Laminated sheet, vehicle interior material comprising the laminated sheet, method for manufacturing the laminated sheet, and laminated sheet for textured processing.

Abstract

To provide a technology that can suppress the formation of irregularities on the back side of a laminated sheet with an uneven surface. [Solution] This technology provides a laminated sheet having a foam layer having a first surface with an uneven surface, and a backing material laminated on the second surface opposite to the first surface of the foam layer, wherein the foam layer and the backing material are bonded together with a hot melt adhesive. In the laminated sheet according to this technology, a moisture-curing hot melt adhesive can be used as the hot melt adhesive.

Description

[Technical Field]

[0001] This technology relates to laminated sheets. More specifically, this technology relates to laminated sheets having an uneven surface, vehicle interior materials comprising the laminated sheet, a method for manufacturing the laminated sheet, and laminated sheets for uneven processing. [Background technology]

[0002] In the fields of construction, transportation, and other industries, laminated sheets with various characteristics have been developed for purposes such as thermal insulation, heat resistance, sound insulation, soundproofing, sound absorption, fire prevention, flame retardancy, impact resistance, and cushioning.

[0003] Laminated sheets can be processed into various forms depending on the purpose, and various technologies are being developed to apply uneven surfaces to them, for example. For example, Patent Document 1 discloses a laminated sheet in which a flexible surface member made of woven fabric or the like is laminated and integrated onto the surface of a soft polyurethane foam with an ester value of 40 to 400 mgKOH / g and a compression set of 0 to 15% by frame lamination or the like, thereby enabling the creation of a clear uneven pattern even when using a soft polyurethane foam with a low compression set.

[0004] Furthermore, Patent Document 2 discloses a urethane resin-based surface material that consists of a thermoplastic urethane resin layer and a flexible polyurethane slab foam layer, wherein the thermoplastic urethane resin layer is embossed and the flexible polyurethane slab foam layer is compressed to 10-60% of its original thickness, thereby providing good emboss transferability. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2014-184580 [Patent Document 2] Japanese Patent Publication No. 2003-211612 [Overview of the project] [Problems that the invention aims to solve]

[0006] One method for creating a textured surface on a laminated sheet is to use a mold with protrusions or a roll with a textured surface for thermal compression. However, this method has the following problems. As shown in Figure 10, when a heated mold D is pressed into the surface of a foam with a laminated backing material (see Figure 10B), the surface material 1004 and backing material 1002 are pulled by the foam 1001, which is compressed at high temperature. When the mold is returned to its original position (see Figure 10C), the foam 1001 and surface material 1004 return to some extent, and the backing material 1002 is pulled in the direction of the surface. This problem becomes more pronounced as the texture of the surface becomes deeper.

[0007] If irregularities are formed on the backing material 1002, the smoothness of the backing material decreases, and problems such as peeling or lifting may occur when bonding the backing material 1002 to other components, for example, due to a reduction in the bonding area.

[0008] In order to prevent the formation of irregularities on the backing material 1002, it is necessary to make the irregularities on the surface shallower, which makes it impossible to form deep irregularities that would give a good design, and this can lead to problems such as a decrease in aesthetic appeal.

[0009] While hardening the backing material 1002 can prevent the formation of irregularities on the backing material 1002, doing so makes winding difficult, leading to problems such as difficulties in winding when manufacturing long sheets and the occurrence of wrinkles during winding.

[0010] For short products, it is possible to harden the backing material 1002. However, if the backing material 1002 is hardened by increasing its basis weight, for example, the increased basis weight will worsen the thermal conductivity of the backing material 1002, requiring a higher temperature during the textured processing. This will increase damage to the surface material 1004, resulting in problems such as pitting on the surface and a decrease in aesthetic appeal.

[0011] Therefore, the main objective of this technology is to provide a technique that can suppress the formation of irregularities on the back side of a laminated sheet with irregularities on its surface. [Means for solving the problem]

[0012] The inventors of this invention conducted diligent research to solve the aforementioned problem and discovered that differences in the bonding method between the foam layer and the backing material affect the formation of irregularities on the back side. By bonding the foam layer and the backing material with a hot-melt adhesive, they succeeded in suppressing the formation of irregularities on the back side, thus completing this technology.

[0013] In other words, in this technology, first, a foam layer having a foam with a first surface that has irregularities, The foam layer has a backing material laminated on a second surface opposite to the first surface, The present invention provides a laminated sheet in which the foam layer and the backing material are bonded together with a hot-melt adhesive. In the laminated sheet relating to this technology, a moisture-curing hot-melt adhesive can be used as the hot-melt adhesive. The backing material of the laminated sheet according to this technology may be breathable. A surface material may be laminated on the first surface of the foam layer of the laminated sheet according to this technology. The laminated sheet relating to this technology can be used as an interior material for vehicles.

[0014] In this technology, the next step is to bond a backing material to one side of a foam layer having foam using a hot melt adhesive, A process of creating a textured surface on the side of the foam layer opposite to the side on which the backing material is laminated, by applying a textured surface by thermal compression, The present invention provides a method for manufacturing laminated sheets having the following characteristics:

[0015] This technology further includes a foam layer having a foam with a first surface on which an uneven surface is to be applied, The foam layer has a backing material laminated on a second surface opposite to the first surface, Provided is a laminated sheet for embossing, in which the foam layer and the backsheet are adhered by a hot melt adhesive.

Brief Description of Drawings

[0016] [Figure 1] It is a conceptual cross-sectional view schematically showing a first embodiment of a laminated sheet 1 according to the present technology. [Figure 2] It is a conceptual cross-sectional view schematically showing a second embodiment of a laminated sheet 1 according to the present technology. [Figure 3] It is a conceptual cross-sectional view schematically showing a third embodiment of a laminated sheet 1 according to the present technology. [Figure 4] It is a conceptual cross-sectional view for explaining the effect of suppressing the formation of irregularities on the back side of the laminated sheet 1 according to the present technology. [Figure 5] It is a schematic conceptual diagram schematically showing an example of an adhesion step in a method for manufacturing a laminated sheet 1 according to the present technology. [Figure 6] It is a schematic conceptual diagram schematically showing an example of an embossing step in a method for manufacturing a laminated sheet 1 according to the present technology. [Figure 7] It is a schematic conceptual diagram schematically showing an example of a modified example of a method for manufacturing a laminated sheet 1 according to the present technology. [Figure 8] It is a conceptual cross-sectional view schematically showing a first embodiment of a laminated sheet 10 for embossing according to the present technology. [Figure 9] It is a micrograph in an example. [Figure 10] It is a conceptual cross-sectional view for explaining the formation of irregularities on the back side when embossing a conventional laminated sheet 100.

Modes for Carrying Out the Invention

[0017] Hereinafter, preferred embodiments for carrying out the present technology will be described with reference to the drawings. The embodiments described below show an example of a typical embodiment of the present technology, and any of the embodiments can be combined. Also, the scope of the present technology is not construed narrowly thereby.

[0018] 1. Laminated sheet 1 Figure 1 is a schematic conceptual cross-sectional view showing a first embodiment of the laminated sheet 1 according to this technology. The laminated sheet 1 according to this technology comprises a foam layer 11 and a backing material 12, and the foam layer 11 and the backing material 12 are bonded together with a hot melt adhesive 13. The laminated sheet 1 according to this technology may also include a surface material 14, etc., as needed. The following describes each component in detail.

[0019] (1) Foam layer 11 The foam layer 11 is a layer having foam 111. In this technology, the foam layer 11 and the backing material 12 are bonded together with a hot-melt adhesive 13, which suppresses the formation of irregularities on the back side as described later, and consequently improves the aesthetic appearance of the front side. Therefore, as in the technology described in Patent Document 1, there is no need to control the physical properties of the foam 111 used in the foam layer 11. Also, as in the technology described in Patent Document 2, there is no need to devise the shape of the foam layer 11, such as its thickness. Accordingly, in the laminated sheet 1 according to this technology, it is possible to freely select the foam 111 according to its application.

[0020] The foam layer 11 has a first surface 11a with an uneven surface. A surface material 14, described later, may be laminated onto the first surface 11a. A back surface material 12, described later, is laminated onto the second surface 11b of the foam layer 11, which is opposite to the first surface 11a.

[0021] As the foam 111 that can be used in this technology, one or more types of foams that can be used in general laminated sheets can be freely selected and used, as long as they do not impair the function or effect of this technology. Specifically, for example, layers using polyurethane foam, polyethylene foam, polypropylene foam, vinyl chloride foam, polystyrene foam, etc. In this technology, polyurethane foam is particularly preferred among these.

[0022] Polyurethane foam is manufactured using a polyurethane foam manufacturing composition containing polyols, blowing agents, catalysts, foam stabilizers, isocyanates, and various additives as needed. The raw materials for polyurethane foam are described below.

[0023] <Polyol> The polyol used in the polyurethane foam manufacturing composition may be one or more polyols that can be used in the manufacture of polyurethane foam, as long as the function and effects of this technology are not impaired. Specifically, examples include polyether polyols obtained by adding alkylene oxides such as ethylene oxide (EO) and propylene oxide (PO) to polyhydric alcohols such as ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, neopentyl glycol, glycerin, pentaerythritol, trimethylolpropane, sorbitol, and sucrose; polyester polyols obtained by polycondensation of aliphatic carboxylic acids such as malonic acid, succinic acid, and adipic acid, or aromatic carboxylic acids such as phthalic acid, with aliphatic glycols such as ethylene glycol, diethylene glycol, and propylene glycol; polyether ester polyols obtained by polyesterizing the polyether polyol with a polybasic acid; and polyether ester polyols having both polyether and polyester segments in one molecule.

[0024] <Foaming agent> The blowing agent used in the polyurethane foam manufacturing composition can be freely selected from one or more blowing agents that can be used in the manufacture of polyurethane foam, as long as they do not impair the action and effects of this technology. Specifically, examples include water, methylene chloride, carbon dioxide, pentane, etc. The amount of blowing agent used is not particularly limited as long as it does not impair the action and effects of this technology, but for example, it is preferable to use 1 to 15 parts by mass of blowing agent per 100 parts by mass of polyol.

[0025] <Catalyst> The catalyst used in the polyurethane foam manufacturing composition can be freely selected from one or more catalysts that can be used in the manufacture of polyurethane foam, as long as the action and effects of this technology are not impaired. Specifically, examples include amine-based catalysts such as triethylamine, dimethylaminohexanol, triethylenediamine, and tetramethylguanidine; tin-based catalysts such as stanus octoate; and metal catalysts such as phenylmercury propionate and lead octenoate (also referred to as "organometallic catalysts"). The amount of catalyst used is not particularly limited as long as the action and effects of this technology are not impaired, but for example, it is preferable to use 0.1 to 10 parts by mass of catalyst per 100 parts by mass of polyol.

[0026] <Foam stabilizer> The foam stabilizers used in the polyurethane foam manufacturing composition can be freely selected from one or more types of foam stabilizers that can be used in the manufacture of polyurethane foam, as long as they do not impair the function and effects of this technology. Specifically, examples include silicone-based foam stabilizers, fluorine-containing compound-based foam stabilizers, surfactants, etc. The amount of foam stabilizer used is not particularly limited as long as it does not impair the function and effects of this technology, but for example, it is preferable to use 0.5 to 10 parts by mass of foam stabilizer per 100 parts by mass of polyol.

[0027] <Isocyanate> The isocyanates used in the polyurethane foam manufacturing composition may be freely selected from one or more isocyanates that can be used in the manufacture of polyurethane foam, as long as the function and effects of this technology are not impaired. Specifically, examples include aliphatic isocyanates such as hexamethylene diisocyanate, isophorone diisocyanate, and dicyclohexamethane diisocyanate; aromatic isocyanates such as toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), naphthalene diisocyanate, xylylene diisocyanate, and polymeric polyisocyanate (crude MDI); and modified polyisocyanates obtained by modifying these.

[0028] Furthermore, the isocyanate index of the polyurethane foam is not particularly limited as long as it does not impair the function and effect of this technology, but for example, polyurethane foam with an isocyanate index of 90 to 120 can be used in the foam layer 11. In this technology, the isocyanate index is a value calculated as [(equivalent amount of isocyanate in the polyurethane foam manufacturing composition / equivalent amount of active hydrogen in the polyurethane foam manufacturing composition) × 100].

[0029] <Other ingredients> The polyurethane foam manufacturing composition may contain, as necessary, one or more additives that can be used in the manufacture of polyurethane foam, provided that they do not impair the function or effect of this technology. Specifically, examples include flame retardants, stabilizers, plasticizers, colorants, pigments, antioxidants, crosslinking agents, antibacterial agents, dispersants, and ultraviolet absorbers, but this technology is not limited to these.

[0030] Figure 2 is a schematic conceptual cross-sectional view showing a second embodiment of the laminated sheet 1 according to this technology. The foam layer 11 of the laminated sheet 1 according to this technology may have other layers 112 made of materials other than foam 111. Any material can be selected for the other layers 112, depending on the application of the laminated sheet 1, as long as it does not impair the function or effect of this technology.

[0031] Other layers 112 include fiber layers, and the fibers used in the fiber layers include, for example, layers using one or more fibers selected from inorganic fibers such as carbon fibers, glass fibers, rock wool, and metal fibers.

[0032] Other layers 112 are not shown in the diagram, but may consist of two or more layers depending on the purpose. If two or more other layers 112 are provided, each layer may be the same layer or different layers.

[0033] The arrangement of the other layers 112 can also be freely arranged according to the application, etc., as long as it does not impair the function or effect of this technology. For example, it is not limited to the configuration in which the layers are laminated on the surface material side of the foam 111 as shown in Figure 2, but it is also possible to laminate them on the back material side of the foam 111, although this is not shown. Furthermore, if two or more layers 112 are provided, the other layers 112 can be arranged on both sides of the foam 111, or if two or more layers of foam 111 are also provided, the foam 111 and the other layers 112 can be arranged alternately, etc., allowing for free design.

[0034] If other layers 112 are provided, the bonding of the other layers 112 to the foam layer 11 can be performed by freely selecting one or more bonding methods commonly used for laminated sheets, as long as the function and effects of this technology are not impaired. Specific bonding methods for the other layers 112 to the foam layer 11 include, for example, frame lamination, bonding using adhesives, and integral molding of the foam 111 with the surface material 14. If an adhesive-based method is selected, it is also possible to use the hot-melt adhesive 13 described later.

[0035] (2) Backing material 12 As described above, the laminated sheet 1 relating to this technology includes a backing material 12. The materials constituting the backing material 12 can be freely combined in one or more types, depending on the application and purpose of the laminated sheet 1, as long as they do not impair the function and effect of this technology. Specifically, examples include woven fabrics, knitted fabrics, nonwoven fabrics, etc., using one or more types of fibers such as polyethylene terephthalate (PET) fibers, polyester fibers, polypropylene fibers, polyamide fibers, acrylic fibers, vinylon fibers, polyurethane fibers (spandex), glass fibers, carbon fibers, and natural fibers (e.g., wool, cotton, cellulose nanofibers, etc.).

[0036] The backing material 12 is preferably breathable. Having breathability allows the hot-melt adhesive 13 (described later) to penetrate more easily, further improving the effect of suppressing the formation of irregularities on the back side.

[0037] The basis weight of the backing material 12 is not particularly limited as long as it does not impair the function or effect of this technology. For example, the lower limit of the basis weight of the backing material 12 is 20 g / m². 2 Preferably 25 g / m² 2 Above, a comfortable 30g / m 2 More preferably 35 g / m² 2 That concludes the explanation. By setting the lower limit of the basis weight of the backing material 12 within this range, the effect of suppressing the formation of irregularities on the back side can be further improved.

[0038] For example, the upper limit for the weight of the backing material 12 is 60 g / m². 2 Preferably 55 g / m 2 More preferably 50g / m 2 More preferably 45 g / m 2 The following applies: By setting the upper limit of the basis weight of the backing material 12 within this range, it is possible to improve workability such as winding when forming the laminated sheet 1 into a long shape, and to suppress the occurrence of wrinkles during manufacturing.

[0039] It should be noted that the backing material 12 is positioned on the furthest back surface among the essential structures of the laminated sheet 1 related to this technology, and therefore, for convenience, the term "back surface" is used. However, in actual products, it is not limited to being positioned on the furthest back surface. For example, it is possible to laminate a desired material on the surface of the backing material 12, to cover the backing material 12 with a desired material, or to cover the entire laminated sheet 1 with a desired material.

[0040] (3) Hot melt adhesive 13 Examples of hot melt adhesives 13 that can be used in this technology include thermoplastic hot melt adhesives and moisture-curing hot melt adhesives. Examples of thermoplastic hot melt adhesives include one or more thermoplastic hot melt adhesives selected from ethylene vinyl acetate (EVA), polyolefin (PO), polyamide (PA), acrylic (ACR), synthetic rubber (SR), and polyurethane (PU).

[0041] In this technology, it is preferable to use a moisture-curing hot-melt adhesive as the hot-melt adhesive 13. By using a moisture-curing hot-melt adhesive, the adhesive does not melt and lose its adhesive properties when the surface of the laminated sheet 1 is textured, thus broadening the range of processing methods and further improving the design.

[0042] Moisture-curing hot melt adhesives are adhesives that, like general hot melt adhesives, are applied to the object to be bonded in a heated and melted state. They then cool and solidify, similar to general hot melt adhesives, to achieve initial adhesion and initial peel strength. After that, they exhibit final peel strength through a cross-linking reaction with moisture (water) contained in the air.

[0043] In this technology, it is preferable to use a urethane-based moisture-curing hot-melt adhesive as the moisture-curing hot-melt adhesive. A urethane-based moisture-curing hot-melt adhesive is a hot-melt adhesive that exhibits adhesive properties through a reaction between a polyol and an isocyanate compound. The details of the polyol and isocyanate are the same as those used in the polyurethane foam that can be used in the foam 111 described above, so a detailed explanation is omitted here.

[0044] (4) Skin material 14 The surface of the laminated sheet 1 according to this technology, opposite to the backing material 12, i.e., the front surface, may be provided with a surface material 14. The surface material 14 is not an essential component in this technology, and this technology also includes laminated sheets 1 without a surface material 14, as shown in the third embodiment in Figure 3. However, it is possible to provide a surface material 14 for improved design or for the intended application.

[0045] The materials constituting the surface material 14 can be any combination of one or more materials, depending on the application and purpose of the laminated sheet 1, as long as they do not impair the function and effect of this technology. For example, the same materials that can be used for the backing material 12 described above can be used, or synthetic leather (e.g., PVC, urethane, etc.), genuine leather, etc. may be used.

[0046] Although the surface material 14 is positioned on the outermost surface in the structure of the laminated sheet 1 according to the first and second embodiments, and therefore the term "surface" is used for convenience, it is not limited to being positioned on the outermost surface in actual products. For example, it is possible to laminate a desired material on the surface of the surface material 14, cover the surface material 14 with a desired material, or cover the entire laminated sheet 1 with a desired material.

[0047] The bonding of the surface material 14 and the foam layer 11 can be performed using one or more adhesive methods commonly used for laminated sheets, as long as they do not impair the function or effect of this technology. Specific bonding methods for the surface material 14 and the foam layer 11 include, for example, frame lamination, adhesive bonding, and integral molding of the foam 111 with the surface material 14. When using an adhesive method, the aforementioned hot melt adhesive 13 can also be used.

[0048] (5) Regarding the effect of suppressing the formation of irregularities on the reverse side The laminated sheet 1 according to this technology can suppress the formation of irregularities on the back side by bonding the foam layer 11 and the back material 12 with a hot melt adhesive 13. The principle will be explained with reference to Figure 4. As shown in Figure 4, when a heated mold D or the like is pressed into the laminated sheet 1 from the surface material 14 side (see Figure 4B), the hot melt adhesive 13 gels due to the high temperature and impregnates the surface of the back material 12. When the mold or the like is returned to its original position in this state (see Figure 4C), the temperature drops rapidly and the gelled hot melt adhesive 13 hardens. Since the surface of the back material 12 is also hardened by the hardened hot melt adhesive 13, the pulling of the back material 12 by the foam layer 11 and the surface material 14 is suppressed, and as a result, the formation of irregularities on the back side can be suppressed.

[0049] (6) Applications of Laminated Sheet 1 The laminated sheet 1 relating to this technology can be used in any application as long as it does not impair the function or effect of this technology. For example, it can be used in vehicle interior materials such as door trims, trunk trims, console boxes, airbag covers, instrument panels, meter covers, crash pads, vehicle ceiling materials, armrests, headrests, seats, pillar covers, and rear trays; in building interior materials such as flooring, building ceiling materials, wall materials, and wallpaper materials; and in furniture such as carpets, sofas, cushions, duvet covers, pillows, and mattresses.

[0050] Furthermore, the laminated sheet 1 relating to this technology can be given any function depending on the application and purpose, as long as it does not impair the function and effect of this technology. For example, functions such as heat insulation, heat resistance, sound insulation, soundproofing, sound absorption, fire resistance, flame retardancy, impact resistance, and cushioning can be given. In addition, the desired function can be given to each layer constituting the laminated sheet 1, or to the laminated sheet 1 as a whole.

[0051] 2. Manufacturing method of laminated sheet 1 The manufacturing method for the laminated sheet 1 according to this technology involves at least an adhesive step and a textured surface processing step. Other steps may also be performed as needed. Each step will be described in detail below.

[0052] (1) Adhesion process Figure 5 is a schematic conceptual diagram illustrating an example of the bonding process in the manufacturing method of the laminated sheet 1 according to this technology. The bonding process involves bonding the backing material 12 to one side (second side 11b) of the foam layer 11 having the foam 111 using a hot melt adhesive 13.

[0053] A specific example of the bonding process will be explained with reference to Figure 5. First, the foam layer 11 is unwound from a roll on which a long foam sheet (foam layer 11) is wound and continuously supplied onto a conveyor (not shown). At this time, the foam layer 11 being transported by the conveyor has its upper surface as the second surface 11b.

[0054] Above the conveyor, a coating device for applying the hot-melt adhesive 13 is arranged, and the molten hot-melt adhesive 13 is applied to the second surface 11b of the foam layer 11. The method of applying the hot-melt adhesive 13 is not particularly limited as long as the functions and effects of the present technology are not impaired. Depending on the type and physical properties of the hot-melt adhesive 13, one or more common methods of applying the hot-melt adhesive 13 can be freely selected and used. Examples of the application method include spray coating, coating using a coating tool such as a brush or spatula, transfer coating, etc. In the present technology, it is preferable to select spray coating.

[0055] The application amount of the hot-melt adhesive 13 is not particularly limited as long as the functions and effects of the present technology are not impaired, and can be freely set according to the type of the foam layer 11, the back material 12, and the hot-melt adhesive 13, etc. As the lower limit value of the application amount of the hot-melt adhesive 13, for example, 20 g / m 2 or more, preferably 25 g / m 2 or more, more preferably 30 g / m 2 or more, still more preferably 35 g / m 2 or more. By setting the lower limit value of the application amount of the hot-melt adhesive 13 within this range, the adhesiveness between the foam layer 11 and the back material 12 can be improved, and the effect of suppressing the formation of unevenness on the back side can be further improved.

[0056] As the upper limit value of the application amount of the hot-melt adhesive 13, for example, 60 g / m 2 or less, preferably 55 g / m 2 or less, more preferably 50 g / m 2 or less, still more preferably 45 g / m 2 or less. By setting the upper limit value of the application amount of the hot-melt adhesive 13 within this range, the curing time can be shortened, and in the uneven processing step described later, it is possible to suppress the over-curing of the back material 12 impregnated with the hot-melt adhesive 13, improve the workability such as winding when forming the laminated sheet 1 in a long strip shape, and also suppress the generation of wrinkles during manufacturing.

[0057] Next, the backing material 12 is laminated onto the second surface 11b to which the hot melt adhesive 13 has been applied. For example, the backing material 12 can be laminated onto the second surface 11b of the foam layer 11 by unwinding the backing material 12 from a roll on which a long piece of backing material 12 is wound, using a roller or the like.

[0058] It is preferable to cure the foam layer 11, on which the backing material 12 is laminated, by winding it up as appropriate and allowing it to cure for a predetermined time. By curing it, for example, when a moisture-curing hot-melt adhesive is used as the hot-melt adhesive 13, the moisture-curing reaction proceeds, and the foam layer 11 and the backing material 12 can be bonded more firmly.

[0059] The curing time when curing is performed can be freely set as long as it does not impair the function or effect of this technology. The lower limit of the curing time is, for example, 1 hour or more, preferably 3 hours or more, more preferably 6 hours or more, and even more preferably 9 hours or more. By setting the lower limit of the curing time within this range, the foam layer 11 and the backing material 12 can be bonded even more firmly. The upper limit of the curing time is not particularly limited, and for example, when a moisture-curing hot melt adhesive is used as the hot melt adhesive 13, it may be set to, for example, 48 hours or less, 36 hours or less, etc., depending on the curing speed of the moisture-curing hot melt adhesive.

[0060] (2) Concave and convex machining process Figure 6 is a schematic conceptual diagram illustrating an example of the texture processing step in the manufacturing method of the laminated sheet 1 according to this technology. The texture processing step involves applying a textured surface by thermal compression to the surface (first surface 11a) opposite to the surface (second surface 11b) on which the backing material 12 of the foam layer 11 is laminated.

[0061] A specific example of the uneven surface processing process will be explained with reference to Figure 6. The example in Figure 6 is an example of performing uneven surface processing using molds D1 and D2. First, the foam layer 11, which has the backing material 12 laminated after the bonding process, is cut to the desired size and placed between molds D1 and D2. At this time, the first surface 11a of the foam layer 11 is positioned so that it faces the mold D1 side where the uneven surface is formed (see A in Figure 6).

[0062] Next, as shown in Figure 6B, the heated molds D1 and D2 are closed and thermal compression is performed. The conditions during thermal compression can be freely set according to the type of foam layer 11, surface material 14, etc. used, as long as they do not impair the function and effect of this technology.

[0063] The temperature during thermal compression is not particularly limited as long as it does not impair the function or effect of this technology, but it is preferable to perform the compression at a temperature above the gelation temperature of the hot melt adhesive 13 that bonds the foam layer 11 and the backing material 12. Performing the compression at a temperature above the gelation temperature allows the gelled hot melt adhesive 13 to penetrate the backing material 12, further improving the effect of suppressing the formation of irregularities on the back side.

[0064] Specifically, the lower limit of the temperature during thermal compression is, for example, 100°C or higher, preferably 110°C or higher, and more preferably 120°C or higher. The upper limit of the temperature during thermal compression is, for example, 220°C or lower, preferably 210°C or lower, and more preferably 200°C or lower. The lower limit of the pressure during thermal compression is, for example, 1.0 MPa or higher, preferably 1.3 MPa or higher, and more preferably 1.5 MPa or higher. The upper limit of the pressure during thermal compression is, for example, 2.0 MPa or lower, preferably 1.8 MPa or lower, and more preferably 1.5 MPa or lower. The lower limit of the thermal compression time is, for example, 10 seconds or more, preferably 15 seconds or more, and more preferably 20 seconds or more. The upper limit of the thermal compression time is, for example, 70 seconds or less, preferably 65 seconds or less, and more preferably 60 seconds or less.

[0065] Furthermore, as long as the method of creating the embossed surface does not impair the function or effect of this technology, any general embossing method can be freely selected and used. For example, in addition to the embossing method using the mold D(D1,D2) shown in Figure 6, it is also possible to employ a method of creating the embossed surface using a heatable embossing roll E as shown in Figure 7.

[0066] (3) Other processes The manufacturing method for the laminated sheet 1 according to this technology may include, as necessary, additional steps that are commonly performed in the manufacturing of laminated sheets. Examples of these additional steps include a surface material 14 lamination step in which a surface material 14 is laminated onto the foam layer 11, a cutting step in which the laminated sheet 1 or each layer before lamination is cut into a desired shape, and a secondary processing step in which the laminated sheet 1 is further processed into a desired shape.

[0067] When performing the surface material lamination process, the order of the process is not particularly limited. For example, it may be performed either before or after the bonding process, or either before or after the texture processing process. More specifically, for example, the surface material lamination process may be performed either before or after the bonding process, followed by the texture processing process, or the bonding process may be performed, followed by the texture processing process, and then the surface material lamination process.

[0068] When performing the surface material lamination process, the method of bonding the foam layer 11 and the surface material 14 is not particularly limited as long as it does not impair the function and effect of this technology. Examples of bonding methods for the foam layer 11 and the surface material 14 include frame lamination, bonding using an adhesive, and integral molding of the foam 111 with the surface material 14. When selecting a method using an adhesive, it is also possible to use the hot melt adhesive 13 described above.

[0069] When performing the cutting process, there are no particular restrictions on the order of the process. For example, it may be performed before or after the bonding process described above, or before or after the textured surface processing process described above. Furthermore, when performing the surface material lamination process described above, it may be performed before or after the surface material lamination process. More specifically, for example, when performing the textured surface processing process on a short length as shown in Figure 6 described above, the cutting process may be performed before the textured surface processing process. Also, when performing the textured surface processing process on a long length as shown in Figure 7 described above, the cutting process may be performed after the textured surface processing process.

[0070] The cutting process can be performed multiple times as needed. For example, it is possible to perform a textured surface processing step after the cutting process, and then perform the cutting process again.

[0071] When performing secondary processing steps, the order of these steps is not particularly limited, as long as they are performed after the surface texture processing step. For example, when performing the aforementioned surface material lamination or cutting steps, these steps can be performed either before or after the surface material lamination or cutting steps. More specifically, for example, secondary processing steps may be performed after all other steps have been completed, or, for example, cutting steps may be performed after the surface texture processing step or secondary processing step.

[0072] The specific methods of secondary processing performed in the secondary processing step are not particularly limited. For example, methods include combining different components according to the intended use of the laminated sheet 1, performing surface treatment on the backing material 12 and the surface material 14, or sewing the laminated sheet 1.

[0073] 3. Laminated sheet for textured surface processing 10 Figure 8 is a schematic conceptual cross-sectional view showing a first embodiment of the laminated sheet 10 for textured processing according to this technology. The laminated sheet 10 for textured processing according to this technology is a laminated sheet before the textured processing step described above is performed. That is, the laminated sheet 10 for textured processing according to this technology has a foam layer 11 having a foam 111 having a first surface 11a on which textured processing is to be applied, and a backing material 12 laminated on the second surface 11b opposite to the first surface 11a of the foam layer 11, and the foam layer 11 and the backing material 12 are bonded together with a hot melt adhesive 13, making it a laminated sheet for textured processing.

[0074] A surface material 14 may be laminated on the first surface 11a of the foam layer 11 of the laminated sheet 10 for textured processing according to this technology. The details of the foam layer 11, backing material 12, hot melt adhesive 13, and surface material 14 of the laminated sheet 10 for textured processing according to this technology are the same as those of the foam layer 11, backing material 12, hot melt adhesive 13, and surface material 14 of the laminated sheet according to this technology described above, so a detailed explanation is omitted here.

[0075] Furthermore, this technology can also be configured as follows: [1] A foam layer having a foam with a first surface that has an uneven surface, The foam layer has a backing material laminated on a second surface opposite to the first surface, A laminated sheet in which the foam layer and the backing material are bonded together with a hot-melt adhesive. [2] The laminated sheet according to [1], wherein the hot melt adhesive is a moisture-curing hot melt adhesive. [3] The backing material is a laminated sheet as described in [1] or [2], which is breathable. [4] A laminated sheet according to any one of [1] to [3], wherein a surface material is laminated on the first surface of the foam layer. [5] Vehicle interior material using a laminated sheet as described in any of [1] to [4]. [6] A bonding process in which a backing material is bonded to one side of a foam layer having foam using a hot melt adhesive, A process of creating a textured surface on the side of the foam layer opposite to the side on which the backing material is laminated, by applying a textured surface by thermal compression, A method for manufacturing laminated sheets, having the following characteristics. [7] A foam layer having a foam with a first surface on which an uneven surface is to be applied, The foam layer has a backing material laminated on a second surface opposite to the first surface, A laminated sheet for creating uneven surfaces, wherein the foam layer and the backing material are bonded together with a hot-melt adhesive. [Examples]

[0076] The present technology will be described in more detail below based on the following examples. The examples described below are representative examples of the present technology and should not be interpreted as narrowing the scope of the present technology.

[0077] [Experimental Example 1] In Experimental Example 1, we investigated the state of the unevenness formed on the back surface of a laminated sheet with a textured surface, depending on the method of bonding the foam layer and the backing material.

[0078] 1.Material Foam material: Flexible polyurethane foam (EL-67F manufactured by Inoac Corporation) Backing material: Nylon nonwoven fabric (Weight: 40g / m²) 2 (Manufactured by Asada Yu Co., Ltd.) Hot melt adhesive: Moisture-curing urethane-based hot melt adhesive (Example 1 of Patent No. 6714373) Outer material: Synthetic leather ("Roomish E421Y" manufactured by Kyowa Leather Co., Ltd.)

[0079] 2. Manufacturing of surface-textured laminated sheets <Example 1> A surface material was laminated onto one side of a 3mm thick foam sheet with a 1mm melt allowance, and the sheet was wound up at a speed of 1m / sec. A hot melt adhesive was spray-applied to the other side of the foam sheet with the surface material laminated onto it, and the backing material was laminated onto it, wound up at a speed of 1m / sec, and cured for 24 hours. After curing, the laminated sheet was subjected to thermal compression processing for 30-50 seconds under a pressure of 2.0 MPa (approximately 5 tons) using a mold with a convex portion formed on the surface side (convex portion side (surface side) temperature: 110℃, backing side temperature: 180℃) from the surface material side, to produce a laminated sheet with a textured surface.

[0080] <Comparative Example 1> A laminated sheet was manufactured by frame lamination. Specifically, both sides of a 4 mm thick foam sheet were melted with a melting allowance of 0.5 mm each, and the backing material and surface material were laminated. The sheet was then wound up at a speed of 1 m / s and cured for 24 hours. After curing, the surface of the laminated sheet was given a textured surface in the same manner as in Example 1 to manufacture a textured laminated sheet.

[0081] 3. Measuring the height of uneven areas Using a microscope, the height of the protrusions on the surface material and the depth of the recesses on the back surface were measured.

[0082] 4.Results Microscope images are shown in Figure 9, and the measurement results are shown in Table 1 below.

[0083] [Table 1]

[0084] 5. Discussion As shown in the micro-micrograph in Figure 9, Example 1, in which the foam and backing material were bonded with a hot-melt adhesive, showed that, compared to Comparative Example 1, in which the materials were bonded by frame lamination, the protrusions on the surface material side were firmly formed, while the depth of the recesses on the backing material side was shallower. From these results, it was found that in a surface-textured laminated sheet, bonding the foam and backing material with a hot-melt adhesive can reduce the irregularities on the backing material side and improve the aesthetic appearance of the surface.

[0085] [Experimental Example 2] In Experimental Example 2, the effect of different bonding methods between the foam layer and the backing material on the peel strength between the backing material and the polypropylene board was investigated in a laminated sheet with a textured surface.

[0086] 1.Material The same materials as in Experimental Example 1 were used.

[0087] 2. Measurement of peel strength The peel strength of the backing material of the laminated sheet before and after embossing was measured using the following method. Measurements were taken in both the TD direction and the MD direction with a sample size of 3, and the average value was calculated. The laminated sheet was cut to a width of 25 mm and a length of 150 mm, and attached to a polypropylene board of the same size (thickness 1 mm) with double-sided tape (width 20 mm, length 150 mm, manufactured by Nitto Denko Corporation, TW-Y01). The laminated sheet was then fixed to the polypropylene board by stroking it five times with a roller weighing 10 kg. The laminated sheet was peeled off the polypropylene board at a 180° angle at a tensile speed of 200 mm / min, and its peel strength was measured.

[0088] 3.Results The results are shown in Table 2 below.

[0089] [Table 2]

[0090] 4. Discussion As shown in the results of Comparative Example 2, when the backing material and the foam material are bonded using frame lamination, the peel strength between the backing material and the foam material decreases due to the application of uneven processing. However, it was confirmed that the decrease in peel strength can be suppressed by bonding the backing material and the foam material using hot melt adhesive. [Explanation of Symbols]

[0091] 1 Laminated sheet 11 Foam layer 11a 1st page 11b Side 2 12 Backing material 13 Hot melt adhesive 14 Skin material 111 Foam 112 Other layers D, D1, D2 molds 100 Conventional laminated sheets

Claims

1. A foam layer having a foam with a first surface that has an uneven surface, The foam layer has a backing material laminated on a second surface opposite to the first surface, A laminated sheet in which the foam layer and the backing material are bonded together with a hot-melt adhesive.

2. The laminated sheet according to claim 1, wherein the hot melt adhesive is a moisture-curing hot melt adhesive.

3. The laminated sheet according to claim 1, wherein the backing material is breathable.

4. The laminated sheet according to claim 1, wherein a surface material is laminated on the first surface of the foam layer.

5. Vehicle interior material using a laminated sheet according to any one of claims 1 to 4.

6. A bonding process in which a backing material is bonded to one side of a foam layer having foam using a hot melt adhesive, A process of creating a textured surface on the side of the foam layer opposite to the side on which the backing material is laminated, by applying a textured surface by thermal compression, A method for manufacturing laminated sheets, having the following characteristics.

7. A foam layer having a foam having a first surface on which an uneven surface is to be applied, The foam layer has a backing material laminated on a second surface opposite to the first surface, A laminated sheet for creating uneven surfaces, wherein the foam layer and the backing material are bonded together with a hot-melt adhesive.

Images