JPH0432740B2 - - Google Patents

Description

Detailed Description of the Invention (Industrial Application Field) The present invention relates to a laminate sheet for a cover material of a seat cushion body (hereinafter also referred to as a laminate sheet) in which a surface material and a back material are laminated on a base material made of polyurethane foam. and its manufacturing direction.

(Description of Prior Art) A cover material having a predetermined shape is attached to the surface of a seat cushion of an automobile.

Conventionally, as a cover material for the seat cushion body,
A laminate sheet having the structure shown in FIGS. 1 and 2 is used. The laminate sheet 10 has a three-layer structure in which a surface material 12 is laminated on one side of a base material 11 made of soft polyurethane foam, and a back surface 13 is laminated on the other side. In another laminate sheet 20, a base material 21 is formed of two soft polyurethane foams 21a and 21b with different properties, and a surface material 22 is laminated on one side of this base material 21, and a back surface material 23 is laminated on the other surface. It consists of a structure. Of course, the base material may have more layers depending on required physical properties, etc.

In addition, the laminate sheet for the cover material of the seat cushion body includes the surface materials 12 and 22 and the base materials 11 and 2.
1 and backing materials 13 and 23 are entirely bonded to each other, and then formed into a predetermined shape to match the shape of the seat cushion body and attached to the surface of the cushion body.

(Problems to be Solved by the Invention) However, the surface of the seat cushion body is not usually made of only a flat surface. A portion thereof has a curved surface or an uneven shape.

For this reason, in the conventional laminate sheets used as cover materials for seat cushions, if a thick or hard material is used for the surface material, it may be difficult to form a predetermined shape to fit the seat cushion, and the surface of the cushion When it is deformed by bending or the like during installation, creases a are formed in the surface material 12 as shown in Fig. 3, and these creases do not disappear even after it is attached to the cushion body, resulting in an unfavorable appearance. was.

SUMMARY OF THE INVENTION Therefore, the present invention provides a laminate sheet for a cover material of a seat cushion body that does not cause creases when formed into a predetermined shape to match the seat cushion body and when deformed when attached to the surface of the seat cushion body, and the laminate sheet for a cover material of a seat cushion body. A manufacturing method is provided.

(Means for Solving the Problems) The present inventor has discovered that the conventional laminate sheet for the cover material of a seat cushion body has a surface material, a base material, and a back material that are entirely adhesively bonded to each other, so that when deformed, the laminate sheet becomes convex. The elongation of the side facing material, e.g. the backing material, is restricted, which forces the concave side facing material, e.g. the facing material, to sag, and the sagging portion of the facing material is then attached to the base material as shown in Figure 3. The present invention was completed by conceiving the idea of forming creases a in the surface material 12 by sinking into the surface material 11.

That is, the present invention provides a laminate sheet for a cover material of a seat cushion body in which a surface material, a base material made of polyurethane foam, and a back material are laminated and integrated, and the base material and the back material are bonded together by partially applied adhesive. The gist is that the two are partially glued together.

In addition, the method for manufacturing the laminate sheet for the cover material of the seat cushion is to apply adhesive to the polyurethane foam by rotating an adhesive application roller holding the adhesive in a plurality of recesses formed on the surface of the polyurethane foam. The gist is to partially apply the polyurethane foam and partially adhere the base material made of the polyurethane foam to the backing material.

(Function) In the laminate sheet of the present invention, since the base material and the backing material are partially bonded, there is little restriction on the elongation of the backing material and the base material when deformation such as bending is applied, and as a result, the surface This reduces the amount of slack in the material and prevents creases from forming. In addition, since the adhesive for partially bonding the base material and the backing material is applied partially, unlike when the adhesive is applied over the entire surface, the softness of the base material made of polyurethane foam The adhesive does not impair the soft feel of the cover material.

On the other hand, in the method for manufacturing a laminate sheet of the present invention, when the adhesive application roll having a plurality of recesses on its surface rotates and contacts the surface of the base material, the adhesive in the recesses adheres to the base material. Partially applied to the surface of the substrate. Then, the base material and the backing material are partially adhered by the partially applied adhesive.

(Example) Examples of the present invention will be described below.

FIG. 4 is an exploded perspective view of one embodiment of the laminate sheet according to the present invention. The laminate sheet 30 consists of a base material 31, a front material 32, and a back material 33.

The base material 31 is mainly used to give the laminate sheet 30 a soft feel that is preferable as a cover material for a seat cushion body. The base material 31
are two soft polyurethane foams 31 with different properties, such as physical properties such as hardness, thickness, composition, etc.
a, 31b.

The surface material 32 is used to protect the surface of the base material 31 and to provide decorative properties to the laminate sheet 30, and is made of a stretchable material such as polyester knit.

The back material 33 is for protecting the back surface of the base material 31 and for improving the slippage of the back surface when the laminate sheet 30 is attached to the surface of the seat cushion as a cover material, and is made of cheesecloth, nonwoven fabric, or the like.

The two polyurethane foams 31a and 31b constituting the base material 31, the base material 31, and the back surface material 33 are partially adhered with an adhesive b such as an acrylic emulsion that remains flexible even after adhesion. Note that it is preferable that the adhesive b contains a flame retardant. In addition, the base material 31 and the surface agent 3
2 and 2 are bonded together by flame welding (flame lamination).

In this example, a laminate sheet with an overall four-layer structure consisting of two layers is shown, but a laminate sheet with a three-layer structure consisting of one layer or a multilayer structure consisting of three or more layers may also be used. has the same structure and will not be described again.

Next, a method for manufacturing the laminate sheet will be explained. FIG. 5 is a diagram showing a part of the steps in one embodiment of the method for manufacturing the laminate sheet.

The back surface of the base material 41 made of polyurethane foam that is continuously supplied is partially coated with the adhesive b in an emulsion state by an adhesive coating roll 44 . Thereafter, the base material 41 is crimped together with a backing material 43 supplied from the other side by a crimping roll 45 . And the following drying oven 4
6, the base material 41 is pressed by the presser roll 47.
The adhesive b is dried and hardened while the backing material 43 and the backing material 43 are in close contact with each other.

After the base material 41 and the back surface material 43 are integrated by partial adhesion in this manner, a surface material (not shown) is flame welded (flame lamination) onto the base material 41, and according to the third aspect of the present invention. A laminate sheet consisting of a layered structure is obtained.

The adhesive is applied to the polyurethane foam constituting the base material 41 by bringing the adhesive partially held on the surface of the adhesive application roll 44 into contact with the base material 41. This adhesive application roll 4
4, adhesive holding is carried out by rotating the adhesive supply roll 48, which is partially attached to the adhesive b in the adhesive tank 47, while being in contact with the adhesive application roll 44, and applying the adhesive around the adhesive supply roll 48. This is done by holding the adhered adhesive in the recessed portions of the adhesive application roll 44, which will be described later.

FIG. 6 is a partially cutaway perspective view of the adhesive applicator roll 44, and FIG. 7 is a partially cutaway perspective view of an adhesive applicator roll 44' of another embodiment. The adhesive application roll 44' is the adhesive application roll 44'.
It can be used instead of. Therefore, in the following description, a case will also be described in which an adhesive coating roll 44' is used in place of the adhesive coating roll 44 shown in FIG. 5.

The adhesive application rolls 44, 44' have adhesive holding layers 44b', 44'b made of rubber or synthetic resin formed on the outer periphery of drum-shaped core bodies 44a, 44'a. Adhesive application roll 44, 4
A plurality of recesses 44c, 44'c are formed on the surface of the recess 4'. The recesses 44c, 44'c are recessed shapes 44c, 44c formed in the adhesive holding layers 44, 44',
It consists of a hole shape 44'c. The concave shape and hole shape are
The shape is not limited to a circle, but can be various shapes such as an ellipse, a polygon, and a star shape. Further, a concave shape and a hole shape may be provided together. An example of this adhesive holding layer is one in which the material is a polyurethane elastomer with a thickness of 3 mm, and circular concave shapes with a diameter of 7 mm and a depth of 1 mm are formed at 15 mm intervals in the polyurethane elastomer. In addition, as another example of the adhesive application roll, there can be mentioned one in which the core bodies 44a, 44'a and the adhesive holding layers 44b, 44'b are formed from an integral body made of the same material such as metal. .

When the adhesive application rolls 44, 44' come into contact with the adhesive supply roll 48 shown in FIG.
Receive and hold within 4'c. Note that a small amount of adhesive may adhere to areas other than the recesses on the surface of the adhesive application roll, but even in that case, the amount of adhesive adhered to areas other than the recesses is not large enough to bond the base material and backing material.

On the other hand, since the base material is in close contact with the surface of the adhesive application rolls 44, 44' in a somewhat compressed state, a part of the base material enters into the recesses 44c, 44'c on the surface of the adhesive application roll. The adhesive in the recesses 44c, 44'c is reliably applied onto the base material. Thereby, the adhesive is partially applied to the substrate.

FIG. 8 is a diagram illustrating a part of the steps in an example of manufacturing a laminate sheet having a four-layer structure as a whole, and the base material is composed of two layers.

Continuously supplied polyurethane foam 41
Adhesives b and c are partially applied to the lower and upper surfaces of a, by adhesive application rolls 44 and 44'. After that, the polyurethane foam 41a
The back material 43 and another polyurethane foam 411b supplied from the other side are crimped together by a crimping roll 45. And then the drying oven 46
Inside, the polyurethane foams 41a, 41b and the backing material 43 are brought into close contact with each other by the presser roll 47, and the adhesives b and c are dried and hardened. Thereafter, a surface material is laminated on the polyurethane foam 41b by frame lamination to obtain a laminate sheet having a four-layer structure according to the present invention.

The adhesive b is applied to the polyurethane foam 41a in the same manner as in the case shown in FIG. 5, and the adhesive c is applied in the following manner. That is, while rotating the adhesive application roll 44' and the adhesive application roll 49 in close contact with each other, the adhesive c is supplied to the contact area, and the adhesive c is held in the recessed part of the surface of the adhesive application roll 44'. let Then, the adhesive application roll 44' is brought into contact with the upper surface of the polyurethane foam 41a while being rotated to partially apply the adhesive c in the recessed portion to the polyurethane foam 41a.

Note that the adhesives b and c may be the same or different, and the adhesive application rolls 44 and 44' may be the same. Moreover, instead of using the method shown in FIG. 8, by the method shown in FIG. 5, one polyurethane foam and the backing material are first partially bonded, and then another polyurethane foam is attached first using the same process. may be partially adhered to polyurethane foam.

(Effects of the Invention) The laminate sheet for the cover material of the seat cushion body of the present invention is made into one piece by partially adhering the base material and the back material. Therefore, when deformation such as bending is applied, there is less restriction on the elongation of the backing material and the base material, thereby reducing the sagging of the facing material and preventing creases.
However, since the adhesive that bonds the base material and backing material is applied partially, the presence of the adhesive affects the soft feel of the base material (i.e., the soft feel required for the cover material of the seat cushion body). ) will not be damaged. An unexpected effect was also obtained in that partial adhesion can also increase flame retardancy.

On the other hand, in the method for producing a laminate sheet of the present invention, an adhesive application roll holding adhesive in a plurality of recesses formed on the surface is brought into rotational contact with the polyurethane foam forming the base material, so that the adhesive is partially applied. It is very rational because it allows continuous coating and thus allows continuous production of laminate sheets.

[Brief explanation of drawings]

1 and 2 are perspective views explaining the structure of a laminate sheet, FIG. 3 is a perspective view of a conventional laminate sheet, and FIG. 4 is an exploded perspective view of an embodiment of a laminate sheet according to the present invention. Figures 5 to 8 illustrate an embodiment of the manufacturing method of the present invention, in which Figures 5 and 8 show a part of the manufacturing process, and Figures 6 and 7 show adhesive application. A partially cutaway perspective view of the roll is shown. 31, 41...Base material, 31a, 31b, 41
a, 41b...polyurethane foam, 32...
Surface material, 33, 43... Back material, 44, 44'...
...Adhesive application roll, 44c, 44c'...Recessed portion.

Claims (1)

[Scope of Claims] 1. A laminate sheet for a cover material of a seat cushion body, in which a surface material, a base material made of polyurethane foam, and a back material are laminated and integrated,
A laminate sheet for a cover material of a seat cushion body, characterized in that a base material and a backing material are partially adhered by a partially applied adhesive. 2. A laminate sheet for a cover material of a seat cushion body according to claim 1, wherein the base material is formed by partially adhering multiple layers of polyurethane foam to each other. 3. An adhesive application roll that retains adhesive in a plurality of recesses formed on the surface in the production of a laminate sheet for a cover material of a seat cushion body in which a surface material, a base material made of polyurethane foam, and a back material are laminated and integrated. A cover material for a seat cushion body, characterized in that an adhesive is partially applied to the polyurethane foam by rotating it in contact with the polyurethane foam, and a base material made of the polyurethane foam and a backing material are partially adhered. A method for manufacturing laminated sheets for use.