JP6529645B2 - Laminated sheet having a concavo-convex pattern on its surface and method of manufacturing the same - Google Patents

Description

  The present invention relates to a laminated sheet having a surface on which a flexible surface member is laminated and integrated with a flexible polyurethane foam and having an uneven pattern formed by heat compression molding, and a method of manufacturing the same.

DESCRIPTION OF RELATED ART As a skin material used for a seat skin of vehicles, such as a motor vehicle, or a skin for furniture, there exists a lamination sheet which has a concavo-convex pattern on the surface.
The laminated sheet having the uneven pattern on its surface is manufactured by laminating and integrating a flexible surface member on a flexible polyurethane foam, and thermally compressing the surface with a pressing device having the uneven pattern formed on the surface.

  However, the conventional laminated sheet having a concavo-convex pattern on the surface is not flexible unless it is used as a flexible polyurethane foam having a compressive residual strain (JIS K 6400-4: 70 ° C. × 22 hours × 50% compression) of 25 to 50%. Since the pattern can not be formed clearly, the compressive strain due to the long-term use of the product is large, and there is a problem that the concavo-convex pattern becomes unclear and the appearance is deteriorated by the long-term use.

JP, 2007-331222, A

  The present invention has been made in view of the above-mentioned points, and even if a flexible polyurethane foam having a smaller compression residual strain than in the prior art can be used, the asperity pattern can be made sharp and the compression strain due to long-term use of the product is small. It is an object of the present invention to provide a laminated sheet having on the surface thereof a concavo-convex pattern capable of maintaining a favorable concavo-convex pattern even by long-term use and a method of manufacturing the same.

The invention of claim 1 is a laminate sheet having a flexible polyurethane foam integrally laminated with a flexible surface member, and having a concavo-convex pattern formed by heat compression molding on the surface, wherein the flexible polyurethane foam has an ester group. When other polyols are contained together with the polyol having an ester group, when at least one of a phosphate ester type flame retardant or an ester type additive is contained together with the ester group-containing polyol, the ester ester group containing polyol is not contained, a phosphate ester based flame retardant or The ester value (in accordance with JIS K 0070) in these cases is 40 to 400 mg KOH / g, and the compression residual strain (JIS K 6400-4 6.2B method, 70), in any of the cases where at least one of the ester additives is included. 1% to 15% after a 50% compression) of 22 ° C. for 22 hours; Hardness (JIS K 6400-2: 2004) of 60 to 200 N, and the height of the convex or concave portion of the concavo-convex pattern formed on the surface is 3 to 30 mm. It is characterized by
According to a second aspect of the present invention, in the first aspect, the flexible polyurethane foam is 50% of the original thickness using a spacer of 5 mm with respect to the flexible polyurethane foam having a square cross section of 50 mm on one side and a thickness of 10 mm. It is characterized in that it is made of a flexible polyurethane foam having a forming ratio of 70 to 100% calculated by the following equation using a thickness compressed at 80 ° C. for 240 seconds and compressed.
Forming ratio (%) = [(original thickness−thickness after compression) / (original thickness−spacer thickness)] × 100

According to the invention of claim 3, the surface of the laminated sheet obtained by laminating and integrating the flexible surface member on the flexible polyurethane foam is thermally compressed by pressing the surface with the pressurizing device having the surface on the surface. In the method for producing a laminated sheet, when the flexible polyurethane foam contains another polyol together with a polyol having an ester group, the flexible polyurethane foam contains at least one of a phosphate ester-based flame retardant or an ester based additive together with a polyol having an ester group. In this case, the ester does not contain a polyol having an ester group, and at least one of a phosphoric acid ester-based flame retardant or an ester-based additive, and the ester value (in accordance with JIS K0070) in these cases is 40 to 400 mg KOH / G, compressive residual strain (JIS K 6400-4 6.2B method, 70 ° C. × 22 Between 1 and 15%), the density (JIS K 7222: 1999) of the flexible polyurethane foam is 15 to 80 kg / m 3, and the hardness (JIS K 6400-2: 2004) is 60. The surface member is any of a knitted fabric and a flexible and stretchable woven fabric, and the surface member and the flexible polyurethane foam are welded by frame lamination, and It is characterized in that the height of the convex portion or the depth of the concave portion of the formed uneven pattern is 3 to 30 mm.
According to a fourth aspect of the present invention, in the third aspect, the flexible polyurethane foam is 50% of the original thickness using a spacer of 5 mm with respect to the flexible polyurethane foam having a square cross section of 50 mm on one side and a thickness of 10 mm. 80 ° C., is compressed 240 seconds heat molding rate calculated by the following equation is characterized by comprising the flexible polyurethane foam is 70 to 100% using the compressed thickness.
Forming ratio (%) = [(original thickness−thickness after compression) / (original thickness−spacer thickness)] × 100

  According to the invention of claims 1 and 2, the flexible polyurethane foam has an ester value (according to JIS K 0070) of 40 to 400 mg KOH / g, compressive residual strain (JIS K 6400-4 6.2 B method, 70 ° C. × 22 hours × By using 1 to 15% of after 50% compression), even when using a flexible polyurethane foam with small compression residual strain, the unevenness pattern can be made sharp, and the compression residual strain of the product is small, and the long-term A good uneven pattern can be maintained also by use.

  According to the invention of claims 3 and 4, it is easy to easily form a laminated sheet having a concavo-convex pattern on the surface which has a sharp concavo-convex pattern on the surface and small compressive residual strain and can maintain a favorable concavo-convex pattern even after long-term use. You can get it.

It is a sectional view showing a part of lamination sheet which has a concavo-convex pattern of an embodiment on the surface. It is a schematic sectional drawing which shows manufacture of the lamination sheet which has an uneven | corrugated pattern on the surface. It is sectional drawing which shows the other example of the uneven | corrugated shaped uneven | corrugated surface.

  Hereinafter, embodiments of the present invention will be described. The laminated sheet 10 having the concavo-convex pattern shown in FIG. 1 is used as an interior material of a vehicle, for example, a seat cover, a door trim, a furniture cover, etc. Is integrally laminated, and has a concavo-convex pattern 23 formed by heat compression molding on the surface. The concavo-convex pattern 23 is not limited to the one in which the convex portions 24 are arranged in a lattice shape, but may be arranged so as to constitute a required pattern, and the convex portions 24 and the concave portions 25 may be formed. The arrangement of Moreover, as for the height (the depth of the recessed part 25) of the said convex part 24, about 3-30 mm is preferable.

  The flexible polyurethane foam 11 has an ester value (according to JIS K 0070) of 40 to 400 mg KOH / g, more preferably 45 to 400 mg KOH / g, compressive residual strain (JIS K 6400-4 6.2B method, 70 ° C. × 22 Time × 50% after compression) consists of 1 to 15%. When the ester value is less than 40 mg KOH / g, the irregular shape is reduced. On the other hand, when it exceeds 400 mg KOH / g, the heat and moisture resistance of the urethane foam may be deteriorated and it may not be suitable as a surface material for automobiles. In addition, when the compression residual strain (JIS K 6400-4 6.2B method, 70 ° C. × 22 hours × 50% compression) is less than 1%, the molding time required for the concavo-convex shaping tends to be long, and the molding cycle May be longer. On the other hand, if it exceeds 15%, the compressive residual strain of the product is aggravated, and the projected pattern often tends to be unclear due to the long-term use of the product, leading to a decrease in the design of the irregularities.

The flexible polyurethane foam 11 is formed of a polyurethane raw material including a polyol, a foaming agent, a catalyst, a foam stabilizer, a polyisocyanate, and appropriate additives. The density (according to JIS K 7222: 1999) of the flexible polyurethane foam 11 is 15 to 80 kg / m ³ , the hardness (based on JIS K 6400-2: 2004) is 60 to 200 N, more preferably 60 to 160 N, and the thickness About 3 to 30 mm is preferable. If the hardness exceeds 200 N, the foam surface becomes too hard, and the cushioning property and feel as a laminated sheet deteriorate.

The polyol may be any of polyether polyol, polyester polyol and polyether ester polyol, and one or more of them may be used.
Examples of polyether polyols include ethylene oxide (EO) (polyethylene glycol) such as ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, neopentyl glycol, glycerin, pentaerythritol, trimethylolpropane, sorbitol, sucrose, etc. And polyether polyols to which alkylene oxides such as propylene oxide (PO) are added. When the polymer polyol is used at 50% or more of the polyol component, the hardness becomes too hard, and the distortion also becomes worse.

Examples of polyester polyols include polycondensed from aliphatic carboxylic acids such as malonic acid, succinic acid and adipic acid, and aromatic carboxylic acids such as phthalic acid and aliphatic glycols such as ethylene glycol, diethylene glycol and propylene glycol And polyester polyols obtained by
Further, examples of the polyether ester polyol include those obtained by reacting the above-mentioned polyether polyol with a polybasic acid to form a polyester, or those having both a segment of a polyether and a polyester in one molecule.
In the present invention, the use of a polyol having an ester group, specifically, a polyester polyol or a polyether ester polyol as the polyol, can make the ester value of the flexible polyurethane foam 11 a specific range, and the foam is It is more preferable in terms of improving the formability and distortion.

  As the blowing agent, water or a hydrocarbon such as pentane can be used alone or in combination. In the case of water, carbon dioxide gas is generated during the reaction of the polyol and the polyisocyanate, and the carbon dioxide gas causes foaming. The amount of the foaming agent is properly selected, but in the case of water, 1 to 8 parts by mass is suitable with respect to 100 parts by mass of the polyol.

  As catalysts, known ones for flexible polyurethane foams can be used. For example, mention may be made of amine catalysts such as triethylamine and tetramethylguanidine, tin catalysts such as stannas octoate, and metal catalysts such as phenylmercuric propionate or lead octenoate (also referred to as an organic metal catalyst). Can. The general amount of catalyst is 0.1 to 2 parts by weight with respect to 100 parts by weight of polyol.

  As a foam stabilizer, those known for flexible polyurethane foams can be used. For example, silicone based foam stabilizers, fluorine-containing compound based foam stabilizers and known surfactants can be mentioned. The general amount of the foam stabilizer is 0.5 to 3 parts by mass with respect to 100 parts by mass of the polyol.

  As the polyisocyanate, aliphatic or aromatic polyisocyanates having two or more isocyanate groups, mixtures thereof, and modified polyisocyanates obtained by modifying them can be used. Examples of aliphatic polyisocyanates include hexamethylene diisocyanate, isophorone diisocyanate, and dicyclohexamethane diisocyanate. Examples of aromatic polyisocyanates include toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), naphthalene diisocyanate, and xylyl diisocyanate. There may be mentioned diisocyanate, polymeric polyisocyanate (crude MDI) and the like. Other prepolymers can also be used.

  The isocyanate index is preferably 90 to 120. The isocyanate index is a value obtained by dividing the number of moles of isocyanate groups in the polyisocyanate by the number of moles of hydroxyl groups of the polyol and the total number of active hydrogen groups such as water as a foaming agent by 100 and multiplying [NCO equivalent of polyisocyanate / Equivalent hydrogen equivalent × 100].

  Examples of suitable additives include flame retardants, ester additives, colorants, auxiliary blowing agents and the like. Examples of flame retardants include halogenated polymers such as polyvinyl chloride, chloroprene rubber and chlorinated polyethylene, phosphoric acid esters and halogenated phosphoric acid ester compounds, organic flame retardants such as melamine resin and urea resin, antimony oxide and hydroxylated water Inorganic flame retardants, such as aluminum, etc. can be mentioned. In particular, a flame retardant comprising a phosphoric acid ester can increase the ester number of the flexible polyurethane foam 11 together with the improvement of the flame retardancy, but particularly when the polyol uses only polyether polyol, the ester number of the flexible polyurethane foam 11 Within the scope of the present invention, the shapeability is improved. The general amount of the flame retardant is 2 to 30 parts by mass with respect to 100 parts by mass of the polyol.

The ester-based additive is used to prepare the ester value of the flexible polyurethane foam 11, and examples thereof include rosin esters and the like. In particular, when the polyether polyol alone is used as the polyol and the flame retardant is not a phosphoric acid ester, the ester value of the flexible polyurethane foam can be facilitated within the scope of the present invention by the use of an ester-based additive. Examples of ester-based additives include rosin esters and acrylic esters. When an ester-based additive is used, the addition amount thereof varies depending on the type of polyol, the type of flame retardant, and the like, but, for example, 1 to 30 parts by mass with respect to 100 parts by mass of polyol.
Examples of the auxiliary blowing agent include volatile solvents, methylene chloride (methylene chloride, CH ₂ Cl ₂ ), fluorocarbon compounds (trichlorofluoromethane, dichlorodifluoromethane, etc.), liquefied carbon dioxide gas, and the like.

  The flexible polyurethane foam 11 is made to react by mixing and reacting polyurethane raw materials comprising the above-mentioned polyol, blowing agent, catalyst, foam stabilizer, appropriate additives (flame retardant, ester additive etc.) and polyisocyanate etc. with a stirrer. It forms by the well-known foaming method to foam. Moreover, what the said flexible polyurethane foam 11 cut | judged the soft slab foam to predetermined thickness is preferable. The soft slab foam is a flexible polyurethane foam obtained by carrying out the reaction and foaming of the polyurethane raw material at normal temperature and atmospheric pressure, and is rich in mass productivity and has a yield higher than that of mold molding.

The flexible polyurethane foam 11 can be obtained by using a polyol having an ester group, or by using a phosphoric acid ester flame retardant, or by using an ester additive, or by using them in combination. The ester value (in accordance with JIS K 0070) can be 40 to 400 mg KOH / g.
Moreover, the compression residual strain (JIS K 6400-4 6.2B method, after 70 ° C. × 22 hours × 50% compression) of the flexible polyurethane foam 11 uses a polyol having an ester group as a polyol, and a large amount of polymer polyol is used. (50% or more) and can be obtained by using polyetherpolyol, polyesterpolyol and polyetheresterpolyol.

The surface member 21 is made of an appropriate material such as a knitted fabric, a flexible / stretchable woven fabric, a non-woven fabric, and the like, and is selected according to the use of the laminated sheet. Specifically, the surface member is a knitted fabric such as tricot, jersey, double russell, etc., a woven fabric / non-woven fabric made of fibers including elastic fibers having stretchability, and a non-woven fabric having many embossed portions formed thereon. And those to which elasticity is imparted, and needle punched non-woven fabrics having excellent elasticity which crimps fibers in a spiral shape are preferable.
The integration of the surface member 21 and the flexible polyurethane foam 11 is performed by welding using a frame laminate or the like, an adhesive, or the like as described later.
In addition, depending on the use of the laminated sheet 10 having the uneven pattern on the surface, the back base fabric may be integrally laminated on the back surface of the flexible polyurethane foam 11 on the opposite side to the surface member 21.
The laminated sheet 10 is preferably a three-layer composite sheet obtained by laminating a back base cloth, in particular, a woven or non-woven fabric with little stretchability on the back surface of the flexible polyurethane foam 11. Specifically, in the case of non-woven fabric, woven fabric or knitted fabric made of nylon polyester having a basis weight of 30 g / m ² or more, queen-knitted fabric is preferable. The presence of the less stretchable back base fabric is preferable because a firm feeling is generated and the soft polyurethane foam formed on the unevenness weakens the force to return smooth.
The laminated sheet 10 having the uneven pattern on the surface is used by being made into a predetermined shape by sewing or the like according to the application. For example, in the case of the skin of the seat, the laminated sheet 10 having the uneven pattern on the surface is formed into a bag shape by sewing or the like with the uneven pattern outside, and covers the cushion body.

The manufacturing method of the lamination sheet 10 which has the said uneven | corrugated pattern on the surface is demonstrated. The manufacturing method of the lamination sheet 10 which has the said uneven | corrugated pattern on the surface consists of a lamination integration process and an uneven | corrugated pattern shaping process.
In the lamination integration step, the surface member 21 is laminated and integrated on one surface of the flexible polyurethane foam 11 by a known lamination integration method such as frame lamination, lamination using an adhesive, etc. The laminated sheet 10A before shaping shown in) is obtained. In addition, when using a back base cloth, the back base cloth is laminated | stacked at this process, and the lamination sheet of the three-layer structure before shaping is obtained.

The frame laminate is a method of melting the surface of the flexible polyurethane foam 11 by irradiation of a flame burner or the like, laminating the surface member 21 on the molten surface and welding. The frame laminate is usually continuous by continuously melting the surface of the flexible polyurethane foam 11 with a flame burner or the like while continuously feeding the flexible polyurethane foam 11 and continuously laminating the surface member 21 on the molten surface. It is done by molding. The temperature of the flame burner or the like is generally about 600 to 1300 ° C. Further, in the case of using the back base cloth, after welding of the surface member, the other surface of the flexible polyurethane foam 11 is melted by a flame burner or the like to weld the back base cloth to the molten surface.
On the other hand, in a laminate using an adhesive, the adhesive is applied to the adhesive surface of at least one of the flexible polyurethane foam 11 and the surface member 21 so as to sandwich the adhesive coated surface, the flexible polyurethane foam 11 and the surface member 21 are It is a method of overlapping and bonding. As the adhesive, a hot melt adhesive or the like is used. When the back base cloth is used, the back base cloth is adhered to the other side of the flexible polyurethane foam 11 with an adhesive.

  In the concavo-convex pattern shaping step, the surface of the surface member 21 of the laminated sheet 10A before shaping is thermally compressed by a concavo-convex shaping device having a concavo-convex pattern formed on the surface to form a concavo-convex pattern. The heat compression by the concavo-convex shaping apparatus having the concavo-convex pattern formed on the surface includes a heat pressing method using a concavo-convex shaping type having the concavo-convex pattern formed on the surface, a roll thermal compression method using an embossing roll, and the like.

  The heat pressing method will be described. In the heat pressing method, as shown in (2-B) of FIG. 2, the surface member 21 has irregularities between the base 31 and the heatable irregularity shaping mold 33 which can heat the laminated sheet 10A before shaping. As shown in (2-C) of FIG. 2, the convex portion 35 of the irregular shaped surface 33 of the irregular shaped surface 33 is heated so as to face the uneven surface 34 of the shaped shape 33. The surface member 21 of the laminated sheet 10A before shaping is thermally compressed to form an uneven pattern on the surface. The concavo-convex surface 34 of the concavo-convex shaping mold 33 is constituted by a plurality of convex portions 35 and concave portions 36 formed at predetermined intervals. Further, the concavo-convex shaping mold 33 can be heated by disposing a heat plate on the back surface, or by disposing a heating wire inside. 170-210 degreeC of the heating temperature of the said concavo-convex shaping type 33 is preferable. Moreover, as for the pressurization time with respect to 10 A of lamination sheets before the said shaping | molding, 60 to 400 seconds are preferable. Even in the case of using a three-layered laminated sheet in which a back base fabric is laminated as the laminated sheet 10A, the surface member 21 is thermally compressed so as to face the uneven surface 34 of the uneven shape forming mold 33.

  The concavo-convex shape of the concavo-convex shaping type is a concavo-convex surface 34A having an R-shaped cross section as in the concavo-convex shaping type 33A shown in (3-A) of FIG. As in the case of 33B, it is also possible to form a freely designed shape such as a slanted tapered uneven surface 34B to gradually change the compression state. Even in this case, it is possible to shape the shape along the uneven surface shape of the above-mentioned uneven shape forming type by using the polyurethane foam of the present invention with good heat formability.

  On the other hand, in the roll thermal compression method, the surface member 21 of the pre-forming laminated sheet 10A continuously supplied is thermally compressed by an emboss roll (not shown) having a concavo-convex pattern on the surface and made heatable. Form an uneven pattern on the surface. The heating temperature of the emboss roll is preferably 180 to 220 ° C., and the supply speed of the lamination sheet 10A before shaping is preferably about 1 to 10 m / min.

  Using polyurethane raw materials prepared by blending the following polyols, blowing agents, catalysts, foam stabilizers, flame retardants and polyisocyanates according to the composition of Table 1, flexible polyurethane foams of each example, reference example and comparative example are obtained by slab foaming method Created. About the flexible polyurethane foam of each Example, a reference example, and a comparative example, an ester value (JIS K0070 conformity), a compression residual strain (JIS K 6400-4 6.2B method, 70 degreeC x 22 hours after 50% compression), a density The hardness (in accordance with JIS K7222) and the hardness (in accordance with JIS K 6400-2: 2004) were measured. The measurement results are shown in the middle part of Table 1.

-Polyol A: Polyether polyol, molecular weight 3000, functional group number 3, hydroxyl value 56 mg KOH / g, product name: Sannix GP 3000, Sanyo Chemical Industries, Ltd.-Polyol B: Polyether ester polyol, functional group number 3, hydroxyl value 56 mg KOH / g Product name: Actocol L-50 manufactured by Mitsui Takeda Chemical Co., Ltd. Polyol C: polyester polyol, molecular weight 2500, functional group number 2.7, hydroxyl value 60.5 mg KOH / g, product name: polyol N2200 manufactured by Nippon Polyurethane Industry Co., Ltd. -Foaming agent: Water-Auxiliary foaming agent: Methylene chloride-Amine-based catalyst: Mixture of triethylenediamine and dipropylene glycol in a weight ratio of 1: 2, Product name: DABCO 33-LV, manufactured by Air Products Japan Co., Ltd.-Tin-based catalyst: Sta Nass octoate, goods : MRH-110, Johoku Chemical Industry Co., Ltd.-Stabilizer: silicone foam stabilizer, Name: DABCO DC 5160, Air Products Japan Ltd.-Flame retardant: phosphate ester flame retardant, Name: CR-504L, Daihachi Chemical Polyisocyanate: Tolylene diisocyanate (TDI in which 2,4-TDI and 2,6-TDI are in a ratio of 80:20), product name: TDI-80, manufactured by Nippon Polyurethane Industry Co., Ltd.

What cut the soft polyurethane foam of each Example and Comparative Example into a thickness of 15 mm was continuously supplied, and the following surface members and back base cloth were integrally laminated by frame lamination to prepare a laminated sheet before shaping. The flexible polyurethane foam feed rate is 20 m / min.
Surface member: Tricot, basis weight 300 g / m ² .
Back base cloth: non-woven fabric, material: nylon, 30 g / m ^{2 of} fabric weight.

The laminated sheet before shaping is thermally compressed from the surface member side by heat pressing using the concavo-convex shaping type shown in (2-B) and (2-C) in FIG. The laminated sheet which has the uneven | corrugated pattern of a comparative example on the surface was created. The plurality of convex portions formed in the concavo-convex shape have a square cross section with one side of 500 mm, and consist of a columnar body with a height of 13 mm, and the convex portions are arranged in a grid with an interval of 40 mm. . The heating temperature of the uneven shaping type is 180 ° C., and the pressurizing time is 240 seconds. The formability of the concavo-convex pattern on the surface and the formability after hot pressing were determined for the laminated sheet having the concavo-convex pattern of the example, the reference example and the comparative example on the surface.
The formability is judged by the forming ratio after hot pressing, and if the forming ratio is 100 to 90% or more, “「 ”, if less than 90 to 70%,“ o ”, if less than 70% It was "x". In addition, the forming ratio of urethane foam after heat pressing is as follows: heat compression molding of a square cross section of 50 mm on one side and a 10 mm thick urethane foam at 80 ° C. for 240 seconds using a 5 mm spacer (original thickness The thickness after compression was measured. The results are shown at the bottom of Table 1.
The forming ratio was determined by the following formula.
Forming ratio (%) = [(original thickness−thickness after compression) / (original thickness−spacer thickness)] × 100

  In the comparative example having an ester value of less than the range of the present invention, the surface irregularities were unclear and the moldability was inferior. On the other hand, in each of the examples, the surface irregularities were sharp and the formability was good.

  Thus, the laminated sheet having the concavo-convex pattern in the present invention has a compressive residual strain of flexible polyurethane foam (JIS K 6400-4 6.2B method, after 70 ° C. × 22 hours × 50% compression) than before. Even if it is small, the unevenness pattern can be made sharp, and by using a flexible polyurethane foam whose compression residual strain is smaller than that in the past, the unevenness pattern can be used even when used for a long time as a skin material of a seat etc. Can suppress blurring and maintain a good uneven pattern.

10 Laminated sheet having a concavo-convex pattern on the surface 11 flexible polyurethane foam 21 surface member 23 concavo-convex pattern 24 convex part 25 concave part

Claims (4)

In a laminate sheet in which a flexible surface member is laminated and integrated on a flexible polyurethane foam, and the uneven pattern formed by heat compression molding is on the surface,
The flexible polyurethane foam is
When including other polyols with a polyol having an ester group,
When at least one of a phosphate ester-based flame retardant or an ester-based additive is contained together with a polyol having an ester group,
Any of the cases where it does not contain a polyol having an ester group, and contains at least one of a phosphoric acid ester-based flame retardant or an ester-based additive,
The ester value (JIS K 0070) in these cases is 40 to 400 mg KOH / g, and the compressive residual strain (JIS K 6400-4 6.2B method, 70 ° C. × 22 hours, after 50% compression) is 1 to 15%. ,
The hardness of the flexible polyurethane foam (according to JIS K 6400-2: 2004) is 60 to 200 N,
A laminated sheet having a concavo-convex pattern on the surface, wherein the height of the convex portion or the depth of the concave portion of the concavo-convex pattern formed on the surface is 3 to 30 mm. The flexible polyurethane foam was thermally compressed at 80 ° C. for 240 seconds to 50% of its original thickness using a spacer of 5 mm with respect to a flexible polyurethane foam having a square cross section of 50 mm on a side and a thickness of 10 mm. The laminated sheet having the concavo-convex pattern according to claim 1, which is made of a flexible polyurethane foam having a forming ratio of 70 to 100% calculated by the following equation using a thickness.
Forming ratio (%) = [(original thickness−thickness after compression) / (original thickness−spacer thickness)] × 100 A method of manufacturing a laminated sheet having a concavo-convex pattern on the surface by thermally compressing the surface of a laminated sheet in which a flexible surface member is integrally laminated on a flexible polyurethane foam with a pressing device having a concavo-convex pattern formed on the surface. In
The flexible polyurethane foam is
When including other polyols with a polyol having an ester group,
When at least one of a phosphate ester-based flame retardant or an ester-based additive is contained together with a polyol having an ester group,
Any of the cases where it does not contain a polyol having an ester group, and contains at least one of a phosphoric acid ester-based flame retardant or an ester-based additive,
The ester value (JIS K 0070) in these cases is 40 to 400 mg KOH / g, and the compressive residual strain (JIS K 6400-4 6.2B method, 70 ° C. × 22 hours, after 50% compression) is 1 to 15%. ,
The density (JIS K 7222: 1999) of the flexible polyurethane foam is 15 to 80 kg / m ³ , and the hardness (JIS K 6400-2: 2004) is 60 to 200 N,
The surface member is either a knitted fabric or a flexible / stretchable woven fabric,
The surface member and the flexible polyurethane foam are welded by frame lamination,
The method for producing a laminated sheet having a concavo-convex pattern on the surface, wherein the height of the convex portion or the depth of the concave portion of the concavo-convex pattern formed on the surface is 3 to 30 mm. The flexible polyurethane foam was thermally compressed at 80 ° C. for 240 seconds to 50% of its original thickness using a spacer of 5 mm with respect to a flexible polyurethane foam having a square cross section of 50 mm on a side and a thickness of 10 mm. method for producing a laminated sheet having an uneven pattern according to the surface to claim 3 forming rate calculated by the following equation using the thickness is characterized in that it consists of flexible polyurethane foam is 70 to 100%.
Forming ratio (%) = [(original thickness−thickness after compression) / (original thickness−spacer thickness)] × 100

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