JP7591110B2 - Laminated foam sheets and skin materials - Google Patents

Description

This invention relates to a laminated foam sheet in which a skin material is laminated onto a foam and an uneven pattern is formed on the surface, and to a method for manufacturing the same.

Surface materials are provided on the surfaces of automobile and motorcycle seats, vehicle interior materials such as door trims and instrument panels, and furniture such as chairs and sofas for the purpose of decorating and protecting the target components, and laminated foam sheets with an uneven surface pattern are known as such surface materials. Such laminated foam sheets are manufactured by laminating a flexible skin material onto soft polyurethane foam, and then thermally compressing the surface with a heating and compression device that forms an uneven surface pattern (Patent Document 1).

JP 2014-184580 A

Conventional laminated foam sheets can realize three-dimensional designs that utilize the shadows and other effects of the uneven pattern on their surface. However, conventional laminated foam sheets have a monotonous color that depends on the material used for the skin, and the decorativeness of the uneven pattern is limited. Here, although it is possible to enrich the color of the uneven pattern of the laminated foam sheet by using a skin material with an appropriate color pattern and performing heat compression, it is necessary to precisely align the color pattern imparted to the skin material with the uneven pattern formed by heat compression, and the precision required for processing creates problems in productivity.

In other words, the objective of the present invention is to provide a laminated foam sheet that can enrich the color of the surface of the uneven pattern and a method for manufacturing the same.

In order to overcome the above problems and achieve the intended object, the first invention provides:
A laminated foam sheet in which a skin material is laminated on one side of a foam and an uneven pattern is formed on the skin material side by thermal compression molding,
the skin material comprises a surface layer having a permeation portion that connects at least the concave portions of the uneven pattern to the front and back, and a thermoplastic colored resin layer located at the formation position of the permeation portion in the surface layer and between the foam body,
The colored resin layer melted during thermal compression molding permeates the permeation portion of the surface layer and is exposed on the surface of the recess.
In this way, the colored resin layer melted during the thermal compression molding penetrates into the penetration part of the surface layer and is exposed on the surface of the recessed parts, so that the uneven pattern can be made to have a variety of colors, making it possible to enrich the design. Also, since the colored resin layer penetrates into the penetration part of the surface layer and colors the surface of the recessed parts, the three-dimensional uneven pattern and the color pattern do not shift, and a desired design can be realized.

The second invention is
The surface layer is a fibrous sheet body in which the penetration portion is formed between the fibers, and the colored resin layer melted during thermal compression molding penetrates between the fibers of the sheet body and is exposed on the surface.
In this way, the color of the uneven pattern of the laminated foam sheet whose surface is decorated with a fiber sheet body can be made diverse.

The third invention is
The surface layer is a sheet body having holes formed therethrough as the infiltration portions in accordance with the positions at which the recesses of the uneven pattern are formed, and the colored resin material melted during thermal compression molding infiltrates into the holes of the sheet body and is exposed on the surface.
In this way, even if the surface layer is made of a material that the molten colored resin layer cannot penetrate, the colored resin layer that penetrates into the holes in the surface layer and is exposed on the surface of the recesses can add variety to the colors of the uneven pattern, thereby enriching the design.

The fourth invention is
A method for producing a laminated foam sheet, comprising laminating a skin material on one side of a foam and forming a concave-convex pattern on the skin material side by thermal compression molding, comprising the steps of:
The skin material is formed by forming a thermoplastic colored resin layer on a surface layer having a permeation portion that connects the front and back of the skin material so that the colored resin layer is located on the foam side.
The position where the penetration portion in the skin material is to be formed is thermally compressed to form recesses of the uneven pattern, and the colored resin layer melted during the thermal compression is allowed to penetrate into the penetration portion of the skin material and be exposed on the surface of the recesses.
In this way, the colored resin layer melted during the thermal compression molding penetrates the penetration part of the surface layer and is exposed on the surface of the recesses, so that the uneven pattern can be rich in color and design. Also, because the colored resin layer penetrates the penetration part of the surface layer and colors the surface of the recesses, the three-dimensional uneven pattern and the color pattern do not shift, and a desired design can be realized.

The fifth invention is
The surface layer is a fibrous sheet body in which the penetration portion is formed between the fibers, and the colored resin layer melts during thermal compression and penetrates between the fibers of the sheet body, causing it to be exposed on the surface.
In this way, the uneven pattern of the laminated foam sheet having a fibrous sheet body as a surface layer can be made colorful.

The sixth invention is
The surface layer is a sheet body having holes formed therethrough as the penetration portion, and the colored resin layer melted during thermal compression is allowed to penetrate into the holes of the skin material and be exposed on the surface.
In this way, even if the surface layer is made of a material that the molten colored resin layer cannot penetrate, the colored resin layer that penetrates into the holes in the surface layer and is exposed on the surface of the recesses can enrich the design by giving the uneven pattern a variety of colors.

The seventh invention is
The method comprises applying molten colored resin to a mold in a predetermined thickness, placing a sheet body that forms the surface layer on top of the molten colored resin, and cooling and hardening the colored resin to form the skin material.
In this way, by overlapping a sheet body forming a surface layer on the molten colored resin, the surface layer and the colored resin layer can be reliably integrated, so that the molten colored resin layer can be reliably penetrated into the penetration portion of the surface layer during thermal compression molding and exposed on the surface of the recess.

The eighth invention is
The gist of the invention is that a transparent hot melt film is laminated between a sheet body forming the surface layer and a colored resin sheet of a predetermined thickness, and the skin material is formed by melting the hot melt film.
In this way, the surface layer and the colored resin layer can be reliably integrated by the hot melt film, so that the colored resin layer melted during the thermal compression molding can be reliably permeated into the permeation portion of the surface layer and exposed on the surface of the recessed portion. In addition, by using a transparent hot melt film, the surface of the recessed portion can be colored in a color corresponding to the color of the colored resin layer.

The laminated foam sheet and manufacturing method thereof according to the present invention can enrich the color of the uneven surface pattern.

FIG. 1(a) is a schematic diagram showing a laminated foam sheet using a fiber surface sheet as a skin material, FIG. 1(b) is a schematic diagram showing the state before thermal compression in which a skin material using a fiber surface sheet and a foam are laminated, and FIG. 1(c) is a schematic diagram showing the state in which a molten colored resin layer has penetrated into the penetration portion of the surface layer during thermal compression molding. FIG. 1(a) is a schematic diagram showing a laminated foam sheet using a sheet of synthetic leather or the like as a skin material, FIG. 1(b) is a schematic diagram showing the state before thermal compression in which a skin material using a surface sheet of synthetic leather or the like and a foam are laminated, and FIG. 1(c) is a schematic diagram showing the state in which a molten colored resin layer has penetrated into the penetration portion of the surface layer during thermal compression molding. FIG. 1 is a schematic diagram showing a laminate of a skin material and a foam before thermal compression, in which (a) shows a laminate of the skin material and the foam using a fiber surface sheet, (b) shows a state in which the skin material in which the perforated surface sheet is laminated to a colored resin layer is laminated to the foam, and (c) shows a state in which the skin material in which the surface sheet and the colored resin layer are perforated is laminated to the foam. FIG. 1 is a schematic diagram showing a manufacturing process for a laminated foam sheet, in which (a) shows a laminate of a skin material and a foam using a fiber surface sheet placed on the base of a heating and compression device, and (b) shows the laminate of (a) being thermally compressed. FIG. 1 is a schematic diagram showing the manufacturing process of a laminated foam sheet, in which (a) shows a laminate of a perforated skin material and a foam on a surface sheet body, the laminate being placed on the base of a heating and compressing device, and (b) shows the laminate of (a) being thermally compressed.

Next, the laminated foam sheet and its manufacturing method according to the present invention will be described below with reference to the attached drawings. In this embodiment, a laminated foam sheet that can be suitably used as a cover for a seat of a vehicle such as an automobile and its manufacturing method will be described as an example.

1 and 2, the laminated foam sheet 10 has a skin material 14 laminated on one side of the foam 12, and the foam 12 is crushed on the skin material 14 side by thermal compression molding to form an uneven pattern. The skin material 14 of the laminated foam sheet 10 has a surface layer 16 exposed on the surface of the sheet 10 and a thermoplastic colored resin layer 20 provided so as to be located at the formation position of the recesses 11a forming the uneven pattern in the surface layer 16 and between the foam 12, and is configured so that the colored resin layer 20 melted during thermal compression molding penetrates the penetration portion 18 of the skin material 14 and is exposed on the surface of the recesses 11a. The uneven pattern of the laminated foam sheet 10 is formed by crushing the foam 12 by thermal compression molding, and can be formed in any shape depending on the design, such as a regular pattern such as a lattice pattern, or a pattern like an animal or plant. The height of the convex portions 11b (depth of the concave portions 11a) of the uneven pattern is not particularly limited, but is preferably about 3 to 30 mm. Furthermore, the height of the convex portions 11b (depth of the concave portions 11a) of the uneven pattern does not need to be constant, and the height of the convex portions 11b (depth of the concave portions 11a) may be varied depending on the design, etc. In FIG. 1 etc., for ease of explanation, the height of the convex portions 11b (depth of the concave portions 11a) is set to a constant value.

As the foam 12 of the laminated foam sheet 10, various types of conventionally known foams 12 such as soft polyurethane foam, polyethylene foam, EVA foam, etc. can be used. The foam 12 may be composed of one type of foam 12, or may be composed by laminating a plurality of foams 12. As the foam 12, it is preferable to use a soft polyurethane foam, which has excellent cushioning properties and durability and can easily form an uneven pattern by thermal compression molding. Such a soft polyurethane foam is formed by a known method in which polyurethane raw materials containing polyol, blowing agent, catalyst, foam stabilizer, polyisocyanate, and appropriate additives (flame retardant, ester-based additives, etc.) are mixed in a mixer and reacted to foam.

The thickness of the foam 12 is not particularly limited, but it is preferable to form it to a thickness of about 5 to 30 mm. In particular, by making the foam 12 10 mm or more thick, the three-dimensional effect of the uneven pattern formed by thermal compression molding is enhanced, and a laminated foam sheet 10 with excellent design can be obtained. For example, a soft polyurethane foam as this foam 12 can be formed by cutting a soft slab foam 12 obtained by foaming polyurethane raw material at room temperature and atmospheric pressure to a predetermined thickness. By cutting such a soft slab foam 12 to a predetermined thickness, the foam 12 can be obtained efficiently.

The skin material 14 comprises a surface sheet body (surface layer) 16 having permeation areas 18 at least in the recesses 11a of the uneven pattern, and a thermoplastic colored resin layer 20 provided so as to be positioned at the formation positions of the recesses 11a of the uneven pattern in the surface sheet body 16 and between the foam body 12. This surface sheet body 16 can be suitably made of a fiber sheet body mainly made of fibers such as flexible and stretchable knitted fabric, woven fabric, or nonwoven fabric, or a sheet body such as synthetic leather or natural leather.

Specifically, the fiber surface sheet body 16 is preferably a knitted fabric such as tricot, jersey, or double raschel, a woven fabric or nonwoven fabric made of fibers containing elastic fibers having elasticity, a nonwoven fabric roll with many embossed parts formed thereon that is stretched to give elasticity, or a needle-punched nonwoven fabric with excellent elasticity obtained by spirally crimping the fibers. In addition, the fibers used for the fiber sheet body include natural fibers such as cotton, hemp, and wool, and synthetic fibers such as rayon, acetate, polyamide, polyacrylonitrile, polyethylene terephthalate, and vinylon. Such a fiber sheet body can be preferably one having air permeability in which a permeation part 18 that connects the front and back is formed by the gaps between the fibers, and the colored resin layer 20 melted during the thermal compression molding can be permeated into the permeation part 18 between the fibers and exposed to the surface. In addition, when a fiber sheet body that does not have sufficient permeation parts 18 between the fibers is used, holes are formed as the permeation parts 18 in the fiber sheet body by drilling or the like as described below, so that the colored resin layer 20 melted during thermal compression molding can permeate into the permeation parts 18 between the fibers and be exposed on the surface. In addition, the symbol TE in Figures 1 and 4 indicates the colored part formed by the permeation of the molten colored resin layer 20 into the permeation parts 18 between the fibers.

The surface sheet body 16 of synthetic leather can be formed by a conventional method of impregnating and applying synthetic resin such as polyvinyl chloride or thermosetting polyurethane to a base material such as knitted fabric, woven fabric, or nonwoven fabric. Such a sheet body of synthetic leather or natural leather is configured so that holes are formed as the permeation portion 18 by a hole-making process or the like as described below, and the molten colored resin layer 20 can be permeated into the hole as the permeation portion 18 during thermal compression molding and exposed to the surface. The symbol TE in Figures 2 and 5 indicates the colored portion formed by the permeation of the molten colored resin layer 20 into the hole as the permeation portion 18.

The colored resin layer 20 is formed of a thermoplastic synthetic resin, and is formed into an appropriate color by kneading a colorant or pigment of an appropriate color with the synthetic resin using a mixer. The synthetic resin for forming the colored resin layer 20 is not particularly limited, and polyethylene, polyvinyl chloride, polyethylene terephthalate, or other conventionally known thermoplastic synthetic resins can be used. The colored resin layer 20 may be formed of a solid layer of synthetic resin, or may be formed of a foamed synthetic resin. The thickness of the colored resin layer 20 is not particularly limited, but can be determined according to the thickness of the surface sheet body 16 so that the colored resin layer 20 melted during thermal compression molding can penetrate the penetration portion 18 of the surface sheet body 16 and be exposed on the surface of the recess 11a. Specifically, it is preferable to form the colored resin layer 20 so that it is 1/4 to 2 times the thickness of the surface sheet body 16, and it is more preferable to make the thickness of the colored resin layer 20 1/2 to 1.5 times. By forming the colored resin layer 20 in such a range, the molten colored resin layer 20 can be reliably permeated to the surface of the surface sheet body 16, imparting a predetermined color to the uneven pattern. A synthetic resin having a lower melting point than the synthetic fibers and synthetic leather that form the surface sheet body 16 is used for this colored resin layer 20. By forming the colored resin layer 20 from a material with a lower melting point than the surface sheet body 16, the colored resin layer 20 can be melted without melting the surface sheet body 16 during thermal compression molding, and the colored resin layer 20 can be permeated into the permeation portion 18 of the surface sheet body 16.

Depending on the application of the laminated foam sheet 10, the skin material 14 may have a backing layer (not shown) laminated on the side of the colored resin layer 20 opposite the surface sheet body 16. Such a backing layer may be made of a woven or nonwoven fabric with low elasticity, or a synthetic resin sheet. By providing a backing layer, the skin material 14 can have a so-called firm texture.

1 to 5, the laminated foam sheet 10 having a concave-convex pattern on its surface may have a backing fabric 22 laminated on the back surface of the foam 12, which is the side opposite to the skin material 14. For such a backing fabric 22, it is preferable to use a woven fabric or nonwoven fabric with low elasticity, and more preferably a nonwoven fabric or woven fabric made of nylon or polyester with a basis weight of 30 g/ ^m2 or more, or a queens knitted fabric if it is a knitted fabric. The presence of a low elasticity backing fabric gives the laminated foam sheet 10 a firm feel, and the force with which the concave-convex shaped soft polyurethane foam tries to return to a smooth surface can be weakened.

Next, we will explain the manufacturing method of the laminated foam sheet 10 according to this embodiment.

The manufacturing method of the laminated foam sheet 10 of this embodiment includes a skin forming process for forming the skin 14, a laminate forming process for forming the laminate 24 by laminating the skin 14 on the foam 12, and an uneven pattern forming process for forming an uneven pattern on the skin 14 side of the laminate 24.

The skin forming process is a process for forming a skin 14 by laminating a thermoplastic colored resin layer 20 at least in accordance with the formation position of the permeation portion 18 on a surface sheet body 16 having a permeation portion 18 that connects the front and back. As a first example of this skin forming process, a synthetic resin colored in a predetermined color is melted and applied to a mold to a predetermined thickness by an application device such as a coater, and the surface sheet body 16 is placed on the molten synthetic resin, and the synthetic resin is cooled and hardened, and then removed from the mold, thereby forming a skin 14 in which the surface sheet body 16 and the colored resin layer 20 are laminated. In other words, by placing the surface sheet body 16 on the molten synthetic resin and cooling and hardening it, the synthetic resin itself can function as an adhesive to be integrated. In addition, by applying the molten synthetic resin to a release material placed on the mold, the skin 14 can be easily removed from the mold. Additionally, the skin material 14 with a lining layer can be formed by placing the woven fabric, nonwoven fabric, or synthetic resin sheet that will form the lining layer in a mold, applying molten synthetic resin, and then placing the surface sheet body 16 on top in the same manner as above to cool and harden the synthetic resin.

In addition, as a second example of the skin material forming process, a transparent hot melt film is placed on one side of a colored sheet formed of a synthetic resin colored in a predetermined color to a predetermined thickness, and a surface sheet body 16 is placed on the hot melt film. In this state, the hot melt film is melted to bond the colored sheet and the surface sheet body 16, thereby forming a skin material 14 in which the surface sheet body 16 and the colored resin layer 20 are laminated. This hot melt film can be melted by high-frequency heating, ultrasonic sealing, heat pressing, etc. In addition, various conventionally known films such as polyacrylic, polyolefin, and polyester can be used as the hot melt film, and can be appropriately selected according to the material of the surface sheet body 16 and the colored sheet to be bonded. In addition, it is preferable to use a hot melt film with a lower melting point than the colored sheet. In this way, by using a hot melt film with a lower melting point than the colored sheet, it is possible to prevent the colored sheet from melting in the process of melting the hot melt film. The skin material 14 with a lining layer can be formed by placing a hot melt film on a lining layer such as a woven fabric, nonwoven fabric, or synthetic resin sheet, placing a colored sheet on the hot melt film, and then placing a transparent hot melt film and a surface sheet body 16 on the colored sheet in the same manner as above, and melting each hot melt film. The hot melt film between the lining layer and the colored resin layer 20 does not have to be transparent.

In addition, in the skin material forming process, a hole-making process is performed to form holes as permeation sections 18 that connect the front and back of the surface sheet body 16 according to the material of the surface sheet body 16 used and the position and shape according to the design of the color to be applied to the surface of the surface sheet body 16. This hole-making process can be performed either before or after the surface sheet body 16 and the colored resin layer 20 are integrated together. That is, the surface sheet body 16 that has been previously perforated by a hole-making device can be placed so as to be overlaid on the molten synthetic resin or colored sheet as described above, or the permeation section 18 can be formed in the surface sheet body 16 of the skin material 14 by performing a hole-making process on the surface sheet body 16 and the colored resin layer 20 laminated together by a hole-making device. In this way, by overlapping the surface sheet body 16, which has been previously perforated, on the molten synthetic resin or colored sheet as described above, a skin material 14 in which the permeation portion 18 is formed only in the surface sheet body 16 can be formed as shown in FIG. 3(b), and by perforating the surface sheet body 16 and the colored resin layer 20 laminated together, a skin material 14 in which the permeation portion 18 is formed in each of the surface sheet body 16 and the colored layer can be formed as shown in FIG. 3(c). The holes as the permeation portion 18 formed in the surface sheet body 16 can be formed in an appropriate position and shape depending on the design of the laminated foam sheet 10 to be finally obtained. In addition, when a fiber sheet body in which gaps that connect the front and back are formed between the fibers is used as the surface sheet body 16, the perforation process can be omitted and the gaps between the fibers can be used as the permeation portion 18 (FIG. 3(a)). When perforating a surface sheet body 16 in which gaps are formed between the fibers that connect the front and back, the difference in shape and size of the permeation parts 18 formed by the gaps (permeation parts 18) between the fibers and the holes (permeation parts 18) formed by the perforation process can enrich the variety of colors exposed on the surface.

In the laminate formation process, as shown in FIG. 3, the skin material 14 is laminated on the foam 12 with the surface sheet 16 facing outward to form a laminate 24. In this laminate formation process, the skin material 14 may be integrated on one side of the foam 12 by a known integration method such as frame lamination, lamination using an adhesive, etc. Here, in a configuration in which a lining layer is not provided, or in a configuration in which a lining layer is provided but the surface sheet 16 and the colored resin layer 20 are integrated and then holes are opened to form the infiltration portion 18, the skin material 14 and the foam 12 can be integrated by the molten colored resin layer 20 during thermal compression molding, and integration by frame lamination or the like can be omitted.

Here, frame lamination is a method in which the surface of the foam 12 is melted by irradiation with a flame burner or the like, and the skin material 14 is laminated and welded onto the molten surface. The temperature of the flame burner or the like is generally about 600 to 1300°C. Meanwhile, lamination using an adhesive is a method in which an adhesive is applied to at least one of the adhesive surfaces of the foam 12 and the skin material 14, and the foam 12 and the skin material 14 are layered and bonded together with the adhesive-coated surface sandwiched between them. A hot melt adhesive or the like is used as the adhesive. Furthermore, when a backing fabric 22 is used, the other surface of the foam 12 is melted with a flame burner or the like, and the backing fabric 22 is welded to the molten surface, or the backing fabric is bonded to the other surface of the foam 12 with an adhesive.

In the uneven pattern forming process, the surface of the skin material 14 of the laminate 24, which is made by laminating the skin material 14 and the foam 12, is thermally compressed by a heating and compressing device 26 having a surface formed with an uneven pattern, thereby crushing the foam 12 and forming the uneven pattern. Examples of thermal compression using the heating and compressing device 26 having a surface formed with an uneven pattern include a heat press method using a compression mold having a surface formed with an uneven pattern, and a roll heat compression method using an embossing roll.

The heat pressing method will be described. In the heat pressing method, as shown in FIG. 4 or FIG. 5, the laminate 24 is placed between the compression mold 30 formed into the required uneven shape and the base 28 with the skin material 14 facing the compression mold 30. Then, the convex portion 30a of the compression mold 30 heated to a temperature at which the colored resin layer 20 of the skin material 14 melts by a heating means such as an electric heating wire (not shown) is pressed against the position where the infiltration portion 18 is formed in the skin material 14 (surface sheet body 16) to perform heat compression, whereby the foam 12 is crushed to form a recess 11a on the surface of the laminate 24 to form an uneven pattern. In this way, the colored resin layer 20 is melted by pressing the convex portion 30a of the heated compression mold 30 against the base 28 and heat compression is performed, and the molten colored resin layer 20 is infiltrated into the infiltration portion 18 of the surface sheet body 16. Thereafter, the compression mold 30 is separated from the laminate 24 to harden the molten colored resin layer 20, thereby producing a laminated foam sheet 10 in which the colored resin layer 20 is exposed on the surface of the recesses 11a formed on the surface of the laminate 24 and the recesses 11a of the uneven pattern are colored with the color of the colored resin layer 20. Here, the heating temperature of the compression mold 30 is not particularly limited, but is preferably 170 to 210°C. In addition, the thermal compression may be performed for a time that allows the colored resin layer 20 to melt and penetrate into the penetration portion 18 of the surface sheet body 16, and is preferably 60 to 400 seconds.

On the other hand, in the roll heat compression method, the skin material 14 is heated to a temperature at which the colored resin layer 20 melts, and the laminate 24 is continuously fed to an embossing roll (not shown) having a convex portion on its surface to heat-compress the skin material 14, thereby crushing the foam 12 and forming an uneven pattern on the surface of the laminate 24. In this way, the colored resin layer 20 is melted by pressing the convex portion of the heated embossing roll against the laminate 24 and heat-compressing it, and the molten colored resin layer 20 is allowed to penetrate into the penetration portion 18 of the surface layer. After that, the colored resin layer 20 of the laminate 24 sent out from the embossing roll hardens and is exposed on the surface of the concave portion 11a formed on the surface of the laminate 24, and the concave portion 11a of the concave pattern is colored with the color of the colored resin layer 20 to produce a laminate foam sheet 10. Here, the heating temperature of the embossing roll is not particularly limited, but it is preferable to set it to 180 to 220°C. The feed speed (feed rate) of the laminate 24 to the embossing roll may be such that the colored resin layer 20 can melt and penetrate the penetration portion 18 while being pressed against the convex portion of the embossing roll for thermal compression, and is preferably about 1 to 10 m/min. In either case of the thermal press method or the roll thermal compression method, the molten colored resin layer 20 may be hardened by natural cooling, or the molten colored resin layer 20 may be hardened by cooling using a cooling means (not shown) such as a blower.

In this way, in the laminated foam sheet 10 according to the present invention, the colored resin layer 20 melted during thermal compression molding permeates the permeation portion 18 of the surface sheet body 16 and is exposed on the surface of the recesses 11a, so that the color of the uneven pattern can be varied to produce a laminated foam sheet 10 with a high design quality. In addition, since the colored resin layer 20 permeates the permeation portion 18 of the surface sheet body 16 and colors the surface of the recesses 11a of the uneven pattern, the three-dimensional uneven pattern and the color pattern do not shift, and a desired design can be realized. At this time, by using a fiber sheet body as the surface sheet body 16 as shown in FIG. 1 or FIG. 4, the color of the uneven pattern of the laminated foam sheet 10 whose surface is decorated with a fiber sheet body can be varied. As shown in FIG. 2 or 5, even if the surface sheet 16 is made of a material that the molten colored resin layer 20 does not penetrate, such as synthetic leather, the colored resin layer 20 penetrates into the holes formed in the surface sheet 16 and is exposed on the surface of the recesses 11a, making the color of the uneven pattern more colorful and providing a highly designed laminated foam sheet 10. As shown in FIG. 2 or 5, the molten colored resin layer 20 does not penetrate into holes provided in positions that are not thermally compressed, so the color of the laminated foam sheet 10 can be made more diverse. The same applies when a fiber sheet is used as the surface sheet 16.

In addition, by applying the molten colored resin to a mold with a predetermined thickness, placing the surface sheet body 16 on the molten colored resin, and cooling and hardening the colored resin to form the skin material 14, the surface sheet body 16 and the colored resin layer 20 can be reliably integrated in a state that matches the formation position of the permeation portion 18 of the surface sheet body 16, so that the colored resin layer 20 melted during thermal compression molding can be reliably permeated into the permeation portion 18 of the surface sheet body 16 and exposed on the surface of the recess 11a. And, even when the surface sheet body 16 and the colored resin layer 20 are reliably integrated by a hot melt film, the surface sheet body 16 and the colored resin layer 20 can be reliably integrated in a state that matches the formation position of the permeation portion 18 of the surface sheet body 16, so that the colored resin layer 20 melted during thermal compression molding can be reliably permeated into the permeation portion 18 of the surface sheet body 16 and exposed on the surface of the recess 11a. In addition, by using a transparent hot melt film, the surface of the recess 11a can be colored in a color corresponding to the color of the colored resin layer 20.

10 Laminated foam sheet, 12 Foam, 14 Skin material, 16 Surface sheet body (surface layer)
18 Permeation portion (gaps between fibers, holes), 20 Colored resin layer

Claims (4)

A laminated foam sheet in which a skin material is laminated on one side of a foam and an uneven pattern is formed on the skin material side by thermal compression molding,
The skin material has a surface layer having a permeation portion that penetrates at least the recesses of the uneven pattern from the front to the back,
a thermoplastic colored resin layer located at a position where the infiltrated portion is formed in the surface layer and between the foam body,
The penetration portion forms a space communicating with the front and back of the surface layer,
A laminated foam sheet, characterized in that the resin of the colored resin layer melted during thermal compression molding permeates into the spaces and is exposed on the surfaces of the recesses. A laminated foam sheet in which a skin material is laminated on one side of a foam and an uneven pattern is formed on the skin material side by thermal compression molding,
The skin material includes a surface layer of a fiber sheet body that forms spaces between the fibers,
a thermoplastic colored resin layer on the foam side of the surface layer,
A laminated foam sheet, characterized in that the resin of the colored resin layer melted during thermal compression molding permeates into the spaces between the fibers and is exposed on the surfaces of the recesses of the uneven pattern . A skin material laminated to a foam body,
A surface layer;
A thermoplastic colored resin layer is laminated on the back surface of the surface layer ,
The surface layer is
(1) Having a through-hole that penetrates from the front to the back and through which the resin of the colored resin layer can penetrate,
or (2) a fiber sheet through which the resin of the colored resin layer can permeate;
Skin material. The skin material according to claim 3;
a foam laminated on the colored resin layer of the skin material;
A laminated foam sheet comprising:

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