JPH031911A - Production of skin integrated molding - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for manufacturing a skin integrally molded product, and in particular, to a skin member in which a skin material and a slab layer are laminated together, a soft resin layer is integrally molded. The present invention relates to a method for manufacturing a skin-body molded product while maintaining a slab layer of a skin member in a good condition.

[Prior Art] Conventionally, materials in which a skin member and (i1 fat) are bonded have been widely used as interior materials for vehicles. Injection acid formation is performed by bonding a soft resin layer that has been foam-molded using post-processing adhesive processing, or by inserting a trim cover or the like as a skin member into the mold cavity in advance. Then, resin was injected into the mold and foamed to integrally mold the skin member and the resin layer.

[Problems to be Solved by the Invention] According to the first prior art described above, a manufacturing process is required in which the skin member and the soft resin layer are manufactured separately and then the skin member and the soft resin layer are bonded in a post-process. However, it is disadvantageous in terms of the number of parts and assembly man-hours, and when manufactured in this way, there is a problem in terms of uniformity of the product.

In addition, in the second prior art described above, when a skin member is inserted in advance into the cavity of a mold, and then raw material resin is injected into the mold and foam molded, the foamed resin liquid is inserted into the skin member. There was a problem of impregnation. If the skin material is impregnated with the foamed resin liquid in this way, the elastic part of the slab layer constituting the skin material cannot be used effectively, and there is a hardened layer under the skin layer, making it difficult to use the product at the shallow end. There were problems such as a negative effect on layer feel and shape followability due to contact with the human body. Therefore, many techniques have been used, such as further laminating a film on the back side of the skin member or the soft resin layer laminated on the skin member, and using this film to prevent impregnation.

The object of the present invention is to provide a skin-integrated product in which a soft resin layer is integrally molded to a skin member made by laminating a skin material and a slab layer, while suppressing and preventing foam impregnation during the foaming process of a foaming stock solution. An object of the present invention is to provide a method for manufacturing a molded article.

[Means for Solving the Problems] The present invention has been made to achieve the above objects, and
The method for manufacturing an integrally molded skin product of the present invention is a method for manufacturing an integrally molded skin product formed by polymerizing a skin member formed by integrally molding a skin material and a slab layer, and the skin member and a soft resin layer. There is a step of mounting the skin member in a mold and partially or completely impregnating the slab layer pretreated with various water-absorbing resins, etc., and mixing the reaction-adjusted water component and prepolymer. A step of injecting a stirred urethane stock solution into the mold in which the skin member is placed, a step of foaming, gelling, and curing the injected solution, and a step of demolding and drying the cured product. It is configured.

Further, the top prepolymer is a prepolymer manufactured from a polyol having a high content of ethylene oxide and having terminal isocyanate groups.

Furthermore, if a skin member in which a film layer is disposed between the skin material and the slab layer is used as the structure of the skin member, shrinkage of the skin member, such as a woven material made of vegetable fibers or an Illuminated material due to moisture, and surface feeling may be reduced. Suitable for preventing changes.

[Function] As described above, the skin-integrated molded product of the present invention fills all or part of the space in the slab layer that has been pretreated with various water-absorbing resins that are bonded to the skin, which is a constituent material of the skin member. The water-containing composition is placed in a mold in a water-absorbed state, and mixed with a pre-reacted water component and a prepolymer, such as a polyol with a high content of ethylene oxide and having terminal isocyanate groups as shown in the examples. A urethane stock solution made by mixing and stirring the produced prepolymer is injected, foamed, gelled, and cured, and then demolded. In other words, due to water retention (water absorption, moisture absorption, water content), the water-absorbing resin retains water tens to thousands of times its own weight, swells, and fills the voids in the slab (
In other words, the hydrated urethane foam can be kept floating on the (occluded) slab layer and can be further gelled, thereby preventing the foam from impregnating the urethane stock solution and the slab layer during the foaming process. Note that the water absorption rate may be adjusted to a desired level by adjusting the amount of water-absorbing resin retained in the slab, the amount of water absorbed, etc. through a test in advance. Moreover, when the mold is removed from the mold and dried by scattering moisture, the moisture present at the boundary between the slab layer and the urethane foam layer obtained by foaming and preventing the impregnation of foam is scattered. As the interface between the slab layer and the slab layer, which had retained moisture to prevent impregnation, dries and scatters the moisture, the boundary between the slab layer and the urethane foam layer obtained by foaming is exposed to the reaction. There is no formation, and it is possible to obtain an integrally molded product in a porous state.

[Embodiments] Hereinafter, embodiments of the present invention will be described based on the drawings. Note that the method described below does not limit the present invention,
Various modifications can be made within the spirit of the present invention.

1A and 1B show a trim cover as a skin member used in the present invention, and the trim cover 10 of this example is made of PVC leather, l! This is a trim cover constructed by laminating a skin material 11 made of a skin material such as a woven fabric and a urethane slab layer 12 as a wadding material, and is made to have air permeability. In this example, the slab layer 12 is a soft urethane sliced product of 1 mm to 3 mm.
0 mm and the above-mentioned skin material 11 are bonded by a softened and melted layer 13 of a urethane slab made of, for example, a hot-melt type adhesive or frame lamination.

The trim cover 10 has an opening (not shown) for injection of urethane stock solution, etc., and is pre-processed by high-frequency welding and ultrasonic welding.

L1! ! ! Preliminary processing is performed into the desired design shape using methods such as the following.

Then, the trim cover 10 is placed in the mold (lower mold) 21, and at this time, the trim cover 10 is placed with the water-absorbing side (the slab layer 12, which is a slab pretreated with fat and treated with water absorption treatment to retain water) on the upper side. Then, a predetermined urethane component 20 is injected into the mold to perform integral foam molding.

The water-absorbing resin used in the present invention includes vinyl acrylate alcohol copolymer, sodium acrylate polymer, modified polyethylene oxide, etc., and has functions such as water swelling, hydrophilicity, water retention, and barrier properties. It has the following.

This is a polymer electrolyte that has a three-dimensional structure of the resin itself, which has the property of rapidly absorbing water based on the osmotic pressure caused by the functional groups present in the structure, or by the three-dimensional network structure of the polymer. Commercially available products include Sumitomo Chemical's 5P-520, NP-1010, and R-3O.
L, [Kura L/KI Gel 201 includes -F2, etc.

In addition, as the urethane component 20, a polyol containing a high amount of ethylene oxide and having a high addition polymerization amount of ethylene oxide is reacted with an isocyanate compound having more than a chemical equivalent of isocyanate groups to this polyol as a blended liquid A. The main ingredient is a terminal isocyanate prepolymer obtained by Also, formulation B
As a liquid, it contains a foam stabilizer (for example, a foam stabilizer for silicone urethane) that stabilizes the foam during foaming and gelation, and tertiary amines, metal soaps, etc. to adjust the reaction with water. Use. Then, the mixture A liquid and the mixture B liquid are stirred and mixed. More specifically, the following are used as the urethane components (compound A liquid and blend B liquid).

Blend A (parts by weight) Urethane prepolymer EGH401 (Free!!llNCO3.2%) 100 parts Blend B
(Parts by weight) Water 30 parts Silicone oil 1 part Figures 2A to 2D show a method of manufacturing an integrally molded skin product H using the above 1 to rim cover 10.

First, the trim cutter-10 was pre-processed as described above.
is installed in the foaming mold (lower mold) 21. At this time, the slab layer 12, which has been partially or completely pretreated with a water-absorbing resin, is attached as the upper surface. Next, as shown in FIG. 2A, the slab layer 12 made of soft urethane foam of the trim cover 10 is sprayed with water so that it absorbs water or becomes hydrated.
(not shown) by other known means to hydrate or moisten. Moisture content is 20% to 700%, preferably 70%
~80% is preferred. Next, the urethane component 20, the blend Ail and the blend B solution, are measured in the usual manner, mixed and stirred, and immediately poured into the lower mold 21 to which the trim cover 10 is attached.

Then, after closing the upper mold (,1) 22, for about 1-10 minutes,
Foam, gel, and cure (see Figure 2C). Next, the cured product is demolded and dried to obtain a product)-1 (Figure 2D). In addition, the pressurization of the mold may be the same as normal urethane foam molding, and the heating is preferably in the range of 20 ° C to 60 ° C, since the skin member is placed in the mold.
A temperature of 30°C to 55°C is preferred. Further, the temperature of the water to be hydrated is not particularly limited, but is preferably 20°C to 25°C.

Next, a specific example will be described for better understanding of the above embodiment.

[Example 1] A skin member is formed by laminating a soft urethane sheet that has been sewn into a desired product shape onto a skin fabric, and this skin member is set in a mold. Next, tackifier #55 (Sumitomo 3M ■ Co., Ltd.) was applied to the inner urethane surface. To this, water absorbent resin 5P-520 (manufactured by Sumitomo Chemical Co., Ltd.)
was maintained at a rate of 1 to 1.5 g per 100 cm'', and 10 to 30 g of water was applied per 100 cm'' so that the water absorbent resin swelled by water absorption and the surface voids of the urethane sheet were almost closed. . Thereafter, the mixture A and B were uniformly stirred and mixed, immediately injected into the mold, and foamed and hardened at room temperature. After 10 minutes, the mold was demolded and heated to 70°C.
The drying process was carried out for 1 hour while it was open. When the product obtained in this way was cut, the boundary between the urethane sheet and the urethane sheet that had been cured by injection foaming was porous and flexible, which is different from the hardened layer that is impregnated with foamed resin by ordinary integral foaming. A molded product with an integrated skin that does not give any discomfort was obtained.

[Example 2] As a skin member, a soft urethane sheet was laminated onto the skin fabric using wavy hot melt. The slab block for the flexible urethane sheet used was manufactured as follows. That is, slab form 1000 cm
Water absorption per 5 (Resin NP-1010 (Sumitomo Chemical ■
In order to make the polyol contain 3 to 6 g of polyol, the individual components were homogeneously mixed with the polyol in advance, and each component was mixed and stirred in the stirrer section in the same manner as in the production of normal slab blocks. Manufactured by Then, this was sliced to a thickness of 15 mm using an ordinary slice cutter, and this was used as the above-mentioned flexible urethane sheet for lamination. Next, the skin material and the wavy hot melt were laminated, and the skin material was processed into a desired product shape by cutting and sewing to form a skin member. This skin member was set in a mold, and water was sprayed onto the urethane surface (inner surface) until the voids in the skin layer of the urethane sheet were closed. Injected into the mold using the same method, foamed and hardened at room temperature, and removed from the mold after 10 minutes.
Drying treatment was carried out in the same manner as in Example 1. When the product thus obtained was cut, a skin-integrated molded product was obtained which had a boundary layer that was as flexible as Example 1 or better and did not cause discomfort.

FIG. 3 shows a trim cover used in another embodiment of the invention. In this example, the same materials and the like as in FIG. The trim cover 30 of this example is made by laminating a skin material 11 and a slab layer 12 with an air-impermeable film 31 disposed between them.

When the trim cover 30 of this example is used, even if water is soaked from the slab layer 12 side with a scrubber or the like, the film 31 can prevent the influence of the water on the skin material 11 side so that it is in a water-absorbing to wet state. Even if the skin material 11 is pre-impregnated with water and left to stand, it does not affect the skin material 11, and therefore the water absorption to wet state can be easily adjusted. Moreover, the molding process is also favorable because water does not affect the skin surface of the trim cover 30.

[Effects of the Invention] Since the present invention is configured as described above, the water-containing urethane foam can be made to float on the water-retaining (water-absorbing, moisture-absorbing, water-containing) slab layer, and is further gelled. As a result, it is possible to prevent foam from impregnating the urethane stock solution and the slab layer during the foaming process. Furthermore, when the mold is dried to disperse moisture after being removed from the mold, the moisture present at the boundary between the slab layer and the urethane foam layer obtained by foaming and preventing the impregnation of foam is dispersed. As the interface between the slab layer and the slab layer, which had previously retained moisture to prevent impregnation, dries and scatters, the boundary between the slab layer and the urethane foam layer obtained by foaming is exposed to the reaction. It is possible to obtain an integrally molded product in a porous state without formation.

[Brief explanation of drawings]

Figure 1 is a partial cross-sectional view explaining the trim cover, Figure 1B is a partial cross-sectional view explaining the state in which the trim cover is hydrated, and Figures 2A, 2B, 2C, and 2D are manufacturing steps, respectively. FIG. 3 is a partial sectional view of another trim cover. 10.30... Skin member (trim cover), 11...
- Skin material, 12... Slab layer, 31... Film layer, I-1... Skin integrally molded product. Patent applicant Nitokyo Seat Co., Ltd.

Claims (1)

[Scope of Claims] 1. A method for manufacturing a skin integrally molded product formed by integrally molding a skin member formed by joining a skin material and a slab layer, and the skin member and a soft resin layer, comprising: The step of installing the skin member in the mold and partially or completely impregnating the slab layer with pre-treatment with various water-absorbing resins, etc., and preparing the urethane stock solution by mixing and stirring the reaction-adjusted water component and prepolymer. A skin integral molding method comprising the steps of: injecting the injected liquid into a mold in which the skin member is placed; foaming, gelling, and curing the injection solution; and removing the cured product from the mold and drying it. method of manufacturing the product. 2. The method for producing an integral skin molded article according to claim 1, wherein the prepolymer is a prepolymer produced from a polyol containing a high content of ethylene oxide and having terminal isocyanate groups. 3. Claim 1, wherein the skin member is a skin member in which a film layer is disposed between the skin material and the slab layer.
and 2. The method for manufacturing a skin-integrated molded product.