JPH0355214A - Manufacture of foamed article with leather skin - Google Patents

Abstract

PURPOSE:To manufacture simply without damaging the soft surface feelings and senses of a leather by adhering a polyurethane skin to a leather surface material through reactive hardening of a polyurethane skin film, after that, injecting and then foaming a liquid foamable material in the inner surface of a leather skin. CONSTITUTION:A leather surface material 18 is press-bonded to the surface of a polyurethane skin film 20 being reactive hardening, and a polyurethane skin film 22 and leather surface material 18 are adhered to each other through reactive hardening of the polyurethane skin film 20 and thus forming a leather skin 14. Thereafter, a liquid foamable material 26 is injected into the inner surface of the leather skin 24 and foamed therein. Accordingly, a foam-molded article 32 with a leather skin manufactured herein is of a type wherein the liquid foamable material 26 is not infiltrated and hardened inside of the leather skin. Whereby foam-molded article 32 with a leather skin can be obtained by a simple work without damaging the soft surface feelings and senses of a leather itself.

Description

[Detailed description of the invention] (Industrial application field) This invention injects a liquid foaming raw material into the inner surface of the leather skin,
The present invention relates to a method for manufacturing a foam molded product with a skin, which is foamed integrally with the skin.

(Prior art) As a method for manufacturing foam molded products with a skin, such as automobile headrests or armrests, in which a foam is covered with a skin, the skin-integrated foaming method (Japanese Patent Laid-Open No. 62-135
No. 511, etc.) are often used. The skin-integrated foaming method involves injecting a liquid foaming raw material such as a polyurethane foam raw material into the inner surface of a liquid-impermeable skin and foaming it integrally with the skin to obtain a foam molded product with a skin. In this skin-integrated foam molding method, the skin can be applied to the surface of the crystalline foam at the same time as the foam molded product is produced, so there is no need to apply the skin in the subsequent work, and the skin has a good surface without wrinkles. It has the advantage of producing molded products. (Problems to be Solved by the Invention) By the way, with the recent trend toward higher quality, it has become desirable for headrests, armrests, etc. to be made of leather.

However, since leather products are breathable, when the skin-integrated foaming process is performed using a leather skin formed from a single piece of leather, the leather skin is impregnated with a liquid foaming material and hardened, resulting in a leather product. There was a problem that the surface of foamed products with a skin became hard. Therefore, in order to solve this problem, a method can be considered in which an adhesive is applied to the back side of the leather to adhere a plastic film to the leather, and the plastic film prevents the liquid foaming material from impregnating the leather skin.

However, in this case, a hardened layer of adhesive is formed on the back side of the leather, and this hardened adhesive layer causes a problem in that the leather skin becomes hard.

Alternatively, it is possible to form a plastic film or paint film on the back side of the leather by applying liquid resin or paint to the back side of the leather and curing it. Because it is impregnated and cured, it was not possible to prevent the leather surface from becoming reflective. This invention has been made in view of the above points! The purpose of this invention is to provide a method for easily producing a foam molded article made of C with a skin without impairing the soft surface feel inherent to leather. (Means for Solving the Problems) The gist of this invention consisting of the above object is to inject a liquid foaming raw material into the inner surface of a leather skin and foam it integrally with the skin, thereby producing a foam molded product with a leather skin.
(1) Pressing a leather surface material onto the surface of a polyurethane film that is in the middle of reaction curing, and bonding the polyurethane film and leather surface material by reaction curing of the polyurethane film to form a leather skin; Thereafter, a method for manufacturing a foam molded article with a skin, characterized in that a liquid foaming raw material is injected into the inner surface of the leather skin and foamed, and (2) a leather foam is applied to one side of the polyurethane film during reaction curing. At the same time, a backing material made of a thin flexible polyurethane foam lined with a plastic film is crimped onto the other surface of the polyurethane film, and by reaction hardening of the polyurethane film, the leather surface material and backing material are bonded together. A method for producing a foamed molded article with a skin, characterized in that a leather skin is formed by adhering the leather skin with a polyurethane film, and then a liquid foaming raw material is injected into the inner surface of the leather skin to cause foaming. (Function) The polyurethane film, which is in the process of reaction and curing, leaves the liquid state and
It is in a state similar to freshly made rice cake and has adhesive properties on its surface. Therefore, the leather surface material that is pressure-bonded to the surface of the polyurethane film that is in the process of being reactively cured, or the back material that is made of solid polyurethane foam lined with a plastic film, adheres to the polyurethane film due to the reaction hardening of the polyurethane film. They are integrated to form the leather skin. Moreover, when the plastic film is bonded and integrated, the plastic film has already changed from a liquid state to a semi-solid state, so the raw material for forming the plastic film is
Alternatively, it does not impregnate and harden the thin polyurethane foam of the backing material, and does not harden the leather skin.

Thereafter, the liquid foaming material injected into the inner surface of the violet skin is prevented from impregnating into the inside of the leather skin by the polyurethane film on the inside of the violet skin or by the plastic film of the backing material inside the leather skin. It is foamed and filled with leather inside the outer skin. Then, a foam molded article with a leather skin is formed by foaming and hardening integrally with the leather skin.

The foam molded product with leather skin manufactured in this way is
Since the liquid foaming material is not impregnated into the leather skin and hardened, it maintains the soft surface feel that is inherent to leather. Especially that l6
If the leather skin is made of a leather facing material, a polyurethane film, and a top material made of a thin polyurethane foam lined with a polyurethane film, the polyurethane foam of the back material will improve the soft feel of the leather skin surface. It is further enhanced.

(Implementation rIA) Figures 1 to 5 are examples of this invention! FIG. 3 is a sectional view showing the manufacturing process in step 3. Hereinafter, an example of a single dog will be explained according to its feeding schedule.

■First, form a polyurethane film that is in the middle of curing (first
figure). The shape of the polyurethane film is determined as follows.
First, the release paper 14 is sandwiched between two upper and lower rolls 12, and a predetermined amount of polyurethane film forming raw material 16 is discharged onto the surface of the release paper 14 immediately in front of the rolls 10.

Next, pull the female pattern 14 in the direction of the arrow and roll 1.
0. 12, and by the pressure of the roll 12, the polyurethane film-formed raw material 16 is spread on the release paper 14 (Table 1) into a film having a thickness of about 10 to 100ν. Then, in this state, the reaction and curing of the raw material for forming the polyurethane film proceeds. As a result, the raw material 16 for forming the polyurethane film on the surface of the release paper 14 changes from its initial liquid state to a freshly baked rice cake-like state, and becomes a polyurethane film in the process of reaction and becoming adhesive on the surface.

The raw material for forming the polyurethane film is preferably a one-component polyurethane raw material that hardens at room temperature with moisture in the air. An example of the one-component polyurethane raw material is a prebolymer (NCO%
2.5 to 4.0) to a viscosity of 300±50c depending on the solvent.
ps, and was manufactured by Apollo Chemical Company (Apolio
A from Chemicals limit, ed)
One-component urethane that cures at room temperature commercially available as Strolok A-84, or Goldschmidt (G
There is a moisture-curing single-component urethane available commercially as TEGCOL 281 1 from J.D. Oldshmidt.

■Next, the leather surface material 18 is made by cutting the leather material into a predetermined shape.
is pressure-bonded to the surface of the polyurethane film 20, which is in the process of reaction and curing, on the surface of the release paper 14 (FIG. 2).

At this time, since the polyurethane film 20 in the middle of reaction curing has already left the liquid state and become a semi-solid state as described above, the shape or raw material of the polyurethane film impregnates the leather surface material 18 and hardens. There is no. The reaction and curing of the polyurethane film 20 which is press-bonded to the leather surface material 18 and which is in the process of being cured undergoes further reactions over time, and the leather surface material 18 is adhered to the surface of the polyurethane film 20, and the reaction and curing are completed.

As a result, a laminate is formed in which the polyurethane film is adhered to the inner surface of the leather surface material. ■114 Leather surface material 1
The laminate formed by adhering the polyurethane film 22 to the inner surface of the film 8 is peeled off from the release paper 14 to obtain the jYi-clad skin 24 (
Figure 3). The leather skin 24 obtained in this way is then coated with altIT, Sa, etc. as required to give it a desired shape. Note that the portion of the polyurethane film 22 protruding from the leather surface N18 is removed before or after peeling off the laminate.

■Polyurethane foaming raw material 26 is injected into the inner surface of the leather covering 24, and foam molding is carried out integrally with the skin (Fig. 4).

In the skin-integrated foam molding, the leather skin 24 is placed on the cavity surface 30 of the foam mold 28 so that the polyurethane film 22 after hardening is open inward, and the leather skin 24 is placed on the cavity surface 30 of the foam mold 28.
4. Polyurethane foaming raw material 26 is injected into the inner surface and foamed. The polyurethane foaming raw material 26 injected into the inside of the leather skin 24 is foamed by the urethane film 22 on the inner surface of the leather skin 24 without being included in the skin Z4, and fills the inside of the skin 24 to form a leather skin. It becomes a foam molded product.

■Then, the foamed product 32 with a leather skin is made into a foamed molded product 28.
(Figure 5).

This yields the desired product. Got it! 'I
In the foamed or shaped crystal 32 with a skin made of ¥, the leather skin 24 is not impregnated with the polyurethane foaming raw material and the raw material for forming the polyurethane film 22 is not impregnated and hardened, and the leather surface material 18 is not impregnated and hardened. In order to confirm the effect of the present invention, a foam molded product 32 made in England with a skin (Example 1) was subjected to IH'r according to the above example.
The surface hardness was measured for a conventional foamed or shaped product (conventional example) obtained using a skin made of a single piece of leather. The hardness was measured by pushing a semicircular sphere with a diameter of 20 mm into the skin surface of the foamed product and measuring the load at that point with a push bull gauge. The measurement results were as shown in the table below.

Next, an example of manufacturing a foamed molded product with a leather skin that has a softer surface feel than the above example will be described. First, as shown in FIG. 6, a back material 38 is prepared by pasting a plastic film 36 on one side of a thin flexible polyurethane foam 34.

The thin flexible polyurethane foam 34 preferably has a thickness of several U to 201, a density of 0.01 to 0.03 g/oa, and a hardness of 5 to 20 kg (based on JIS SK6401). Further, it is preferable to use a polyurethane film as the plastic film 36 in order to ensure good adhesion to the polyurethane foaming raw material that is subsequently injected into the surface layer. The plastic film 36 can be attached by directly foaming or shaping a soft polyurethane foam on the surface of the plastic film 36 and using its adhesive properties during foaming, or by attaching the surface of a separately shaped flexible polyurethane foam. It is easy to perform so-called flame welding, in which the plastic film is melted by flame and welded to the plastic film.

Next, in the same manner as in Examples (1) and (2) above, the Chinese surface material 18 is pressure-bonded to the surface of the polyurethane film 20 which is in the middle of reaction and hardening (FIGS. 1 and 2).

After leaving it as it is for 5 to 10 minutes, as shown in Figure 7, the leather surface material 1 is removed before the polyurethane film 20 is completely cured.
8 and a polyurethane film 20 in the middle of reaction and curing.
Peel it off from the release paper 14. At this time, polyurethane film 2
The non-laminated surface of 0 < i4 pattern paper l4 side surface) still maintained adhesiveness. Subsequently, as shown in FIG. 8, the surface of the polyurethane film 20 which is in the middle of reaction hardening on the inner surface of the laminate 40 and the back material 38 are removed.
The surface of the soft polyurethane foam 34 is pressed to complete the reaction and curing of the polyurethane film 20. As a result, a leather skin 42 is obtained in which the leather surface material 18, the cured polyurethane skin g22, the soft polyurethane foam 34, and the plastic film 36 are laminated and integrated as shown in FIG. At this time, since the polyurethane film 20 in the middle of reaction and curing is in a semi-solid state, the shape or raw material of the polyurethane film does not impregnate and harden into the soft polyurethane foam 34 of the backing material 38, and the leather outer skin 42 is It never gets hard.

The leather skin 42 thus obtained is cut, sewn, etc. as necessary to form a predetermined shape, and then foamed or
It is placed on the cavity surface of a mold (not shown), and a polyurethane foaming raw material is injected into the inner surface of the leather skin 42 to carry out skin integral foam molding. At this time, the polyurethane foaming raw material injected into the inner surface of the leather skin is prevented from impregnating and hardening into the leather skin 42 by the plastic film 36 on the inside surface of the skin, so that it does not harden the leather skin 42. epidermis 4
2 and becomes a foam molded product with a leather skin.

After that, the desired product can be obtained by demolding the molded product. FIG. 10 is a partial cross-sectional view of the foamed crystal 44 with a leather skin obtained in this way, and 46 is a polyurethane foam formed within the leather skin 42. The foamed product 44 with a leather skin has the surface feel of leather because the polyurethane foam raw material is not impregnated into the leather skin 42 and hardened, and the leather skin has a thin polyurethane foam 34 on one side. Since it is a hollow member, it has an extremely soft feel.

Note that the thin soft polyurethane foam 34 forming the back material 38 of the leather skin 42 has a thickness of 5 mm and a density of 0.02 g/
cIll: 1, hard cloth 10kg (J I SK64 0
The surface hardness of the foamed crystal 44 with a leather skin of the above example manufactured as a sample (according to No. 1) was examined in the same manner as described above. The results are shown as implementation flA2 in the following table. (Effects) Since the present invention has the above-described structure, a foamed molded article with a leather skin can be obtained by simple operations without impairing the soft surface feel inherent to leather. Furthermore, by using a thin polyurethane foam lined with plastic film as the backing material for the leather skin, we were able to obtain a foam molded product with a leather skin that has an even softer feel.

[Brief explanation of drawings]

1 to 5 are cross-sectional views showing the manufacturing process of one embodiment of the present invention, FIGS. 6 to 9 are cross-sectional views showing the A process of another embodiment of the present invention, and FIG. 10 is a partial cross-sectional view of a foamed product with a leather skin obtained in the other example. 10, 12: o-ru, 14: IT pattern 16: Polyurethane film forming raw material, 18: Leather surface material, 20: Polyurethane film during reaction and curing, 22: Polyurethane film after curing, 24: Leather skin, 30 : 32= 34: 36: 40: 44: 46: Cavity surface, foam molded product with leather skin, thin flexible polyurethane foam, plastic film, 38: Back material, laminate, 42:
Leather skin, foam molded product with leather skin, polyurethane foam patent applicant Inoue MTB Co., Ltd. Figure 1 Figure 5 Figure 2 Figure 6

Claims (2)

[Claims] (1) In a method for manufacturing a foam molded article with a leather skin by injecting a liquid foaming raw material into the inner surface of the leather skin and foaming it together with the skin, the leather surface material is applied to the surface of the polyurethane film that is in the middle of reaction curing. The leather is characterized in that a leather skin is formed by bonding the polyurethane film and the leather surface material by reaction curing of the polyurethane film, and then injecting a liquid foaming raw material into the inner surface of the leather skin to cause foaming. A method for producing a foamed molded product with a skin. (2) In a method for producing a foam molded article with a leather skin by injecting a liquid foaming raw material into the inner surface of the leather skin and foaming it together with the skin, one side of the polyurethane film that is undergoing reaction hardening is applied to the leather surface. At the same time, a backing material made of a thin flexible polyurethane foam lined with a plastic film is crimped onto the other surface of the polyurethane film,
The leather surface material and the back surface material are bonded together through the polyurethane film by reaction curing of the polyurethane film to form a leather skin, and then a liquid foaming material is injected into the inner surface of the leather skin to cause foaming. A method for producing a foam molded product with a leather skin.