Method for producing laminate
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Solution Overview
Problem
Existing methods for preventing polyurethane foam leakage from sewed portions in automotive instrument panels require complex and costly processes, particularly when using thermoplastic resin materials, which involve heating and special apparatuses.
Innovation Solution
A method involving sewing a sheet using threads that are impregnated with a liquid before, during, or after sewing, and then laminating a polyurethane foam layer onto the sheet-type molded body, with the impregnation focusing on the areas where the threads penetrate, to effectively seal the seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tape for sealing or crosslinking curing treatment is used to seal sewed portions, then polyurethane leakage is prevented, but the process becomes complex and costly
Solution Approach 1:
The thread is impregnated with liquid resin before sewing, so that the sealing action is performed in advance during the sewing process itself, rather than requiring a separate sealing step after sewing is completed
Solution Approach 2:
The thread serves dual functions: both stitching the skin and sealing the sewed portions. The liquid resin on the thread self-seals the holes during the sewing operation, eliminating the need for separate sealing apparatus or processes
2Reliability
If heating apparatus and special processing are used to melt and seal thermoplastic resin stitches, then polyurethane leakage is prevented, but the cost increases
Solution Approach 1:
The invention uses a simple liquid resin impregnation method that can be applied during standard sewing operations, replacing expensive heating apparatus and special processing equipment with a cost-effective liquid resin application process
Solution Approach 2:
The invention changes the state of the thread from dry to liquid-impregnated, allowing the thread to seal holes through the liquid resin filling mechanism rather than requiring thermal melting, thus avoiding the need for heating apparatus
3Reliability
If multiple sealing steps are added to prevent polyurethane leakage, then sealing reliability improves, but production time increases
Solution Approach 1:
The sewing operation and sealing function are merged into a single process step. The thread impregnated with liquid resin performs both stitching and sealing simultaneously, eliminating the need for separate sealing steps and maintaining high production efficiency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for easy prevention of polyurethane foam leakage from sewed portions at a lower cost, maintaining the design quality and commercial value of the automotive instrument panels.
Implementation Method 1
impregnating at least part of the thread with liquid before, after, or during said sewing
Data Source
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AI summary
Provided is a method for producing a laminate, the method comprising: sewing a sheet using thread; impregnating at least part of the thread with liquid before, after, or during said sewing; and laminating a polyurethane foam layer to at least one surface of a sheet-type molded body that is obtained by said sewing and said impregnating, the method for producing a laminate being able to easily prevent leakage of polyurethane from sewed portions at low cost, in the step of laminating the sewed sheet-type molded body and the polyurethane foam layer.