Method for manufacturing laminate with concave-convex shape, laminate for forming concave-convex shape, and laminate with concave-convex shape

Abstract

To obtain a laminate having a good concave-convex shape formed by using a general-purpose soft polyurethane foam without using a soft polyurethane foam having a special structure.SOLUTION: There is provided a method for manufacturing a laminate with a concave-convex shape, comprising: laminating a soft polyurethane foam and a flexible surface member via a moisture-curing hot-melt adhesive; curing the moisture-curing hot-melt adhesive; laminating and integrating the soft polyurethane foam and the surface member with each other to form a laminate for forming a concave-convex shape; heating and compressing the laminate for forming a concave-convex shape by a heating compression device having a concave-convex shape on a pressing surface thereof to perform forming of a concave-convex shape on a surface of the laminate for forming a concave-convex shape.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for producing a laminate having a textured surface, a laminate for forming textured surfaces, and a laminate having a textured surface. [Background technology]

[0002] BACKGROUND ART As a covering material used for coverings of seats of vehicles such as automobiles or for coverings of furniture, there is a laminate having a concave-convex shape. The unevenly shaped laminate is produced by laminating a flexible surface member onto a soft polyurethane foam, and then heating and compressing the surface with a heating and compressing device having an uneven surface.

[0003] Conventional unevenly shaped laminates include those made by using flexible polyurethane foam that is made easier to thermoform by blending polyols, flame retardants, etc. and specifying the ester value, and welding the flexible polyurethane foam and surface material together using frame lamination (Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 6389589 Summary of the Invention [Problem to be solved by the invention]

[0005] However, when a flexible polyurethane foam containing a polyol, a flame retardant, etc. and a specific ester value is welded to a surface member using frame lamination, the flexible polyurethane foam that can be used is limited, and general-purpose flexible polyurethane foam cannot be used.

[0006] In view of the above, an object of the present invention is to make it possible to form irregularities using a general-purpose flexible polyurethane foam without using a special flexible polyurethane foam. [Means for solving the problem]

[0007] The first means is a method for manufacturing a laminate with a textured surface, characterized in that a soft polyurethane foam and a flexible surface member are laminated via a moisture-curing hot melt adhesive to form a laminate for textured surfaces, and the laminate for textured surfaces is heated and compressed using a heating and compression device having textured surfaces on its pressure surface, thereby forming textures on the laminate for textured surfaces.

[0008] The second means is a laminate for forming uneven surfaces, in which a flexible surface member is laminated and integrated onto a soft polyurethane foam, and is characterized in that the soft polyurethane foam and the surface member are bonded together with a moisture-curing hot melt adhesive.

[0009] The third means is a laminate in which a flexible surface member is laminated and integrated onto a flexible polyurethane foam and formed into an uneven surface, characterized in that the flexible polyurethane foam and the surface member are bonded together with a moisture-curing hot melt adhesive. [Effects of the Invention]

[0010] According to the present invention, the soft polyurethane foam and the flexible surface member are bonded together using a moisture-curing hot melt adhesive, and good unevenness can be formed using a general-purpose soft polyurethane foam without using a soft polyurethane foam with a special configuration. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 2 is a cross-sectional view showing a portion of an unevenly shaped laminate according to one embodiment. [Figure 2] 1 is a schematic cross-sectional view showing a process for producing a laminate for forming projections and recesses. [Figure 3] FIG. 10 is a schematic cross-sectional view showing the unevenness forming step. [Figure 4] 1 is a table showing the configuration of an embodiment; [Figure 5] 10 is a table showing the configuration of a comparative example. [Figure 6] 1 is a table showing the contents of moisture-curable hot melt adhesives. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, an embodiment of the present invention will be described. The unevenly shaped laminate 10 shown in FIG. 1 is used for vehicle interior materials, such as seat coverings, door trim, or furniture coverings. The laminate 10 is composed of a flexible polyurethane foam 11, a surface member 21 bonded to one side of the flexible polyurethane foam 11 with a moisture-curing hot-melt adhesive 15, and a back member 31 bonded to the other side with the moisture-curing hot-melt adhesive 15, and has an uneven surface 35 formed thereon. The back member 31 is a member that is provided as needed. Details of each member will be described later.

[0013] The illustrated unevenness 35 has a configuration in which a first protrusion 36, a recess 37, a second protrusion 38, and a recess 39 are adjacent to each other, and extends linearly in one direction (e.g., the length direction) of the unevenly shaped laminate 10. The configuration of the unevenness 35 is not limited to the illustrated configuration in which the protrusions and recesses extend linearly. For example, any appropriate configuration may be used, such as a grid, a diamond shape, or a circle formed by the recesses or protrusions. Furthermore, the illustrated protrusions are configured with two types of protrusions, the first protrusion 36 and the second protrusion 38, which have different heights, but may be configured with one type or three or more types of protrusions.

[0014] The unevenly shaped laminate 10 is manufactured by a step of producing an unevenly shaped laminate and a step of unevenly shaping the laminate. The process for producing the unevenness-forming laminate is shown in FIG. 2 (2-1). A surface member 21 and a back member 31 are laminated on a flexible polyurethane foam 11 via a moisture-curing hot melt adhesive 15, and the moisture-curing hot melt adhesive 15 is cured by reaction with moisture such as humidity in the air, thereby laminating and integrating the flexible polyurethane foam 11 with the surface member 21 and the back member 31. This forms the unevenness-forming laminate 10A shown in Fig. 2(2-2). When the back surface member 31 is not laminated, the moisture-curable hot melt adhesive for the back surface member 31 is also not necessary.

[0015] The flexible polyurethane foam 11 is formed from polyurethane raw materials containing polyol, blowing agent, catalyst, foam stabilizer, polyisocyanate, and appropriate additives, and a general-purpose flexible polyurethane foam can be used. Flexible polyurethane foams include ether-based polyurethane foams that use ether-based polyols as polyols, and ester-based polyurethane foams that use ester-based polyols. Either type of flexible polyurethane foam 11 may be used, but ether-based polyurethane foams, which are less susceptible to moist heat degradation, are more preferred.

[0016] The density of flexible polyurethane foam 11 (JIS K 7222 compliant) is 13 to 80 kg / m 3 , more preferably 15 to 70 kg / m 3 The hardness (according to JIS K 6400-2) is 40 to 350 N, more preferably 60 to 200 N, and the thickness (before forming unevenness) is 2 to 30 mm, more preferably 3 to 20 mm. If the flexible polyurethane foam 11 is too hard, it becomes difficult to form unevenness and the cushioning properties and tactile feel deteriorate. Furthermore, if the thickness of the flexible polyurethane foam 11 is too thin, the unevenness formed by the unevenness formation becomes inconspicuous.

[0017] The moisture-curing hot melt adhesive 15 is an adhesive that is heated, melted, and applied, and then reacts and cures with moisture such as water in the air, and is preferably one whose main component is a urethane prepolymer having an isocyanate group at the end. The urethane prepolymer having a terminal isocyanate group is composed of a urethane prepolymer made from a polyol component and a polyisocyanate component. Examples of the polyol component that can be preferably used include polyester polyols, polyether polyols, and polyether / polyester block polyols or mixtures thereof. The number-average molecular weight of the polyol is preferably 500 to 5,000, more preferably 1,000 to 4,000, and even more preferably 1,500 to 3,000. The number of functional groups of the polyol is preferably 2 to 4, more preferably 2 to 3. A small amount of monool (functional group 1) may be contained. As the polyisocyanate component, for example, toluene diisocyanate, diphenylmethane diisocyanate, and polymeric MDI are used. The NCO group content of the urethane prepolymer is not particularly limited, but is preferably 0.3% to 25%, more preferably 0.7 to 15%, and even more preferably 1 to 10%. If the NCO group content is low, the curing reaction is not sufficient, resulting in poor heat resistance and poor formability of the laminate. On the other hand, if the NCO group content is high, the curing reaction is achieved, but the adhesive layer becomes hard, the feel of the laminate becomes poor, and the laminate structure becomes difficult to form. In addition to the moisture-curing hot melt adhesive used in this invention, there are also thermoplastic hot melt adhesives that use thermoplastic resins. Thermoplastic hot melt adhesives can be repeatedly activated by heating and cured by cooling. However, if the adhesive layer made with the same adhesive is heated again, the adhesive strength may decrease due to the thermal history. The melting point of the urethane prepolymer is preferably 30 to 100° C., more preferably 35 to 80° C., and even more preferably 40 to 70° C. The viscosity of the urethane prepolymer is preferably 1000 to 10000 mPa·s, more preferably 1500 to 8000 mPa·s, and even more preferably 2000 to 6000 mPa·s.

[0018] The moisture-curable hot melt adhesive 15 can be applied to the flexible polyurethane foam 11 by a roll coater having a heat roll, a roll coater using a gravure roll, a T-die head, or by spraying a liquefied moisture-curable hot melt adhesive. The heat-melting temperature of the moisture-curable hot melt adhesive is 70 to 180°C, and the application amount is 5 to 70 g / m. 2 is preferred.

[0019] The surface member 21 is made of a flexible material, such as knitted fabric, woven fabric, nonwoven fabric, synthetic leather, natural leather, or the like, and is selected depending on the intended use of the concave-convex laminate 10. For example, knitted fabrics include tricot, jersey, and double raschel, woven fabrics include plain weave and vermilion weave, and synthetic leathers include vinyl chloride resin leather and polyurethane resin leather. Examples of knitted and woven fabric materials include nylon, polyester, and rayon. The backing member 31, which is laminated as necessary, is made of an appropriate material such as knitted fabric, woven fabric, nonwoven fabric, etc. Examples of knitted fabrics include nylon tricot 17 decitex (NY-17 dtex), nylon marquise, and ester tricot, examples of woven fabrics include gold cloth, and examples of nonwoven fabrics include nylon nonwoven fabric 30 g / m 2 , polyester nonwoven fabric 50g / m 2 etc. are used.

[0020] In the unevenness-forming step, unevenness is formed on the surface of the unevenness-forming laminate 10A by heating and compressing the unevenness-forming laminate 10A using a heating and compressing device having unevenness on the pressing surface, thereby obtaining the unevenness-formed laminate 10 shown in Fig. 1. When heating and compressing the unevenness-forming laminate 10A, it is preferable to set the heating temperature on the surface member 21 side lower than on the other side (back member 31) to prevent thermal deterioration of the surface member 21.

[0021] Examples of the heat compression method include a heat press method using a concave-convex mold having a concave-convex surface, and a roll heat compression method using an embossing roll.

[0022] An embodiment of forming uneven surfaces by a heat press method will be described. The heat compression device 41 used in the heat pressing method shown in FIG. 3 comprises a front side mold 50 and a back side mold 70, and in the illustrated example, the front side mold 50 corresponds to the upper mold and the back side mold 70 corresponds to the lower mold. The surface side mold 50 is a mold that is positioned opposite the surface member 21 of the uneven shaping laminate 10A, has unevenness 67 on the pressure surface that presses against the surface member 21, and is configured to be able to be heated to a predetermined temperature by a heating device such as an electric heater. The back surface side mold 70 is a mold disposed opposite the back surface member 31 of the unevenness-forming laminate 10A, and the pressure surface for pressing the back surface member 31 is configured as a flat surface 71 in the illustrated example. The front side mold 50 is positioned above the back side mold 70 with the irregularities 67 facing downward, and is capable of approaching and moving away from the back side mold 70. The vertical positional relationship between the front side mold 50 and the back side mold 70 may be reversed.

[0023] The unevenness 67 of the front side mold 50 is composed of a first recess 63, a protrusion 64, a second recess 65, and a protrusion 66, and is intended to form the first protrusion 36, the recess 37, the second protrusion 38, and the recess 39 of the unevenly shaped molded body 10. The unevenness may be adjusted by adding a taper or the like to the unevenness 67. Furthermore, the back side mold 70 may also be provided with unevenness similar to that of the front side mold 50.

[0024] As shown in Figure 3 (3-1), the unevenness-forming laminate 10A is placed between the front side mold 50 and the back side mold 70 with the surface member 21 facing upward so that it faces the unevenness 67 of the front side mold 50.

[0025] Next, as shown in FIG. 3 (3-2), the surface-side mold 50 and the back-side mold 70 are brought close to each other, and the uneven-shaping laminate 10A is heated and compressed between the surface-side mold 50 and the bottom mold 70. The temperatures of the surface-side mold 50 and the back-side mold 70 may be in the range of 110 to 220°C, with a range of 130 to 180°C being preferred from the viewpoint of material deterioration and discoloration. It is also preferable to lower the temperature of the surface-side mold 50 on the surface member 21 side than the temperature of the back-side mold 70 to prevent thermal deterioration of the surface member 21 of the uneven-shaping laminate 10A. Furthermore, as an example of mold temperature, the lower limit of the temperature of the surface-side mold 50 is preferably 110°C or higher, more preferably 115°C or higher, and even more preferably 120°C or higher. The upper limit of the temperature of the surface-side mold 50 is preferably 200°C or lower, more preferably 180°C or lower, and even more preferably 160°C or lower. The lower limit of the temperature of the back side mold 70 is preferably 130° C. or higher, more preferably 140° C. or higher, and even more preferably 150° C. or higher. The upper limit of the temperature of the back side mold 70 is preferably 220° C. or lower, more preferably 210° C. or lower, and even more preferably 200° C. or lower.

[0026] During the heat compression, the unevenness-forming laminate 10A is compressed by the convex portions 64, 66 of the front surface side mold 50 and the back surface side mold 70, and the compressed portions crush the flexible polyurethane foam 11 between the front surface member 21 and the back surface member 31. Then, in a state where the flexible polyurethane foam 11 is crushed by the convex portions 64, 66 of the front surface side mold 50, it is plastically deformed by heating, and recesses (recesses 37, 39 of the unevenly-formed laminate 10) are formed at positions corresponding to the convex portions 64, 66 of the front surface side mold 50. In addition, in the first recess 63 and the second recess 65 of the surface side mold 50, the surface member 21 and the soft polyurethane foam 11 of the unevenness-forming laminate 10A enter the first recess 63 and the second recess 65 and become raised, forming convex portions (the first convex portion 36 and the second convex portion 38 of the unevenly-formed laminate 10).

[0027] The dimensions of the unevenness 67 of the surface-side mold 50 are preferably set so that, when the unevenness-forming laminate 10A is heated and compressed, gaps S1 and S2 are generated between the inner surfaces of the first and second recesses 63 and 65 and the surface member 21 of the unevenness-forming laminate 10A. This makes it possible to prevent the surface member 21 from coming into contact with the inner surfaces of the first and second recesses 63 and 65 when the unevenness-forming laminate 10A is heated and compressed, thereby suppressing thermal deterioration of the surface member 21.

[0028] Furthermore, in the unevenness-forming laminate 10A, the soft polyurethane foam 11, the surface member 21, and the back member 31 are bonded by the reactive hardening of the moisture-curing hot melt adhesive 15, so the moisture-curing hot melt adhesive 15 is not reactivated even when heated during the heat compression process in the unevenness-forming process, and the surface member 21 and the back member 31 do not shift or float up relative to the soft polyurethane foam 11, thereby forming good unevenness.

[0029] Thereafter, the gap between the front-side mold 50 and the back-side mold 70 is widened, and the compression on the unevenness-forming laminate 10A is released, thereby obtaining the unevenness-formed laminate 10 shown in Fig. 1. By releasing the compression, the first convex portions 36 and the second convex portions 38 of the unevenness-forming laminate 10 also rise toward the back surface member 31 due to the restoring force of the flexible polyurethane foam 11, and unevenness is formed on the back surface member 31 side as well.

[0030] On the other hand, in the roll thermocompression method (not shown), the surface member 21 of the continuously supplied shaping laminate 10A is thermocompressed with an embossing roll having a textured surface and capable of being heated, thereby forming a textured surface pattern. The heating temperature of the embossing roll is preferably 180 to 220°C, and the supply speed of the shaping laminate 10A is preferably about 1 to 10 m / min. [Example]

[0031] The examples and comparative examples shown in FIGS. 4 and 5 will be described. In Examples 1 to 3, the surface material is polyester tricot with a basis weight of 300 g / m 2The backing material is nylon nonwoven fabric 30g / m 2 (Basis weight 30g / m 2 ) using soft polyurethane foam A, ether-based polyurethane foam, density 20 kg / m 3 In this example, a laminate for forming uneven surfaces was produced using a 10mm thick, ... Examples 4 to 6 are examples in which the laminated structure of Examples 1 to 3 was used, except that the backing member was changed to nylon tricot 17 decitex (NY-17 dtex). Urethane-based moisture-curing hot melt adhesive Type A was produced by placing 100 parts by mass of polyester polyol with a number average molecular weight of 2000 (adipic acid / butanediol) and functionality of 2, kept at 80°C, into a four-neck flask equipped with a thermometer, a stirrer, and an inert gas inlet, and adding 19 parts by mass of the isocyanate component MDI. The mixture was reacted at 80°C and 40 rpm for 3 to 4 hours, producing a urethane-based moisture-curing hot melt adhesive with an NCO group content of 1.8%.

[0032] The unevenness-forming laminate was produced as follows: A moisture-curable hot melt adhesive was heated to 120°C to make it liquid, and applied to the surface of a flexible polyurethane foam in an amount of 30 g / m using a T-die coating device. 2 , 15g / m applied to the back 2 The moisture-curing hot melt adhesive was applied at 100°C. A surface member and a back member were laminated on both sides of the flexible polyurethane foam via the applied moisture-curing hot melt adhesive, and the surface member, back member, and flexible polyurethane foam were sandwiched between pressure plates and pressed together for 20 seconds, causing the moisture-curing hot melt adhesive to react and cure with the moisture in the air. After application and pressing, the adhesive was left to cure for 10 hours or more at room temperature (23°C) and a humidity of 50% RH or higher. Curing under these conditions for 5 hours or more is preferable in terms of adhesive performance. The adhesive state between the surface member, back member, and flexible polyurethane foam was good.

[0033] The uneven shaping was performed using the front side mold 50 and the back side mold 70 shown in Fig. 3. The first recess 63 of the front side mold 50 had an internal depth (height) of 15 mm and a width of 23 mm, the protrusions 64 and 66 had a width of 1 mm, and the second recess 65 had an internal depth (height) of 8 mm and a width of 6 mm. During the heat compression, the distance between the convex portions 64, 66 of the front side die 50 and the die surface of the back side 70 is 0.5 mm. The processability in the lamination process column in Figures 4 and 5 was marked "good" when the surface member and the back member were well adhered to the flexible polyurethane foam during the production of the unevenness-forming laminate. In addition, the moldability of the uneven shaping in Figures 4 and 5 was rated as "Good" if there was no peeling or lifting on the front and back members, "Average" if there was slight peeling or lifting, and "Poor" if there was clear peeling or lifting.

[0034] Example 1 In Example 1, the temperature of the front side mold during the formation of the unevenness was 135°C, the temperature of the back side mold was 180°C, and the compression time was 50 seconds. No defects such as peeling or lifting were observed in the front and back members, and good unevenness was formed.

[0035] In Example 2, the temperature of the front side mold during the formation of the unevenness was 135°C, the temperature of the back side mold was 180°C, and the compression time was 40 seconds. No peeling or lifting was observed on the front and back members, and good unevenness was formed.

[0036] In Example 3, the temperature of the upper mold on the surface member side during the formation of the unevenness was 135°C, the temperature of the lower mold on the back member side was 180°C, and the compression time was 30 seconds. No peeling or lifting was observed on the surface member or back member, and good unevenness was formed.

[0037] In Example 4, the temperature of the front side mold during the formation of the unevenness was 130°C, the temperature of the back side mold was 175°C, and the compression time was 50 seconds. No peeling or lifting was observed on the front and back members, and good unevenness was formed.

[0038] In Example 5, the temperature of the front side mold during the formation of the unevenness was 120°C, the temperature of the back side mold was 170°C, and the compression time was 50 seconds. No peeling or lifting was observed on the front and back members, and good unevenness was formed.

[0039] Example 6 Example 6 is an example in which the thickness of the flexible polyurethane foam used in the unevenness-forming laminate was 5 mm, and the other conditions were the same as in Example 5, and the unevenness-forming laminate was produced and unevenness was formed. In Example 6, similar to Example 5, no peeling or lifting was observed on the front surface member and the back surface member, and good unevenness was formed.

[0040] Example 7 In Example 7, the flexible polyurethane foam was a flexible polyurethane foam B, a polyether polyurethane foam having an ester component, and a density of 20 kg / m 3 This is an example in which a laminate for forming unevenness was produced and unevenness was formed using a material having a hardness of 100N, product number EL-64, manufactured by Inoac Corporation, and a thickness of 10 mm, with the other conditions being the same as in Example 4. In Example 7, similar to Example 4, no peeling or lifting was observed on the front surface member and the back surface member, and good unevenness was formed.

[0041] Example 8 Example 8 is an example in which a laminate for forming unevenness was produced and unevenness was formed using synthetic leather as the surface member, the compression time for forming unevenness was 40 seconds, and other conditions were the same as in Example 4. The synthetic leather used was a synthetic resin sheet (backing material: knitted laminate) made of polyvinyl chloride and 1.3 mm thick. In Example 8, similar to Example 4, no peeling or lifting was observed on the front surface member and the back surface member, and good unevenness was formed.

[0042] Example 9 In Example 9, a urethane-based moisture-curing hot melt adhesive type B (NCO group content = 4.0%, polyester polyol and MDI prepolymer type, manufactured by Inoac Corporation) was used to form the uneven surface under the same conditions as in Example 4. Urethane-based moisture-curing hot melt adhesive type B was produced in the same manner as urethane-based moisture-curing hot melt adhesive type A, except that the NCO group content was changed to 4.0%. In Example 9, similar to Example 4, no peeling or lifting was observed on the front surface member and the back surface member, and good unevenness was formed.

[0043] Example 10 In Example 10, a urethane-based moisture-curing hot melt adhesive Type C (NCO group content = 1.8%, a combination of polyester polyol and polyether polyol, a prepolymer type with MDI, manufactured by Inoac Corporation) was used to form the uneven surface under the same conditions as in Example 4. Type C urethane-based moisture-curing hot melt adhesive was produced by adding 50 parts by mass of polyester polyol with a number average molecular weight of 2000 (sebacic acid / hexanediol) and functionality of 2, both kept at 80°C, to a four-neck flask equipped with a thermometer, stirrer, and inert gas inlet, and 50 parts by mass of polyether polyol with a number average molecular weight of 2000 (polypropylene glycol) and functionality of 2, both kept at 80°C, to which 19 parts by mass of the isocyanate component MDI was added. The mixture was allowed to react at 80°C and 40 rpm for 3 to 4 hours, producing a urethane-based moisture-curing hot melt adhesive with an NCO group content of 1.8%. In Example 10, similar to Example 4, no peeling or lifting was observed on the front surface member and the back surface member, and good unevenness was formed.

[0044] The moisture-curable hot melt adhesives types A to C used in Examples 1 to 10 are shown in the table of FIG. The NCO group content of the urethane-based moisture-curing hot melt adhesive was measured according to the toluene / dibutylamine-hydrochloric acid method of JIS K1603-2007, the melting point was measured according to the method for measuring the transition temperature of plastics of JIS K7121-1987, and the viscosity was measured using an Anton Paar MCR302 rheometer at an angular frequency of 1 rad / s and a temperature of 140°C.

[0045] Comparison Example 1 Comparative Example 1 is an example in which a thermoplastic hot melt adhesive, part number TN716Z, manufactured by Moresco Co., Ltd., was used instead of the moisture-curing hot melt adhesive used in Example 1, and the procedure was carried out under the same conditions as Example 1, except for the preparation of the laminate for forming uneven surfaces. In Comparative Example 1, the laminate for forming uneven surfaces was prepared by heating the thermoplastic hot melt adhesive to 180°C to make it liquid, and applying it to the front surface of the flexible polyurethane foam at a coating rate of 30 / m2 and to the back surface at a coating rate of 15 / m2 using a T-die coating device.The surface and back surface members were laminated on both sides of the flexible polyurethane foam via the applied thermoplastic hot melt adhesive, and the laminate was pressed between pressure plates for 20 seconds, and the thermoplastic hot melt adhesive was hardened by cooling. The processability of the unevenness-forming laminate in Comparative Example 1 was evaluated as "good" because the front surface member and the back surface member were well adhered to the flexible polyurethane foam. In addition, the moldability of the uneven surface formation in Comparative Example 1 was evaluated as "×" because peeling and lifting were observed on the surface and back surfaces due to the thermoplastic hot melt adhesive being reactivated during the heating and compression process for uneven surface formation.

[0046] Comparison Example 2 Comparative Example 2 is an example in which synthetic leather (the same material as in Example 8) is used as the surface member, and a thermoplastic hot melt adhesive is used to bond the flexible polyurethane foam to the surface member and the back member. In Comparative Example 2, the laminate for imparting irregularities and the imparting of irregularities were produced under the same conditions as in Comparative Example 1, except that the surface member was made of synthetic leather. The processability of the unevenness-forming laminate in Comparative Example 2 was evaluated as "good" because the front surface member and the back surface member were well adhered to the flexible polyurethane foam, similar to Comparative Example 1. In addition, the moldability of the uneven shaping in Comparative Example 2 was evaluated as "X" because the thermoplastic hot melt adhesive was reactivated during the heating and compression process for uneven shaping, resulting in peeling and lifting of the surface and back components, as in Comparative Example 1.

[0047] Comparative Example 3 In Comparative Example 3, an ester polyurethane foam was used as the flexible polyurethane foam, and the flexible polyurethane foam was bonded to the surface member and back member by frame lamination. The surface member was nylon tricot, the same as in Comparative Example 1. In Comparative Example 3, flexible polyurethane foam B (same as in Example 7) was used, both sides of the flexible polyurethane foam were heated with a burner to melt, and a surface member and a back member were laminated and bonded to the melted surface to prepare a laminate for forming unevenness. The unevenness forming process for the laminate for forming unevenness was the same as in Comparative Example 1. The processability of the unevenness-forming laminate in Comparative Example 3 was evaluated as "good" because the front surface member and the back surface member were well adhered to the flexible polyurethane foam. Furthermore, the moldability of the uneven surface forming in Comparative Example 3 was evaluated as "good" because no peeling or lifting was observed on the front surface member and the back surface member.

[0048] Comparative Example 4 Comparative Example 4 is an example in which a polyether-based polyurethane foam B having an ester component is used in the soft polyurethane foam, and the soft polyurethane foam is bonded to the surface member and the back member using frame lamination.The procedure was the same as Comparative Example 3, except that the mold temperature during uneven formation was 5°C lower than the temperature of the surface side mold and the back side mold in Comparative Example 3, and the compression time was 30 seconds. The temperatures of the front side mold and the back side mold in Comparative Example 4 are the same as those of the front side mold and the back side mold in Example 7. The processability of the unevenness-forming laminate in Comparative Example 4 was evaluated as "good" because the front surface member and the back surface member were well adhered to the flexible polyurethane foam. In addition, in Comparative Example 4, although there was no peeling or lifting of the surface and back members, the molding ability of the uneven surface was poor due to the short molding time, and the uneven surface 35 in Figure 1 was not sufficiently pressed, making the recesses unclear, and the evaluation was "△".

[0049] Comparative Example 5 Comparative Example 5 is an example in which ether-based polyurethane foam A was used as the flexible polyurethane foam, and the flexible polyurethane foam was bonded to the front surface member and the back surface member by frame lamination. In Comparative Example 5, when producing the laminate for forming uneven surfaces, the soft polyurethane foam was an ether-based polyurethane foam, so the surface member and the back member could not be adhered to the soft polyurethane foam, and the processability was evaluated as "X". Since a laminate for forming unevenness was not obtained, the subsequent unevenness forming process could not be carried out.

[0050] Comparative Example 6 Comparative Example 6 is an example in which the surface member is synthetic leather, and frame lamination and uneven shaping are carried out in the same manner as in Comparative Example 3 using polyether polyurethane foam B having an ester component in the flexible polyurethane foam. In Comparative Example 6, similarly to Comparative Example 3, the processability of the uneven-forming laminate was evaluated as "good" and the moldability of uneven shaping was evaluated as "good".

[0051] Thus, according to the present invention, it is possible to form good unevenness using a general-purpose flexible polyurethane foam, without using a flexible polyurethane foam with a special structure. The present invention is not limited to the examples, and can be modified within the scope of the invention. [Industrial Applicability]

[0052] The laminate of the present invention can be used for interior materials of vehicles, such as seat coverings, door trims, and furniture coverings. [Explanation of symbols]

[0053] 10. Laminated body with concave and convex shapes 10A Laminate for forming uneven surfaces 11 Flexible polyurethane foam 15 Moisture-curing hot melt adhesive 21 Surface material 31 Back surface material 35 Unevenness 41 Heat compression device 50 Front side type 67 Unevenness 70 Back side type

Claims

1. A soft polyurethane foam and a flexible surface member are laminated via a moisture-curing hot melt adhesive to form a laminate for forming unevenness; A method for producing a laminate with a textured surface, characterized in that the laminate for textured formation is heated and compressed using a heating and compressing device having textured surfaces, and textured formation is performed on the laminate for textured formation.

2. 2. The method for producing a laminate according to claim 1, wherein the flexible polyurethane foam is an ether-based polyurethane foam.

3. A method for manufacturing a textured laminate as described in claim 1 or 2, characterized in that the heat compression of the textured laminate is performed on the surface member side of the textured laminate at a lower temperature than on the other surface member side.

4. The method for manufacturing a textured laminate described in claim 1 or 2, characterized in that the dimensions of the recess on the pressure surface that compresses the surface member side of the textured laminate are set so that a gap is created between the inner surface of the recess and the surface member of the textured laminate during the thermal compression.

5. A laminate for forming uneven surfaces, in which a flexible surface member is laminated and integrated onto a soft polyurethane foam, characterized in that the soft polyurethane foam and the surface member are bonded together with a moisture-curing hot melt adhesive.

6. A laminate in which a flexible surface member is laminated integrally with a flexible polyurethane foam and formed into a concave-convex shape, The unevenly shaped laminate is characterized in that the flexible polyurethane foam and the surface member are bonded together with a moisture-curing hot melt adhesive.

7. 7. The laminate according to claim 6, wherein the uneven shape is formed by heat compression.

Images