Method for manufacturing a concavo-convex shaped laminate, laminate for concavo-convex shaping, and concavo-convex shaped laminate

Abstract

The purpose of the present invention is to provide a laminate shaped to have fine irregularities using a general-purpose soft polyurethane foam without using a soft polyurethane foam having a special configuration.　A soft polyurethane foam and a flexible surface member are laminated via a moisture-curing hot-melt adhesive. By curing the moisture-curing hot-melt adhesive, the soft polyurethane foam and the surface member are laminated and integrated with each other to form a laminate for shaping irregularities. The laminate for shaping irregularities is heated and compressed by a heating compression device having irregularities on a pressing surface thereof to shape irregularities on a surface of the laminate for shaping irregularities.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a laminated body with unevenness, a laminated body for imparting unevenness, and a laminated body with unevenness imparted thereto.

Background Art

[0002] As a skin material used for the seat skin of vehicles such as automobiles or the skin of furniture, there is a laminated body with unevenness imparted thereto. The laminated body with unevenness imparted thereto is manufactured by laminating and integrating a flexible surface member on a soft polyurethane foam and heating and compressing the surface with a heating and compressing device having unevenness formed on the surface.

[0003] As a conventional laminated body with unevenness imparted thereto, there is one in which a soft polyurethane foam made easy to thermoform by blending polyol, a flame retardant, etc. and specifying the ester value, etc. is used, and the soft polyurethane foam and the surface member are welded by frame lamination (Patent Document 1).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in the case where a soft polyurethane foam and a surface member are welded by frame lamination using a blend of polyol, a flame retardant, etc. and a specific ester value, etc., the usable soft polyurethane foam is limited, and a general-purpose soft polyurethane foam cannot be used.

[0006] In view of the above points, an object of the present invention is to enable unevenness to be imparted using a general-purpose soft polyurethane foam without using a special one for the soft polyurethane foam.

Means for Solving the Problem

[0007] The first means is a method for manufacturing a laminated body with unevenness. A laminated body for unevenness formation is formed by laminating a flexible surface member and a soft polyurethane foam through a moisture-curing hot melt adhesive, and the laminated body for unevenness formation is heated and compressed by a heating and compressing device having unevenness on the pressing surface, and unevenness is formed on the laminated body for unevenness formation.

[0008] The second means is a laminated body for unevenness formation in which a flexible surface member is laminated and integrated with a soft polyurethane foam. The soft polyurethane foam and the surface member are adhered by a moisture-curing hot melt adhesive.

[0009] The third means is a laminated body in which a flexible surface member is laminated and integrated with a soft polyurethane foam and unevenness is formed. The soft polyurethane foam and the surface member are adhered by a moisture-curing hot melt adhesive.

Advantages of the Invention

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

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Embodiments for Carrying Out the Invention

[0012] Hereinafter, embodiments of the present invention will be described. The laminated body 10 with concavo-convex shapes shown in FIG. 1 is used for vehicle interior materials, such as seat covers, door trims, or furniture covers. The laminated body 10 is composed of a soft polyurethane foam 11, a surface member 21 adhesively bonded to one side of the soft polyurethane foam 11 with a moisture-curing hot melt adhesive 15, and a back member 31 adhesively bonded to the other side with the moisture-curing hot melt adhesive 15, and the surface is provided with concavo-convex shapes 35. The back member 31 is a member provided as required. Details of each member will be described later.

[0013] The illustrated concavo-convex shapes 35 are composed of a configuration having a first convex portion 36, a concave portion 37, a second convex portion 38, and a concave portion 39 adjacent to each other, and are in a state of linearly extending in one direction (for example, the length direction) of the laminated body 10 with concavo-convex shapes. The aspect of the concavo-convex shapes 35 is not limited to the aspect in which the convex and concave portions linearly extend as shown in the figure. For example, the concave or convex portions may be configured in a lattice, rhombus, circular, or other appropriate patterns. In addition, the illustrated convex portions are composed of two types of convex portions, namely, the first convex portion 36 and the second convex portion 38 having different heights, but may also be composed of one type or three or more types of convex portions.

[0014] The production of the laminated body 10 with concavo-convex shapes is carried out by a process of producing a laminated body for concavo-convex shaping and a concavo-convex shaping process. The process of producing the laminated body for concavo-convex shaping is shown in FIG. 2(2-1). The surface member 21 and the back member 31 are laminated on the soft polyurethane foam 11 via the moisture-curing hot melt adhesive 15, and the moisture-curing hot melt adhesive 15 is reaction-cured with moisture such as moisture in the air, thereby laminating and integrating the soft polyurethane foam 11, the surface member 21, and the back member 31. Thereby, the laminated body 10A for uneven shape forming shown in Fig. 2 (2-2) is formed. When the back member 31 is not laminated, the moisture-curing hot melt adhesive for the back member 31 is also unnecessary.

[0015] The soft polyurethane foam 11 is formed from a polyurethane raw material containing a polyol, a foaming agent, a catalyst, a foam stabilizer, a polyisocyanate, and appropriate additives, and a general-purpose soft polyurethane foam can be used. Further, among soft polyurethane foams, there are an ether-based polyurethane foam using an ether-based polyol for the polyol and an ester-based polyurethane foam using an ester-based polyol. The soft polyurethane foam 11 in the present invention may be either, but an ether-based polyurethane foam that is less likely to cause wet heat deterioration is more preferable.

[0016] The density (conforming to JIS K 7222) of the soft polyurethane foam 11 is 13 to 80 kg / m 3 , more preferably 15 to 70 kg / m 3 and the hardness (conforming to JIS K 6400-2) is 40 to 350 N, more preferably 60 to 200 N, and the thickness (before uneven shape forming) is 2 to 30 mm, more preferably 3 to 20 mm. If the soft polyurethane foam 11 is too hard, it becomes difficult to form uneven shapes and the cushioning property and touch feel deteriorate. Also, if the thickness of the soft polyurethane foam 11 is too thin, the uneven shapes formed will not be prominent.

[0017] The moisture-curing hot melt adhesive 15 is an adhesive that is heated and melted and then applied and reacts and cures by moisture such as moisture in the air, and is preferably one mainly composed of a urethane prepolymer having an isocyanate group at the terminal. The urethane prepolymer having terminal isocyanate groups is composed of a urethane prepolymer using a polyol component and a polyisocyanate component as raw materials. As the polyol component, for example, polyester polyols, polyether polyols, polyether / polyester block polyols or mixed systems are preferably used. The number average molecular weight of the polyol is preferably 500 to 5000, more preferably 1000 to 4000, and even more preferably 1500 to 3000. The functionality of the polyol is preferably 2 to 4, more preferably 2 to 3. A small amount of monoalcohol (functionality 1) may be included. Further, as the polyisocyanate component, for example, toluene diisocyanate, diphenylmethane diisocyanate, 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%. When the NCO group content is low, since the curing reaction cannot be sufficiently obtained, the heat resistance is inferior, and the shape-forming property of unevenness also tends to be inferior. Further, when the NCO group content is high, although the curing reaction can be obtained, the adhesive layer becomes hard, the touch feeling of the laminated product becomes poor, and a laminated structure that is difficult to shape is formed. In addition, in the hot melt adhesive, in addition to the moisture-curing type hot melt adhesive used in the present invention, there is a thermoplastic hot melt adhesive using a thermoplastic resin. The thermoplastic hot melt adhesive can repeat activation by heating and curing by cooling. However, when the adhesive layer of the same adhesive is heated again, the adhesive strength may decrease at the stage where the heat history is applied. 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 application methods of the moisture-curing hot melt adhesive 15 to the soft polyurethane foam 11 include application by a roll coater having a hot roll, application by a roll coater using a gravure roll, application by a T-die head, a method of spray-applying the liquefied moisture-curing hot melt adhesive, and the like. The heating and melting temperature of the moisture-curing 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 and is selected according to the use of the laminated body 10 having uneven shapes, such as knitted fabric, woven fabric, non-woven fabric, synthetic leather, natural leather, etc. For example, as knitted fabrics, there are tricot, jersey, double raschel, etc., as woven fabrics, there are tenjiku-ori, suzaku-ori, etc., and as synthetic leathers, there are vinyl chloride resin leather, polyurethane resin leather, etc. In addition, examples of the materials for knitted and woven fabrics include nylon, polyester, rayon, etc. The back member 31 laminated as necessary is composed of an appropriate material such as knitted fabric, woven fabric, non-woven fabric, etc. As knitted fabrics, there are nylon tricot 17 dtex (NY-17dtex), nylon marker, ester tricot, etc., as woven fabrics, there is gold brocade, etc., and as non-woven fabrics, there are nylon non-woven fabric 30 g / m 2 and ester non-woven fabric 50 g / m 2 etc. are used.

[0020] In the uneven shape forming step, the uneven shape forming laminated body 10A is heated and compressed by a heating and compression device having unevenness on the pressing surface, so that unevenness is formed on the surface of the uneven shape forming laminated body 10A, and the uneven shape formed laminated body 10 shown in FIG. 1 is obtained. It is preferable to perform the heating and compression of the uneven shape forming laminated body 10A with the heating temperature on the surface member 21 side being lower than that on the other side (back member 31) to suppress thermal deterioration of the surface member 21.

[0021] As the heating and compression method, there are a hot press method using an uneven mold having unevenness formed on the surface, a roll hot compression method using an embossing roll, and the like.

[0022] An embodiment of uneven shape forming by the hot press method will be described. The heating and compressing device 41 used in the hot pressing method shown in FIG. 3 is composed of a front surface side mold 50 and a back surface side mold 70. In the illustrated example, the front surface side mold 50 corresponds to the upper mold, and the back surface side mold 70 corresponds to the lower mold. The front surface side mold 50 is a mold arranged to face the front surface member 21 of the uneven shape-imparting laminate 10A. The pressing surface against the front surface member 21 has unevenness 67 and is configured to be heatable to a predetermined temperature by a heating device such as an electric heater. The back surface side mold 70 is a mold arranged to face the back surface member 31 of the uneven shape-imparting laminate 10A. The pressing surface against the back surface member 31 is configured as a flat surface 71 in the illustrated example. The front surface side mold 50 is positioned above the back surface side mold 70 with the unevenness 67 facing downward and can approach and separate from the back surface side mold 70. Note that the vertical positional relationship between the front surface side mold 50 and the back surface side mold 70 may be reversed.

[0023] The unevenness 67 of the front surface side mold 50 is composed of a first concave portion 63, a convex portion 64, a second concave portion 65, and a convex portion 66, and is for forming the first convex portion 36, concave portion 37, second convex portion 38, and concave portion 39 of the shaped body 10 with uneven shape imparted. Note that a taper or the like may be provided on the unevenness 67 to adjust the uneven feeling. Also, the back surface side mold 70 may be provided with unevenness similar to that of the front surface side mold 50.

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

[0025] Next, as shown in (3-2) of FIG. 3, the front-side mold 50 and the back-side mold 70 are brought closer, and the uneven-shape-imparting laminate 10A is heated and compressed between the front-side mold 50 and the lower mold 70. The temperature of the front-side mold 50 and the back-side mold 70 at this time may be in the range of 110 to 220°C, and further in the range of 130 to 180°C is preferable from the viewpoint of material deterioration and discoloration. Moreover, it is preferable to make the temperature of the front-side mold 50 on the surface member 21 side lower than the temperature of the back-side mold 70 to suppress thermal deterioration of the surface member 21 of the uneven-shape-imparting laminate 10A. Further, for example, regarding the mold temperature, the lower limit value of the temperature of the front-side mold 50 is preferably 110°C or higher, more preferably 115°C or higher, and still more preferably 120°C or higher. The upper limit value of the temperature of the front-side mold 50 is preferably 200°C or lower, more preferably 180°C or lower, and still more preferably 160°C or lower. The lower limit value of the temperature of the back-side mold 70 is preferably 130°C or higher, more preferably 140°C or higher, and still more preferably 150°C or higher. The upper limit value of the temperature of the back-side mold 70 is preferably 220°C or lower, more preferably 210°C or lower, and still more preferably 200°C or lower.

[0026] During heating and compression, the uneven-shape-imparting laminate 10A is compressed by the convex portions 64, 66 of the front-side mold 50 and the back-side mold 70, and the soft polyurethane foam 11 between the surface member 21 and the back member 31 is crushed at the compressed portion. Then, in a state where the soft polyurethane foam 11 is crushed by the convex portions 64, 66 of the front-side mold 50, it undergoes plastic deformation by heating, and concave portions (the concave portions 37, 39 of the uneven-shape-imparted laminate 10) are formed at positions corresponding to the convex portions 64, 66 of the front-side mold 50. Also, in the first concave portion 63 and the second concave portion 65 of the front-side mold 50, the surface member 21 and the soft polyurethane foam 11 of the uneven-shape-imparting laminate 10A enter and bulge into the first concave portion 63 and the second concave portion 65, and convex portions (the first convex portion 36, the second convex portion 38 of the uneven-shape-imparted laminate 10) are formed.

[0027] The unevenness 67 of the surface-side mold 50 is preferably set such that gaps S1 and S2 are formed between the inner surfaces of the first recess 63 and the second recess 65 and the surface member 21 of the unevenness-forming laminate 10A when the unevenness-forming laminate 10A is heated and compressed. Thereby, when the unevenness-forming laminate 10A is heated and compressed, it is possible to prevent the surface member 21 from coming into contact with the inner surfaces of the first recess 63 and the second recess 65, and it is possible to suppress thermal deterioration of the surface member 21.

[0028] Further, in the unevenness-forming laminate 10A, since the soft polyurethane foam 11, the surface member 21, and the back member 31 are adhered by the reaction curing of the moisture-curing hot melt adhesive 15, the moisture-curing hot melt adhesive 15 is not reactivated even by the heating during the heat compression in the unevenness-forming process. The surface member 21 and the back member 31 do not shift or float with respect to the soft polyurethane foam 11, and good unevenness is formed.

[0029] Thereafter, by increasing the distance between the surface-side mold 50 and the back-side mold 70 and releasing the compression on the unevenness-forming laminate 10A, the unevenness-formed laminate 10 shown in FIG. 1 is obtained. By releasing the compression, the portions of the first convex portion 36 and the second convex portion 38 of the unevenness-formed laminate 10 also bulge toward the back member 31 side by the restoring force of the soft polyurethane foam 11, and unevenness is also formed on the back member 31 side.

[0030] On the other hand, in the roll heat compression method (not shown), the surface member 21 of the shaping laminate 10A that is continuously supplied is heat-compressed with an embossing roll having an uneven pattern on the surface and being heatable, thereby forming an uneven pattern on the surface. 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.

Examples

[0031] Each example and each comparative example shown in FIGS. 4 and 5 will be described. Examples 1 to 3 use polyester tricot as the surface member, with a basis weight of 300 g / m 2Using a nylon non-woven fabric of 30 g / m² for the back member 2 (basis weight 30 g / m² 2 ), using a soft polyurethane foam A, an ether-based polyurethane foam, with a density of 20 kg / m³ 3 , a hardness of 98 N, part number: EL-45, manufactured by Inoac Corporation, with a thickness of 10 mm, and using a urethane-based moisture-curing hot melt adhesive, urethane-based moisture-curing hot melt adhesive type A (NCO group content = 1.8%, prepolymer type of polyester-based polyol and MDI, manufactured by Inoac Corporation), a laminated body for embossing is produced, and this is an example where the embossing conditions for the laminated body for embossing are varied. Examples 4 to 6 are examples carried out with the configuration of Examples 1 to 3, with a laminated structure in which the back member is changed to nylon tricot 17 dtex (NY-17dtex). Urethane-based moisture-curing hot melt adhesive type A was produced by charging 100 parts by mass of polyester polyol with a number average molecular weight of 2000 (adipic acid / butanediol) and a functionality of 2, which was kept at 80°C, into a four-necked flask equipped with a thermometer, a stirrer, and an inert gas inlet, adding 19 parts by mass of the isocyanate component MDI, reacting at 80°C at 40 rpm for 3 to 4 hours, to obtain a urethane-based moisture-curing hot melt adhesive with an NCO group content of 1.8%.

[0032] The laminated body for embossing was produced as follows. The moisture-curing hot melt adhesive was heated to 120°C to make it liquid, and was applied to the surface of the soft polyurethane foam by a T-die coater at an application rate of 30 g / m² 2 and to the back surface at an application rate of 15 g / m² 2 . The surface member and the back member were laminated on both sides of the soft polyurethane foam through the applied moisture-curing hot melt adhesive, and the surface member, the back member, and the soft polyurethane foam were sandwiched between pressure plates and crimped for 20 seconds, so that the moisture-curing hot melt adhesive was reacted and cured by moisture in the air. After application and crimping, it was cured for 10 hours or more at room temperature (23°C) and a humidity of 50% R.H. or more. Curing for 5 hours or more under these conditions is preferable for adhesion performance. The adhesion state between the surface member, the back member, and the soft polyurethane foam was good.

[0033] The concavo-convex profiling was performed using the surface-side mold 50 and the back-side mold 70 shown in FIG. 3. The first concave portion 63 of the surface-side mold 50 has an internal depth (height) of 15 mm, a width of 23 mm, the convex portions 64 and 66 have a width of 1 mm, and the second concave portion 65 has an internal depth (height) of 8 mm and a width of 6 mm. The distance between the convex portions 64 and 66 of the surface-side mold 50 and the mold surface of the back-side mold 70 during heating and compression is 0.5 mm. In addition, the workability in the lamination processing column in FIGS. 4 and 5 was marked as "〇" when the surface member and the back member were well adhered to the soft polyurethane foam during the production of the lamination body for concavo-convex profiling. Also, the formability of the concavo-convex profiling in FIGS. 4 and 5 was marked as "〇" when there was no peeling or lifting on either the surface member or the back member, "△" when there was a slight presence, and "×" when it was clearly present.

[0034] ·Example 1 Example 1 is an example where the temperature of the surface-side mold during concavo-convex profiling is 135°C, the temperature of the back-side mold is 180°C, and the compression time is 50 seconds. There were no problems such as peeling or lifting on the surface member and the back member, and good concavo-convex shapes were formed.

[0035] Example 2 is an example where the temperature of the surface-side mold during concavo-convex profiling is 135°C, the temperature of the back-side mold is 180°C, and the compression time is 40 seconds. There were no peeling or lifting seen on the surface member and the back member, and good concavo-convex shapes were formed.

[0036] Example 3 is an example where the upper mold temperature on the surface member side during concavo-convex profiling is 135°C, the lower mold temperature on the back member side is 180°C, and the compression time is 30 seconds. There were no peeling or lifting seen on the surface member and the back member, and good concavo-convex shapes were formed.

[0037] Example 4 is an example where the temperature of the surface-side mold during concavo-convex profiling is 130°C, the temperature of the back-side mold is 175°C, and the compression time is 50 seconds. There were no peeling or lifting seen on the surface member and the back member, and good concavo-convex shapes were formed.

[0038] Example 5 is an example where the temperature of the front mold during uneven shaping is 120°C, the temperature of the back mold is 170°C, and the compression time is 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 where the thickness of the soft polyurethane foam used in the laminate for uneven shaping is 5 mm, and the laminate for uneven shaping is produced and uneven shaping is performed under the same conditions as in Example 5 for other conditions. Example 6, similar to Example 5, showed no peeling or lifting on the front and back members, and good unevenness was formed.

[0040] · Example 7 Example 7 uses, as the soft polyurethane foam, soft polyurethane foam B, a polyether-based polyurethane foam having an ester component, a density of 20 kg / m 3 , a hardness of 100 N, product number: EL-64, manufactured by Inoac Corporation, and a thickness of 10 mm, and the laminate for uneven shaping is produced and uneven shaping is performed under the same conditions as in Example 4 for other conditions. Example 7, similar to Example 4, showed no peeling or lifting on the front and back members, and good unevenness was formed.

[0041] · Example 8 Example 8 is an example where the front member is synthetic leather, the compression time during uneven shaping is 40 seconds, and the laminate for uneven shaping is produced and uneven shaping is performed under the same conditions as in Example 4 for other conditions. The synthetic leather used was a synthetic resin sheet (lining material: knitted laminate) made of polyvinyl chloride with a thickness of 1.3 mm. Example 8, similar to Example 4, showed no peeling or lifting on the front and back members, and good unevenness was formed.

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

[0043] · Example 10 Example 10 was carried out under the conditions of Example 4 using a urethane-based moisture-curing hot melt adhesive Type C (NCO group content = 1.8%, combined system of polyester polyol + polyether-based polyol, prepolymer type with MDI, manufactured by Inoac Corporation) to form unevenness in the same manner. For the urethane-based moisture-curing hot melt adhesive Type C, 50 parts by mass of a polyester polyol with a number average molecular weight of 2000 (sebacic acid / hexanediol) and a functionality of 2, maintained at 80°C, and 50 parts by mass of a polyether polyol with a number average molecular weight of 2000 (polypropylene glycol) and a functionality of 2, maintained at 80°C, were charged into a four-necked flask equipped with a thermometer, a stirrer, and an inert gas inlet. Then, 19 parts by mass of the isocyanate component MDI was added, and the reaction was carried out at 80°C and 40 rpm for 3 to 4 hours to produce a urethane-based moisture-curing hot melt adhesive with an NCO group content of 1.8%. In Example 10, as in Example 4, no peeling or lifting was observed on the surface member and the back member, and good unevenness was formed.

[0044] The details of the moisture-curing hot melt adhesives Types A to C used in Examples 1 to 10 are shown in the table of Fig. 6. The NCO group content of the urethane-based moisture-curing hot melt adhesive was measured according to the toluene / dibutylamine hydrochloride method of JIS K1603-2007, the melting point was measured according to the plastic transition temperature measurement method of JIS K7121-1987, and the viscosity was measured using a rheometer MCR302 from Anton Paar at an angular frequency of 1 rad / s and a temperature of 140 °C.

[0045] · Comparative Example 1 Comparative Example 1 is an example in which a thermoplastic hot melt adhesive with the product number TN716Z, manufactured by Moresco Corporation, was used instead of the moisture-curing hot melt adhesive of Example 1, and was carried out under the same conditions as Example 1 except for the production of the laminated body for embossing. In the production of the laminated body for embossing in Comparative Example 1, the thermoplastic hot melt adhesive was heated to 180 °C to make it liquid, and was applied to the surface of the soft polyurethane foam by a T-die coater at an application amount of 30 / m 2 and 15 / m on the back surface 2 The surface member and the back member were laminated on both sides of the soft polyurethane foam through the applied thermoplastic hot melt adhesive, sandwiched between pressure plates and crimped for 20 seconds, and the thermoplastic hot melt adhesive was cured by cooling. The processability of the laminated body for embossing in Comparative Example 1 was that the surface member and the back member adhered well to the soft polyurethane foam, and the evaluation was "〇". In addition, the formability of the embossing in Comparative Example 1 was that the thermoplastic hot melt adhesive was reactivated during the hot compression during embossing, resulting in peeling and lifting on the surface member and the back member, and the evaluation was "×".

[0046] · Comparative Example 2 Comparative Example 2 is an example in which synthetic leather (the same material as in Example 8) was used for the surface member, and a thermoplastic hot melt adhesive was used for the adhesion between the soft polyurethane foam and the surface member and the back member. In Comparative Example 2, the production of the laminated body for embossing and the embossing were carried out under the same conditions as in Comparative Example 1 except that the surface member was synthetic leather. In Comparative Example 2, the processability of the laminate for uneven shape forming was evaluated as "〇" because the surface member and the back member adhered well to the soft polyurethane foam, similar to Comparative Example 1. Also, in Comparative Example 2, the moldability of the uneven shape forming was evaluated as "×" because peeling and lifting were observed on the surface member and the back member when the thermoplastic hot melt adhesive was reactivated during heat compression during uneven shape forming, similar to Comparative Example 1.

[0047] · Comparative Example 3 Comparative Example 3 is an example in which an ester-based polyurethane foam is used for the soft polyurethane foam, and the soft polyurethane foam is adhered to the surface member and the back member by frame lamination. The surface member is the same nylon tricot as in Comparative Example 1. In Comparative Example 3, soft polyurethane foam B (the same as in Example 7) was used. Both sides of the soft polyurethane foam were heated with a burner until melted, and the surface member and the back member were laminated and adhered to the melted surfaces to produce a laminate for uneven shape forming. The uneven shape forming of the laminate for uneven shape forming was performed in the same manner as in Comparative Example 1. In Comparative Example 3, the processability of the laminate for uneven shape forming was evaluated as "〇" because the surface member and the back member adhered well to the soft polyurethane foam. Also, in Comparative Example 3, the moldability of the uneven shape forming was evaluated as "〇" because no peeling or lifting was observed on the surface member and the back 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 for the soft polyurethane foam, and the soft polyurethane foam is adhered to the surface member and the back member by frame lamination. The mold temperature during uneven shape forming was set 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 set to 30 seconds. Otherwise, it was the same as in Comparative Example 3. Note that the temperatures of the surface side mold and the back side mold in Comparative Example 4 are the same as those of the surface side mold and the back side mold in Example 7. In Comparative Example 4, the processability of the laminate for uneven shape forming was evaluated as "〇" because the surface member and the back member adhered well to the soft polyurethane foam. In Comparative Example 4, although there was no peeling or lifting on the surface member and the back member in the forming of the uneven shape, since the shaping time was short, the uneven shape forming property was poor, the crimping of the unevenness 35 in FIG. 1 was insufficient, the concave portion became unclear, and the evaluation was "△".

[0049] · Comparative Example 5 Comparative Example 5 is an example in which an ether-based polyurethane foam A is used for the soft polyurethane foam, and the soft polyurethane foam, the surface member, and the back member are adhered by frame lamination. In Comparative Example 5, in the production of the laminate for uneven shape forming, since the soft polyurethane foam is an ether-based polyurethane foam, the surface member and the back member cannot be adhered to the soft polyurethane foam, and the evaluation of workability is "×". In addition, since the laminate for uneven shape forming could not be obtained, the subsequent uneven shape forming process could not be performed.

[0050] · Comparative Example 6 Comparative Example 6 is an example in which the surface member is synthetic leather, and frame lamination and uneven shape forming are performed in the same manner as in Comparative Example 3 using a polyether-based polyurethane foam B having an ester component for the soft polyurethane foam. In Comparative Example 6, similar to Comparative Example 3, the evaluation of the workability of the laminate for uneven shape forming was "〇", and the evaluation of the formability of the uneven shape forming was "〇".

[0051] Thus, according to the present invention, good unevenness can be formed using a general-purpose soft polyurethane foam without using a soft polyurethane foam having a special configuration. Note that the present invention is not limited to the examples, and can be changed without departing from the gist of the invention.

Industrial Applicability

[0052] The laminate of the present invention can be used for interior materials of vehicles, for example, seat covers, door trims, or furniture covers.

Explanation of Signs

[0053] 10 Concavo-convex shaped laminate 10A Laminate for concavo-convex shaping 11 Flexible polyurethane foam 15 Moisture-curing hot melt adhesive 21 Surface member 31 Back member 35 Concavo-convex 41 Heating and compressing device 50 Surface side type 67 Concavo-convex 70 Back side type

Claims

1. A laminate for embossing is formed by laminating a flexible surface member to a flexible polyurethane foam (excluding flexible polyurethane foams having an ester value (conforming to JIS K0070) of 40 to 400 mgKOH / g) via a moisture-curing hot melt adhesive, and the laminate for embossing is heat-compressed by a heating and compressing device having unevenness on the compression surface to emboss the laminate for embossing. A method for manufacturing an embossed laminate, characterized by comprising the steps of:

2. In a laminate for embossing in which a flexible surface member is laminated and integrated with a flexible polyurethane foam (excluding flexible polyurethane foams having an ester value (conforming to JIS K0070) of 40 to 400 mgKOH / g), the flexible polyurethane foam and the surface member are adhered by a moisture-curing hot melt adhesive, the surface member is selected from knitted fabrics, woven fabrics, non-woven fabrics, and synthetic leather, and the viscosity of the moisture-curing hot melt adhesive at 140°C is 1000 to 4500 mPa·s. A laminate for embossing, characterized by comprising the steps of:

3. In a laminate in which a flexible surface member is laminated and integrated with a flexible polyurethane foam (excluding flexible polyurethane foams having an ester value (conforming to JIS K0070) of 40 to 400 mgKOH / g), and the flexible polyurethane foam and the surface member are embossed, the flexible polyurethane foam and the surface member are adhered by a moisture-curing hot melt adhesive. An embossed laminate, characterized by comprising the steps of:

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