JP2007276285A - Skin material for seat of vehicle having uneven pattern and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a skin material for a seat of a vehicle which can form a deep and clear concave-convex pattern on a laminated sheet hardly emboss-processible to form deep a concavity and convexity such as a low thermal conductivity laminated sheet having an air layer or one obtained by stacking synthetic leathers, and provide a method for manufacturing the same at a high productivity. <P>SOLUTION: A laminated sheet having an air layer, obtained by stacking and integrating at least one kind of outer material selected from woven fabrics and knitted fabrics, and at least one kind of base material to be a cushion layer selected from a flexible polyurethane foam material, woven fabrics and knitted fabrics, or a laminated sheet obtained by integrating an outer material composed of a synthetic leather and a fibrous base material is passed through a pair of embossing roller set at 100-250°C temperature and disposed with a predetermined spacing and a heating roller in a pressed state at the processing speed of 0.3-10 m/min, so that a concave-convex pattern is deeply and clearly formed thereon. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a seat material for a vehicle seat having a concavo-convex pattern that is suitably used as a seat material for a vehicle such as an automobile or a railway vehicle, and a method for manufacturing the same.

In recent years, as a skin material for a seat sheet of an automobile, a material having a concavo-convex pattern on the surface has been demanded in order to enhance design properties. Conventionally, a skin material having such a concavo-convex pattern is manufactured by heating a surface layer and a flexible polyurethane foam material laminated and integrated as a laminated sheet, and forming a concavo-convex pattern on the surface by flat embossing. It was.

However, flat embossing has a problem of low yield and poor production efficiency because of batch processing. Furthermore, in recent years, as a countermeasure, as proposed in Patent Document 1, it is manufactured by forming an uneven pattern by rotary embossing with high production efficiency.

However, in the above-mentioned rotary embossing, the laminated sheet having an air layer has low thermal conductivity, so that the uneven pattern is not deep and clear, and the vehicle has a pattern-like gloss rather than the uneven pattern. Only the skin material for seats could be manufactured, and the design could not be improved sufficiently.

As a means for obtaining synthetic leather, a one-component polyurethane is coagulated to form a microporous layer, and a surface finishing layer made of polyurethane is formed on the surface, a so-called wet method, a two-layer polyurethane skin layer. A so-called dry method of laminating on a fibrous base material via a type polyurethane adhesive is known.

The synthetic leather obtained by the above wet method has a thermoplastic microporous layer obtained by wet coagulation of a one-pack type polyurethane solution, so that it is possible to form irregularities in shape by embossing, but wear resistance And unevenness satisfying various physical properties such as interlaminar fracture strength could not be formed, and it was unsuitable as a skin material for seat sheets of automobiles.

On the other hand, synthetic leather by the dry method is used as a skin material for seats of automobiles, but when forming an uneven pattern on the surface, use a thing with unevenness such as a squeezed pattern as a release paper, A method of transferring the unevenness formed on the release paper to the surface of the fibrous base material has been adopted. That is, in the synthetic leather obtained by the dry method in which the two-component polyurethane adhesive has already been cured, the uneven pattern of the synthetic leather obtained by the dry method is obtained by transferring the unevenness such as the drawing pattern of the release paper. However, deep irregularities could not be formed, and so-called fullness was poor. Therefore, Patent Document 2 proposes a method of embossing while the fluidity before the two-component polyurethane adhesive is solidified, but it is not possible to form sufficiently deep irregularities stably. It was a thing.
JP 11-268120 A Japanese Patent Laid-Open No. 9-158056

The present invention has been made in view of such a technical background, and has been considered to be difficult to form a concavo-convex pattern, a laminated sheet having an air layer with low thermal conductivity, and embossing to form deep concavo-convex A method of manufacturing a vehicle skin material having a concavo-convex pattern with high production efficiency, and a skin material for a vehicle seat having such a concavo-convex pattern, capable of forming a concavo-convex pattern deeply and clearly in a synthetic leather that is difficult to process. The purpose is to provide.

In order to achieve the above object, the present invention provides the following means.

[1] In a rotary embossing processing apparatus comprising an embossing roll and a heat roll, the embossing roll and the heat roll are heated and pressed by passing between the two rolls, thereby applying a concave and convex pattern to the laminated sheet. A method for manufacturing a skin material.

[2] The laminated sheet is obtained by laminating and integrating a base material that becomes at least one cushion layer selected from a flexible polyurethane foam material, a woven fabric, a knitted fabric, and a nonwoven fabric on at least one surface selected from a woven fabric, a knitted fabric, and a nonwoven fabric. The manufacturing method of the skin material for seats of the vehicle as described in the preceding clause [1] which is a laminated sheet.

[3] The vehicle according to [1], wherein the laminated sheet is a laminated sheet obtained by laminating and integrating at least one fibrous base material selected from a woven fabric, a knitted fabric, and a nonwoven fabric on a surface made of synthetic leather. A method of manufacturing a skin material for a seat.

[4] In the rotary embossing apparatus, the heating temperature of the pair of embossing rolls and the heat roll for imparting a concavo-convex pattern to the laminated sheet is set to 100 ° C. to 250 ° C. Of manufacturing a skin material for seats of Japanese vehicles.

[5] The vehicle seat skin described in [1] to [4] above, wherein in the rotary embossing apparatus, a processing speed for imparting a concavo-convex pattern to the laminated sheet is 0.3 m / min to 10 m / min. A method of manufacturing the material

[6] A skin material for a seat of a vehicle having a concavo-convex pattern manufactured by the manufacturing method according to items 1 to 5 above.

According to the invention of [1], since the laminated sheet passes between the heated embossing roll and the heat roll in a pressed state, the concavo-convex pattern is deeply and clearly formed on the laminated sheet, and the design is excellent. It can be set as the manufacturing method of the skin material for seats of the vehicle which has an uneven | corrugated pattern. In addition, the obtained vehicle seat covering material having a concavo-convex pattern does not collapse or deform into a concavo-convex shape even when used for a long period of time, and is excellent in durability. Furthermore, by using an embossing roll, continuous processing is possible, and a processing method with higher production efficiency than flat embossing is achieved.

According to the invention of [2], since the base material to be the cushion layer is laminated and integrated, the laminated sheet having an air layer and having low thermal conductivity is pressed between the heated embossing roll and the heat roll. Since the sheet is allowed to pass through in a state where it is formed, a method for producing a skin material for a vehicle seat having a concavo-convex pattern that is deeply and clearly formed on the laminated sheet and has an excellent aesthetic design can be obtained.

According to the invention of [3], since the synthetic leather is laminated and the laminated sheet that is difficult to be embossed to form deep irregularities is passed between the heated embossing roll and the heat roll in a pressed state, An uneven pattern is deeply and clearly formed on the laminated sheet, and it can be a method for manufacturing a skin material for a vehicle seat having an uneven pattern excellent in design.

According to the invention of [4], since both the pair of embossing rolls and heat rolls are heated to 100 ° C. to 250 ° C., the unevenness pattern is deeply and clearly formed on the laminated sheet, and the unevenness excellent in design. It can be set as the manufacturing method of the skin material for seats of the vehicle which has a pattern.

According to the invention of [5], since the processing speed for imparting a concavo-convex pattern to the laminated sheet is 0.3 m / min to 10 m / min, the concavo-convex shape does not collapse or deform even when used for a long time. In addition, a method for manufacturing a skin material for a seat of a vehicle having a concavo-convex pattern having excellent durability can be provided.

According to the invention of [6], the skin material produced by the method of the invention of [1] to [5] has a deep and uneven pattern, and there is no wrinkle or looseness on the outer surface, and appearance appearance Furthermore, even if it is used for a long period of time, it can be used as a vehicle seat covering material having a concave and convex pattern that is not deformed or deformed on the surface and has an excellent concave and convex pattern.

The present invention is a laminated sheet obtained by laminating and integrating at least one surface selected from woven fabrics, knitted fabrics and nonwoven fabrics, and a base material which becomes at least one cushion layer selected from flexible polyurethane foam materials, woven fabrics, knitted fabrics and nonwoven fabrics Or a laminated sheet obtained by laminating and integrating at least one kind of fibrous base material selected from synthetic leather and woven fabrics, knitted fabrics and nonwoven fabrics, with a stamping portion protruding from 100 ° C. to 250 ° C. By passing between a pair of embossing rolls and heat rolls set at a predetermined temperature at a predetermined interval while being pressed at a processing speed of 0.3 m / min to 10 m / min, an air layer is provided, Even in laminated sheets with low thermal conductivity, or laminated sheets with synthetic leather that is difficult to form deep irregularities, the surface of the vehicle seat material Found that uneven pattern is deeply clearly formed, there is provided a present invention.

As a surface of the laminated sheet in the method of the present invention, a woven fabric, a knitted fabric, a nonwoven fabric, a composite material thereof, or the like can be used. Moreover, the surface material which provided various characteristics, such as a flame retardance, according to a use may be sufficient.

As a base material that has an air layer in the method of the present invention and serves as a cushion layer of a laminated sheet having a low thermal conductivity, a flexible polyurethane foam material, a woven fabric, a knitted fabric, a nonwoven fabric, a composite material thereof, or the like can be used, and the type is particularly It is not limited.

In order to obtain a cushioning property suitable as a vehicle skin material, the base material for the cushion layer is preferably a soft polyurethane foam material, and the soft polyurethane foam material used may have defects such as wrinkles. The density, hardness, and thickness can be selected within a range where the cushioning property is good. Preferably, the density is 0.015 to 0.045 g / cm ³ , the hardness is 60 to 180 N, and the thickness is 1 to 10 mm.

The woven fabric, knitted fabric, and nonwoven fabric that can be used can be selected in density, hardness, and thickness within a range of elongation that does not cause defective portions such as wrinkles.

The method of laminating and integrating the outer material and the base material to be the cushion layer can be performed by a frame laminating method, an adhesive laminating method, a coating method or the like depending on the selected outer material and the base material. Of these, the frame laminating method is preferable from the viewpoint of adhesive strength, and the strength of integration of the base material to be the outer material and the cushion layer in a state where the uneven pattern is shaped can be further improved.

On the other hand, according to the manufacturing method of the present invention, synthetic leather by a dry method, which has been considered unsuitable for embossing for the purpose of forming deep irregularities, can be used as the outer surface of the laminated sheet.

Any polyurethane can be used as long as it is conventionally used for synthetic leather to form the skin layer of synthetic leather. Specific examples include polyester polyurethane, polyether polyurethane, polycaprolactone polyurethane, polyester / polyether copolymer polyurethane, polyamino acid / polyurethane copolymer resin, or a mixture thereof. In addition, polyvinyl chloride, synthetic rubber, or the like may be mixed with the polyurethane as long as various physical properties as synthetic leather are not impaired.

As the fiber base material of synthetic leather used in the present invention, synthetic fibers such as polyester, polyamide and polyacrylonitrile, natural fibers such as cotton and hemp, recycled fibers such as rayon, suf and acetate, or a blend of these alone Any material may be used as long as it is conventionally used as a fibrous base material for synthetic leather, such as knitted fabric, woven fabric, and non-woven fabric. Further, the fibrous base material may be raised or not raised.

The synthetic leather used in the present invention is obtained by applying a one-component polyurethane solution having bubbles on a releasable carrier and drying to form a foamed polyurethane skin layer, and the two-component polyurethane on the foamed polyurethane skin layer After applying a system adhesive, it is manufactured by laminating a fibrous base material.

The embossing roll and the heat roll suitable for the present invention are made of metal whose surface is plated and heated from the inside of the roll. The diameter is preferably 150 mm to 600 mm.

Although the surface temperature of the heat roll in normal embossing is 80 to 200 ° C., the surface temperature of the heat roll in the present invention takes into account the temperature drop of the laminated sheet until it reaches the cooling device in the subsequent process. 100 ° C. to 250 ° C. is preferable, the surface is heated with the heat roll, and is heated and pressurized with the emboss roll while maintaining the state, so that the pattern is easily fixed and a sharp embossed pattern Can be granted. Therefore, even in a sheet having an air layer, which has been impossible until now, a skin material having a three-dimensional uneven pattern on the surface can be produced. If it is less than 100 degreeC, a three-dimensional uneven | corrugated pattern cannot be formed, and when it exceeds 250 degreeC, a fracture | rupture will arise in a lamination sheet.

Further, the laminated sheet is sufficiently heated by passing the laminated sheet while being pressed at a processing speed of 0.3 m / min to 10 m / min between the embossing roll and the heat roll arranged at appropriate intervals. It is possible to provide a skin material with further excellent durability. If the processing speed is less than 0.3 m / min, the laminated sheet breaks or the laminated sheet becomes hard and the elongation physical properties deteriorate. If it exceeds 10 m / min, a three-dimensional uneven pattern cannot be formed.

The embossing portions on the surface of the embossing roll in the present invention are arranged in a dispersed state, the height of the embossing portions is preferably 3.0 mm to 6.0 mm, and the total area of the embossing surfaces of these embossing portions is the embossing roll It is preferable to set to 1 to 60% with respect to the area of the pressing surface. Since a large number of embossed portions are arranged in a dispersed state, the concave and convex portions of the resulting skin material are formed in a dispersed state on the surface, and the design of the skin material is significantly improved, The texture of the skin material is further improved and the cushioning property is also improved.

Hereinafter, an embodiment of a skin material for a seat of a vehicle having an uneven pattern according to the present invention will be described with reference to the drawings. FIG. 1 is a schematic manufacturing process diagram of a skin material having a concavo-convex pattern with a height difference according to one embodiment of the present invention, and FIG. 2 is a diagram of a vehicle having a concavo-convex pattern according to another embodiment of the present invention. It is a schematic manufacturing-process figure of the skin material for seats. (1) Heat roll, (2) Emboss roll, (3) Laminated sheet, (4) Calendar roll.

According to the method for manufacturing a skin material for a seat of a vehicle having a concavo-convex pattern according to the present invention, a laminated sheet (3) obtained by laminating and integrating a surface material and a flexible polyurethane foam material is used for the emboss roll (2) and the heat roll (1). In the meantime, as shown in FIG. 1, the embossing roll (2) and the laminated sheet (3) are arranged so that the outer surfaces of the embossing roll (2) face each other, embossing is performed, and the embossing roll is set at a temperature of 100 ° C. to 250 ° C. The heat roll is set to a temperature of 100 ° C. to 250 ° C., and the processing speed is 0.3 m / min to 10 m / min.

According to this manufacturing method, not only one of the conventional rolls is heated, but both the heat roll and the embossing roll are set at a temperature of 100 ° C. to 250 ° C. For laminated seats with a low air layer and synthetic leather that is difficult to emboss to form deep irregularities, the laminated sheet is deeply and clearly formed, and for vehicle seats with irregularities with excellent design. It can be set as the manufacturing method of a skin material. In addition, since the processing speed for imparting a concavo-convex pattern to the laminated sheet is 0.3 m / min to 10 m / min, the concavo-convex shape does not collapse or deform even when used for a long period of time, and it has excellent durability. It can be set as the manufacturing method of the skin material for seats of the vehicle which has the uneven | corrugated pattern.

Furthermore, in the case of a sheet having an extremely low thermal conductivity such that the thickness of the laminated sheet (3) is 1.3 mm or more, the case where the surface of the laminated sheet is extremely hard, and further if the height difference of the emboss is to be increased. As shown in FIG. 2, the calender roll (4) as a pressing roll is placed on the side opposite to the heat roll (1) so that the laminated sheet (3) is in contact with the emboss roll (2) for a long time. ) And a method of embossing so that the laminated sheet (3) is in half contact with the embossing roll (2). By this construction method, the uneven pattern can be formed deeply and clearly, and the durability effect can be improved.

Examples of the present invention will be described below, but the present invention is not limited to the following examples.

<Example 1> A double jersey (surface) made of polyester yarn and having a thickness of 5 mm, a density of 0.018 g / cm <3>, and a hardness of 110 N, a flexible polyurethane foam material (base material to be a cushion layer), Were laminated and integrated by a frame laminating method to obtain a laminated sheet.

Furthermore, while the interval between the embossing roll and the heat roll is set to 0.15 mm, the embossing roll with a 5 mm-high embossed portion protruding from the embossing roll and the outer surface of the laminating sheet face each other. Then, the temperature is set to 200 ° C. for the embossing roll and 200 ° C. for the heat roll, the embossing is performed under the processing speed of 3 m / min, and the surface of the vehicle has an uneven pattern as shown in FIG. A skin material was obtained. In the obtained vehicle skin material, the thickness of the outer material was 1.2 mm, and the thickness of the flexible polyurethane foam material was 4 mm. Further, the height difference between the convex and concave portions of the concave and convex pattern of the vehicle seat skin material was 3.0 mm.

In addition, the total area of the embossing roll stamping part was 25% with respect to the area of the embossing roll surface.

<Example 2> A vehicle skin material having a concavo-convex pattern was obtained in exactly the same manner as in Example 1 except that the embossing roll was set to 120 ° C and the heat roll was set to 120 ° C.

<Example 3> A skin material for a vehicle seat having a concavo-convex pattern was obtained in exactly the same manner as in Example 1 except that the embossing roll was set to 230 ° C and the heat roll was set to 230 ° C.

<Example 4> A seat material for a vehicle seat having a concavo-convex pattern was obtained in exactly the same manner as in Example 1 except that the processing speed was 1.0 m / min.

<Example 5> A skin material for a vehicle seat having a concavo-convex pattern was obtained in exactly the same manner as in Example 1 except that the processing speed was 8 m / min.

<Example 6> A synthetic leather (density 0.018 g / cm 3, hardness 150 N) coated with urethane having a thickness of 1 mm was used for a tricot (base material) made of polyester yarn and having a thickness of 1.2 mm. Except for this, a vehicle skin material having a concavo-convex pattern was obtained in exactly the same manner as in Example 1.

<Comparative Example 1> A seat material for a vehicle seat having a concavo-convex pattern was obtained in exactly the same manner as in Example 1 except that the temperature of the heat roll was set to room temperature. (Conventional rotary embossing)

<Comparative Example 2> A vehicle skin material having an uneven pattern was obtained in exactly the same manner as in Example 1 except that the embossing roll was set to 80 ° C and the heat roll was set to 80 ° C.

<Comparative Example 3> A vehicle skin material having a concavo-convex pattern was obtained in the same manner as in Example 1 except that the embossing roll was set to 300 ° C and the heat roll was set to 300 ° C.

<Comparative Example 4> A vehicle skin material having a concavo-convex pattern was obtained in exactly the same manner as in Example 1 except that the processing speed was 0.1 m / min.

<Comparative Example 5> A vehicle skin material having a concavo-convex pattern was obtained in exactly the same manner as in Example 1 except that the processing speed was 15 m / min.

The skin material for vehicle seats having the concavo-convex pattern of Examples 1 to 6 obtained as described above has an excellent appearance appearance without wrinkles and slackness on the outer surface, has good cushioning properties, and has a concavo-convex pattern. The design was deep and clear, and the design was unprecedented and the texture was unique and good (comfortable).

In addition, on the seat structure of the vehicle seat seat (seat pad made of polyurethane foam having a thickness of 200 mm), the vehicle seat skin material having the uneven patterns of Examples 1 to 6 is covered. When I actually put it on and sat down, I got a good seating feeling with good cushioning and no sense of incongruity.

In addition, for the vehicle seat skin material having each uneven pattern obtained as described above, the wear test and the height difference between the convex and concave portions of the uneven pattern are measured by the following wear test method. The disappearance and reduction of the pattern and the degree of sharpness of the uneven pattern were examined. The results are shown in Tables 1 and 2.

<Abrasion Test Method> Test pieces each having a width of 100 mm and a length of 300 mm are prepared one by one from the vertical direction and the horizontal direction. A slab urethane foam having the same size as that of the test piece is attached to the back surface of the test piece. In this manner, the test piece is fixed on a flat table so as not to loosen. Next, a friction piece having a surface covered with cotton cloth is brought into contact with the test piece, and is reciprocated 10,000 times at a speed of 60 times / minute between two points 160 mm apart on the test piece. At this time, the load applied to the friction element is set to 9.8 ± 0.098N.

After observing the surface of the car seat material having the uneven pattern after the above-mentioned wear test, if the uneven pattern is still deep and clear (no change before and after the wear test), “○” indicates that the pattern has a slightly reduced sharpness but maintains a deep concavo-convex pattern, “△” indicates that the depth of the concavo-convex pattern has been reduced but the concavo-convex pattern itself remains, The case where the concavo-convex pattern almost disappeared was designated as “x”.

As can be seen from Table 1, the vehicle seat skin materials of Examples 1 to 6 were all excellent in wear resistance and obtained vehicle seat skin materials having a sufficiently uneven pattern.

On the other hand, as is clear from Table 2, the vehicle seat skin material of Comparative Examples 1, 2, and 5 is inferior in wear resistance and has a concavo-convex pattern with no height difference. It became. In Comparative Examples 3 and 4, sheet breakage occurred, making it impossible to produce a product.

It is a schematic process drawing of the skin material for the seat of the vehicle which has an uneven pattern concerning one embodiment of the present invention. It is a schematic process drawing of the skin material for seats of a vehicle having an uneven pattern according to another embodiment of the present invention. It is a schematic perspective view of the embossing part of the surface of the embossing roll concerning embodiment of this invention. It is a schematic perspective view which shows the skin material for seats of the vehicle which has the uneven | corrugated pattern by which the rotary embossing process of this invention was carried out.

Explanation of symbols

1 ... Heat roll 2 ... Emboss roll 3 ... Laminated sheet 4 ... Calender roll 5 ... Embossed part

Claims (6)

In a rotary embossing apparatus comprising an embossing roll and a heat roll, the embossing roll and the heat roll are heated and pressed by passing between the two rolls to apply pressure, thereby providing an uneven pattern on the laminated sheet. Manufacturing method. A laminated sheet obtained by laminating and integrating a base material that becomes at least one cushion layer selected from a flexible polyurethane foam material, a woven fabric, a knitted fabric, and a nonwoven fabric on at least one surface material selected from a woven fabric, a knitted fabric, and a nonwoven fabric. The method for manufacturing a skin material for a vehicle seat according to claim 1. The skin material for a vehicle seat according to claim 1, wherein the laminated sheet is a laminated sheet obtained by laminating and integrating at least one fibrous base material selected from a woven fabric, a knitted fabric, and a nonwoven fabric on a surface material made of synthetic leather. Manufacturing method. 4. The skin material for a vehicle seat according to claim 1, wherein in the rotary embossing apparatus, the heating temperature of the pair of embossing rolls and heat rolls for imparting an uneven pattern to the laminated sheet is set to 100 ° C. to 250 ° C. 5. Manufacturing method. 5. The method for manufacturing a skin material for a vehicle seat according to claim 1, wherein in the rotary embossing apparatus, a processing speed for imparting an uneven pattern to the laminated sheet is 0.3 m / min to 10 m / min. A skin material for a vehicle seat having a concavo-convex pattern manufactured by the manufacturing method according to claim 1.

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