JPH0583053B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a method for producing a molded article having cushioning properties for use in seats in transportation vehicles, headrests of automobiles, door trims, chairs, sofas, and the like.

[Conventional technology]

Cushionable molded products used as interior materials for vehicles such as automobiles and trains include, for example, a fabric such as natural or synthetic leather or woven fabric that serves as the outer skin, and a synthetic resin foam that serves as the core. The combination is known.

Such a cushionable molded product is made by separately molding a synthetic resin foam core into a predetermined shape, and then attaching a material to the outside of the resulting foam molded product by sewing, welding, molding, or other means. A skin sheet formed into a predetermined shape is wrapped and fixed by adhesion or welding.

On the other hand, as a method for obtaining foam molded products such as automobile headrests, for example, Japanese Patent Application Laid-Open No. 62-5821 discloses that a core is inserted into a bag-shaped outer skin material in a mold, and a liquid foaming raw material is poured into the mold. A technique is disclosed in which foaming is carried out under the closed condition of the outer skin material.

[Problem to be solved by the invention]

In the conventional method of manufacturing a cushionable molded article, in which the core synthetic resin foam is molded separately, the skin sheet and the foamed molded article are separate bodies, which tends to cause misalignment when integrating the two. In particular, when fabric is used for the skin body, significant misalignment occurs due to the stretchability of the fabric.

On the other hand, the method described in JP-A No. 62-5821, in which a core body and a liquid foaming material are injected into the inside of a bag-shaped outer skin material and foam-molded, can be used for outer skin materials made of fabric such as woven or knitted fabrics. If a skin material made by sewing cut fabrics is used in addition to fabric, the liquid foaming material will leak out through the fabric's weave and seams and solidify, impairing the appearance and damaging the cushion of the molded product. However, there is a problem in that the inconvenience of reducing the sexiness occurs.

In view of the current situation, it is an object of the present invention to provide a molded article having a soft feeling of use and excellent cushioning properties at a low cost by using fabric as the skin layer.

[Means to solve the problem]

In order to achieve the above object, the method for producing a cushionable molded article of the present invention involves cutting a skin sheet made of fabric, natural leather, synthetic leather, etc. lined with a gas shielding layer, and cutting the fabric of the cut skin sheet. A skin body of a predetermined shape is formed by sewing with the inside surface, and an adhesive tape made of a polyurethane film with a thickness of 15 to 80 μm is attached to the seam portion of the skin body on the gas shielding layer side, including the seam allowance. After sealing, the skin body to which the adhesive tape is attached is set in a mold, a foamed resin raw material is injected into the gas shielding layer side, and the foamed molded body and fabric are formed as a surface layer by foam molding. It integrates the epidermis.

In this invention, the outer surface of the skin sheet is made of fabric, natural leather, or synthetic leather, and the fabric is a cloth such as a woven or knitted fabric, and a material with a moderate amount of napping on the surface provides a soft feeling of use. be able to.

The gas shielding layer lining such a fabric is
It is composed of a resin film, a foam made of closed cells, etc. When a urethane resin is used as the foamed resin, it is desirable to construct the gas shielding layer using a polyurethane film.

The skin sheet is cut and sewn with fabric etc. on the inside, maintaining an appropriate seam allowance to form a skin body with a predetermined outline shape, but the seam allowance should be around 5 mm. preferable.

Seam allowances due to sutures are created on the gas shielding layer on the back side of the skin because the fabric is sutured with the fabric as the inside surface. Adhesive tape consisting of polyurethane film coated with adhesive is applied.

The polyurethane film has high elasticity,
In addition, since it is flexible, it has the feature of following three-dimensional shapes, which is not the case with adhesive tapes made of other resin films such as polyethylene.

In particular, when a foamed urethane resin or a polyurethane film is used as the adhesive surface, the adhesive tape has the advantage that the bonding and integration with the adhesive tape made of the polyurethane film becomes even stronger.

The adhesive tape has a thickness of 15-80μ, preferably 20μ
~30μ and its width is preferably 15mm or more. Extremely thin films with a thickness of less than 15 μm do not have a stiffness, making them difficult to handle during application, and pinholes are likely to occur during film manufacturing, so shielding is often incomplete.
In addition, if the thickness exceeds 80μ, it will have poor conformability to the surface to which it is attached, and the seams that are attached will be likely to be stretched and wrinkled, and may often peel off due to tension. .

The skin thus obtained is set in contact with the mold surface of a mold with the fabric as the surface, and then a foamed resin made of polyurethane, polystyrene, polyvinyl chloride, polyethylene, etc. is injected into the mold and foamed. By letting
A resin foam having a predetermined shape is integrally formed on the gas shielding layer on the back surface of the skin, and a molded article with desired cushioning properties can be obtained.

[Effect]

In this invention, a skin sheet made of fabric lined with a gas shielding layer is cut and sewn with the fabric side facing inside. Since it is covered with an adhesive tape made of film, when the skin body and the foamed molded body are integrally bonded by injecting the foamed resin raw material into the gas shielding layer side, the liquid fabric is covered by the gas shielding layer. This prevents leaching into the epidermis.

Furthermore, since the seam portion is protected with adhesive tape, the urethane resin liquid is prevented from hardening due to impregnation into the seam allowance and from seeping out onto the fabric surface.

In addition, by using a highly compatible urethane resin in the combination of the gas shielding layer of the skin sheet, the adhesive tape, and the resin liquid injected into the inside of the skin body, the combination can be further strengthened. I can do it.

〔Example〕

EMBODIMENT OF THE INVENTION Hereinafter, as an example of the method for manufacturing a cushionable molded article of the present invention, manufacturing of an automobile headrest will be specifically described with reference to the accompanying drawings.

In FIG. 1, numeral 1 indicates a headrest formed of a skin body 2 made of a soft-touch fabric with brushed outside.
It is sutured by.

As shown in FIG. 2, the skin body 2 is formed of a fabric 5 and a skin sheet 4 consisting of a soft polyurethane foam layer 6 and a polyurethane film 7 integrally provided on the back surface of the fabric 5. This skin body 2 is made by forming a polyurethane foam layer 6 and a polyurethane film 7 into a fabric 5.
It can be easily obtained by known means of heating and fusing.

The skin sheet 4 is cut into a predetermined shape and sewn together to form the outline of the desired headrest, as shown in FIG.
Insertion holes 10a, 10 for inserting and fixing a pair of stays (not shown) at the lower sides of the headrest
b, of which the insertion hole 10a is the nozzle 11.
It also serves as a liquid injection hole for flowing urethane resin liquid etc. into the inside.

This sewing is reversed from the normal state,
That is, as shown in FIG. 3, the skin sheet 4 and the seam portion 3 are sewn together so that their seam allowances are on the outer surface.

In this state, apply 25μ thick platylon to the seams 3 of each part of the skin body 2 with the seam allowance on the front side.
Adhesive tape 8 made of polyurethane film U01 (trade name of polyurethane film manufactured by Nippon Rilsan Co., Ltd.) with an acrylic adhesive coated on one side.
is pasted to seal this sutured portion 3.

At this time, the adhesive tape 8 is used to securely adhere the adhesive tape 8 including the seam allowance of the seam portion 3 to prevent liquid leakage from the seam portion 3.

When this operation is completed, the skin body 2 is turned over and the skin body 2 is in its normal state with the fabric 5 on the surface.
Then, this skin body 2 is placed in a split mold (not shown), the split mold is closed, and the nozzle 1 is inserted through the urethane resin liquid injection hole 10a provided on one side of the lower part of the skin body 2.
The urethane resin liquid, foaming additives, and other additives are injected through 1 and reacted to foam.

The injected resin liquid does not penetrate into the seam allowances of the seam parts 3 and harden because each seam part 3 inside the skin body 2 is sealed with the adhesive tape 8, and the resin liquid does not harden. A core material 9 made of foam is formed inside the skin body 2 by foaming inside the skin body 2 to increase the apparent volume without leaking out from the seams and filling the inside of the skin body 2.

This core material 9 is in contact with a gas shielding layer consisting of a polyurethane foam layer 6 and a polyurethane film 7 on the inside of the skin body 2, and is integrated with the gas shielding layer due to compatibility with the gas shielding layer to shape the skin body 2 into a predetermined shape. It is held to form a headrest.

〔Effect of the invention〕

This invention uses fabric as the material for forming the skin, lines the fabric with a gas shielding layer to form a skin sheet, and cuts and sews this skin sheet to form a seam on the back side of the skin body. An adhesive tape made of a polyurethane film having a thickness within a predetermined range including the seam allowance is attached and sealed to the surface, and this skin body is set in a mold and a foamed resin raw material is injected into the gas shielding layer side. A cushionable molded product is produced by integrating a foamed molded product and a skin body by foam molding.When injecting a foamed resin raw material into the gas shielding layer side, By applying adhesive tape to the seam formed on the gas shielding layer side to seal the seam, it is possible to prevent the foam resin raw material from leaking into the fabric. A cushionable molded article can be produced without curing due to impregnation.

In addition, the cushioning molded article obtained by the present invention has a surface covered with a sewn fabric with a particularly soft feel, and an interior made of urethane foam, which has particularly excellent cushioning properties among various synthetic resin foams. Since it is made of resin foam, it has both a luxurious appearance and an excellent usability, and by covering the seams of the skin with adhesive tape, liquid can seep through the seams onto the surface of the fabric, etc. Since the molded article is prevented from penetrating into the seam allowance and solidifying, the obtained molded article can have even better cushioning properties and usability.

[Brief explanation of the drawing]

The drawings show an example of manufacturing a headrest, which is an example of the cushionable molded article of the present invention, and FIG. 1 is a perspective view of the headrest, FIG. 2 is a longitudinal sectional view of a skin sheet constituting the outer body of the headrest, and FIG. 3 4 is a perspective view showing an inverted state of the skin, and FIG. 4 is a longitudinal sectional view of the headrest. 1... Head rest, 2... Epidermal body, 3... Suture portion, 4... Epidermal sheet, 5... Fabric,
6... Polyurethane foam layer, 7... Polyurethane film, 8... Polyurethane adhesive tape, 9...
... Core material (polyurethane foam), 10a, 10b
...Supporting material insertion hole, 11...Nozzle.

Claims (1)

[Claims] 1 A skin sheet made of fabric, natural leather, synthetic leather, etc. lined with a gas shielding layer is cut, and a skin body of a predetermined shape is formed by sewing the fabric etc. of the cut skin sheet as the middle surface, and the skin body is sewn into a predetermined shape. Adhesive tape made of polyurethane film with a thickness of 15 to 80 μm is applied to the seam on the gas shielding layer side of the body, including the seam allowance, to seal it, and then the skin body with the adhesive tape applied is set in the mold. A method for manufacturing a cushionable molded article, comprising: injecting a foamed resin raw material into the gas shielding layer side, and then integrating the foamed molded article and a skin body having a surface layer such as fabric by foam molding.