WO2021100652A1 - 積層成形体及びその製造方法 - Google Patents

積層成形体及びその製造方法 Download PDF

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Publication number
WO2021100652A1
WO2021100652A1 PCT/JP2020/042599 JP2020042599W WO2021100652A1 WO 2021100652 A1 WO2021100652 A1 WO 2021100652A1 JP 2020042599 W JP2020042599 W JP 2020042599W WO 2021100652 A1 WO2021100652 A1 WO 2021100652A1
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WO
WIPO (PCT)
Prior art keywords
cushion layer
opening
laminated molded
molded product
laminated
Prior art date
Application number
PCT/JP2020/042599
Other languages
English (en)
French (fr)
Inventor
那 賽
秀治 東根
Original Assignee
ミドリオートレザー株式会社
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 ミドリオートレザー株式会社 filed Critical ミドリオートレザー株式会社
Priority to US17/778,191 priority Critical patent/US20220410554A1/en
Priority to JP2021558364A priority patent/JP7248817B2/ja
Priority to EP20890167.8A priority patent/EP4063104A4/en
Priority to CN202080080355.XA priority patent/CN114746252B/zh
Publication of WO2021100652A1 publication Critical patent/WO2021100652A1/ja

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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
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    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/436—Joining sheets for making articles comprising cushioning or padding materials, the weld being performed through the cushioning material, e.g. car seats
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    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
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    • B29C66/7294—Non woven mats, e.g. felt
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/748—Joining plastics material to non-plastics material to natural products or their composites, not provided for in groups B29C66/742 - B29C66/746
    • B29C66/7484—Leather
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/94—Measuring or controlling the joining process by measuring or controlling the time
    • B29C66/949—Measuring or controlling the joining process by measuring or controlling the time characterised by specific time values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2711/00—Use of natural products or their composites, not provided for in groups B29K2601/00 - B29K2709/00, for preformed parts, e.g. for inserts
    • B29K2711/08—Leather
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/58—Upholstery or cushions, e.g. vehicle upholstery or interior padding
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/771—Seats
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207—Heat-activated adhesive
    • B32B2037/1215—Hot-melt adhesive
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2601/00—Upholstery
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings

Definitions

  • the present invention relates to a laminated molded product and a method for producing the same.
  • a laminated molded body used for an interior material of an automobile or the like is known to have irregularities formed on its surface (see, for example, Patent Documents 1 and 2).
  • Patent Document 1 discloses a configuration in which unevenness is formed on a laminated molded body by subjecting urethane foam sandwiched between two non-woven fabrics to a quilting process and joining a skin material layer to the upper surface thereof.
  • Patent Document 2 discloses a configuration in which irregularities are formed on a laminated molded body by pressing a sheet layer with a mold using a template having an opening formed.
  • Patent Document 1 has a problem that it is difficult to shorten the manufacturing time of the laminated molded product because quilting processing is required to form irregularities on the laminated molded product.
  • a sheet layer is sandwiched between a cushion layer provided with protrusions and a template provided with an opening having a shape suitable for the protrusions, and the laminated molded body is subjected to unevenness. Since it is formed, there is a problem that the design has an angular, straight, hard-feeling unevenness, and the surface of the laminated molded body may be damaged.
  • the present invention is a method for manufacturing a laminated molded product and a laminated molding which can improve the aesthetic appearance by avoiding damage to the surface and can easily shorten the manufacturing time while making the design have soft-feeling irregularities.
  • the purpose is to provide the body.
  • the method for producing a laminated molded body of the present invention includes a cutting step of cutting a cushion layer to form a cut portion so as to form an opening, and the cushion cut in the cutting step.
  • a base material laminating step of arranging a base material on the lower surface of the layer via an adhesive sheet having an adhesive force by heating to form a first laminated body, and a heat insulating material are applied to the cut portion of the first laminated body. From the heat insulating material mounting step to be attached, the first thermocompression bonding step of thermocompression bonding the first laminated body to which the heat insulating material is attached, and the first thermocompression bonding body thermocompression bonded in the first thermocompression bonding step.
  • the skin laminating step of forming the second laminated body and the second laminated body are thermocompression bonded, and the skin is bonded to the lower layer material arranged in the lower layer of the cushion layer having the opening at the opening. It is characterized by including a second thermocompression bonding step.
  • the laminated molded body of the present invention includes a cushion layer, a skin bonded to the upper surface of the cushion layer, and a base material bonded to the lower surface of the cushion layer, and the cushion.
  • the layer comprises an opening
  • the epidermis is joined to the substrate at the opening
  • the cushion layer is formed of polyurethane foam having a thickness of 2 to 15 mm and a density of 20 to 35 kg / m 3. It is characterized by being done.
  • the laminated molded body of the present invention includes a cushion layer, a skin bonded to the upper surface of the cushion layer, and a base material bonded to the lower surface of the cushion layer, and the cushion.
  • the layer includes a first cushion layer and a second cushion layer arranged on the lower surface of the first cushion layer, and at least one of the first cushion layer and the second cushion layer has a first opening. It is characterized by being prepared.
  • the laminated molded product of the present invention and the manufacturing method thereof configured in this manner have a design having unevenness with a soft feeling, improve the aesthetic appearance by avoiding damage to the surface, and easily shorten the manufacturing time. be able to.
  • FIG. It is sectional drawing explaining the skin laminating process of Example 1.
  • FIG. It is sectional drawing explaining the 2nd thermocompression bonding process of Example 1.
  • FIG. It is sectional drawing which shows the arrangement of the laminated molded article of Example 2.
  • FIG. It is sectional drawing which shows the laminated molded body of Example 2.
  • FIG. It is sectional drawing which shows schematic arrangement of the laminated molded article of Example 3.
  • FIG. It is sectional drawing which shows typically the laminated molded article of Example 3.
  • FIG. It is sectional drawing which shows schematic arrangement of the laminated molded article of Example 4.
  • FIG. It is sectional drawing which shows typically the laminated molded article of Example 4.
  • FIG. It is a perspective view which shows the cushion layer of another Example. It is a top view which shows the cushion layer of another Example.
  • Example 1 The laminated molded body in Example 1 is applied to a vehicle seat.
  • FIG. 1 is a perspective view showing a sheet of the first embodiment. Hereinafter, the configuration of the sheet of the first embodiment will be described.
  • the seat 1 includes a seat portion 2 that supports the occupant's buttocks and a back surface portion 3 that supports the back surface of the occupant.
  • the laminated molded body 10 is used for the central portion of the seat portion 2 in the vehicle width direction and the central portion of the back portion 3 in the vehicle width direction.
  • the laminated molded body 10 may be used for the peripheral edge portion of the seat portion 2 or may be used for the peripheral edge portion of the back surface portion.
  • FIG. 2 is a cross-sectional view showing the laminated molded product 10 of the first embodiment.
  • the configuration of the laminated molded body 10 of Example 1 will be described.
  • the laminated molded body 10 has a first cushion layer 11 as a cushion layer and an epidermis arranged on the upper surface of the first cushion layer 11 via a second adhesive layer 12b as an adhesive layer 12. 15 and a base material 13 arranged on the lower surface of the first cushion layer 11 via the first adhesive layer 12a as the adhesive layer 12 are provided.
  • the first cushion layer 11 can be, for example, a polyurethane foam having a thickness of about 2 to 15 [mm] and a density of 20 to 35 [kg / m 3].
  • the first cushion layer 11 has a main body portion 11a and a first opening portion 11c as an opening portion.
  • the first opening 11c is formed as an opening that penetrates the first cushion layer 11 in the thickness direction.
  • the width of the first opening 11c can be 70% or more of the thickness of the first cushion layer 11. For example, when the thickness of the first cushion layer 11 is 5 mm, the width of the first opening 11c can be 7 mm. When the thickness of the first cushion layer 11 is 10 mm, the width of the first opening 11c can be 10 mm.
  • the skin 15 can be, for example, genuine leather.
  • the thickness of the epidermis 15 can be, for example, about 1 to 1.4 [mm].
  • the epidermis 15 may be synthetic leather, artificial leather, PVC (polyvinyl chloride), cloth, or the like.
  • a plurality of through holes 15a penetrating in the thickness direction of the epidermis 15 are formed in the epidermis 15.
  • the base material 13 can be, for example, nylon.
  • the base material 13 can also be a non-woven fabric or the like.
  • the base material 13 may be formed in a mesh shape.
  • a second adhesive layer 12b is interposed between the main body portion 11a of the first cushion layer 11 and the skin 15.
  • a first adhesive layer 12a is interposed between the main body portion 11a of the first cushion layer 11 and the base material 13.
  • the skin 15 is joined to the base material 13 via the second adhesive layer 12b to form irregularities on the laminated molded body 10.
  • FIG. 3 is a plan view showing the first cushion layer 11 cut in the cutting step of the first embodiment.
  • FIG. 4 is a cross-sectional view illustrating the substrate mounting process of the first embodiment.
  • FIG. 5 is a cross-sectional view illustrating the heat insulating material placing process of the first embodiment.
  • FIG. 6 is a plan view showing a heat insulating material used in the heat insulating material mounting step of the first embodiment.
  • FIG. 7 is a cross-sectional view illustrating the first thermocompression bonding step of the first embodiment.
  • FIG. 8 is an explanatory diagram illustrating the peeling step of the first embodiment.
  • FIG. 9 is a plan view showing a first laminated body whose cut portion has been peeled off in the peeling step of Example 1.
  • FIG. 10 is a cross-sectional view illustrating the skin laminating step of Example 1.
  • FIG. 11 is a cross-sectional view illustrating the second thermocompression bonding step of the first embodiment.
  • the rectangular plate-shaped first cushion layer 11 is cut so as to form the first opening 11c (see FIG. 9), and the plurality of diamond-shaped main body portions 11a are cut. , And the cutting portion 11b.
  • the first opening 11c is formed between the main body portions 11a. In the cutting step, the cutting portion 11b is not peeled off from the first cushion layer 11.
  • Base material laminating process As shown in FIG. 4, in the base material laminating step, the base material 13 is arranged on the lower surface of the first cushion layer 11 cut in the cutting step via the first adhesive sheet 12A as an adhesive sheet, and the base material 13 is arranged. 1 Laminated body 10A is formed. That is, the base material 13 is arranged on the lower surfaces of the main body portion 11a and the cutting portion 11b via the first adhesive sheet 12A to form the first laminated body 10A.
  • the first adhesive sheet 12A a thermoplastic sheet that melts by heating and has adhesive strength, for example, a polyamide-based, polyolefin-based, polyurethane-based, or polyester-based hot melt adhesive can be used.
  • the temperature (melting range) at which the hot melt of the hot melt adhesive melts can be 90 to 115 ° C.
  • the first adhesive sheet 12A for example, a web-like (spider web-like), a net-like (mesh-like), or a film-like one can be used, but from the viewpoint of breathability, the web-like one or the first adhesive sheet 12A can be used. A net-like one is preferable.
  • the first adhesive sheet 12A is melted by heating to form the first adhesive layer 12a as the adhesive layer 12.
  • the heat insulating material 16 is placed on the upper surface of the cut portion 11b of the first laminated body 10A.
  • the heat insulating material 16 for example, about three sheets of the same material having the same thickness as the skin 15 may be used.
  • the heat insulating material 16 is formed to have substantially the same size as the cut portion 11b in the width direction. That is, the heat insulating material 16 is formed in a shape that surrounds the main body portion 11a.
  • thermocompression bonding process As shown in FIG. 7, in the first thermocompression bonding step, the first laminated body 10A to which the heat insulating material 16 is attached is set in the mold 50 and thermocompression bonded.
  • the mold 50 is composed of an upper mold 51 and a lower mold 52.
  • the upper mold 51 has a heater function.
  • the divided surface (parting surface) of the upper die 51 and the lower die 52 is formed to be substantially flat.
  • thermocompression bonding is performed at a temperature of 120 to 140 ° C. and a pressure of 0.1 to 0.8 MPa for about 5 to 40 seconds.
  • the portion of the first adhesive sheet 12A adjacent to the main body portion 11a to which the heat insulating material 16 is not attached is melted and has adhesive strength. 1
  • An adhesive layer 12a is formed. As a result, the main body portion 11a is joined to the base material 13.
  • the portion of the first adhesive sheet 12A adjacent to the cutting portion 11b to which the heat insulating material 16 is attached remains the first adhesive sheet 12A which is not melted by the heat insulating material 16 and does not exhibit the adhesive force.
  • the cut portion 11b is not joined to the base material 13.
  • the cut portion 11b to which the heat insulating material 16 is attached is peeled from the first layered body 10A thermocompression-bonded in the first thermocompression bonding step.
  • the first adhesive sheet 12A adjacent to the cutting portion 11b is also peeled off.
  • the first adhesive sheet 12A adjacent to the cut portion 11b may remain on the base material 13 without being peeled off.
  • the first cushion layer 11 is formed with the first opening 11c between the main bodies 11a.
  • the skin 15 is arranged on the upper surface of the first laminated body 10A from which the cut portion 11b has been peeled off via the second adhesive sheet 12B as an adhesive sheet, and the second laminating is performed.
  • Form body 10B When the second adhesive sheet 12B is heated, it melts to form a second adhesive layer 12b as an adhesive layer 12 having an adhesive force.
  • thermocompression bonding process As shown in FIG. 11, in the second thermocompression bonding step, the second laminated body 10B is set in the mold 50 and thermocompression bonded.
  • the temperature is 140 to 160 ° C.
  • the pressure is 0.5 to 1.2 MPa
  • the thermocompression bonding is performed for about 10 to 40 seconds.
  • the portion of the second adhesive sheet 12B adjacent to the main body portion 11a is melted to form a second adhesive layer 12b having adhesive strength.
  • the main body portion 11a is joined to the skin 15.
  • the portion of the second adhesive sheet 12B adjacent to the first opening 11c is also melted to form a second adhesive layer 12b having an adhesive force.
  • the skin 15 is joined to the base material 13 which is a lower layer material, which is arranged in the lower layer of the first cushion layer 11 having the first opening 11c in the first opening 11c.
  • the laminated molded body 10 is manufactured.
  • the method for producing the laminated molded body 10 of the first embodiment includes a cutting step of cutting the cushion layer (first cushion layer 11) to form the cut portion 11b so as to form the opening (first opening 11c).
  • the base material 13 is arranged on the lower surface of the cushion layer (first cushion layer 11) cut in the cutting step via an adhesive sheet (first adhesive sheet 12A) having an adhesive force by heating, and the first laminated body is formed.
  • the cutting portion 11b was peeled off from the first layered body 10A that was thermocompression-bonded in the thermocompression bonding step and the first thermocompression bonding step to form a (first opening 11c), and the cutting portion 11b was peeled off.
  • the laminate 10B is thermocompression bonded, and the skin 15 is arranged at the opening (first opening 11c) under the cushion layer (first cushion layer 11) having the opening (first opening 11c). It includes a second thermocompression bonding step of joining to the lower layer material (base material 13) (FIGS. 2 to 11).
  • the skin 15 is joined to the lower layer material (base material 13) arranged in the lower layer of the cushion layer (first cushion layer 11) having the opening (first opening 11c) at the opening (first opening 11c).
  • unevenness can be formed on the laminated molded body 10. Therefore, it is possible to form the laminated molded body 10 having unevenness with a soft feeling without damaging the surface of the skin 15. Therefore, the aesthetic appearance of the laminated molded body 10 can be improved.
  • the laminated molded body 10 having irregularities without performing the troublesome work of applying an adhesive to the back surface of the cut cushion layer (first cushion layer 11).
  • a mold having a flat divided surface is used, and the opening has a width of 70% or more of the thickness of the cushion layer. (Fig. 11).
  • the skin in the second thermocompression bonding step, when the skin is joined to the lower layer material using a mold with a flat split surface, even if the cushion layer is crushed and protrudes into the opening, the entire opening is closed. It is possible to prevent it from becoming. Therefore, in the second thermocompression bonding step, the skin can be firmly joined to the lower layer material by using a mold having a flat split surface.
  • the laminated molded body 10 of Example 1 includes a cushion layer, a skin bonded to the upper surface of the cushion layer, and a base material bonded to the lower surface of the cushion layer, and the cushion layer includes an opening and a skin. Is bonded to the substrate at the opening, and the cushion layer is made of polyurethane foam having a thickness of 2 to 15 mm and a density of 20 to 35 kg / m 3 (FIG. 2).
  • Example 1 since the polyurethane foam having a cushion layer thickness of 2 to 15 mm and a cushion layer density of 20 kg / m 3 or more is used, the epidermis is bonded to the base material through the opening. Since the cushion layer sandwiched between the epidermis and the base material has a certain degree of repulsive force, it is only slightly crushed. Therefore, it is possible to form gentle irregularities on the surface of the epidermis.
  • Example 1 since a polyurethane foam having a cushion layer thickness of 2 to 15 mm and a density of 35 kg / m 3 or less is used, when the skin is bonded to the base material through the opening, the cushion is used. The repulsive force of the layer can be reduced, and the epidermis can be prevented from peeling off from the base material. Therefore, it is possible to form gentle irregularities on the surface of the epidermis.
  • thermocompression bonding is performed using a mold having a flat divided surface without using a template, there is no risk of damaging the surface of the skin 15. Therefore, the appearance of the laminated molded product can be improved and the manufacturing time can be shortened.
  • the laminated molded product of Example 2 is different from the laminated molded product of Example 1 in that the structure of the cushion layer is different.
  • FIG. 12 is a cross-sectional view showing the arrangement of the laminated molded product of Example 2.
  • FIG. 13 is a cross-sectional view showing the laminated molded product of Example 2.
  • the configuration of the laminated molded product of Example 2 will be described. The same or equivalent parts as those described in the above examples will be described using the same terms or the same reference numerals.
  • the laminated molded body 110 of the second embodiment is arranged on the first cushion layer 11 as a cushion layer and the upper surface of the first cushion layer 11 via a second adhesive sheet 12B as an adhesive sheet.
  • a second adhesive sheet 12B as an adhesive sheet.
  • the second cushion layer 111 as a cushion layer and the lower surface of the second cushion layer 111 are arranged via the first adhesive sheet 12A as an adhesive sheet.
  • a base material 13 arranged via a third adhesive sheet 12C as an adhesive sheet is provided.
  • the first cushion layer 11 has the same configuration as the first cushion layer 11 of the first embodiment, and has a first opening 11c.
  • the second cushion layer 111 can be, for example, a rectangular plate-shaped polyurethane foam.
  • the second cushion layer 111 can be, for example, a polyurethane foam having a thickness of about 2 to 15 [mm] and a density of 20 to 35 [kg / m 3].
  • the epidermis 15 may be formed with a plurality of through holes 15a penetrating in the thickness direction of the epidermis 15.
  • the plurality of through holes 15a are configured as performance holes.
  • the base material 13 may be formed in a mesh shape.
  • the laminated molded body 110 arranged in this way is set in the mold 50 and thermocompression bonded, so that the skin 15 and the main body portion 11a of the first cushion layer 11 are secondly bonded as shown in FIG. They are joined via layer 12b. Further, the skin 15 is joined to the second cushion layer 111 at the first opening 11c of the first cushion layer 11 via the second adhesive layer 12b. The first cushion layer 11 and the second cushion layer 111 are joined via the first adhesive layer 12a. The second cushion layer 111 and the base material 13 are joined via the third adhesive layer 12c.
  • the laminated molded body 110 of Example 2 includes a cushion layer, a skin 15 bonded to the upper surface of the cushion layer, and a base material 13 bonded to the lower surface of the cushion layer, and the cushion layer is a first cushion layer. 11 and a second cushion layer 111 arranged on the lower surface of the first cushion layer are provided, and the first cushion layer 11 includes a first opening 11c (FIG. 3).
  • the first cushion layer 11 is provided with the first opening 11c, unevenness can be easily formed on the surface of the epidermis 15 with a simple structure without performing a time-consuming quilting process. Further, by having the second cushion layer 111, the cushioning property of the laminated molded body 110 can be improved. Therefore, with a simple structure, it is possible to obtain a laminated molded body 110 having a soft feeling and unevenness with improved cushioning properties. As a result, the aesthetic appearance of the laminated molded product 110 can be improved and the manufacturing time can be shortened.
  • the skin 15 is joined to the second cushion layer 111 at the first opening 11c.
  • the urethane in the vicinity of the stitch is compressed by the two non-woven fabrics and the stitch, and the elasticity of the laminated molded body is impaired.
  • the non-woven fabric is interposed between the cushion layer and the skin, the elasticity of the laminated molded product is impaired. Therefore, there is a problem that the soft texture of the laminated molded product is impaired.
  • the laminated molded product 110 of Example 1 no quilting process is performed, and no non-woven fabric is interposed between the cushion layer and the skin 15. Therefore, the soft texture of the laminated molded body 110 can be obtained.
  • the laminated molded product 110 of Example 1 is not quilted, no stitch marks are formed on the surface of the skin 15. Therefore, the design of the laminated molded body 110 can be improved.
  • the non-woven fabric is interposed between the cushion layer and the epidermis, so that the air permeability of the laminated molded product is improved. There is a problem that it is not good.
  • the laminated molded product 110 of Example 1 no non-woven fabric is interposed between the cushion layer and the skin 15. Therefore, the air permeability of the laminated molded body 110 can be improved.
  • the base material 13 is formed in a mesh shape.
  • the air permeability of the laminated molded body 110 can be improved.
  • the air permeability of the laminated molded body 110 can be improved.
  • the laminated molded product of Example 3 is different from the laminated molded product of Examples 1 and 2 in that the structure of the cushion layer is different.
  • FIG. 14 is a cross-sectional view schematically showing the arrangement of the laminated molded product of Example 3.
  • FIG. 15 is a cross-sectional view schematically showing the laminated molded product of Example 3.
  • the configuration of the laminated molded product of Example 3 will be described. The same or equivalent parts as those described in the above examples will be described using the same terms or the same reference numerals.
  • the laminated molded product 210 of Example 3 includes a first cushion layer 11 as a cushion layer and a second cushion layer 211 as a cushion layer.
  • the first cushion layer 11 has the same configuration as the first cushion layer 11 of the first embodiment, and has a first opening 11c.
  • the second cushion layer 211 has a main body portion 211a and a second opening portion 211c.
  • the center position of the first opening 11c and the center position of the second opening 211c are formed at the same position in the width direction orthogonal to the thickness direction of the second cushion layer 211.
  • the width W2 of the second opening 211c of the second cushion layer 211 is formed to be smaller than the width W1 of the first opening 11c of the first cushion layer 11.
  • the thickness of the second cushion layer 211 can be substantially the same as the thickness of the first cushion layer 11 (for example, about 2 to 15 [mm]).
  • the second cushion layer 211 can be, for example, a polyurethane foam having a thickness of about 2 to 15 [mm] and a density of 20 to 35 [kg / m 3].
  • the laminated molded body 210 arranged in this way is set in the mold 50 and thermocompression bonded, so that the skin 15 is formed in the first opening 11c of the first cushion layer 11 as shown in FIG. It is joined to the second cushion layer 211 via the adhesive layer 12. Further, the skin 15 is bonded to the base material 13 at the second opening 211c of the second cushion layer 211 via the adhesive layer 12.
  • the second cushion layer 211 includes a second opening 211c smaller than the width of the first opening 11c at the same position as the first opening 11c (FIG. 15).
  • a two-step step can be formed with the step formed in 211c. Therefore, the design of the laminated molded body 210 can be improved.
  • the laminated molded product of Example 4 is different from the laminated molded product of Examples 1 to 3 in that the structure of the cushion layer is different.
  • FIG. 16 is a cross-sectional view schematically showing the arrangement of the laminated molded product of Example 4.
  • FIG. 17 is a cross-sectional view schematically showing the laminated molded product of Example 4.
  • the configuration of the laminated molded product of Example 4 will be described. The same or equivalent parts as those described in the above examples will be described using the same terms or the same reference numerals.
  • the laminated molded product 310 of Example 4 As shown in FIG. 16, the laminated molded product 310 of Example 4, the first cushion layer 11 as a cushion layer, and the second cushion layer 311 as a cushion layer are provided.
  • the first cushion layer 11 has the same configuration as the first cushion layer 11 of the first embodiment, and has a first opening 11c.
  • the thickness of the second cushion layer 311 can be substantially the same as the thickness of the first cushion layer 11 (for example, about 2 to 15 [mm]).
  • the second cushion layer 311 can be, for example, a polyurethane foam having a thickness of about 2 to 15 [mm] and a density of 20 to 35 [kg / m 3].
  • the second cushion layer 311 includes a main body portion 311a and a second opening 311c formed at a position different from the opening of the first cushion layer 11 in the width direction orthogonal to the thickness direction of the second cushion layer 311. To be equipped.
  • the width W1 of the first opening 11c of the first cushion layer 11 can be substantially the same as the width W3 of the second opening 311c of the second cushion layer 311.
  • the laminated molded body 310 arranged in this way is set in the mold 50 and thermocompression bonded, so that the skin 15 is formed in the first opening 11c via the adhesive layer 12 as shown in FIG. , Joined to the second cushion layer 311.
  • the first cushion layer 11 is bonded to the base material 13 at the second opening 311c via the adhesive layer 12.
  • the second cushion layer 311 includes the second opening 311c at a position different from that of the first opening 11c, and the skin 15 has the second cushion layer in the first opening 11c. It is bonded to 311 and the first cushion layer 11 is bonded to the base material 13 at the second opening 311c (FIG. 17).
  • the shape of the unevenness formed on the surface of the skin 15 by joining the skin 15 to the second cushion layer 311 at the first opening 11c, and the first cushion layer 11 at the second opening 311c.
  • the shape of the unevenness formed on the surface of the skin 15 can be changed. Therefore, the design of the laminated molded product 310 can be improved.
  • the laminated molded product of the present invention has been described above based on Examples 1 to 4. However, the specific configuration is not limited to these examples, and as long as the gist of the invention according to each claim of the claims is not deviated, design changes, additions, combinations of each example, etc. may be made. Permissible.
  • the first cushion layer and the second cushion layer showed an example in which openings were formed so as to form a diamond-shaped main body portion.
  • the opening 411c may be a hole.
  • the opening 511c may be star-shaped, circular, quadrangular, or triangular.
  • first cushion layer and the second cushion layer are made of polyurethane foam.
  • first cushion layer and the second cushion layer are not limited to this embodiment, and resin foam such as polyethylene foam or polyester foam, or non-woven fabric can be used.
  • Examples 2 to 4 an example was shown in which the thicknesses of the first cushion layer and the second cushion layer were substantially the same.
  • the thickness of the first cushion layer may be thicker than the thickness of the second cushion layer, or the thickness of the second cushion layer may be thicker than the thickness of the first cushion layer.
  • the unevenness of the laminated molded product can be expressed in a variety of designs.
  • Example 2 an example in which the first opening 11c is formed in the first cushion layer 11 is shown. However, the first opening may be formed in the second cushion layer.
  • the width W2 of the second opening 211c is formed smaller than the width W1 of the first opening 11c.
  • the width of the second opening may be formed larger than the width of the first opening.
  • the width W1 of the first opening 11c of the first cushion layer 11 is substantially the same as the width W3 of the second opening 311c of the second cushion layer 311.
  • the width of the opening of the first cushion layer and the width of the opening of the second cushion layer can be made different.
  • the unevenness of the laminated molded product can be expressed in a variety of designs.
  • Example 3 the first opening 11c and the second opening 211c are formed at the same position. Further, in Example 4, the first opening 11c and the second opening 311c are formed at different positions. However, the first opening and the second opening may be formed so as to partially overlap each other.
  • Examples 1 to 4 an example in which the laminated molded product of the present invention is applied to a central portion in the vehicle width direction of a vehicle seat is shown.
  • the laminated molded article of the present invention can also be applied to the peripheral edge of a vehicle seat.
  • the laminated molded product of the present invention can also be applied to a vehicle door trim, a vehicle center console, furniture and the like.

Abstract

柔らかい感じの凹凸を有する意匠とし、かつ、表面の損傷を回避することにより美観を向上させると共に、簡易に製造時間を短縮することができる積層成形体の製造方法及び積層成形体を提供する。　クッション層（第１クッション層（１１））を裁断して裁断部（１１ｂ）を形成する裁断工程と、第１積層体（１０Ａ）を形成する基材積層工程と、裁断部（１１ｂ）に断熱材（１６）を取り付ける断熱材載置工程と、第１積層体（１０Ａ）を熱圧着する第１熱圧着工程と、裁断部（１１ｂ）を剥離して（第１開口部（１１ｃ））を形成する剥離工程と、第２積層体（１０Ｂ）を形成する表皮積層工程と、第２積層体（１０Ｂ）を熱圧着して、表皮（１５）を、開口部（第１開口部（１１ｃ））において、開口部（第１開口部（１１ｃ））を有するクッション層（第１クッション層（１１））の下層に配置される下層材（基材（１３））に接合する第２熱圧着工程と、を含む。

Description

積層成形体及びその製造方法
　本発明は、積層成形体及びその製造方法に関するものである。
　例えば、自動車等の内装材に使用される積層成形体は、その表面に凹凸を形成したものが知られている（例えば、特許文献１，２参照）。
　特許文献１には、２枚の不織布で挟んだ発泡ウレタンにキルティング加工を施し、その上面に表皮材層を接合することで、積層成形体に凹凸を形成する構成が開示されている。
　特許文献２には、開口部が形成されたテンプレートを使用して、金型によってシート層を押圧することで、積層成形体に凹凸を形成する構成が開示されている。
国際公開第２０１８／０９６９４４号 米国特許第１０１１８５２５号明細書
　しかしながら、特許文献１に記載の発明は、積層成形体に凹凸を形成するために、キルティング加工を要するため、積層成形体の製造時間の短縮化が困難となる、という問題がある。
　また、特許文献２に記載の発明は、突起を設けたクッション層と、この突起に適合した形状の開口部を設けたテンプレートとの間にシート層を挟んで押し付けて、積層成形体に凹凸を形成するため、角張った直線的な硬い感じの凹凸を有する意匠になってしまうとともに、積層成形体の表面が損傷するおそれがあるという問題がある。
　そこで、本発明は、柔らかい感じの凹凸を有する意匠とし、かつ、表面の損傷を回避することにより美観を向上させると共に、簡易に製造時間を短縮することができる積層成形体の製造方法及び積層成形体を提供することを目的とする。
　前記目的を達成するために、本発明の積層成形体の製造方法は、開口部を形成するようにクッション層を裁断して裁断部を形成する裁断工程と、前記裁断工程で裁断された前記クッション層の下面に、加熱によって接着力を有する接着シートを介して、基材を配置して、第１積層体を形成する基材積層工程と、前記第１積層体の前記裁断部に断熱材を取り付ける断熱材載置工程と、前記断熱材が取り付けられた前記第１積層体を熱圧着する第１熱圧着工程と、前記第１熱圧着工程で熱圧着された前記第１積層体から、前記裁断部を剥離して前記開口部を形成する剥離工程と、前記裁断部が剥離された前記第１積層体の上面に、加熱によって接着力を有する接着シートを介して、表皮を配置して、第２積層体を形成する表皮積層工程と、前記第２積層体を熱圧着して、前記表皮を、前記開口部において、前記開口部を有する前記クッション層の下層に配置される下層材に接合する第２熱圧着工程と、を含むことを特徴とする。
　前記目的を達成するために、本発明の積層成形体は、クッション層と、前記クッション層の上面に接合される表皮と、前記クッション層の下面に接合される基材と、を備え、前記クッション層は、開口部を備え、前記表皮は、前記開口部において、前記基材に接合され、前記クッション層は、厚さが２～１５ｍｍで、密度が２０～３５ｋｇ／ｍ３のポリウレタンフォームで形成されていることを特徴とする。
　前記目的を達成するために、本発明の積層成形体は、クッション層と、前記クッション層の上面に接合される表皮と、前記クッション層の下面に接合される基材と、を備え、前記クッション層は、第１クッション層と、前記第１クッション層の下面に配置される第２クッション層と、を備え、前記第１クッション層及び前記第２クッション層の少なくとも一方は、第１開口部を備えることを特徴とする。
　このように構成された本発明の積層成形体及びその製造方法は、柔らかい感じの凹凸を有する意匠とし、かつ、表面の損傷を回避することにより美観を向上させると共に、簡易に製造時間を短縮することができる。
実施例１のシートを示す斜視図である。 実施例１の積層成形体を示す断面図である。 実施例１の裁断工程で裁断された第１クッション層を示す平面図である。 実施例１の基材取付工程を説明する断面図である。 実施例１の断熱材載置工程を説明する断面図である。 実施例１の断熱材載置工程で使用する断熱材を示す平面図である。 実施例１の第１熱圧着工程を説明する断面図である。 実施例１の剥離工程を説明する説明図である。 実施例１の剥離工程で裁断部が剥離された第１積層体を示す平面図である。 実施例１の表皮積層工程を説明する断面図である。 実施例１の第２熱圧着工程を説明する断面図である。 実施例２の積層成形体の配列を示す断面図である。 実施例２の積層成形体を示す断面図である。 実施例３の積層成形体の配列を概略的に示す断面図である。 実施例３の積層成形体を概略的に示す断面図である。 実施例４の積層成形体の配列を概略的に示す断面図である。 実施例４の積層成形体を概略的に示す断面図である。 別の実施例のクッション層を示す斜視図である。 別の実施例のクッション層を示す平面図である。
　以下、本発明による積層成形体及びその製造方法を実現する実施形態を、図面に示す実施例１～４に基づいて説明する。
　実施例１における積層成形体は、車両のシートに適用される。
［シートの構成］
　図１は、実施例１のシートを示す斜視図である。以下、実施例１のシートの構成を説明する。
　図１に示すように、シート１は、乗員のお尻を支持する座部２と、乗員の背面を支持する背面部３と、を備える。
　座部２の車両幅方向の中央部分と、背面部３の車両幅方向の中央部分には、積層成形体１０が使用される。なお、積層成形体１０は、座部２の周縁部に使用されてもよいし、背面部の周縁部に使用されてもよい。
［積層成形体の構成］
　図２は、実施例１の積層成形体１０を示す断面図である。以下、実施例１の積層成形体１０の構成を説明する。
　図２に示すように、積層成形体１０は、クッション層としての第１クッション層１１と、第１クッション層１１の上面に、接着層１２としての第２接着層１２ｂを介して配置される表皮１５と、第１クッション層１１の下面に、接着層１２としての第１接着層１２ａを介して配置される基材１３と、を備える。
　第１クッション層１１は、例えば、厚さが２～１５［ｍｍ］程度で、密度が２０～３５［ｋｇ／ｍ３］のポリウレタンフォームとすることができる。第１クッション層１１は、本体部１１ａと、開口部としての第１開口部１１ｃと、を有する。
　第１開口部１１ｃは、第１クッション層１１の厚さ方向に貫通する開口として形成される。第１開口部１１ｃの幅は、第１クッション層１１の厚さの７０％以上とすることができる。例えば、第１クッション層１１の厚さが５ｍｍである場合、第１開口部１１ｃの幅は、７ｍｍとすることができる。また、第１クッション層１１の厚さが１０ｍｍである場合、第１開口部１１ｃの幅は、１０ｍｍとすることができる。
　表皮１５は、例えば、本革とすることができる。表皮１５の厚さは、例えば、１～１．４［ｍｍ］程度とすることができる。なお、表皮１５は、合成皮革や、人工皮革や、ＰＶＣ（polyvinyl chloride）や、布等にすることもできる。表皮１５には、表皮１５の厚さ方向に貫通する複数の貫通孔１５ａが形成される。
　基材１３は、例えば、ナイロンとすることができる。なお、基材１３は、不織布等にすることもできる。基材１３は、メッシュ状に形成されてもよい。
　第１クッション層１１の本体部１１ａと表皮１５との間には、第２接着層１２ｂが介在する。第１クッション層１１の本体部１１ａと基材１３との間には、第１接着層１２ａが介在する。第１クッション層１１の第１開口部１１ｃにおいては、表皮１５は、第２接着層１２ｂを介して、基材１３に接合されることで、積層成形体１０に凹凸を形成する。
［積層成形体の製造方法］
　図３は、実施例１の裁断工程で裁断された第１クッション層１１を示す平面図である。図４は、実施例１の基材取付工程を説明する断面図である。図５は、実施例１の断熱材載置工程を説明する断面図である。図６は、実施例１の断熱材載置工程で使用する断熱材を示す平面図である。図７は、実施例１の第１熱圧着工程を説明する断面図である。図８は、実施例１の剥離工程を説明する説明図である。図９は、実施例１の剥離工程で裁断部が剥離された第１積層体を示す平面図である。図１０は、実施例１の表皮積層工程を説明する断面図である。図１１は、実施例１の第２熱圧着工程を説明する断面図である。以下、実施例１の積層成形体１０の製造方法を説明する。
（裁断工程）
　図３に示すように、裁断工程では、第１開口部１１ｃ（図９参照）を形成するように矩形の板状の第１クッション層１１を裁断して、複数のひし形状の本体部１１ａと、裁断部１１ｂと、を形成する。
　第１クッション層１１から裁断部１１ｂを剥離する（切り離す）ことで、本体部１１ａ間に第１開口部１１ｃが形成されることになる。なお、裁断工程では、裁断部１１ｂは、第１クッション層１１から剥離されていない状態とする。
（基材積層工程）
　図４に示すように、基材積層工程では、裁断工程で裁断された第１クッション層１１の下面に、接着シートとしての第１接着シート１２Ａを介して、基材１３を配置して、第１積層体１０Ａを形成する。すなわち、本体部１１ａと裁断部１１ｂの下面に、第１接着シート１２Ａを介して、基材１３を配置して、第１積層体１０Ａを形成する。
　第１接着シート１２Ａは、加熱することで、溶解して接着力を有する熱可塑性シート、例えば、ポリアミド系、ポリオレフィン系、ポリウレタン系、ポリエステル系のホットメルト接着剤を用いることができる。ホットメルト接着剤のホットメルトが溶解する温度（溶融範囲）は、９０～１１５℃とすることができる。第１接着シート１２Ａは、例えば、ウェブ状（クモの巣状）のものや、ネット状（網目状）のものや、フィルム状のものを使用することができるが、通気性の観点から、ウェブ状又はネット状のものが好ましい。
　第１接着シート１２Ａは、加熱することで、溶解して、接着層１２としての第１接着層１２ａを形成する。
（断熱材載置工程）
　図５に示すように、断熱材載置工程では、第１積層体１０Ａの裁断部１１ｂの上面に、断熱材１６を載置する。断熱材１６は、例えば、表皮１５と同じ厚さの同じ材料を３枚程度貼り合わせたものを使用することもできる。
　断熱材１６は、図５及び図６に示すように、幅方向において、裁断部１１ｂと略同じ大きさに形成される。すなわち、断熱材１６は、本体部１１ａを取り囲むような形状に形成される。
（第１熱圧着工程）
　図７に示すように、第１熱圧着工程では、断熱材１６が取り付けられた第１積層体１０Ａを、金型５０にセットして、熱圧着する。金型５０は、上型５１と下型５２とから構成される。上型５１は、ヒータ機能を有する。上型５１及び下型５２の分割面（パーティング面）は、略平坦に形成されている。第１熱圧着工程では、例えば、温度が１２０～１４０℃で、圧力０．１～０．８ＭＰａで、５～４０秒間程の熱圧着を行う。
　第１熱圧着工程で第１積層体１０Ａが熱圧着されると、断熱材１６が取り付けられていない本体部１１ａに隣接する第１接着シート１２Ａの部分は、溶解して、接着力を有する第１接着層１２ａを形成する。これにより、本体部１１ａは、基材１３に接合される。
　一方、断熱材１６が取り付けられた裁断部１１ｂに隣接する第１接着シート１２Ａの部分は、断熱材１６により、溶解せず、接着力を発揮しない第１接着シート１２Ａのままである。これにより、裁断部１１ｂは、基材１３に接合されない。
（剥離工程）
　図８に示すように、剥離工程では、第１熱圧着工程で熱圧着された第１積層体１０Ａから、断熱材１６が取り付けられた裁断部１１ｂを剥離する。この際、裁断部１１ｂに隣接する第１接着シート１２Ａも剥離する。なお、裁断部１１ｂに隣接する第１接着シート１２Ａは、剥離されずに基材１３に残ってもよい。
　これにより、第１クッション層１１には、図８及び図９に示すように、本体部１１ａ間に第１開口部１１ｃが形成される。
（表皮積層工程）
　図１０に示すように、表皮積層工程では、裁断部１１ｂが剥離された第１積層体１０Ａの上面に、接着シートとしての第２接着シート１２Ｂを介して表皮１５を配置して、第２積層体１０Ｂを形成する。第２接着シート１２Ｂは、加熱することで、溶解して接着力を有する、接着層１２としての第２接着層１２ｂを形成する。
（第２熱圧着工程）
　図１１に示すように、第２熱圧着工程では、第２積層体１０Ｂを、金型５０にセットして、熱圧着する。第２熱圧着工程では、例えば、温度が１４０～１６０℃で、圧力が０．５～１．２ＭＰａで、１０～４０秒間程の熱圧着を行う。
　第２熱圧着工程で第２積層体１０Ｂが熱圧着されると、本体部１１ａに隣接する第２接着シート１２Ｂの部分は、溶解して接着力を有する第２接着層１２ｂを形成する。これにより、本体部１１ａは、表皮１５に接合される。
　また、第１開口部１１ｃに隣接する第２接着シート１２Ｂの部分も、溶解して接着力を有する第２接着層１２ｂを形成する。これにより、表皮１５は、図２に示すように、第１開口部１１ｃにおいて、第１開口部１１ｃを有する第１クッション層１１の下層に配置される、下層材である基材１３に接合される。
　このような工程を経て、積層成形体１０が製造される。
［積層成形体の作用］
　以下、実施例１の積層成形体１０の作用を説明する。実施例１の積層成形体１０の製造方法は、開口部（第１開口部１１ｃ）を形成するようにクッション層（第１クッション層１１）を裁断して裁断部１１ｂを形成する裁断工程と、裁断工程で裁断されたクッション層（第１クッション層１１）の下面に、加熱によって接着力を有する接着シート（第１接着シート１２Ａ）を介して、基材１３を配置して、第１積層体１０Ａを形成する基材積層工程と、第１積層体１０Ａの裁断部１１ｂに断熱材１６を取り付ける断熱材載置工程と、断熱材１６が取り付けられた第１積層体１０Ａを熱圧着する第１熱圧着工程と、第１熱圧着工程で熱圧着された第１積層体１０Ａから、裁断部１１ｂを剥離して（第１開口部１１ｃ）を形成する剥離工程と、裁断部１１ｂが剥離された第１積層体１０Ａの上面に、加熱によって接着力を有する接着シート（第２接着シート１２Ｂ）を介して、表皮１５を配置して、第２積層体１０Ｂを形成する表皮積層工程と、第２積層体１０Ｂを熱圧着して、表皮１５を、開口部（第１開口部１１ｃ）において、開口部（第１開口部１１ｃ）を有するクッション層（第１クッション層１１）の下層に配置される下層材（基材１３）に接合する第２熱圧着工程と、を含む（図２～図１１）。
　表皮１５は、開口部（第１開口部１１ｃ）において、開口部（第１開口部１１ｃ）を有するクッション層（第１クッション層１１）の下層に配置される下層材（基材１３）に接合されることで、積層成形体１０に凹凸を形成することができる。そのため、表皮１５の表面を傷付けることなく、柔らかい感じの凹凸のある積層成形体１０を形成することができる。そのため、積層成形体１０の美観を向上させることができる。
　また、裁断されたクッション層（第１クッション層１１）の裏面に接着剤を塗布するような面倒な作業をすることなく、凹凸のある積層成形体１０を製造することができる。また、作業に時間のかかるキルティング加工をすることなく、凹凸のある積層成形体１０を製造することができる。そのため、積層成形体１０の製造時間を短縮することができる。
　実施例１の積層成形体１０の製造方法において、第２熱圧着工程では、分割面が平坦な金型を使用し、開口部は、クッション層の厚さの７０％以上の幅を有している（図１１）。
　第２熱圧着工程において、分割面が平坦な金型を使用して、表皮を下層材に接合する際に、クッション層が押し潰されて、開口部にはみ出したとしても、開口部を全部塞いでしまうことを防止することができる。そのため、第２熱圧着工程において、分割面が平坦な金型を使用して、表皮を下層材にしっかりと接合することができる。
　実施例１の積層成形体１０は、クッション層と、クッション層の上面に接合される表皮と、クッション層の下面に接合される基材と、を備え、クッション層は、開口部を備え、表皮は、開口部において、基材に接合され、クッション層は、厚さが２～１５ｍｍで、密度が２０～３５ｋｇ／ｍ３のポリウレタンフォームで形成されている（図２）。
　ところで、クッション層の厚さが２～１５ｍｍで密度が２０ｋｇ／ｍ３より小さいポリウレタンフォームの場合、クッション層に形成された開口部を介して、表皮が基材に接合されると、表皮と基材に挟まれているクッション層は、押し潰されてしまい、表皮の表面に凹凸が形成されなくなってしまうという問題がある。
　一方、実施例１では、クッション層の厚さが２～１５ｍｍでクッション層の密度が２０ｋｇ／ｍ３以上のポリウレタンフォームを使用しているため、表皮が開口部を介して基材に接合されると、表皮と基材に挟まれているクッション層は、ある程度の反発力を有するため、多少押し潰されるに留まる。そのため、表皮の表面になだらかな凹凸を形成することができる。
　また、クッション層の厚さが２～１５ｍｍで密度が３５ｋｇ／ｍ３より大きいポリウレタンフォームの場合、クッション層に形成された開口部を介して、表皮が基材に接合されたとしても、クッション層は大きな反発力を有するため、表皮が基材から剥離してしまい、表皮の表面に凹凸が形成されなくなってしまうという問題がある。
　一方、実施例１では、クッション層の厚さが２～１５ｍｍで密度が３５ｋｇ／ｍ３以下のポリウレタンフォームを使用しているため、表皮が開口部を介して基材に接合された場合、クッション層の反発力を低下させることができ、表皮が基材から剥離してしまうことを防止することができる。そのため、表皮の表面になだらかな凹凸を形成することができる。
　すなわち、作業に時間のかかるキルティング加工をすることなく、簡易な構成で、表皮の表面になだらかな凹凸を形成し、柔らかい感じの意匠とすることができる。また、テンプレートを使用せず、分割面が平坦な金型を使用して熱圧着を行うため、表皮１５の表面を損傷するおそれがない。そのため、積層成形体の美観を向上させると共に、製造時間を短縮することができる。
　実施例２の積層成形体は、クッション層の構成が異なる点で、実施例１の積層成形体と相違する。
［積層成形体の構成］
　図１２は、実施例２の積層成形体の配列を示す断面図である。図１３は、実施例２の積層成形体を示す断面図である。以下、実施例２の積層成形体の構成を説明する。なお、上記実施例で説明した内容と同一乃至均等な部分の説明については、同一用語又は同一の符号を用いて説明する。
　図１２に示すように、実施例２の積層成形体１１０は、クッション層としての第１クッション層１１と、第１クッション層１１の上面に、接着シートとしての第２接着シート１２Ｂを介して配置される表皮１５と、第１クッション層１１の下面に、接着シートとしての第１接着シート１２Ａを介して配置されるクッション層としての第２クッション層１１１と、第２クッション層１１１の下面に、接着シートとしての第３接着シート１２Ｃを介して配置される基材１３と、を備える。
　第１クッション層１１は、実施例１の第１クッション層１１と同様の構成であり、第１開口部１１ｃを有する。
　第２クッション層１１１は、例えば、矩形の板状のポリウレタンフォームとすることができる。第２クッション層１１１は、例えば、厚さが２～１５［ｍｍ］程度で、密度が２０～３５［ｋｇ／ｍ３］のポリウレタンフォームとすることができる。
　表皮１５には、表皮１５の厚さ方向に貫通する複数の貫通孔１５ａが形成されてもよい。複数の貫通孔１５ａは、パフォーレーションホールとして構成される。基材１３は、メッシュ状に形成されてもよい。
　このように配列された積層成形体１１０は、金型５０にセットして、熱圧着することで、図１３に示すように、表皮１５と第１クッション層１１の本体部１１ａは、第２接着層１２ｂを介して、接合される。また、表皮１５は、第１クッション層１１の第１開口部１１ｃにおいて、第２接着層１２ｂを介して、第２クッション層１１１に接合される。第１クッション層１１と第２クッション層１１１は、第１接着層１２ａを介して、接合される。第２クッション層１１１と基材１３は、第３接着層１２ｃを介して、接合される。
［積層成形体の作用］
　以下、実施例２の積層成形体１１０の作用を説明する。実施例２の積層成形体１１０は、クッション層と、クッション層の上面に接合される表皮１５と、クッション層の下面に接合される基材１３と、を備え、クッション層は、第１クッション層１１と、第１クッション層の下面に配置される第２クッション層１１１と、を備え、第１クッション層１１は、第１開口部１１ｃを備える（図３）。
　第１クッション層１１が第１開口部１１ｃを備えることで、作業に時間のかかるキルティング加工をすることなく、簡易な構成で、表皮１５の表面に凹凸を容易に形成することができる。また、第２クッション層１１１を有することで、積層成形体１１０のクッション性を向上させることができる。そのため、簡易な構成で、クッション性を向上させた柔らかい感じの凹凸のある積層成形体１１０とすることができる。その結果、積層成形体１１０の美観を向上させると共に、製造時間を短縮することができる。
　実施例２の積層成形体１１０において、表皮１５は、第１開口部１１ｃにおいて、第２クッション層１１１に接合される。
　表皮１５は、第１開口部１１ｃにおいて、第２クッション層１１１に接合されることで、簡易な構成で、表皮１５の表面に凹凸を形成することができる。また、第２クッション層１１１を有することで、積層成形体１１０のクッション性を向上させることができる。そのため、簡易な構成で、クッション性を向上させた凹凸のある積層成形体１１０とすることができる。
　ところで、積層成形体に凹凸を形成する場合、積層成形体にキルティング加工を施すことが考えられる。しかし、キルティング加工には、多くの作業時間を必要とするという問題がある。
　一方、実施例１の積層成形体１１０では、表皮１５は、第１開口部１１ｃにおいて、第２クッション層１１１に接合されるため、キルティング加工をすることなく、積層成形体１１０に凹凸を形成することができる。そのため、凹凸のある積層成形体１１０の製造時間を短縮することができる。
　また、キルティング加工をした積層成形体では、ステッチの近傍のウレタンは、２枚の不織布とステッチとによって圧縮されて、積層成形体の弾力性が損なわれる。特に、キルティング加工をした積層成形体では、クッション層と表皮との間に、不織布を介在させているため、積層成形体の弾力性が損なわれる。そのため、積層成形体の柔らかい風合いを損なってしまうという問題がある。
　一方、実施例１の積層成形体１１０では、キルティング加工をすることもなく、クッション層と表皮１５との間に不織布を介在させることもない。そのため、積層成形体１１０の柔らかい風合いを出すことができる。
　また、２枚の不織布で挟んだクッション層にキルティング加工を施し、その上面に表皮を接合した場合、ステッチの跡が表皮の表面に形成されてしまうという問題がある。
　一方、実施例１の積層成形体１１０は、キルティング加工をすることがないため、表皮１５の表面にステッチの跡が形成されることもない。そのため、積層成形体１１０のデザイン性を向上させることができる。
　また、２枚の不織布で挟んだクッション層にキルティング加工を施し、その上面に表皮を接合した場合、クッション層と表皮との間に、不織布を介在させているため、積層成形体の通気性が良くないという問題がある。
　一方、実施例１の積層成形体１１０では、クッション層と表皮１５との間に不織布を介在させることもない。そのため、積層成形体１１０の通気性を向上させることができる。
　実施例２の積層成形体１１０において、基材１３は、メッシュ状に形成されている。
　基材１３がメッシュ状に形成されることにより、積層成形体１１０の通気性を向上させることができる。
　実施例２の積層成形体１１０において、表皮１５は、複数の貫通孔１５ａが形成されている。
　表皮１５に複数の貫通孔１５ａが形成されることにより、積層成形体１１０の通気性を向上させることができる。
　なお、他の構成及び作用効果については、上記実施例と略同様であるので説明を省略する。
　実施例３の積層成形体は、クッション層の構成が異なる点で、実施例１及び２の積層成形体と相違する。
［積層成形体の構成］
　図１４は、実施例３の積層成形体の配列を概略的に示す断面図である。図１５は、実施例３の積層成形体を概略的に示す断面図である。以下、実施例３の積層成形体の構成を説明する。なお、上記実施例で説明した内容と同一乃至均等な部分の説明については、同一用語又は同一の符号を用いて説明する。
　図１４に示すように、実施例３の積層成形体２１０は、クッション層としての第１クッション層１１と、クッション層としての第２クッション層２１１と、を備える。
　第１クッション層１１は、実施例１の第１クッション層１１と同様の構成であり、第１開口部１１ｃを有する。
　第２クッション層２１１は、本体部２１１ａと、第２開口部２１１ｃと、を有する。第２クッション層２１１の厚さ方向に直交する幅方向において、第１開口部１１ｃの中心位置と、第２開口部２１１ｃの中心位置とは、同じ位置に形成される。第２クッション層２１１の第２開口部２１１ｃの幅Ｗ２は、第１クッション層１１の第１開口部１１ｃの幅Ｗ１より小さく形成される。
　第２クッション層２１１の厚さは、第１クッション層１１の厚さと略同じ厚さ（例えば、２～１５［ｍｍ］程度）とすることができる。第２クッション層２１１は、例えば、厚さが２～１５［ｍｍ］程度で、密度が２０～３５［ｋｇ／ｍ３］のポリウレタンフォームとすることができる。
　このように配列された積層成形体２１０は、金型５０にセットして、熱圧着することで、図１５に示すように、表皮１５は、第１クッション層１１の第１開口部１１ｃにおいて、接着層１２を介して、第２クッション層２１１に接合される。また、表皮１５は、第２クッション層２１１の第２開口部２１１ｃにおいて、接着層１２を介して、基材１３に接合される。
［積層成形体の作用］
　以下、実施例３の積層成形体２１０の作用を説明する。実施例３の積層成形体２１０において、第２クッション層２１１は、第１開口部１１ｃと同じ位置に、第１開口部１１ｃの幅より小さい第２開口部２１１ｃを備える（図１５）。
　表皮１５が第２クッション層２１１に接合されることで形成される、第１開口部１１ｃに形成される段差と、表皮１５が基材１３に接合されることで形成される、第２開口部２１１ｃに形成される段差とで、２段の段差を形成することができる。そのため、積層成形体２１０のデザイン性を向上させることができる。
　なお、他の構成及び作用効果については、上記実施例と略同様であるので説明を省略する。
　実施例４の積層成形体は、クッション層の構成が異なる点で、実施例１乃至３の積層成形体と相違する。
［積層成形体の構成］
　図１６は、実施例４の積層成形体の配列を概略的に示す断面図である。図１７は、実施例４の積層成形体を概略的に示す断面図である。以下、実施例４の積層成形体の構成を説明する。なお、上記実施例で説明した内容と同一乃至均等な部分の説明については、同一用語又は同一の符号を用いて説明する。
　図１６に示すように、実施例４の積層成形体３１０、クッション層としての第１クッション層１１と、クッション層としての第２クッション層３１１と、を備える。
　第１クッション層１１は、実施例１の第１クッション層１１と同様の構成であり、第１開口部１１ｃを有する。
　第２クッション層３１１の厚さは、第１クッション層１１の厚さと略同じ厚さ（例えば、２～１５［ｍｍ］程度）とすることができる。第２クッション層３１１は、例えば、厚さが２～１５［ｍｍ］程度で、密度が２０～３５［ｋｇ／ｍ３］のポリウレタンフォームとすることができる。
　第２クッション層３１１は、本体部３１１ａと、第２クッション層３１１の厚さ方向に直交する幅方向において、第１クッション層１１の開口部と異なる位置に形成される第２開口部３１１ｃと、を備える。
　第１クッション層１１の第１開口部１１ｃの幅Ｗ１は、第２クッション層３１１の第２開口部３１１ｃの幅Ｗ３と略同じ大きさにすることができる。
　このように配列された積層成形体３１０は、金型５０にセットして、熱圧着することで、図１７に示すように、表皮１５は、第１開口部１１ｃにおいて、接着層１２を介して、第２クッション層３１１に接合される。第１クッション層１１は、第２開口部３１１ｃにおいて、接着層１２を介して、基材１３に接合される。
［積層成形体の作用］
　以下、実施例４の積層成形体３１０の作用を説明する。実施例４の積層成形体３１０は、第２クッション層３１１は、第１開口部１１ｃと異なる位置に、第２開口部３１１ｃを備え、表皮１５は、第１開口部１１ｃにおいて、第２クッション層３１１に接合され、かつ、第１クッション層１１は、第２開口部３１１ｃにおいて、基材１３に接合される（図１７）。
　表皮１５が、第１開口部１１ｃにおいて、第２クッション層３１１に接合されることで、表皮１５の表面に形成される凹凸の形状と、第１クッション層１１が、第２開口部３１１ｃにおいて、基材１３に接合されることで、表皮１５の表面に形成される凹凸の形状と、を変えることができる。そのため、積層成形体３１０のデザイン性を向上させることができる。
　なお、他の構成及び作用効果については、上記実施例と略同様であるので説明を省略する。
　以上、本発明の積層成形体を実施例１～４に基づき説明した。しかし、具体的な構成については、これらの実施例に限られるものではなく、請求の範囲の各請求項に係る発明の要旨を逸脱しない限り、設計の変更、追加、各実施例の組み合わせ等は許容される。
　実施例１～４では、第１クッション層及び第２クッション層は、ひし形の本体部を形成するように開口部が形成される例を示した。しかし、図１８に示すように、開口部４１１ｃは、孔であってもよい。また、図１９に示すように、開口部５１１ｃは、星形であってもよいし、円形や、四角形や、三角形であってもよい。
　実施例１～４では、第１クッション層と第２クッション層をポリウレタンフォームとする例を示した。しかし、第１クッション層と第２クッション層は、この態様に限定されず、ポリエチレンフォーム又はポリエステルフォーム等の樹脂フォームや、不織布を用いることができる。
　実施例２～４では、第１クッション層と第２クッション層の厚さを略同じとする例を示した。しかし、第１クッション層の厚さを、第２クッション層の厚さより厚くしてもよいし、第２クッション層の厚さを、第１クッション層の厚さより厚くしてもよい。これにより、積層成形体の凹凸をバリエーションに富んだデザインで表現することができる。
　実施例２では、第１クッション層１１に第１開口部１１ｃを形成する例を示した。しかし、第１開口部は、第２クッション層に形成されてもよい。
　実施例３では、第２開口部２１１ｃの幅Ｗ２は、第１開口部１１ｃの幅Ｗ１より小さく形成される例を示した。しかし、第２開口部の幅は、第１開口部の幅より大きく形成されてもよい。
　実施例４では、第１クッション層１１の第１開口部１１ｃの幅Ｗ１は、第２クッション層３１１の第２開口部３１１ｃの幅Ｗ３と略同じ大きさにする例を示した。しかし、第１クッション層の開口部の幅と、第２クッション層の開口部の幅とを異ならせることもできる。これにより、積層成形体の凹凸をバリエーションに富んだデザインで表現することができる。
　実施例３では、第１開口部１１ｃと第２開口部２１１ｃは、同じ位置に形成される例を示した。また、実施例４では、第１開口部１１ｃと第２開口部３１１ｃは、異なる位置に形成される例を示した。しかし、第１開口部と第２開口部は、一部のみ重なるように形成されてもよい。
　実施例１～４では、本発明の積層成形体を車両のシートの車両幅方向において中央部に適用する例を示した。しかし、本発明の積層成形体は、車両のシートの周縁部に適用することもできる。また、本発明の積層成形体は、車両のドアトリムや、車両のセンターコンソールや、家具等に適用することもできる。
関連出願の相互参照
　本出願は、２０１９年１１月２１日に日本国特許庁に出願された特願２０１９－２１０７７１に基づいて優先権を主張し、その全ての開示は完全に本明細書で参照により組み込まれる。
 

Claims (9)

  1. 　開口部を形成するようにクッション層を裁断して裁断部を形成する裁断工程と、
    　前記裁断工程で裁断された前記クッション層の下面に、加熱によって接着力を有する接着シートを介して、基材を配置して、第１積層体を形成する基材積層工程と、
    　前記第１積層体の前記裁断部に断熱材を取り付ける断熱材載置工程と、
    　前記断熱材が取り付けられた前記第１積層体を熱圧着する第１熱圧着工程と、
    　前記第１熱圧着工程で熱圧着された前記第１積層体から、前記裁断部を剥離して前記開口部を形成する剥離工程と、
    　前記裁断部が剥離された前記第１積層体の上面に、加熱によって接着力を有する接着シートを介して、表皮を配置して、第２積層体を形成する表皮積層工程と、
    　前記第２積層体を熱圧着して、前記表皮を、前記開口部において、前記開口部を有する前記クッション層の下層に配置される下層材に接合する第２熱圧着工程と、を含む
    　ことを特徴とする、積層成形体の製造方法。
  2. 　前記第２熱圧着工程では、分割面が平坦な金型を使用し、
    　前記開口部は、前記クッション層の厚さの７０％以上の幅を有している
    　ことを特徴とする、請求項１に記載の積層成形体の製造方法。
  3. 　クッション層と、
    　前記クッション層の上面に接合される表皮と、
    　前記クッション層の下面に接合される基材と、を備え、
    　前記クッション層は、開口部を備え、
    　前記表皮は、前記開口部において、前記基材に接合され、
    　前記クッション層は、厚さが２～１５ｍｍで、密度が２０～３５ｋｇ／ｍ３のポリウレタンフォームで形成されている
    　ことを特徴とする、積層成形体。
  4. 　クッション層と、
    　前記クッション層の上面に接合される表皮と、
    　前記クッション層の下面に接合される基材と、を備え、
    　前記クッション層は、第１クッション層と、前記第１クッション層の下面に配置される第２クッション層と、を備え、
    　前記第１クッション層及び前記第２クッション層の少なくとも一方は、第１開口部を備える
    　ことを特徴とする、積層成形体。
  5. 　前記第１開口部は、前記第１クッション層に設けられ、
    　前記表皮は、前記第１開口部において、前記第２クッション層に接合される
    　ことを特徴とする、請求項４に記載の積層成形体。
  6. 　前記第１開口部は、前記第１クッション層に設けられ、
    　前記第２クッション層は、前記第１開口部と同じ位置に、前記第１開口部と幅の異なる第２開口部を備える
    　ことを特徴とする、請求項４に記載の積層成形体。
  7. 　前記第１開口部は、前記第１クッション層に設けられ、
    　前記第２クッション層は、前記第１開口部と異なる位置に、第２開口部を備える
    　ことを特徴とする、請求項４に記載の積層成形体。
  8. 　前記基材は、メッシュ状に形成されている
    　ことを特徴とする、請求項３～７の何れか一項に記載の積層成形体。
  9. 　前記表皮は、複数の貫通孔が形成されている
    　ことを特徴とする、請求項３～８の何れか一項に記載の積層成形体。
     
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