Manufacturing method of laminated sheet

Abstract

A method for producing a laminated sheet is provided, which can produce a laminated sheet including an area where perforations are formed in a concentrated manner. [Solution] A method for manufacturing laminated sheets 4, 4A, 4B includes a first perforation portion forming step S1 in which a plurality of perforations 50 are formed by puncturing a laminated sheet material 40 with a plurality of puncture bodies 74A, and a second perforation portion forming step S2 in which a plurality of perforations 50 are formed by puncturing a laminated sheet material 40 with a plurality of puncture bodies 74B. In the first perforation portion forming step S1 and the second perforation portion forming step S2, the puncture bodies 74A and puncture bodies 74B are punctured in different positions on the laminated sheet material 40.

Description

[Technical Field]

[0001] The present invention relates to a method for producing a laminate sheet for use in a vehicle interior member. [Background technology]

[0002] For example, to improve decorativeness, a covering material is attached to the substrate of a vehicle interior member such as an instrument panel, console, door trim, glove box, or pillar garnish of an automobile. Since applying an adhesive or using double-sided tape when attaching a covering material to a substrate is inefficient, it has been proposed to provide an adhesive layer on the covering material in advance.

[0003] If the adhesive layer provided on the covering material has poor breathability, air pockets may form between the covering material and the substrate when the covering material is attached to the substrate, which may impair the appearance of the covering material.

[0004] For example, Patent Document 1 discloses a laminated sheet (surface material) including a foam layer with an open-cell structure, an adhesive layer, and perforated sections that penetrate the adhesive layer and reach the foam layer. Such a laminated sheet allows air to escape through the perforated sections and the foam layer, thereby suppressing the formation of air pockets and eliminating any air pockets that do form.

[0005] Furthermore, Patent Document 1 discloses that the perforated portions of the laminated sheet are formed by a perforator provided so as to protrude from a Thomson die that moves back and forth. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Publication No. 2023-156634 Summary of the Invention [Problem to be solved by the invention]

[0007] When the three-dimensional shape of the surface of a vehicle interior member to which a skin material is attached is complex, air pockets may occur in specific areas with complex shapes even with the laminate sheet of Patent Document 1. One possible solution to the air pockets that occur in specific areas with complex shapes is to provide perforations concentrated in the specific areas.

[0008] However, due to factors such as the strength of the Thomson mold and the space required to place the perforated bodies, it was difficult to concentrate the perforated bodies in the Thomson mold in locations corresponding to the specified regions, posing technical challenges.

[0009] The present invention provides a method for producing a laminated sheet, which can produce a laminated sheet including an area where perforations are formed in a concentrated manner. [Means for solving the problem]

[0010] The present invention provides A method for manufacturing a laminate sheet for a vehicle interior member, the method comprising the steps of: manufacturing a laminate sheet for a vehicle interior member from a laminate sheet material having a surface layer constituting a design surface, a foam layer, and an adhesive layer, the laminate sheet having a plurality of perforated portions formed therein, the perforated portions penetrating the adhesive layer and reaching the foam layer, the method comprising the steps of: a first perforation portion forming step of forming a plurality of the perforation portions by puncturing the laminated sheet material from the adhesive layer side with a plurality of first puncture bodies; a second perforation portion forming step of forming a plurality of the perforations by puncturing the laminated sheet material from the adhesive layer side with a plurality of second puncture bodies, the first puncture portion forming step and the second puncture portion forming step include puncturing the laminated sheet material with the first puncture body and the second puncture body at positions different from each other; A method for manufacturing a laminated sheet.

[0011] The present invention also provides A method for manufacturing a laminate sheet for a vehicle interior member, the method comprising: manufacturing a laminate sheet for a vehicle interior member, the laminate sheet having a plurality of perforations penetrating at least the adhesive layer, from a laminate sheet material having a surface layer constituting a design surface and an adhesive layer disposed in contact with the back side of the surface layer; a first perforation portion forming step of forming a plurality of the perforations by puncturing the laminated sheet material with a plurality of first puncture bodies; a second perforation portion forming step of forming a plurality of the perforations by puncturing the laminated sheet material with a plurality of second puncture bodies, the first puncture portion forming step and the second puncture portion forming step include puncturing the laminated sheet material with the first puncture body and the second puncture body at positions different from each other; A method for manufacturing a laminated sheet. [Effects of the Invention]

[0012] According to the present invention, it is possible to produce a laminated sheet including an area in which perforations are formed in a concentrated manner. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is a partial cross-sectional view of a vehicle interior member 1 including a laminate sheet 4 according to one embodiment of the present invention and a substrate 2 to which the laminate sheet 4 is attached. [Figure 2] FIG. 2 is a diagram illustrating the first perforation forming step S1. [Figure 3] FIG. 3 is a diagram illustrating the second perforation forming step S2. [Figure 4] FIG. 4 is a diagram showing an example of the arrangement of the puncture bodies 74A, 74B and the punching blades 76, 77 in the Thomson dies 73A and 73B. [Figure 5] FIG. 5 is a top view of the laminated sheet 4 produced by the first perforated portion forming step S1 and the second perforated portion forming step S2 carried out using the Thomson die 73A and the Thomson die 73B shown in FIG. [Figure 6] FIG. 6 is a diagram showing an example of a schematic configuration of the processing device 7. As shown in FIG. [Figure 7] 7(a) is a partial cross-sectional view of a laminate sheet 4A of Modification 1, and FIG. 7(b) is a partial cross-sectional view of a laminate sheet 4B of Modification 2. As shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0014] An embodiment of the method for producing a laminate sheet of the present invention will be described below with reference to the accompanying drawings. The drawings should be viewed in the direction indicated by the reference numerals. Please note that for convenience, the drawings may show various dimensions, such as the thickness of the laminate sheet and the diameter of the perforations described below, exaggerated or minimized, and may differ from the actual product.

[0015] [Laminated sheet] FIG. 1 is a partial cross-sectional view of a vehicle interior member 1 including a laminate sheet 4 according to one embodiment of the present invention and a base material 2 to which the laminate sheet 4 is attached. The vehicle interior member 1 is a component that constitutes part of the interior of a vehicle, such as an instrument panel, console, door trim, glove box, or pillar garnish. Although not shown here, the base material 2 has a three-dimensionally curved shape that matches the design shape of the vehicle interior member 1. The laminate sheet 4 forms the front side (design surface) of the vehicle interior member 1, and is attached by overlapping it on the front side of the base material 2 so as to match the surface shape of the base material 2. The laminate sheet 4 is preferably flexible.

[0016] The laminate sheet 4 includes a plurality of layers stacked in the thickness direction of the laminate sheet 4. For example, the laminate sheet 4 includes a skin layer 41 whose front side forms a design surface, a foam layer 42 disposed on the back side of the skin layer 41, and an adhesive layer 43 disposed on the opposite side of the foam layer 42 from the skin layer 41.

[0017] The skin layer 41 may be made of a resin sheet such as a thermoplastic polyolefin elastomer (TPO), a thermoplastic polyurethane elastomer (TPU), rubber (e.g., EPDM), or polyvinyl chloride (PVC), or fabric, either alone or in combination. The skin layer 41 is formed in a sheet shape with a uniform thickness and can be deformed in the thickness direction. The back side of the skin layer 41 is attached to the foam layer 42 by frame lamination, adhesive, or the like.

[0018] The foam layer 42 is made of a resin foam having an open-cell structure and has breathability. For the foam layer 42, for example, polyurethane foam or polyolefin foam can be used.

[0019] The adhesive layer 43 has an adhesive function for attaching the laminate sheet 4 to the base material 2, and is made of an adhesive, double-sided tape, or the like. The adhesive layer 43 is not breathable, or has significantly lower breathability than the foam layer 42. The adhesive layer 43 may be made of, for example, an epoxy-based, acrylic-based, urethane-based, or rubber-based material.

[0020] The laminate sheet 4 may include a functional layer 44 between the foam layer 42 and the adhesive layer 43. If the adhesive layer 43 is formed by applying a liquid adhesive, for example, the presence of the functional layer 44 can prevent the adhesive from permeating the foam layer 42. A mesh sheet or the like can be used as the functional layer 44. The functional layer 44 need not be located between the foam layer 42 and the adhesive layer 43, but may be disposed at any appropriate position using a material appropriate for the required function. The functional layer 44 may also be omitted; for example, if the adhesive layer 43 is formed of double-sided tape, the functional layer 44 is not necessary.

[0021] Before being attached to the substrate 2, the laminate sheet 4 includes a release layer 45 that is disposed on the back side of the adhesive layer 43 (the opposite side to the functional layer 44) (see FIG. 2, etc.). The release layer 45 is a release sheet that covers and protects the adhesive layer 43, and is removed from the adhesive layer 43 when the laminate sheet 4 is attached to the substrate 2. The release layer 45 can be, for example, paper or a resin film provided with a release agent such as a silicone resin.

[0022] The laminate sheet 4 has a plurality of perforations 50 that penetrate the adhesive layer 43 and reach the foam layer 42. When the laminate sheet 4 includes a functional layer 44, the perforations 50 penetrate the adhesive layer 43 and the functional layer 44 and reach the foam layer 42. It is more preferable that the perforations 50 are formed to reach a depth of at least half the thickness of the foam layer 42. The perforations 50 may also reach the skin layer 41, but are formed so as not to penetrate the skin layer 41.

[0023] When attaching the laminate sheet 4 to the base material 2, air pockets may form between the base material 2 and the laminate sheet 4. With the laminate sheet 4 of this embodiment, the air in the pockets can escape to the foam layer 42 through the perforations 50. This makes it possible to suppress the formation of air pockets and eliminate any air pockets that do form.

[0024] [Laminated sheet manufacturing method] When the surface of the substrate 2 of the vehicle interior member 1 has a region with a complex three-dimensional shape, air pockets are likely to occur in this region. In such a region, it is preferable to provide multiple perforations 50 concentrated at close intervals; in other words, it is preferable to provide a larger number of perforations 50 per unit area than in other regions. Although the region with a complex three-dimensional shape formed on the substrate 2 is not shown in FIG. 1, multiple perforations 50 are provided concentrated at close intervals in the region where air pockets are likely to occur.

[0025] The perforated portions 50 of the laminated sheet 4 are formed, for example, by puncturing the laminated sheet material with a puncture body provided on a Thomson die. However, due to factors such as the strength of the Thomson die and the space required to provide the puncture body, it may be difficult to provide multiple perforated portions 50 in a concentrated manner at close intervals on one Thomson die.

[0026] The manufacturing method of the laminated sheet 4 described below realizes the concentrated provision of multiple perforations 50 at close intervals in a specified area of ​​the laminated sheet 4, thereby suppressing the occurrence of air pockets in that area and eliminating any air pockets that do occur.

[0027] 2 and 3, the method for manufacturing a laminated sheet 4 of this embodiment includes a first perforated portion forming step S1 and a second perforated portion forming step S2. These steps are performed by a processing device 7. Reference numeral 40 in the figures denotes a laminated sheet material 40, which is a sheet formed by laminating a surface layer 41, a foam layer 42, a functional layer 44, an adhesive layer 43, and a release layer 45 in this order. The laminated sheet material 40 has, for example, a rectangular shape when viewed from above.

[0028] 2 is a diagram illustrating the first perforated portion forming step S1. The laminated sheet material 40 is placed on the processing table 71 of the processing device 7 with the skin layer 41 of the laminated sheet material 40 facing downward and the peel layer 45 facing upward. A Thomson die 73A is attached to the press mechanism 72 (see FIG. 6) of the processing device 7, and the press mechanism 72 uses an actuator including, for example, a hydraulic cylinder or a motor to move the Thomson die 73A back and forth in the vertical direction relative to the laminated sheet material 40 placed on the processing table 71. The first perforated portion forming step S1 is performed with the laminated sheet material 40 positioned at a predetermined processing position relative to the Thomson die 73A.

[0029] A plurality of puncture bodies 74A are erected on the underside of Thomson die 73A. Each puncture body 74A has, for example, a needle shape with a circular cross section. An elastic body 75 made of polyurethane foam or the like is also arranged on the underside of Thomson die 73A. Elastic body 75 is thicker in the vertical direction than the protrusion amount of puncture body 74A, and is arranged so as to cover the entire puncture body 74A.

[0030] In the first perforation portion forming step S1, the Thomson die 73A is moved relatively toward the laminated sheet material 40 placed on the processing table 71 (FIG. 2(a)), and multiple puncture bodies 74A are punctured into the laminated sheet material 40 from the adhesive layer 43 side (the release layer 45 side) until they reach the foam layer 42 (FIG. 2(b)). Then, the Thomson die 73A is moved relatively away from the laminated sheet material 40 (FIG. 2(c)). In this way, multiple perforation portions 50 are formed in the laminated sheet material 40 by puncturing the laminated sheet material 40 with the multiple puncture bodies 74A from the adhesive layer 43 side.

[0031] The elastic body 75 is pressed against the laminated sheet material 40 placed on the processing table 71 and elastically deforms when the Thomson die 73A moves toward the laminated sheet material 40, and restores its original shape when the Thomson die 73A moves away from the laminated sheet material 40, thereby pushing the laminated sheet material 40 toward the processing table 71. This prevents the laminated sheet material 40 from following the Thomson die 73A.

[0032] The piercer 74A erected on the Thomson die 73A is positioned opposite a predetermined region R1 of the laminated sheet material 40. The predetermined region R1 is located inside the outer shape (outer peripheral edge) of the laminated sheet 4 to be manufactured. In the first perforation portion forming step S1, a plurality of perforations 50 are formed in the region R1 of the laminated sheet material 40.

[0033] 3 is a diagram illustrating the second perforation forming step S2. Similar to the first perforation forming step S1, the second perforation forming step S2 is also performed by a processing device 7 including a processing table 71 and a press mechanism 72. In the second perforation forming step S2, the laminated sheet material 40 is placed on the processing table 71 with the skin layer 41 of the laminated sheet material 40 facing downward and the peel layer 45 facing upward. A Thomson die 73B is attached to the press mechanism 72, and the press mechanism 72 moves the Thomson die 73B back and forth in the vertical direction relative to the laminated sheet material 40 placed on the processing table 71. The second perforation forming step S2 is performed with the laminated sheet material 40 positioned at a predetermined processing position relative to the Thomson die 73B.

[0034] A plurality of puncture bodies 74B are erected on the underside of Thomson mold 73B. Each puncture body 74B has, for example, a needle shape with a circular cross section. An elastic body 75 is also arranged on the underside of Thomson mold 73B. Elastic body 75 is thicker in the vertical direction than the protrusion amount of puncture body 74B, and is arranged so as to cover the entire puncture body 74B.

[0035] In the second perforation portion forming step S2, the Thomson die 73B is moved relatively toward the laminated sheet material 40 placed on the processing table 71 (FIG. 3(a)), and the plurality of puncture bodies 74B are punctured into the laminated sheet material 40 from the adhesive layer 43 side (the release layer 45 side) until they reach the foam layer 42 (FIG. 3(b)). Then, the Thomson die 73B is moved relatively away from the laminated sheet material 40 (FIG. 3(c)). In this way, the plurality of puncture bodies 74B are punctured into the laminated sheet material 40 from the adhesive layer 43 side, thereby forming a plurality of perforations 50 in the laminated sheet material 40.

[0036] Furthermore, punching blades 76, 77 are erected on the underside of Thomson die 73B. Punching blade 76 has a shape that matches the outer shape of laminated sheet 4, and punches out laminated sheet material 40 to the shape of laminated sheet 4. Punching blade 77 is arranged inside punching blade 76, and punches out part of laminated sheet material 40. The protrusion amount of punching blades 76, 77 is greater than the protrusion amount of puncture body 74B. In this way, in second perforation portion forming step S2, multiple perforations 50 are formed in laminated sheet material 40 and punching is performed simultaneously.

[0037] The puncture bodies 74B are erected on the entire underside of the Thomson die 73B in the region inside the punching blade 76. The region where the puncture bodies 74B are erected corresponds to the entire region of the laminated sheet 4 to be manufactured and is wider than region R1. The number of puncture bodies 74B is greater than the number of puncture bodies 74A of the Thomson die 73A. The second perforation portion forming step S2 forms a plurality of perforation portions 50 in a region including region R1 of the laminated sheet material 40 (a region wider than region R1).

[0038] In the first perforation forming step S1 and the second perforation forming step S2, the puncture body 74A and the puncture body 74B are punctured at different positions in the laminated sheet material 40. Here, puncturing at different positions may include a mode in which the perforation portion 50 formed by the puncture body 74A and the perforation portion 50 formed by the puncture body 74B are punctured so as not to overlap in top view, or may include a mode in which they partially overlap in top view.

[0039] According to the method for manufacturing the laminated sheet 4 of this embodiment, two Thomson dies 73A, 73B are used to form a plurality of perforations 50 in the laminated sheet material 40 in a first perforation forming step S1 and a second perforation forming step S2, and the first perforation forming step S1 and the second perforation forming step S2 form perforations 50 at different positions on the laminated sheet material 40, so that perforations 50 can be formed in positions where perforations 50 cannot be formed by the second perforation forming step S2 alone. Therefore, a laminated sheet 4 can be manufactured that includes an area where perforations 50 are formed in a concentrated manner.

[0040] 3(c), in the laminated sheet 4 manufactured by the first perforated portion forming step S1 and the second perforated portion forming step S2, the number of perforated portions 50 formed per unit area (number density) in the region R1 is greater than that outside the region R1. Therefore, it is possible to manufacture a laminated sheet 4 in which the perforated portions 50 are formed concentratedly in the region R1.

[0041] The perforated portion 50 formed in the first perforated portion forming step S1 includes perforated portion 50a formed at a position closer to the processing location with the punching blade 77 than the perforated portion 50 formed in the second perforated portion forming step S2 (see FIG. 3(c)). It may be difficult to erect the puncture body 74B near the punching blade 77 of the Thomson die 73B used in the second perforated portion forming step S2, but it is possible to erect the puncture body 74A at a position corresponding to the vicinity of the punching blade 77 for the Thomson die 73A. Therefore, it is possible to manufacture a laminated sheet 4 in which perforations 50 are formed in a concentrated manner at a position close to the processing location with the punching blade 77.

[0042] Since the first perforated portion forming step S1 is performed before the second perforated portion forming step S2, in the first perforated portion forming step S1, perforated portions 50 are formed in the laminated sheet material 40 before punching. Therefore, the perforated portions 50 can be stably formed in the first perforated portion forming step S1.

[0043] 4 is a diagram showing an example of the arrangement of puncture bodies 74A, 74B and punching blades 76, 77 in Thomson dies 73A and Thomson dies 73B. As described above, in Thomson dies 73A, a plurality of puncture bodies 74A are provided upright in positions corresponding to region R1 of laminated sheet material 40, and in Thomson dies 73B, puncture bodies 74B are provided upright throughout the region inside punching blade 77. In addition, in Thomson dies 73A, a plurality of puncture bodies 74A are also provided upright in region R2 corresponding to the vicinity of punching blade 77.

[0044] The diameter of the puncture bodies 74A, 74B is, for example, 2 mm. Adjacent puncture bodies 74A in the Thomson type 73A are erected at an interval of, for example, 4 mm or more. Similarly, adjacent puncture bodies 74B in the Thomson type 73B are erected at an interval of, for example, 4 mm or more. By leaving an interval of 4 mm or more, the strength of each of the Thomson types 73A, 73B can be ensured.

[0045] 5 is a top view of the laminated sheet 4 manufactured by the first perforation forming step S1 and the second perforation forming step S2, which are carried out using the Thomson die 73A and the Thomson die 73B shown in FIG. In the laminated sheet 4, perforations 50 formed by the puncture body 74A are arranged between perforations 50 formed by the puncture body 74B. As a result, perforations 50 are formed intensively at narrow intervals, particularly in the region R1 punctured by both the puncture body 74A and the puncture body 74B. Specifically, perforations 50 can be formed such that the interval between adjacent perforations 50 is less than 4 mm. Perforations 50 are also formed in the region R2 corresponding to the vicinity of the punching blade 77.

[0046] Fig. 6 is a diagram showing an example of the schematic configuration of processing apparatus 7. The example shown in Fig. 6 includes a single press mechanism 72, and Thomson dies 73A and 73B are attached to the press mechanism 72 adjacent to each other along the conveyance direction. Thomson dies 73A and 73B move forward and backward together in the vertical direction, and the laminated sheet material 40 moves in the conveyance direction (the direction indicated by the white arrow in the figure), thereby sequentially performing a first perforation forming step S1 and a second perforation forming step S2 in the same press operation.

[0047] FIG. 6 shows an example in which two laminated sheets 4 are formed from one laminated sheet material 40 by the processing device 7. When the laminated sheet material 40 is conveyed in the conveyance direction (FIG. 6(a)), a front portion 401 of the laminated sheet material 40 in the conveyance direction is positioned at a position (first position) facing the Thomson die 73A (FIG. 6(b)). At this time, a rear portion 402 of the laminated sheet material 40 in the conveyance direction faces neither the Thomson dies 73A nor 73B. The processing device 7 moves the Thomson dies 73A and 73B relatively toward the laminated sheet material 40 to process the front portion 401 of the laminated sheet material 40. That is, a first perforation forming step S1 is performed on the front portion 401 of the laminated sheet material 40.

[0048] Next, the laminated sheet material 40 is transported to a position (second position) where the front portion 401 faces the Thomson die 73B, and to a position (first position) where the rear portion 402 faces the Thomson die 73A (FIG. 6(c)). The processing device 7 moves the Thomson dies 73A and 73B relatively toward the laminated sheet material 40 to process the front portion 401 and the rear portion 402 of the laminated sheet material 40. That is, a second perforation forming step S2 is performed on the front portion 401 of the laminated sheet material 40, and a laminated sheet 4 is formed from the front portion 401. Furthermore, a first perforation forming step S1 is performed on the rear portion 402 of the laminated sheet material 40. In this way, the first perforation forming step S1 and the second perforation forming step S2 are performed simultaneously.

[0049] Next, the laminated sheet material 40 is transported to a position (second position) where the rear portion 402 faces the Thomson die 73B (FIG. 6(d)). Furthermore, the front portion 401 of another subsequently transported laminated sheet material 40 is transported to a position (first position) where it faces the Thomson die 73A. The processing device 7 moves the Thomson dies 73A and 73B relatively toward the laminated sheet material 40 to process the rear portion 402 of the preceding laminated sheet material 40 and the front portion 401 of the following laminated sheet material 40. That is, the second perforation forming step S2 is performed on the rear portion 402 of the preceding laminated sheet material 40, and the laminated sheet 4 is formed from the rear portion 402. Furthermore, the first perforation forming step S1 is performed on the front portion 401 of the following laminated sheet material 40. In this way, the first perforation forming step S1 and the second perforation forming step S2 are performed simultaneously.

[0050] By continuously performing the processing by the processing device 7 described above, a plurality of laminate sheets 4 are manufactured from a plurality of laminate sheet materials 40. Therefore, the manufacturing efficiency of the laminate sheets 4 can be improved.

[0051] [Evaluation of breathability] To evaluate the breathability of the laminate sheet 4 manufactured by the first perforation forming step S1 and the second perforation forming step S2, the ISO air permeability (μm / Pa·s) and air resistance (sec / 100 ml) were measured in accordance with Japanese Industrial Standard JIS P8117:2009 (Paper and paperboard—Air permeability and air resistance test method (intermediate range)—Gurley method). Note that, in conducting this test, the release layer 45 of the laminate sheet 4 was used as the sample, rather than the laminate sheet 4 manufactured by the first perforation forming step S1 and the second perforation forming step S2 itself. Because the release layer 45 has the same size and number of perforations 50 as the foam layer 42 and the adhesive layer 43, it is believed that even when only the release layer 45 is used as the sample, it is possible to indirectly evaluate the breathability in a similar manner to when the laminate sheet 4 is used as the sample.

[0052] Below are shown the measurement results (No. 1) of a sample in which neither the first perforation portion forming step S1 nor the second perforation portion forming step S2 was performed, and no perforation portion 50 was formed; the measurement results (No. 2) of a sample in which the perforation portion 50 was formed only by the second perforation portion forming step S2 without performing the first perforation portion forming step S1; and the measurement results (No. 3) of a sample in which the perforation portion 50 was formed by performing the first perforation portion forming step S1 and the second perforation portion forming step S2 as in this embodiment.

[0053] [No.1] ·ISO air permeability: unmeasurable ·Air resistance: Unmeasurable [No.2] ·ISO air permeability: 0.39μm / Pa·s Air resistance: 345.2sec / 100ml [No.3] ·ISO air permeability: 0.76μm / Pa·s Air resistance: 175.9sec / 100ml

[0054] Here, the reason why No. 1 was "impossible to measure" is that the sample without the perforated portion 50 has no air permeability (or extremely low air permeability).

[0055] As shown by these measurement results, Nos. 2 and 3, in which perforations 50 were formed, were confirmed to be breathable, unlike No. 1, in which no perforations 50 were formed. Furthermore, measurement results showed that No. 3 according to this embodiment had breathability 1.96 times higher than No. 2. Therefore, it was confirmed that the method of forming perforations 50 in two steps, the first perforation forming step S1 and the second perforation forming step S2, has the effect of significantly improving breathability by increasing the density of the perforations 50. In particular, in a vehicle interior member 1 having a complex three-dimensional shape, it is possible to effectively improve air release performance in areas where air pockets are likely to occur.

[0056] (Variation 1) 7(a) is a partial cross-sectional view of a laminate sheet 4A of Modification 1. The laminate sheet 4A includes a skin layer 41 whose front side forms a design surface, an adhesive layer 43 disposed on the back side of the skin layer 41, and a release layer 45 disposed on the back side of the adhesive layer 43. The laminate sheet 4A does not include a foam layer 42 or a functional layer 44, and the adhesive layer 43 is disposed in contact with the back side of the skin layer 41. The skin layer 41 of the laminate sheet 4A is formed of a breathable material such as fabric.

[0057] The laminate sheet 4A has a plurality of perforations 50 that penetrate the adhesive layer 43 and reach the surface layer 41. The perforations 50 may be formed so as not to penetrate the surface layer 41, or may be formed so as to penetrate the surface layer 41. The laminate sheet 4A allows air trapped when attaching the laminate sheet 4A to the base material 2 to escape through the perforations 50 into the breathable surface layer 41.

[0058] The multiple perforated portions 50 of the laminated sheet 4A are formed in a first perforated portion forming step S1 and a second perforated portion forming step S2, similar to the case of the aforementioned laminated sheet 4. In the first perforated portion forming step S1 and the second perforated portion forming step S2, a laminated sheet 4A including an area where the perforated portions 50 are formed in a concentrated manner can be manufactured.

[0059] (Variation 2) 7(b) is a partial cross-sectional view of a laminate sheet 4B of Modification 2. Like the laminate sheet 4A, the laminate sheet 4B does not include a foam layer 42 or a functional layer 44, and an adhesive layer 43 is disposed in contact with the back side of the skin layer 41. The skin layer 41 of the laminate sheet 4B is formed of a vinyl resin sheet or the like that has no or low breathability.

[0060] The laminate sheet 4B has a plurality of perforations 50 penetrating the adhesive layer 43 and the surface layer 41. The laminate sheet 4B allows air trapped when the laminate sheet 4B is attached to the base material 2 to escape to the outside of the surface layer 41 through the perforations 50.

[0061] The multiple perforated portions 50 of the laminated sheet 4B are formed in a first perforated portion forming step S1 and a second perforated portion forming step S2, similar to the case of the aforementioned laminated sheet 4. This makes it possible to manufacture a laminated sheet 4B including an area where the perforated portions 50 are formed in a concentrated manner.

[0062] When manufacturing laminated sheets 4A, 4B that penetrate the epidermis layer 41 and the adhesive layer 43, in the first perforation forming step S1 and the second perforation forming step S2, the puncture bodies 74A, 74B may puncture the laminated sheet material 40 from the adhesive layer 43 side (peeling layer 45), or may puncture the laminated sheet material 40 from the epidermis layer 41 side.

[0063] Although one embodiment of the present invention has been described above with reference to the accompanying drawings, it goes without saying that the present invention is not limited to such an embodiment. It is clear that a person skilled in the art can conceive of various modifications or alterations within the scope of the claims, and it is understood that these also naturally fall within the technical scope of the present invention. Furthermore, the components of the above embodiment may be combined in any manner without departing from the spirit of the invention.

[0064] In the above-described embodiment, the second perforated portion forming step S2 including punching is performed after the first perforated portion forming step S1, but it may be performed before the first perforated portion forming step S1.

[0065] For example, the laminate sheet 4 may not include the functional layer 44 and / or the release layer 45 as long as it includes the surface layer 41, the foam layer 42, and the adhesive layer 43. Furthermore, the laminate sheets 4A and 4B may not include the release layer 45.

[0066] Furthermore, in the above-described embodiment, the Thomson die 73B used in the second perforation portion forming step S2 is provided with the punching blades 76, 77, but it may not be provided with the punching blades 76, 77. In this case, the processing device 7 may be configured to include another Thomson die adjacent to the Thomson die 73B, and the punching blades 76, 77 may be provided upright on that Thomson die.

[0067] In the above-described embodiment, the cross-sectional shape of the puncture bodies 74A, 74B is circular, but they may be polygonal, such as rectangular. Furthermore, the puncture bodies 74A, 74B are not limited to being needle-shaped, and may be plate-shaped, and may be configured to form perforations 50 in the form of cuts or slits in the laminated sheet material 40, for example.

[0068] This specification describes at least the following: In parentheses, components corresponding to those in the above-described embodiments are shown as examples, but the present invention is not limited to these.

[0069] (1) A method for manufacturing a laminate sheet, which is for manufacturing a laminate sheet (laminate sheet 4) for a vehicle interior member (vehicle interior member 1) from a laminate sheet material (laminate sheet material 40) having a surface layer (surface layer 41), a foam layer (foam layer 42), and an adhesive layer (adhesive layer 43) that constitute a design surface, in which a plurality of perforated portions (perforated portions 50) are formed that penetrate the adhesive layer and reach the foam layer, a first perforation portion forming step (first perforation portion forming step S1) of forming a plurality of the perforations by puncturing a plurality of first puncture bodies (puncture bodies 74A) in the laminated sheet material from the adhesive layer side; a second perforation portion forming step (second perforation portion forming step S2) of forming a plurality of the perforations by puncturing a plurality of second puncture bodies (puncture bodies 74B) in the laminated sheet material from the adhesive layer side, the first puncture portion forming step and the second puncture portion forming step include puncturing the laminated sheet material with the first puncture body and the second puncture body at positions different from each other; A method for manufacturing a laminated sheet.

[0070] According to (1), a plurality of perforations are formed in the laminated sheet material in a first perforation forming step and a second perforation forming step, and the first perforation forming step and the second perforation forming step form perforations at different positions on the laminated sheet material, so that perforations can be formed in positions where perforations cannot be formed in either step alone. Therefore, a laminated sheet including an area where perforations are formed in a concentrated manner can be manufactured.

[0071] (2) A method for producing the laminate sheet according to (1), The first perforated portion forming step forms a plurality of perforated portions in a predetermined region (region R1) of the laminated sheet material, The second perforated portion forming step forms a plurality of perforated portions in an area including at least the predetermined area of ​​the laminated sheet material, In the laminated sheet manufactured by the first perforation portion forming step and the second perforation portion forming step, the number of the perforations formed per unit area in the predetermined region is greater than that outside the predetermined region. A method for manufacturing a laminated sheet.

[0072] According to (2), a laminated sheet can be produced in which perforations are formed in a concentrated manner in a predetermined area.

[0073] (3) A method for producing the laminate sheet according to (1) or (2), The second perforated portion forming step forms a plurality of perforations in the laminated sheet material and performs punching, The perforation portion formed in the first perforation portion forming step includes a perforation portion (perforation portion 50a) formed at a position closer to the processing location where the punching is performed than the perforation portion formed in the second perforation portion forming step. A method for manufacturing a laminated sheet.

[0074] According to (3), a laminated sheet can be produced in which perforations are formed in a concentrated manner near the punching processing points.

[0075] (4) A method for producing a laminate sheet according to any one of (1) to (3), The second perforation forming step includes forming a plurality of perforations in the laminated sheet material and punching the laminated sheet material to match the outer shape of the laminated sheet; The first perforation forming step is performed before the second perforation forming step. A method for manufacturing a laminated sheet.

[0076] According to (4), the first perforated portion forming step is carried out on the laminated sheet material before punching, so that the perforated portions can be formed stably in the first perforated portion forming step.

[0077] (5) A method for producing a laminate sheet according to any one of (1) to (4), After the first perforation forming step, a conveying step is further provided in which the laminated sheet material is conveyed from a first position where the first perforation forming step is performed to a second position where the second perforation forming step is performed; the conveying step includes conveying the stacked sheet material from the first position to the second position and conveying another stacked sheet material to the first position; The second perforation forming step and the first perforation forming step are carried out simultaneously, and the perforations are formed simultaneously in the laminated sheet material and the other laminated sheet material. A method for manufacturing a laminated sheet.

[0078] According to (5), the first perforated portion forming step and the second perforated portion forming step can be carried out continuously on the laminated sheet material, thereby improving the manufacturing efficiency of the laminated sheet.

[0079] (6) A method for manufacturing a laminate sheet, which is for manufacturing a laminate sheet (laminate sheet 4A, 4B) for a vehicle interior member, in which a plurality of perforations (perforation portions 50) penetrating at least the adhesive layer are formed from a laminate sheet material (laminate sheet material 40) having a surface layer (surface layer 41) constituting a design surface and an adhesive layer (adhesive layer 43) arranged in contact with the back side of the surface layer, a first perforation portion forming step (first perforation portion forming step S1) of forming a plurality of the perforations by puncturing the laminated sheet material with a plurality of first puncture bodies (puncture bodies 74A); a second perforation portion forming step (second perforation portion forming step S2) of forming a plurality of the perforations by puncturing the laminated sheet material with a plurality of second puncture bodies (puncture bodies 74B), the first puncture portion forming step and the second puncture portion forming step include puncturing the laminated sheet material with the first puncture body and the second puncture body at positions different from each other; A method for manufacturing a laminated sheet.

[0080] According to (6), a plurality of perforations are formed in the laminated sheet material in a first perforation forming step and a second perforation forming step, and the first perforation forming step and the second perforation forming step form perforations at different positions on the laminated sheet material, so that perforations can be formed in positions where perforations cannot be formed in either step alone. Therefore, a laminated sheet including an area where perforations are formed in a concentrated manner can be manufactured.

[0081] (7) A method for producing the laminate sheet according to (6), The first perforated portion forming step forms a plurality of perforated portions in a predetermined region (region R1) of the laminated sheet material, The second perforated portion forming step forms a plurality of perforated portions in an area including at least the predetermined area of ​​the laminated sheet material, In the laminated sheet manufactured by the first perforation portion forming step and the second perforation portion forming step, the number of the perforations formed per unit area in the predetermined region is greater than that outside the predetermined region. A method for manufacturing a laminated sheet.

[0082] According to (7), a laminated sheet can be produced in which perforations are formed in a concentrated manner in a predetermined area.

[0083] (8) A method for producing the laminate sheet according to (6) or (7), The second perforated portion forming step forms a plurality of perforations in the laminated sheet material and performs punching, The perforation portion formed in the first perforation portion forming step includes a perforation portion (perforation portion 50a) formed at a position closer to the processing location where the punching is performed than the perforation portion formed in the second perforation portion forming step. A method for manufacturing a laminated sheet.

[0084] According to (8), a laminated sheet can be produced in which perforations are formed in a concentrated manner near the punching processing points.

[0085] (9) A method for producing a laminated sheet according to any one of (6) to (8), The second perforation forming step includes forming a plurality of perforations in the laminated sheet material and punching the laminated sheet material to match the outer shape of the laminated sheet; The first perforation forming step is performed before the second perforation forming step. A method for manufacturing a laminated sheet.

[0086] According to (9), the first perforated portion forming step is carried out on the laminated sheet material before punching, so that the perforated portions can be formed stably in the first perforated portion forming step.

[0087] (10) A method for producing a laminate sheet according to any one of (6) to (9), After the first perforation forming step, a conveying step is further provided in which the laminated sheet material is conveyed from a first position where the first perforation forming step is performed to a second position where the second perforation forming step is performed; the conveying step includes conveying the stacked sheet material from the first position to the second position and conveying another stacked sheet material to the first position; The second perforation forming step and the first perforation forming step are carried out simultaneously, and the perforations are formed simultaneously in the laminated sheet material and the other laminated sheet material. A method for manufacturing a laminated sheet.

[0088] According to (10), the first perforated portion forming step and the second perforated portion forming step can be carried out continuously on the laminated sheet material, thereby improving the manufacturing efficiency of the laminated sheet. [Explanation of symbols]

[0089] 1. Vehicle interior components 4 Laminated Sheet 4A Laminated Sheet 4B laminated sheet 40 Laminated sheet material 41 Epidermal layer 42 foam layer 43 Adhesive layer 50 Perforation 50a drilling part 74A Puncture body (1st puncture body) 74B Puncture body (second puncture body) S1 First perforation forming step S2: Second hole forming step

Claims

1. A method for manufacturing a laminate sheet for a vehicle interior member, the method comprising the steps of: manufacturing a laminate sheet for a vehicle interior member from a laminate sheet material having a surface layer constituting a design surface, a foam layer, and an adhesive layer, the laminate sheet having a plurality of perforated portions formed therein, the perforated portions penetrating the adhesive layer and reaching the foam layer, the method comprising the steps of: a first perforation portion forming step of forming a plurality of the perforation portions by puncturing the laminated sheet material from the adhesive layer side with a plurality of first puncture bodies; a second perforation portion forming step of forming a plurality of the perforations by puncturing the laminated sheet material from the adhesive layer side with a plurality of second puncture bodies, the first puncture portion forming step and the second puncture portion forming step include puncturing the laminated sheet material with the first puncture body and the second puncture body at positions different from each other; A method for manufacturing a laminated sheet.

2. A method for producing the laminate sheet according to claim 1, The first perforation portion forming step forms a plurality of perforations in a predetermined region of the laminated sheet material, The second perforation portion forming step forms a plurality of perforations in an area including at least the predetermined area of ​​the laminated sheet material, In the laminated sheet manufactured by the first perforation portion forming step and the second perforation portion forming step, the number of the perforations formed per unit area in the predetermined region is greater than that outside the predetermined region. A method for manufacturing a laminated sheet.

3. A method for producing the laminate sheet according to claim 1 or 2, The second perforated portion forming step includes forming a plurality of perforations in the laminated sheet material and performing punching processing; The perforation portion formed in the first perforation portion forming step includes a perforation portion formed at a position closer to a processing location where the punching is performed than the perforation portion formed in the second perforation portion forming step. A method for manufacturing a laminated sheet.

4. A method for producing the laminate sheet according to claim 1 or 2, The second perforation forming step includes forming a plurality of perforations in the laminated sheet material and punching the laminated sheet material to match the outer shape of the laminated sheet; The first perforation forming step is performed before the second perforation forming step. A method for manufacturing a laminated sheet.

5. A method for producing the laminate sheet according to claim 1 or 2, After the first perforation forming step, a conveying step is further provided in which the laminated sheet material is conveyed from a first position where the first perforation forming step is performed to a second position where the second perforation forming step is performed; the conveying step includes conveying the stacked sheet material from the first position to the second position and conveying another stacked sheet material to the first position; The second perforation forming step and the first perforation forming step are carried out simultaneously, and the perforations are formed simultaneously in the laminated sheet material and the other laminated sheet material. A method for manufacturing a laminated sheet.

6. A method for manufacturing a laminate sheet for a vehicle interior member, the method comprising: manufacturing a laminate sheet for a vehicle interior member, the laminate sheet having a plurality of perforations penetrating at least the adhesive layer, from a laminate sheet material having a surface layer constituting a design surface and an adhesive layer disposed in contact with the back side of the surface layer; a first perforation portion forming step of forming a plurality of the perforations by puncturing the laminated sheet material with a plurality of first puncture bodies; a second perforation portion forming step of forming a plurality of the perforations by puncturing the laminated sheet material with a plurality of second puncture bodies, the first puncture portion forming step and the second puncture portion forming step include puncturing the laminated sheet material with the first puncture body and the second puncture body at positions different from each other; A method for manufacturing a laminated sheet.

7. A method for producing the laminate sheet according to claim 6, The first perforation portion forming step forms a plurality of perforations in a predetermined region of the laminated sheet material, The second perforation portion forming step forms a plurality of perforations in an area including at least the predetermined area of ​​the laminated sheet material, In the laminated sheet manufactured by the first perforation portion forming step and the second perforation portion forming step, the number of the perforations formed per unit area in the predetermined region is greater than that outside the predetermined region. A method for manufacturing a laminated sheet.

8. A method for producing the laminate sheet according to claim 6 or 7, The second perforated portion forming step includes forming a plurality of perforations in the laminated sheet material and performing punching processing; The perforation portion formed in the first perforation portion forming step includes a perforation portion formed at a position closer to a processing location where the punching is performed than the perforation portion formed in the second perforation portion forming step. A method for manufacturing a laminated sheet.

9. A method for producing the laminate sheet according to claim 6 or 7, The second perforation forming step includes forming a plurality of perforations in the laminated sheet material and punching the laminated sheet material to match the outer shape of the laminated sheet; The first perforation forming step is performed before the second perforation forming step. A method for manufacturing a laminated sheet.

10. A method for producing the laminate sheet according to claim 6 or 7, After the first perforation forming step, a conveying step is further provided in which the laminated sheet material is conveyed from a first position where the first perforation forming step is performed to a second position where the second perforation forming step is performed; the conveying step includes conveying the stacked sheet material from the first position to the second position and conveying another stacked sheet material to the first position; The second perforation forming step and the first perforation forming step are carried out simultaneously, and the perforations are formed simultaneously in the laminated sheet material and the other laminated sheet material. A method for manufacturing a laminated sheet.

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