further heated to dry up (the plasticizer is absorbed by the particulate thermoplastic resin, and the mixture becomes further The state was said.) Thereafter, when the dried-up mixture was cooled to a temperature of 100 ° C. or lower, a dusting agent was added to prepare a vinyl chloride resin composition for powder molding as a thermoplastic resin composition.

<Formation of thermoplastic resin layer>
The thermoplastic resin composition obtained above is sprinkled on a mold with a texture heated to a temperature of 250 ° C., allowed to stand for an arbitrary time of about 8 seconds to 20 seconds and melted, and then an excess thermoplastic resin composition Shaken off. Thereafter, the embossed mold sprinkled with the thermoplastic resin composition was allowed to stand in an oven set at a temperature of 200 ° C., and the embossed mold was cooled with water when 60 seconds had passed since the standing. When the mold temperature was cooled to 40 ° C., a vinyl chloride resin sheet having a size of 150 mm long × 200 mm wide × 1 mm thick as a thermoplastic resin layer was removed from the mold.

<Formation of thermoplastic resin layer with backing member>
As shown in FIG. 2, on the back surface of the thermoplastic resin layer obtained above (the surface not directly touching the mold and not subjected to the texture pattern), a non-woven fabric cut to a width of 25 mm as a backing member ( A thermoplastic resin layer with a backing member was obtained by integrally sewing a thermoplastic resin layer and a backing member made of a non-woven fabric in a state where Toyobo Co., Ltd., product number “3301A”, polyester resin) was stacked. Here, for sewing, a sewing machine (manufactured by JUKI, product number “LU-2860-7”), sewing needle (manufactured by Organ Needle, product number “DPx17S”) and thread (manufactured by Onuki Textile Co., Ltd., trade name “ACE Crown Vehicle” Used, polyester resin, product number: upper thread “# 5”, lower thread “# 8”). In addition, two stitches were applied approximately in parallel at a distance of about 8 mm at an interval of 3 stitches / cm and a speed of 3.3 stitches / second (that is, the total number of stitches = 30). × 2 = 60.) Here, the direction of stitching was aligned in the vertical direction according to the product specifications of the nonwoven fabric.
In addition, the property of the used nonwoven fabric is as follows, and these values are the physical property values of goods according to JIS L 1913: 2010.
Weight per unit area: 30 g / m ²
Thickness: 0.20mm
Tear strength: 8N-9N
Tensile strength: 36N / 5cm to 121N / 5cm
Elongation: 31% to 33%
Dry heat shrinkage: 0.3% to 1.4%

<Formation of laminate>
The thermoplastic resin layer with the backing member obtained above is placed in a mold having a length of 200 mm × width of 300 mm × thickness of 10 mm with the surface of the thermoplastic resin layer (skin surface with a texture pattern) facing down. Laid.
Separately, 50 parts of propylene glycol PO (propylene oxide) / EO (ethylene oxide) block adduct (hydroxyl value 28, content of terminal EO unit = 10%, content of internal EO unit 4%), PO of glycerin -50 parts of EO block adduct (hydroxyl value 21, content of terminal EO unit = 14%), 2.5 parts of water, ethylene glycol solution of triethylenediamine (trade name "TEDA-L33" manufactured by Tosoh Corporation) 0.2 parts, 1.2 parts triethanolamine, 0.5 parts triethylamine, and 0.5 parts foam stabilizer (trade name “F-122” manufactured by Shin-Etsu Chemical Co., Ltd.) A mixture was obtained. Moreover, the liquid mixture which mixed the obtained polyol mixture and polymethylene polyphenylene polyisocyanate (polymeric MDI) in the ratio from which the index becomes 98 was prepared. Then, the prepared mixed liquid was poured from above the backing member side of the thermoplastic resin layer with the backing member laid in the mold as described above. Thereafter, the mold was covered with an aluminum plate of 348 mm × 255 mm × 10 mm, and the mold was sealed. A laminate in which a foamed polyurethane layer (thickness: 9 mm, density: 0.2 g / cm ³ ) is lined on a thermoplastic resin layer with a backing member is formed by leaving the mold sealed for 5 minutes. Formed within.
And the formed laminated body was taken out from the metal mold | die, and the leak rate of the component of the polyurethane foam layer was computed according to the above-mentioned method. The results are shown in Table 1.

(Example 2)
In the formation of the thermoplastic resin layer with the backing member, a thermoplastic resin composition was obtained in the same manner as in Example 1, except that the nonwoven fabric was replaced with another product number (product number “3401A”, polyester resin). A thermoplastic resin layer, a thermoplastic resin layer with a backing member, and a laminate were produced. In addition, the property of the used nonwoven fabric is as follows, and these values are the physical property values of goods according to JIS L 1913: 2010.
Weight per unit area: 40 g / m ²
Thickness: 0.24mm
Tear strength: 12N-13N
Tensile strength: 54N / 5cm to 159N / 5cm
Elongation rate: 26% -34%
Dry heat shrinkage: 0.2% to 1.0%
And it observed and calculated by the same method as Example 1. The results are shown in Table 1.

(Example 3)
In the formation of the thermoplastic resin layer with the backing member, a thermoplastic resin composition was obtained in the same manner as in Example 1, except that the nonwoven fabric was replaced with another product number (product number “3501A”, polyester resin manufactured by Toyobo Co., Ltd.) A thermoplastic resin layer, a thermoplastic resin layer with a backing member, and a laminate were produced. In addition, the property of the used nonwoven fabric is as follows, and these values are the physical property values of goods according to JIS L 1913: 2010.
Weight per unit area: 50 g / m ²
Thickness: 0.27mm
Tear strength: 15N
Tensile strength: 70N / 5cm to 183N / 5cm
Elongation: 25% to 34%
Dry heat shrinkage: 0.3% to 1.0%
And it observed and calculated by the same method as Example 1. The results are shown in Table 1.

Example 4
In the formation of the thermoplastic resin layer with the backing member, a thermoplastic resin composition was obtained in the same manner as in Example 1 except that the nonwoven fabric was replaced with another product number (product number “3601A”, polyester resin). A thermoplastic resin layer, a thermoplastic resin layer with a backing member, and a laminate were produced. In addition, the property of the used nonwoven fabric is as follows, and these values are the physical property values of goods according to JIS L 1913: 2010.
Weight per unit area: 60 g / m ²
Thickness: 0.30mm
Tear strength: 20N
Tensile strength: 90N / 5cm to 223N / 5cm
Elongation rate: 29%-32%
Dry heat shrinkage: 0.2% to 0.8%
And it observed and calculated by the same method as Example 1. The results are shown in Table 1.

(Example 5)
In the formation of the thermoplastic resin layer with the backing member, a thermoplastic resin composition was prepared in the same manner as in Example 1, except that the nonwoven fabric was replaced with another product number (product number “3701A”, polyester resin manufactured by Toyobo Co., Ltd.) A thermoplastic resin layer, a thermoplastic resin layer with a backing member, and a laminate were produced. In addition, the property of the used nonwoven fabric is as follows, and these values are the physical property values of goods according to JIS L 1913: 2010.
Weight per unit area: 70 g / m ²
Thickness: 0.31mm
Tear strength: 23N-24N
Tensile strength: 104N / 5cm to 269N / 5cm
Elongation: 27% to 33%
Dry heat shrinkage: 0.4% to 0.8%
And it observed and calculated by the same method as Example 1. The results are shown in Table 1.

(Example 6)
In the formation of the thermoplastic resin layer with the backing member, a thermoplastic resin composition was obtained in the same manner as in Example 1, except that the nonwoven fabric was replaced with another product number (product number “3A01A”, polyester resin manufactured by Toyobo Co., Ltd.) A thermoplastic resin layer, a thermoplastic resin layer with a backing member, and a laminate were produced. In addition, the property of the used nonwoven fabric is as follows, and these values are the physical property values of goods according to JIS L 1913: 2010.
Weight per unit area: 100 g / m ²
Thickness: 0.39mm
Tear strength: 32N-45N
Tensile strength: 132N / 5cm to 324N / 5cm
Elongation rate: 23% -30%
Dry heat shrinkage: 0.3% to 1.2%
And it observed and calculated by the same method as Example 1. The results are shown in Table 1.

(Comparative Example 1)
In the formation of the thermoplastic resin layer with the backing member, the thermoplastic resin composition and the thermoplastic resin layer were the same as in Example 1 except that the nonwoven fabric was not used (that is, the backing member was not used). And laminates were produced.
And it observed and calculated by the same method as Example 1. The results are shown in Table 1.

1) Product name “ZEST (registered trademark) 2500Z” manufactured by Shin-Daiichi PVC Co., Ltd.
2) Product name “ZEST PQLTX” manufactured by Shin Daiichi PVC Co., Ltd.
3) Product name “Trimex N-08” manufactured by Kao Corporation
4) Product name "Adekasizer O-130S" manufactured by ADEKA
5) Product name “Alkamizer (registered trademark) 5” manufactured by Kyowa Chemical Industry Co., Ltd.
6) Product name “MIZUKALIZER DS” manufactured by Mizusawa Chemical Industry Co., Ltd.
7) Product name “Karenz DK-1” manufactured by Showa Denko KK
8) Product name “SAKAI SZ2000” manufactured by Sakai Chemical Industry Co., Ltd.
9) Product name “DA PX 1720 (A) Black” manufactured by Dainichi Seika Co., Ltd.
10) Product names "Ecule (registered trademark)" manufactured by Toyobo Co., Ltd.

From Table 1, the laminated bodies of Examples 1 to 6 in which the thermoplastic resin layer and the backing member made of nonwoven fabric are integrally sewn do not have the backing member made of nonwoven fabric, and the thermoplastic resin layer and backing material are not provided. It was found that the leakage of the components of the foamed polyurethane layer was remarkably suppressed as compared with the laminate of Comparative Example 1 in which integral sewing with the member was not performed (the thermoplastic resin layer was sewn alone).

DESCRIPTION OF SYMBOLS 1 Laminated body 11 Thermoplastic resin layer with backing member 2 Thermoplastic resin layer (skin)
31 thread (upper thread)
32 thread (lower thread)
4 Backing member made of nonwoven fabric 5 Polyurethane foam layer

Claims

A laminate having a thermoplastic resin layer, a backing member made of a nonwoven fabric and a polyurethane foam layer,
The thermoplastic resin layer is an outermost surface layer, and
A laminate in which the thermoplastic resin layer and the backing member are integrally sewn.
The laminate according to claim 1, wherein the backing member contains a polyester resin.
The laminate according to claim 1 or 2, wherein a mass per unit area of the backing member is 50 g / m 2 or more.
The laminate according to any one of claims 1 to 3, which is used for automobile interior parts.
The laminate according to any one of claims 1 to 4, wherein the thermoplastic resin layer is a vinyl chloride resin layer.
A method for producing a laminate having a thermoplastic resin, a backing member made of a nonwoven fabric and a foamed polyurethane layer,
A step of integrally sewing the thermoplastic resin layer and the backing member to obtain a thermoplastic resin layer with a backing member;
Backing the foamed polyurethane layer from the backing member side of the thermoplastic resin layer with the backing member to obtain a laminate;
The manufacturing method of a laminated body which has these.