Perforated laminated sheet and method for manufacturing the same

Abstract

To provide a perforated laminated sheet having a pattern.SOLUTION: A perforated laminated sheet according to the embodiment of the invention is manufactured by processing a raw laminated sheet in which at least one layer of resin sheet is placed between a first cloth on the front side and a second cloth on the back side, and the first cloth, the second cloth, and the resin sheet are stuck together. The perforated laminated sheet has a plurality of supersonic punching holes PH penetrating from the first cloth to the second cloth and has a pattern formed by difference in thickness caused by distribution density of the plurality of supersonic punching holes PH at least on either one of the front surface and the back surface of the raw laminated sheet.SELECTED DRAWING: Figure 7

Description

【Technical Field】 【0001】 This invention relates to a perforated laminated sheet and a method for manufacturing the same. 【Background Art】 【0002】 Conventional punching processing has adopted a method of arranging punches at required positions on the fabric and applying a large pressure thereto to punch out. Conventional punching processing has been limitedly applied to non-woven fabrics, synthetic leathers, natural leathers, etc. in which fibers are entangled. 【0003】 However, fabrics and knitted fabrics, which are currently the mainstream of sheet materials, fray from the processed hole cross-section when subjected to conventional punching processing, resulting in a decrease in strength and no practical performance. It has also been considered to use a laminated sheet composed of a surface fabric, a urethane foam, and a back fabric as a surface material for automobile seats to improve air permeability and reduce the energy consumption of air conditioning and heating, aiming at improving the fuel efficiency of automobiles. Such a thick laminated sheet material has a large resistance during processing and cannot be processed (so-called only thin materials can be punched out). Thus, punching processing can only be applied to so-called thin materials, so it is limited to planar patterns, and materials having a highly artistic pattern with unevenness cannot be applied to automobile seats to improve air permeability and reduce fuel consumption. 【0004】 Patent Document 1 discloses a method for manufacturing a sheet member. This manufacturing method uses a piercing pin whose base is supported by a piercing pin support 12 and which is positioned opposite the drilling table. This piercing pin is inserted through the surface of the sheet member supplied to the drilling table to create micro-holes in the sheet member. In this method, an elastic member fitted around the piercing pin is brought into contact with the surface of the sheet member, which is laminated on a liner member and supplied to the drilling table, to fix the sheet member to the drilling table. The piercing pin unit is then lowered to penetrate the sheet member with the piercing pin, creating micro-holes in the sheet member. Furthermore, in this method, burrs formed around the periphery of the micro-holes are embedded into the surface of the liner member, integrating the laminated sheet member and the liner member. The piercing pin unit is then raised to remove the piercing pin from the sheet member, and after releasing the sheet member, which was fixed to the drilling table by the elastic member, from the drilling table, the liner member is separated. 【0005】 Furthermore, Patent Document 2 discloses a method for manufacturing a laminated sheet material, characterized by forming a three-dimensional uneven pattern on the laminated sheet material using a rotating support roll having an uneven pattern formed on its rotating surface. Specifically, a sheet material is supplied by laminating a thick first sheet material and a second sheet material thinner than the first sheet material into a gap formed between the rotating support roll and the horn of an ultrasonic device disposed opposite the rotating support roll. The sheet material is then pressed towards the rotating support roll by a pressing member provided near the gap just before it is supplied into the gap, thereby transferring the uneven pattern of the rotating support roll. Only the portion in contact with the protrusions of the rotating support roll is softened by frictional heat generated by the ultrasonic device and partially ultrasonically bonded to form a laminated sheet material. At this time, the laminated sheet material is thinned only at the joints, while the laminated sheet material is kept thick without bonding at the non-jointed portions, thereby forming a three-dimensional uneven pattern on the laminated sheet material. 【0006】 Furthermore, Patent Document 3 discloses a laminated sheet. This laminated sheet is a three-layer laminated sheet in which an adhesive sheet located in the middle and a nonwoven fabric located on the front and back are laminated and integrated. The laminated sheet has embossed uneven surfaces, and the overlapping sheets are fitted and joined only at these embossed uneven surfaces. 【0007】 Furthermore, Patent Document 4 discloses an ultrasonic punching apparatus capable of creating clean holes by ultrasonic punching. [Prior art documents] [Patent Documents] 【0008】 [Patent Document 1] Japanese Patent Publication No. 2017-19028 [Patent Document 2] Japanese Patent Publication No. 2015-93391 [Patent Document 3] Japanese Patent Publication No. 2018-89833 [Patent Document 4] Japanese Patent Publication No. 2020-19073 [Overview of the project] [Problems that the invention aims to solve] 【0009】 In an embodiment of the present invention, a perforated laminated sheet having a pattern is provided. [Means for solving the problem] 【0010】 An embodiment of the present invention provides a perforated laminated sheet in which at least one layer of resin sheet is interposed between a first fabric on the surface and a second fabric on the back surface, and the first fabric, the second fabric and the resin sheet are bonded together, wherein at least one of the surface and back surfaces of the original laminated sheet In a planar region Multiple pieces of cloth penetrating from the first cloth to the second cloth The original laminated sheet has multiple punched hole regions in which ultrasonic punching holes are formed at predetermined intervals in the vertical and horizontal directions and exist at a predetermined distribution density, and the area of ​​the planar region of the original laminated sheet in which the multiple punched hole regions exist has non-punched regions in which there are no ultrasonic punching holes, and the ultrasonic punched hole regions are repeated in the planar region in a certain rule, thereby forming a pattern in which the ultrasonic punched hole regions are surrounded by the non-punched regions, and the pattern is created because the thickness of the ultrasonic punched hole regions is thinner than the thickness of the non-punched regions. It is characterized by the following: 【0011】 The perforated laminated sheet according to the present invention is characterized in that the resin sheet is a urethane foam sheet. 【0012】 The perforated laminated sheet according to the present invention is characterized in that the first fabric is any of a woven fabric, knitted fabric, nonwoven fabric, synthetic leather, or natural leather, and the second fabric is any of a nonwoven fabric, woven fabric, or knitted fabric. 【0013】 The perforated laminated sheet according to the present invention is characterized in that the thickness of the resin sheet is 3 mm or more. 【0014】 In the perforated laminated sheet according to the present invention, The aforementioned Having ultrasonically punched holes The aforementioned There are no punched hole areas or ultrasonically punched holes. The aforementioned It is characterized by having a different height or thickness from the non-punched area. 【0015】 The perforated laminated sheet according to the present invention is characterized in that the perforated area has ultrasonic punching holes distributed at intervals of 4 mm to 8 mm in both the vertical and horizontal directions, and the non-punched area does not have ultrasonic punching holes in a band-shaped area with a width of 3 mm or more. 【0016】 The present invention relates to a method for manufacturing a perforated laminated sheet, wherein at least one layer of resin sheet is interposed between a first surface fabric and a second back surface fabric, and the first fabric, the second fabric, and the resin sheet are bonded together to produce a perforated laminated sheet. In the punched area having multiple ultrasonic punching holes, multiple protrusions are formed corresponding to the multiple ultrasonic punching holes, and no protrusions are formed in the non-punched area corresponding to the non-punched area where there are no ultrasonic punching holes. The mold is brought into contact with the surface or back surface of the raw laminated sheet, and an ultrasonic horn for transmitting ultrasonic vibrations is provided at a position opposite the surface of the mold. The raw laminated sheet is movably sandwiched between the mold and the ultrasonic horn, and the ultrasonic horn transmits ultrasonic vibrations from the mold. The aforementioned multipleTransmit ultrasonic vibration toward the convex portion, and while cutting the original laminated sheet by the frictional heat generated at the interface between the ultrasonic horn and the mold, move the original laminated sheet between the mold and the ultrasonic horn The fabric has a punched area having multiple ultrasonic punching holes that penetrate from the first fabric to the second fabric, and a non-punched area where there are no ultrasonic punching holes. It is characterized by manufacturing a perforated laminated sheet. 【0017】 In the method for manufacturing a perforated laminated sheet according to the present invention, Multiple protrusions are formed corresponding to the multiple ultrasonic punching holes, and by changing the distribution density of the protrusions, the distribution density of the multiple ultrasonic punching holes is changed, thereby creating a pattern formed by varying thickness on at least one of the front and back surfaces of the original laminated sheet. It is characterized by the above. 【0018】 In the method for manufacturing a perforated laminated sheet according to the present invention, in the portion corresponding to the punching hole region, the convex portions are provided with a distribution density at intervals of 4 mm or more and 8 mm or less in the vertical and horizontal directions, and in the portion corresponding to the non-punching region, there are no convex portions in a belt-shaped region having a width of 3 mm or more. 【Brief Description of the Drawings】 【0019】 [Figure 1] Side view of the original laminated sheet used for manufacturing the perforated laminated sheet according to the embodiment of the present invention. [Figure 2] Overall configuration diagram of the manufacturing apparatus for a perforated laminated sheet according to the first embodiment of the present invention. [Figure 3] Plan view showing the arrangement of the molds used in the manufacturing apparatus for a perforated laminated sheet according to the first embodiment of the present invention. [Figure 4] Perspective view of an example of the mold used in the manufacturing apparatus for a perforated laminated sheet according to the first embodiment of the present invention. [Figure 5] Perspective view of an example of the convex portion in the mold used in the manufacturing apparatus for a perforated laminated sheet according to the first embodiment of the present invention. [Figure 5A] Front view and cross-sectional view of the convex portion in the mold shown in FIG. 5(b) used in the manufacturing apparatus for a perforated laminated sheet according to the first embodiment of the present invention. [Figure 6] Plan view of an example of the perforated laminated sheet according to the embodiment of the present invention. [Figure 7]A plan view of an example of a perforated laminated sheet according to an embodiment of the present invention. [Figure 8] Figure 7 shows a cross-sectional view of the perforated laminated sheet, line II. [Figure 9] A plan view showing an enlarged view of a key part of an example of a perforated laminated sheet according to an embodiment of the present invention. [Figure 10] Front view and cross-sectional view of a protrusion formed on a mold shown in Figure 5(a) used in a manufacturing apparatus for perforated laminated sheets according to the first embodiment of the present invention. [Figure 11] Front views of several examples of protrusions formed on a mold used in a manufacturing apparatus for perforated laminated sheets according to the first embodiment of the present invention. [Figure 12] A perspective view of an example of an ultrasonic horn in a mold used in a manufacturing apparatus for perforated laminated sheets according to the first embodiment of the invention. [Modes for carrying out the invention] 【0020】 The following describes embodiments of the perforated laminated sheet and the method for manufacturing the perforated laminated sheet according to the present invention with reference to the attached drawings. In each figure, the same components are denoted by the same reference numerals, and redundant explanations are omitted. It should be noted that the present invention is not intended to be limited to the configurations described below, and each configuration can be modified as appropriate without departing from the spirit of the invention. In addition, in each figure, the hole diameters of the ultrasonic punching holes in the perforated laminated sheet do not strictly reproduce the size relationships in an actual perforated laminated sheet, but are exaggerated as appropriate for the sake of clarity in the explanation. Figure 1 shows the original laminated sheet 100 before the production of the perforated laminated sheet according to the embodiment of the present invention. 【0021】 The original laminated sheet 100 is composed of a first surface fabric, the outer fabric 101, a second backing fabric, the lining 102, and a resin sheet 103 sandwiched between the outer fabric 101 and the lining 102. The resin sheet 103 is at least one layer (one sheet). Therefore, there may be two or more layers (two or more sheets) of resin sheet 103. The outer fabric 101, the lining 102, and the resin sheet 103 are bonded together by heat bonding, adhesive, or the like to form a single integrated unit. 【0022】 The first fabric, the outer fabric 101, can be made of any of the following materials: woven fabric, knitted fabric, nonwoven fabric, synthetic leather, or genuine leather. Synthetic leather may include polyurethane synthetic leather and PVC leather, and genuine leather may include split leather. The outer fabric 101 may be colored with dyes or pigments. The type of dye and pigment is not limited. 【0023】 The fibrous material constituting the outer fabric 101 is not particularly limited, but from the viewpoint of durability, thermoplastic fibers are preferred. Examples of thermoplastic fibers include synthetic fibers such as polyester, polypropylene, and nylon, and semi-synthetic fibers such as acetate and triacetate. These can be used individually or in combination of two or more. Among these, synthetic fibers are more preferred, and polyester is even more preferred, due to their superior physical properties, particularly strength, abrasion resistance, and heat resistance. While the fibrous material is preferably composed mainly of thermoplastic fibers, it may also be a combination of fibers other than thermoplastic fibers, such as natural fibers and regenerated fibers, by methods such as blending, filament blending, twisting, weaving, or knitting, as long as it does not affect its physical properties. 【0024】 Furthermore, the second fabric, the lining 102, is not particularly limited, but can be either woven or knitted. The fibrous material constituting the lining 102 is not particularly limited, but synthetic fibers are preferred, and nylon or polyester is more preferred. 【0025】 The resin sheet 103 is not particularly limited, but a urethane foam sheet (flexible polyurethane foam) can be used. The thickness of the resin sheet 103 can be 3 mm or more. 【0026】 Figure 2 shows an overall configuration diagram of a manufacturing apparatus for perforated laminated sheets according to the first embodiment. In this first embodiment, a mold 11 with a length shorter than the width of the raw laminated sheet 100 is used. The length of the mold 11 is, for example, 20 cm, and the width of the raw laminated sheet 100 is, for example, 150 cm. These lengths are merely examples, and other lengths may be used, of course. 【0027】 The manufacturing apparatus for perforated laminated sheets includes a punching section 10 that performs punching by passing the original laminated sheet 100 and a recovery resin sheet 22 between a mold 11 and an ultrasonic horn 12. The ultrasonic horn 12 is connected to a transducer 13 that vibrates the ultrasonic horn 12 to generate ultrasonic vibrations. The transducer 13 is connected to an ultrasonic oscillator 14 that sends high-frequency power of a predetermined frequency to the transducer 13. The resin of the recovery resin sheet 22, as will be described later, is a resin sheet that adheres to and recovers the pieces that are removed from the original laminated sheet 100 when the perforated areas are melted by ultrasonic vibration, and can be an OPP film (polypropylene film) or the like. 【0028】 As shown in Figure 3, the molds 11 described above are arranged in multiples in the horizontal direction. They are also arranged in multiple rows in the vertical direction. When arranged in multiple rows, the molds 11 are arranged in a zigzag pattern. Here, the horizontal direction coincides with the width direction of the original laminated sheet 100. The vertical direction coincides with the transport direction of the original laminated sheet 100. The zigzag-arranged molds 11 slightly overlap at their ends, so that the hole pattern formed on the original laminated sheet 100 is continuous. A shaft 16 passes through each mold 11. A long drive shaft 17, positioned to sandwich each mold 11, is rotated by a motor (not shown). Gears are provided on the drive shaft 17 and the shafts 16, 16 at both ends of each mold 11, and they are driven by being connected by chains 18, 18. 19 indicates a bearing for the shaft 16, which is fixed to a main body (not shown), for example. 【0029】 Each of the above-mentioned molds 11 is provided with an ultrasonic horn 12 having approximately the same length as the mold 11 (for example, (length of mold 11) + 1 cm), which is attached to the bottom of the mold 11. Therefore, multiple sets of the mold 11 and ultrasonic horn 12 are arranged side by side in the width direction of the original laminated sheet 100. In addition, the sets of the mold 11 and ultrasonic horn 12 are arranged in a zigzag pattern in the direction in which the original laminated sheet 100 is transported. 【0030】 As shown in Figure 4, the mold 11 is cylindrical and is used in a horizontally elongated cylindrical state. A protrusion 15 corresponding to the hole to be made in the raw laminated sheet 100 is formed on the surface of the mold 11. In this embodiment, a drive source is provided that drives the ultrasonic horn 12 so as to melt and remove (cut) the portion of the raw laminated sheet 100 corresponding to the portion of the protrusion 15 of the mold 11 by ultrasonic vibration transmitted toward the surface of the mold 11 including the protrusion 15. This drive source is composed of the transducer 13 and ultrasonic oscillator 14 shown in Figure 2. 【0031】 The protrusion 15 is roughly rod-shaped with a thin tip, and as shown in Figure 5(a), it has a tip 15a formed in the shape of a frustocone or truncated pyramidal pyramid that tapers towards the tip, on a disc-shaped base 15b that protrudes from the base surface 11a of the mold 11. Alternatively, as shown in Figure 5(b), the protrusion 15 may have a shape in which multiple prism (or cylindrical) tip 15a of different diameters and thicknesses are stacked on a somewhat thin rectangular base 15b that protrudes from the base surface 11a of the mold 11. The size of the head of the tip 15a is appropriately selected depending on the size of the ultrasonic punching hole PH, but in the mold 11 shown in Figure 4, the diameter is 1 mm. 【0032】 Furthermore, at the tip 15a of the protrusion 15 shown in Figure 5(b), a recess 15h is formed in the shape of a rectangular frame when the tip 15a is viewed from the front, as shown in Figure 5A(a), and the cross-sectional shape of this recess 15h may be rectangular, as shown in Figure 5A(b). 【0033】 The completed perforated laminated sheet 21A of this embodiment is as shown in Figure 6. That is, the sheet has a pattern in which perforated hole regions RA, which have ultrasonically punched holes (shown as black dots in Figure 6), are surrounded by non-punched regions RB, which do not have ultrasonically punched holes. In Figure 6, using the dashed lines that do not actually exist on the perforated laminated sheet 21A, the perforated hole region RA refers to the area inside the hexagon drawn by the dashed lines, and the non-punched region RB is the area outside the hexagon, which in Figure 6 refers to the band-shaped white area. Therefore, the completed perforated laminated sheet 21A of this embodiment has a pattern in which these multiple hexagons are repeated and scattered on a plane according to a certain rule. Note that the shape of the perforated region RA is not limited to a hexagon, but can be various patterns such as polygons, circles, stars, hearts, etc. 【0034】 Figure 7 is an enlarged view of a portion of the perforated laminated sheet 21A in Figure 6. Ultrasonic punching holes PH are provided in the punching hole region RA, but not in the non-punching region RB. As shown in Figure 8, a cross-sectional view along line II of Figure 7, in the portion with ultrasonic punching holes PH, the surface material 101, the resin sheet 103, and the backing material 102 are compressed and welded together in the thickness direction. Therefore, the punching hole region RA has the thickness of the surface material 101, the thickness of the backing material 102, and only the slight thickness of the compressed resin sheet 103. On the other hand, since there are no ultrasonic punching holes PH in the non-punching region RB, the resin sheet 103 is not compressed, and its original thickness remains. Consequently, the perforated laminated sheet 21A has a pattern formed by the thinness of the thickness of the laminated sheet on at least one of the surface and back surfaces of the laminated sheet due to the distribution density of the multiple ultrasonic punching holes PH. In other words, the perforated laminated sheet 21A has different heights or thicknesses between the perforated area RA, which has ultrasonically punched holes PH, and the non-perforated area RB, which does not have ultrasonically punched holes PH. This configuration gives the perforated laminated sheet 21A of this embodiment a three-dimensional and textured appearance, making it possible to obtain a sheet with superior design. 【0035】 The distribution density of multiple ultrasonic punching holes PH in the perforated laminated sheet 21A will be described. Figure 9 shows a plan view of the main part of the perforated laminated sheet 21A. In this embodiment, the mold 11 shown in Figure 4 is used, and the head size of the tip portion 15a of the mold 11 has a diameter of 1 mm, and the diameter of the ultrasonic punching holes is approximately 1 mm. In this embodiment, the distance (lateral distance) between ultrasonic punching holes PH1 and ultrasonic punching holes PH2 formed in the same punching hole region RA is 4 mm, and the distance between ultrasonic punching holes PH1 (or PH2) and ultrasonic punching holes PH3 is 4 mm. Here, the distance between holes PH1 and PH2 is the distance from the center of hole PH1 to the center of hole PH2. An equilateral triangle is formed by line segments connecting the centers of ultrasonic punching holes PH1, PH2, and PH3. In this embodiment, the vertical spacing of the ultrasonic punching holes refers to the distance from, for example, ultrasonic punching hole PH3 to the line segment connecting ultrasonic punching holes PH1 and PH2. In other words, the vertical spacing is the length of the perpendicular line drawn from the vertex PH3 of the equilateral triangle to the base PH1-PH2 of the equilateral triangle (the height of the equilateral triangle), and the horizontal spacing is the length of the base of the equilateral triangle. In this embodiment, the vertical spacing is approximately 4 mm (2 × √3 mm). Regarding ultrasonic punching holes in the punching hole region RA of the perforated laminated sheet, the vertical and horizontal spacing of the ultrasonic punching holes is not particularly limited, but it is preferable that the ultrasonic punching holes be provided with a distribution density of 4 mm to 8 mm in both the vertical and horizontal directions, and more preferably set to 4 mm to 5 mm. The vertical (dimensions) and horizontal (dimensions) of the ultrasonic punching holes described above are merely examples, and other values ​​can be adopted, and they can be set appropriately considering the hole diameter and design of the ultrasonic punching holes. Also, the dimension of "approximately 1 mm" for the hole diameter of the ultrasonic punching holes is merely an example. 【0036】 In this embodiment, the non-punching region RB employs a configuration in which there are no ultrasonic punching holes PH in a strip-shaped region (non-punching region RB) with a width of 7 mm or more. That is, in the example shown in Figure 9, the width w of the non-punching region RB is approximately 7 mm, and the distance between the ends of the two ultrasonic punching holes (e.g., PH3) and the end of the ultrasonic punching hole (e.g., PH4) that straddle this width w is set to be slightly longer than 7 mm. In the non-punched area of ​​the perforated laminated sheet, the width of the strip-shaped area is not particularly limited, but it is preferably set to 3 mm or more, and more preferably to 7 mm or more. Other values ​​can be used for the width of the non-punched area, and it is possible to set it appropriately considering the hole diameter of the ultrasonic punching holes and the design. 【0037】 As shown in Figure 4, the mold 11 for manufacturing the perforated laminated sheet 21A described above has protrusions 15 formed in the perforated laminated sheet 21A corresponding to the ultrasonic punching holes PH in the punching hole region RA which has ultrasonic punching holes PH. Furthermore, in this mold 11, no protrusions 15 are formed in the non-protrusion area NT which corresponds to the non-punching region RB where there are no ultrasonic punching holes PH. 【0038】 In this embodiment, the mold 11 is provided with protrusions 15 at approximately 4 mm intervals in the vertical and horizontal directions, corresponding to the ultrasonic punching holes PH in the punching hole region RA (the distance from the center of the tip 15a of one protrusion 15 to the center of the tip 15a of an adjacent protrusion 15 in the vertical or horizontal direction), and there are no protrusions 15 in the 7 mm wide band-shaped region (non-protrusion area NT) corresponding to the non-punching region RB. The "vertical" in the vertical and horizontal directions refers to the rotation direction of the mold 11 (the transport direction of the original laminated sheet 100), and the "horizontal" in the vertical and horizontal directions refers to the length direction of the mold 11 (the width direction of the original laminated sheet 100). As described above, in the perforated laminated sheet of this embodiment, ultrasonic punching holes are provided at a distribution density of 4 mm to 8 mm intervals in the vertical and horizontal directions, and in the non-punched areas, there are no ultrasonic punching holes in a strip-shaped area with a width of 3 mm or more. Accordingly, in the mold of this embodiment, the protrusions 15 are provided at a distribution density of 4 mm to 8 mm intervals in the vertical and horizontal directions corresponding to the punching hole areas, and in the parts corresponding to the non-punched areas, no protrusions are formed in a strip-shaped area with a width of 3 mm or more. That is, the position of the protrusions of the mold is set in accordance with the vertical and horizontal spacing of the ultrasonic punching holes and the dimensions of the strip-shaped area in the non-punched areas where there are no ultrasonic punching holes in the perforated laminated sheet. The width direction of the perforated laminated sheet 21A coincides with the length direction of the mold 11. The length direction (conveying direction) of the perforated laminated sheet 21A follows the rotation of the mold 11. The direction of the lateral spacing of the ultrasonically punched holes coincides with the width direction of the perforated laminated sheet 21A. The direction of the vertical spacing of the ultrasonically punched holes coincides with the length direction (conveying direction) of the perforated laminated sheet 21A. 【0039】 Furthermore, at the tip 15a of the convex portion 15 shown in Figure 5(a), when the tip 15a is viewed from the front, there is no recess and it is formed as a flat surface as shown in Figure 10(a), and the cross-sectional shape of this convex portion 15 can be configured similarly to the cross-sectional view of a frustocone as shown in Figure 10(b). Also, at the tip 15a of the convex portion 15 shown in Figure 5(a), when the tip 15a is viewed from the front, a ring-shaped recess 15h is formed as shown in Figure 10(c), and the cross-sectional shape of this recess 15h may be an inverted cone as shown in Figure 10(d). 【0040】 Furthermore, the shape of the tip portion 15a can be any desired shape, such as a circle, square, triangle, rectangle, or rhombus, as shown in Figures 11(a) to (e) when the tip portion 15a is viewed from the front. Of course, it can also be a shape with an outline composed of curves, such as a heart shape or a four-leaf clover shape. The hole pattern can be formed by arranging holes of the above shapes on the original laminated sheet 100 at a constant pitch or at appropriately different pitches in the top, bottom, left, and right directions, or by arranging them at predetermined intervals in several straight lines extending diagonally with a desired inclination. Of course, there are no limitations on the pattern. 【0041】 Furthermore, the depth of the hole in the center of the recess 15h and the length (height) of the tip are selected appropriately based on the thickness of the original laminated sheet 100 forming the hole pattern and the size of the ultrasonic punching hole PH. It is desirable that the size (diameter, etc.) of a single hole be approximately 0.8 mm or larger. Also, the distance between two protrusions 15, corresponding to the vertical and horizontal spacing of adjacent ultrasonic punching holes PH, is 4 mm to 8 mm, preferably 4 mm to 5 mm. 【0042】 As shown in Figure 12, the ultrasonic horn 12 comprises a rectangular parallelepiped base portion 31 and a rectangular parallelepiped tip portion 32 formed continuously above it. A slit 33 is formed extending from the base portion 31 toward the tip portion 32, penetrating from the front surface to the back surface, inducing the generation of longitudinal vibrations by ultrasound. 【0043】 With the above configuration, the holes in the perforated pattern are melted and punched out by ultrasonic vibration, ensuring that each hole in the perforated pattern is formed neatly and reliably, and that punching is performed reliably. In this case, the circumferential surface of the opened holes is melted and fixed by ultrasonic vibration, making it possible to obtain a processed sheet with a precisely formed perforated pattern. 【0044】 As shown in Figure 2, a raw material roller 35 is provided on one side of the mold 11 and ultrasonic horn 12, with the raw laminated sheet 100 before ultrasonic punching wound around it. Below the raw material roller 35 and closer to the ultrasonic horn 12, a resin sheet roller 42 is provided, with a recovery resin sheet 22 wound around it for collecting and retrieving the punched-out pieces of the raw laminated sheet 100. 【0045】 The recovery resin sheet 22 is placed beneath the original laminated sheet 100 at the position where the transport roller 48 is located in the transport path leading from the mold 11 to the ultrasonic horn 12, and is then sent between the mold 11 and the ultrasonic horn 12. The original laminated sheet 100 is ultrasonically punched between the mold 11 and the ultrasonic horn 12 and then sent out. When it is sent out after ultrasonic punching, the original laminated sheet 100 becomes a perforated laminated sheet 21A. This perforated laminated sheet 21A and the recovery resin sheet 22 are further transported forward, sandwiched between the press rollers 43 and 44. 【0046】 Separation rollers 45U and 45D are provided in front of the pressing rollers 43 and 44 in the direction of transport. The recovery resin sheet 22 and the perforated laminated sheet 21A, which are transported by the pressing rollers 43 and 44, are separated by the separation rollers 45U and 45D. That is, the perforated laminated sheet 21A and the recovery resin sheet 22 are separated into two sheets before reaching the separation rollers 45U and 45D, and the perforated laminated sheet 21A, which is stacked on top, is sent forward so as to come into contact with the separation roller 45U and reaches the product winding roller 46. The recovery resin sheet 22, which is stacked on bottom, is wound up by the recovery sheet roller 47 via rollers 52 and 53, so as to circle a part of the separation roller 45D. Above rollers 52 and 53, scaffolding boards 51, which are used for inspections and the like, are provided in a manner that does not obstruct the rotation of rollers 52 and 53. In the above, the components provided on the forward side in the conveying direction of the press rollers 43 and 44 constitute the piece recovery and conveying mechanism 40 that separates the recovery resin sheet 22 and the perforated laminated sheet 21A. 【0047】 Furthermore, the transport path from the raw material roller 35 and the resin sheet roller 42 to the mold 11 and the ultrasonic horn 12, the mold 11, the ultrasonic horn 12, the transducer 13, and the ultrasonic oscillator 14 function as a punching section 10 that passes the raw laminated sheet 100 and the recovered resin sheet 22 between the mold 11 and the ultrasonic horn 12 and performs punching by ultrasonic irradiation. 【0048】 In the perforated laminated sheet manufacturing apparatus configured as described above, the raw laminated sheet 100 on the raw material roller 35 and the recovered resin sheet 22 wound around the resin sheet roller 42 are guided through the transport path to the space between the mold 11 and the ultrasonic horn 12, and ultrasonic punching is performed by transmitting ultrasonic vibrations as they pass through this space. In other words, the method for manufacturing a perforated laminated sheet according to this embodiment is a method for manufacturing a perforated laminated sheet by processing the raw laminated sheet 100, which has the first fabric on the surface and the second fabric on the back side bonded together, with at least one layer of resin sheet interposed between them. 【0049】 In the method for manufacturing a perforated laminated sheet according to this embodiment, a mold 11 having a plurality of protrusions 15 corresponding to a plurality of ultrasonic punching holes formed in a perforated laminated sheet is brought into contact with the surface or back surface of the original laminated sheet 100, an ultrasonic horn 12 for transmitting ultrasonic vibrations is provided at a position facing the surface of the mold 11, the original laminated sheet 100 is movably sandwiched between the mold 11 and the ultrasonic horn 12, ultrasonic vibrations are transmitted from the ultrasonic horn 12 toward the protrusions of the mold 11, and the original laminated sheet 100 is moved between the mold 11 and the ultrasonic horn 12 to manufacture a perforated laminated sheet 21A. 【0050】 With the above configuration, during the ultrasonic punching process, the original laminated sheet 100 and the recovery resin sheet 22 are melted and punched out by frictional heat from ultrasonic vibrations at the points in the perforation pattern of the original laminated sheet 100 that correspond to the protrusions 15 of the mold 11, and the points in the recovery resin sheet 22 that correspond to the holes in the perforation pattern of the original laminated sheet 100 are also melted by frictional heat from ultrasonic vibrations. At this time, the pieces punched out from the holes in the perforated laminated sheet 21A, which is the sheet that the original laminated sheet 100 has processed, fuse to the recovery resin sheet 22 immediately after it has melted due to frictional heat from ultrasonic vibrations, and solidify. In this state, the recovery resin sheet 22 and the perforated laminated sheet 21A are transported by the press rollers 43 and 44 in the direction of the product winding roller 46 and the recovery sheet roller 47, and are separated in the process of being guided to the separation rollers 45U and 45D. 【0051】 After separation by the separation rollers 45U and 45D, the fragments removed from the holes in the perforated laminated sheet 21A are attached to or integrated with the melted and solidified recovery resin sheet 22 and transported together with the recovery resin sheet 22. Meanwhile, the perforated laminated sheet 21A, from which the fragments removed from the holes have been taken away by the recovery resin sheet 22, is wound up by the product winding roller 46, and the recovery resin sheet 22 to which the fragments are attached is wound up by the recovery sheet roller 47. 【0052】 Therefore, the perforated laminated sheet 21A can be obtained with a precisely formed perforated pattern without any fragments remaining in the holes of the perforated pattern of the perforated laminated sheet 21A or becoming debris adhering to other parts of the perforated laminated sheet 21A. Since the perforated laminated sheet 21A is made by processing a laminated sheet composed of a surface material, urethane foam, and backing material using the above manufacturing method, it can be used as a surface material for automobile seats to improve breathability, reduce energy consumption for heating and cooling, and aim to improve the fuel efficiency of automobiles. Furthermore, the perforated laminated sheet 21A is extremely effective for applications where a material with a highly decorative pattern (design) with a textured feel is applied to the seats of transport vehicles (automobiles, buses, aircraft, trains, etc.) to improve breathability. [Explanation of symbols] 【0053】 10 Punching section 11 Mold 11a Base surface 12 Ultrasonic horn 13. Transducer 14. Ultrasonic oscillator 15 Convex part 16 Axis 17 Drive shaft 18 Chain 21A Perforated laminated sheet 22 Restoration resin sheet 31 Base section 32 Tip section 33 Slit 35 Roller 40 Piece collection and transport mechanism 42 Resin sheet roller 43, 44 Pressing rollers; 45D, 45U Separating rollers 46 Product winding roller 47 Recovery sheet roller 48 Conveyor rollers 52, 53 Rollers 100 Original laminated sheet 101 Surface material 102 Lining 103 Resin sheet RA: Punched area RB: Non-punched area PH Ultrasonic Punching Hole NT Smooth Area

Claims

[Claim 1] In a perforated laminated sheet using a base laminated sheet in which the first fabric on the surface and the second fabric on the back surface are bonded together, with at least one layer of resin sheet interposed between them, The original laminated sheet has a plurality of punched hole regions in at least one planar region of the front and back surfaces, in which a plurality of ultrasonic punching holes penetrating from the first cloth to the second cloth are formed at predetermined intervals in the vertical and horizontal directions and exist at a predetermined distribution density. A region of the planar area of ​​the original laminated sheet having the plurality of punching hole regions, excluding the plurality of punching hole regions, which has a non-punching region where the ultrasonic punching holes are absent. A perforated laminated sheet characterized in that the ultrasonic punching hole region is repeated in a certain order in the planar region, thereby forming a pattern in which the ultrasonic punching hole region is surrounded by the non-punching region, and the pattern is created because the thickness of the ultrasonic punching hole region is thinner than the thickness of the non-punching region. [Claim 2] The perforated laminated sheet according to claim 1, characterized in that the resin sheet is a urethane foam sheet. [Claim 3] The perforated laminated sheet according to claim 1 or 2, characterized in that the first fabric is any of woven fabric, knitted fabric, nonwoven fabric, synthetic leather, or natural leather, and the second fabric is any of nonwoven fabric, woven fabric, or knitted fabric. [Claim 4] The perforated laminated sheet according to any one of claims 1 to 3, characterized in that the thickness of the resin sheet is 3 mm or more. [Claim 5] A method for manufacturing a perforated laminated sheet, comprising: interposing at least one resin sheet between a first surface fabric and a second back surface fabric, and processing a raw laminated sheet in which the first fabric, the second fabric, and the resin sheet are bonded together, wherein a mold is brought into contact with the surface or back surface of the raw laminated sheet, and an ultrasonic horn that transmits ultrasonic vibrations is brought into contact with the surface or back surface of the raw laminated sheet, wherein a mold is formed in the perforated laminated sheet in a perforated area having a plurality of ultrasonic punching holes, with a plurality of protrusions corresponding to the plurality of ultrasonic punching holes in the punching area, and the protrusions are not formed in the non-protrusion area corresponding to the non-punching area where there are no ultrasonic punching holes, and an ultrasonic horn that transmits ultrasonic vibrations is brought into contact with the surface or back surface of the raw laminated sheet, A method for manufacturing a perforated laminated sheet, characterized by providing the ultrasonic horn at a position facing the surface of the mold, with the raw laminated sheet movably sandwiched between the mold and the ultrasonic horn, transmitting ultrasonic vibrations from the ultrasonic horn toward the plurality of protrusions of the mold, and moving the raw laminated sheet between the mold and the ultrasonic horn while melting the raw laminated sheet with frictional heat generated at the interface between the ultrasonic horn and the mold, thereby manufacturing a perforated laminated sheet having a punched-hole region having a plurality of ultrasonic punching holes penetrating from the first cloth to the second cloth, and a non-punched region without ultrasonic punching holes. [Claim 6] The method for manufacturing a perforated laminated sheet according to claim 5, characterized in that a plurality of protrusions are formed corresponding to the plurality of ultrasonic punching holes, and the distribution density of the plurality of ultrasonic punching holes is changed by changing the distribution density of the protrusions, thereby providing a pattern formed by varying thickness on at least one of the front and back surfaces of the original laminated sheet. [Claim 7] The method for manufacturing a perforated laminated sheet according to claim 6, characterized in that the mold has protrusions provided at a distribution density of 4 mm to 8 mm intervals in the vertical and horizontal directions in the area corresponding to the punching hole area, and no protrusions are formed in a strip-shaped area with a width of 3 mm or more in the area corresponding to the non-punching area.

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