JP3048522B2 - Three-layer laminate sheet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement of a cushioning three-layer laminate sheet used as a skin material of, for example, a vehicle seat or a chair.

[0002]

2. Description of the Related Art Hitherto, as a skin material for a vehicle seat, a chair or the like, a laminated sheet having a skin adhered to one surface of a foamed sheet has been used. At this time, for example, in order to smoothly perform the sewing work, for example, a backing material is often attached to the back surface side for the purpose of enhancing a slipping effect, and the like, and a laminate having a three-layer structure is often used.
Usually, such a laminated sheet is stored in a roll shape or a folded state, cut into necessary dimensions, and sewn into a predetermined shape.

By the way, when such a laminated sheet is used as a skin material of a seat S having a complicated curved surface as shown in FIG. 6, for example, wrinkles e occur at the stage of commercialization, and a load during use is increased. May be repeated and permanent wrinkles e may occur. So, to eliminate such wrinkles,
For example, Japanese Patent Application Laid-Open No. 58-38585,
No. 912 has been proposed. In the former case, when covering the vehicle seat, the minimum direction of the tensile stress of the surface material is set to be the front-back direction of the seat, so that the laminated sheet is easily stretched in the front-rear direction and wrinkles are prevented. Like that. In the latter case, the backing material is easily stretched, and wrinkles are prevented by setting the hardness of the foamed sheet to a predetermined range.

[0004]

However, in the above-mentioned techniques, the materials of the surface material, the backing material, and the foamed sheet are restricted, and it is not possible to use a surface material having poor elasticity. In addition, it is cut from the stored laminated sheet and sewn for the seat and assembled, but in order to eliminate folding wrinkles and sewn wrinkles, heat or steam is generally used to eliminate wrinkles. . At this time, if the backing material is particularly a material that is easily shrunk by heat or steam, the laminated sheet tends to be curved with the front side convex, and this is used for a planar portion or a portion that becomes a concave portion of the product. For example, there is a problem that the backing material is loosened due to the backing material, and wrinkles are generated on the surface material at the stage of commercialization.

[0005] Therefore, wrinkles can be suppressed even when the elasticity is poor as the material of the surface material or the backing material,
In addition, there has been a demand for a laminate sheet having no problem that the front side is convexly curved even when steam or heat is applied to cause wrinkles.

[0006]

According to the present invention, there is provided a three-layer laminate sheet in which a surface material, a foamed sheet, and a backing material are laminated in at least one direction before lamination. The length of the foamed sheet was longer than the length of the surface material. In the second aspect, the length of the foam sheet is set to 1.1 or less when the ratio of the length of the front material to the foam sheet in one predetermined direction is set to 1 for the length of the cover material. And more preferably it is 1.05 or less.

[0007] As described above, by making the foamed sheet longer than the surface material, a force acts to bend (hereinafter, referred to as reverse warpage) in a direction in which the front side is depressed in one predetermined direction. Even when used for a part having a planar shape or a part having a concave shape of a product, the tendency of the surface material to loosen is reduced, which is effective in preventing wrinkles from occurring. In addition, in a portion where the product has a convex shape, even if the laminated sheet is subjected to a tensile force, the surface material is less likely to be loosened, so that there is little problem of wrinkles at the stage of commercialization. Further, for example, when such a laminate sheet is used for a seat or the like, it is general that the surface material side is dented when a load is applied, and the foam sheet side is generally deformed to be a convex part, but it is on the convex part side. Since the foam sheet is longer, distortion is less likely to occur even when a load is applied, and wrinkles are eliminated when the load is released. here,
If the direction in which the length is changed is, for example, the feed direction of the material during the production of the laminate, the production is easy.

According to a third aspect of the present invention, when the ratio of the length of the front material to the backing material in a predetermined direction is set to 1 for the length of the front material,
The length of the backing material was 0.95 to 1.2. If the length of the backing material is longer than that of the surface material, for example, even when the backing material shrinks due to heat or steam, the tendency of the surface material to curve convexly can be suppressed, and the portion or concave shape that becomes the planar shape of the product There is no problem that the surface material is loosened and wrinkles are generated even when it is used for the portion where

In this case, if the length of the backing material on the convex portion side when a load is applied is increased, distortion is less likely to occur even when the load is applied, and wrinkles are easily eliminated when the load is released. Is the same as However, if the backing material does not shrink due to steam or the like, or if the degree of the effect of curving the surface material convexly is small even if it shrinks, the backing material may be shorter than the surface material. When the length is made longer, if the backing material exceeds 1.2 with respect to 1 of the surface material, irregularities may be generated on the back side as a laminate, and if the length is made shorter, the initial purpose is not achieved if the length is less than 0.95. There are cases. Further, when the length is increased, it is more preferably 1.1 or less, and further preferably 1.
06 or less, and more preferably 0.98 or more when shortened.

[0010]

Embodiments of the present invention will be described with reference to the accompanying drawings. Here, FIG. 1 is an explanatory view showing the length when the laminated sheet of the present invention is cut out in the longitudinal direction and peeled into three layers, (A) is a state diagram before peeling, and (B) is a state after peeling. FIG. 2, FIG. 2 is an explanatory view for explaining the operation of the present laminated sheet, FIG. 3 is a view showing an example of a laminating process of the laminated sheet, and FIG. FIG. 5 is an explanatory view showing a state in which wrinkles occur in a conventional laminated sheet.

The three-layer laminate sheet of the present invention is configured as a cushioning skin material for covering the surface of, for example, a vehicle seat or a chair, and as shown in FIG. 2, a foamed resin sheet 3 as a foamed sheet,
A backing cloth 4 as a backing material is laminated to form a three-layer structure. The laminated sheet 1 of the present invention is designed so that wrinkles do not occur even when it is used for a complicated shape part. It is characterized in that the generation of wrinkles is suppressed.

Therefore, before describing the laminated sheet 1 of the present invention, the laminating process of the laminated sheet 1 and the occurrence of wrinkles in the conventional laminated sheet will be described with reference to FIGS.

In a frame laminating system, which is an example of laminating the laminate sheet 1, for example, as shown in FIG. 3, a foam resin sheet 3 is fed by a pair of feed rollers 5a and 5b, and a downstream surface cloth laminating roller is used. 6a and 6b, the one-side surface of the foamed resin sheet 3 is melted by the flame of the burner 7 on the way, and the surface cloth 2 is separately fed between the surface cloth laminating rollers 6a and 6b. The foamed resin sheet 3 is pressed and laminated on the molten surface side.

Next, the two-layer laminated sheet is fed to the backing cloth laminating rollers 8a and 8b further downstream, and the opposite side of the foamed resin sheet 3 is melted by a burner 7, and separately from the backing laminating roller. The backing cloth 4 is fed between the rollers 8a and 8b and pressed against the backside molten surface to produce the laminated sheet 1.

In such a laminating step, the lengths of the front cloth 2, the foamed resin sheet 3 and the back cloth 4 of the laminated sheet 1 are generally set in the vertical direction (the feeding direction in the laminating step). When the foamed resin sheet 3 having a large amount of deformation in the thickness direction when being sandwiched by rollers tends to be slightly shorter than the surface cloth 2 or the like, when the laminated sheet 1 is cut, as shown in FIG. Then, the surface cloth 2 side (upper side) had a tendency to warp so as to be slightly convex.

For example, when steam or the like is applied in order to extend wrinkles during folding at the sewing stage, depending on the type of the backing cloth 4, the backing cloth 4 shrinks to promote warpage as shown in (b). The surface cloth 2 side was more convex.

When the degree of warping is increased, a force is applied to the side opposite to the direction of the warp to use the warp in the flat portion of the product or the concave portion of the product. As shown in FIG. The surface cloth 2 tended to be slackened in response to the tension of No. 4 and wrinkles e were generated. In general, when such a laminate sheet 1 is used for a seat or the like, a load is generally applied in a direction in which the surface cloth 2 becomes concave, and as shown in FIG. When a load was applied to the laminated sheet having a protruding side, wrinkles were generated on the outer cloth 2, and when the load was repeated, permanent wrinkles were easily generated.

Therefore, according to the present invention, a laminated sheet 1 is obtained by laminating a surface cloth 2 and a foamed resin sheet 3 having different longitudinal lengths before lamination. That is, as shown in FIG. 1A, after a part of the laminate sheet 1 is cut out in the vertical direction,
As shown in (B), when the three layers are peeled off, the foamed resin sheet 3 is made longer than the front cloth 2, and preferably the backing cloth 4 is made longer than the foamed resin sheet 3. ing.

When such a laminated sheet 1 is manufactured from a long sheet material, for example, the tension of the top cloth 2, the foam resin sheet 2 and the back cloth 4 is adjusted, or a phase difference is given to the roll rotation. The length can be changed depending on the conditions. Of course, this laminating method is not limited to the frame laminating method, but may be a method using another solvent-based adhesive, a method using a water-soluble adhesive, a method using a hot melt adhesive, or the like. Also, the stacking order is not particularly limited, and is arbitrary. In addition, the timing of lamination is not to laminate three layers at the same time,
A method in which two layers are stacked in advance and wound up, and then unwound and stacked in three layers may be used.

The reason why the generation of wrinkles is suppressed by making the foamed resin sheet 3 longer than the outer cloth 2 is considered as follows. First, by laminating the foamed resin sheet 3 longer than the surface cloth 2, the laminated sheet 1 can be provided with a curved surface having a reverse warpage with the surface cloth 2 side concave in the laminating stage. Even when used on a flat portion or a concave portion of the product, wrinkles are less likely to be generated on the outer cloth 2. In addition, by giving a slight reverse warpage tendency in advance, wrinkles are less likely to occur when the load is applied to the outer cloth 2 and it is dented. Moreover, when the load is released, wrinkles are easily eliminated. From this point, if it is possible to prevent a warp that makes the outer fabric 2 side extremely convex in the laminating stage, for example, as shown in FIG. The length may be the same or, as shown in (B), shorter than the foamed resin sheet 3, or the same length as or slightly shorter than the outer cloth 2.

Next, the effect of making the back cloth 4 longer than the foamed resin sheet 3 is as follows. Even when the back cloth 4 shrinks when steam is applied in order to eliminate folding wrinkles and sewing wrinkles in a sewing process or the like, no warping occurs or wrinkles are hardly generated without large warping. Incidentally, it is said that about 2% of shrinkage occurs in nylon spunbond or the like by steaming.

For the above reasons, it is most effective to prevent the wrinkles from increasing the length of the foamed resin sheet 3 in the order of the front cloth 2 and the backing cloth 4 in the order of the foamed resin sheet 3. Assuming that the length of the outer cloth 2 is 1,
Reduce the length of the foamed resin sheet 3 to 1.1 or less, and
It is effective to make the length 0.95 to 1.2.

The material of the outer cloth 2 may be natural fiber,
Knitted fabrics and woven fabrics made of synthetic fibers and the like can be used, but it is particularly effective for woven fabrics with poor elasticity, such as moquettes, which are conventionally considered to be easily wrinkled. The elongation is preferably 10% or less. Here, the constant load elongation rate is 50 mm in width and 150 mm in length, and 1
The test specimens marked with a line at intervals of
kg), and the elongation δ when pulled for a predetermined time (5 minutes) is divided by the dimension between the marked lines (L = 100 mm) as a percentage (δ / L × 10
0).

The material of the foamed resin sheet 3 is as follows.
Polyurethane foam, polyethylene foam, polypropylene foam, polyvinyl chloride foam and the like can be applied, but polyurethane foam is particularly preferred.
Incidentally, polyester cotton can be used instead of the foamed resin sheet. As the material of the backing cloth 4, knitted fabrics such as general natural fibers and synthetic fibers, woven fabrics, long-fiber nonwoven fabrics such as nylon and polyester by a spunbonding method can be used. In addition, it may be a coating layer.

The effect of suppressing the generation of wrinkles of the laminated sheet 1 described above will be described with reference to FIG. 2. As shown in FIG. Even if this is steamed and the backing cloth 4 shrinks,
As shown in (b), even if it returns to the level of a flat surface, the surface cloth 2 does not warp enough to cause wrinkles. Even if such a laminate sheet 1 is commercialized and a load is applied temporarily as shown in (c) and wrinkles are temporarily generated, the wrinkles are eliminated as shown in (d) when the load is removed. .

[0026]

EXAMPLE Now, a specific example will be described.

(Example 1) The front cloth 2 was a moquette having a thickness of 2.5 mm, the foamed resin sheet 3 was a polyurethane foam having a thickness of 12 mm, and the backing cloth 4 was a nylon spun bond having a thickness of 0.3 mm. The wrinkles were set as shown in Table 1 and the occurrence of wrinkles was compared with the comparative example. Here, the constant load elongation of the moquette was 1% length, and the constant load elongation of the nylon spunbond was 2% vertical.

[0028]

[Table 1]

As a result, in the comparative example, when the laminate sheet 1 was laminated, the surface cloth 2 side was convexly warped by 16 mm, and wrinkles occurred when used in a product.
When the laminate sheet 1 is laminated, the surface cloth 2 side becomes concave -15.
mm Reverse warpage and no wrinkles when used for products.

(Example 2) The front cloth 2 was a jacquard having a thickness of 1 mm, the foamed resin sheet 3 was a polyurethane foam having a thickness of 10 mm, and the backing cloth 4 was a nylon spun bond having a thickness of 0.3 mm. The conditions of wrinkles were set as shown in Table 2 and compared with the comparative example. Here, the constant load elongation of Jacquard was 2%.

[0031]

[Table 2]

As a result, in the comparative example, when the laminated body sheet 1 was laminated, the side of the outer cloth 2 was warped 5 mm in a convex shape and sewed to use the product. As a result, the backing cloth 4 contracted and convex warpage increased, and wrinkles occurred when used for a seat. In the present embodiment, the side of the outer fabric 2 was concavely warped by -12 mm at the stage when the laminated body sheets 1 were laminated, and no wrinkles were generated when used for a product.

The laminated sheet 1 as described above can be widely applied to seats for vehicles, chairs for dining sets, dining chairs, and office chairs, in addition to vehicle seats.

[0034]

As described above, according to the present invention, in the three-layer laminated sheet of the front material, the foamed sheet, and the backing material, the length of the foamed sheet in at least one direction is determined by the length of the surface material. Since the length is longer than the length, it is possible to cause a reverse warpage tendency such that the surface material becomes concave in the laminate sheet, and even when used for a part having a planar shape or a concave shape of a product, wrinkles are hardly generated. Become. Further, even when a load is applied, distortion is unlikely to occur, and when the load is eliminated, wrinkles are easily eliminated. At this time, assuming that the ratio of the length of the surface material to the foam sheet in one predetermined direction is set to 1, the length of the foam sheet is 1.1 or less. This is particularly effective. Further, as in claim 3, when the ratio of the length of the front material and the backing material in one predetermined direction is set to 1 for the length of the front material,
If the length of the backing material is 0.95 to 1.2, it is effective in preventing the occurrence of wrinkles.

[Brief description of the drawings]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an explanatory view showing a length when a laminated sheet of the present invention is cut out in a longitudinal direction and peeled into three layers, (A) is a state diagram before peeling, and (B) is a state diagram after peeling.

FIG. 2 is an explanatory view for explaining the function of the present laminated sheet.

FIG. 3 is an example of a laminating process of a laminated sheet.

FIG. 4 is an explanatory view showing another example of the length of the three-layer material of the laminated sheet;

FIG. 5 is an explanatory view of a state in which wrinkles occur in a conventional laminated sheet.

FIG. 6 is an explanatory diagram of wrinkles generated in a seat.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... laminated sheet, 2 ... table cloth, 3 ... foamed resin sheet, 4
... back cloth.

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 A47C ^7/ 18-7/20

Claims (5)

(57) [Claims] 1. A three-layer laminated structure in which a front material, a foam sheet, and a backing material are laminated, wherein the length of the foam sheet in at least one direction before lamination is longer than the length of the front material. Three-layer laminate sheet. 2. A three-layer laminated structure in which a surface material, a polyester cotton, and a backing material are laminated, wherein the length of the polyester cotton in at least one direction before lamination is longer than the length of the surface material. A three-layer laminate sheet characterized by the above-mentioned. 3. The method of claim 1 or, in a three layer laminate <br/> sheet according to 2, and the table member foamed sheet or Poriesu
The ratio of the length of the predetermined direction of the tell cotton is 1
Wherein the length of the foamed sheet or the polyester cotton is 1.1 or less. 4. The three-layer laminate sheet according to claim 3, wherein the ratio of the length of the front material and the backing material in one predetermined direction is:
When the length of the front material is 1, the length of the backing material is 0.95
1.2. A three-layer laminate sheet, characterized by being 1.2. 5. The three-layer laminate sheet according to claim 3, wherein the length of the backing material is longer than the length of the front material.