JP4286059B2 - Laminated body and method for producing the same - Google Patents

Description

【００４１】
上記表１の結果より、基体１の補修箇所に接着剤を付着させた実施例１〜１０の部材においては、接着剤を用いない従来例２の部材に比して接着シート４の接着状態を良好に向上することができることが確かめられた。
【００４２】
【発明の効果】
以上説明してきたように、本発明によれば、特に、補修箇所を有する被接合面に対して接着シートを適用する場合であっても、被接合面上への接着シートの融着と、それを介した被接着体の接合とを良好に行うことができ、これにより、得られる積層体において優れた接着性を実現することができる積層体およびその製造方法を実現することが可能となる。
【図面の簡単な説明】
【図１】本発明の積層体を示す概略図である。
【図２】（イ）〜（ニ）は、本発明の積層体の製造方法の概要を示す工程図である。
【図３】接着剤の付着状態の一例を示す概略図である。
【図４】ラミネート用熱プレス機を示す概略図である。
【図５】（イ）は、補修箇所を有しない成形ポリウレタンフォームパッドの表面近傍を示す断面写真図であり、（ロ）は、その表面上に接着シートを融着した状態を示す断面写真図である。
【図６】（イ）は、成形ポリウレタンフォームパッドの補修箇所の表面近傍を示す断面写真図であり、（ロ）は、その表面上に接着シートを融着した状態を示す断面写真図である。
【図７】（イ）〜（ヘ）は実施例１〜１０の部材の製造方法を示す説明図である。
【図８】実施例における剥離試験の概要を示す第一の説明図である。
【図９】実施例における剥離試験の概要を示す第二の説明図である。
【符号の説明】
１ 基体
２ 被接着体
３ 接着剤
４ 接着シート
５ 粗面部
１０ 積層体
１１ ウレタンフォーム用接着剤
１２ ムース状ホットメルト剤
１３ 固形ホットメルト剤
１４ クリーム状ホットメルト剤
１５ 離型シート
１６、２０ 熱プレス機
１７ シート状ホットメルト剤
３０ 部材
３１ ポリウレタンフォーム
３２ ホットメルトシート
１００ 積層体形成用基礎部材
２００ 積層体形成用部材[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a laminated body and a method for manufacturing the same, and more specifically, even when a repaired portion is present on a surface to be bonded of a base body, the bonded body can be satisfactorily bonded, thereby manufacturing a strong laminated body. It is related with the laminated body which can be manufactured, and its manufacturing method.
[0002]
[Prior art]
Various techniques relating to adhesion between various molded bodies have been studied conventionally. For example, there is a method of using an adhesive as a general adhesive means, and various adhesives such as a rubber adhesive, a urethane adhesive, and a hot melt adhesive are used depending on the material of the molded object to be bonded. in use.
[0003]
However, depending on the surface properties and materials of the joined surfaces of the molded body, for example, when bonding between thermoplastic resins with low adhesiveness, it is possible to ensure sufficient adhesion by simply using an adhesive. You may not be able to. On the other hand, for example, when using a rubber-based adhesive, the adhesiveness is improved by performing a pretreatment such as pre-corona discharge treatment on the surface or baking with a flame such as a burner to roughen the surface. In addition, in the moisture curable adhesive, a technique is known such as stabilization of adhesive strength by controlling moisture in the air (for example, described in Patent Document 1).
[0004]
In addition, for example, in Patent Document 2, as a technique related to adhesion between a thermoplastic urethane resin film and a nonwoven fabric made of polyolefin-based fibers, the adhesive surface of the nonwoven fabric with a thermoplastic film is subjected to a corona discharge treatment in advance. A technique for obtaining a laminated sheet excellent in adhesiveness, stretchability, etc. by laminating and pressing is described.
[0005]
Further, there is also known a technique for bonding by using a heat-fusing adhesive sheet formed in a web shape (hereinafter also simply referred to as “adhesive sheet”), which is interposed between the molded bodies and melted by heating. ing. Furthermore, the present inventors also proposed a technique relating to a sheet-like foaming adhesive that adheres to an adherend while foaming by heating and a technique relating to a foamable laminate material using the same as a technique relating to adhesion of the foam material. (See Patent Document 3). According to these adhesive sheets, it is possible to realize adhesion to the adherend only by heat treatment. Therefore, in the case of using a general fluid adhesive, there are many related to the selection, application, curing, etc. of the adhesive. Time and effort can be saved, and the bonding operation can be facilitated and improved in efficiency.
[0006]
[Patent Document 1]
JP-A-10-305514 ([0004] etc.)
[Patent Document 2]
JP-A-8-108289 (Claims etc.)
[Patent Document 3]
JP 2002-30262 A (Claims etc.)
[0007]
[Problems to be solved by the invention]
By the way, in the adhesion between the molded bodies using the heat-sealing type adhesive sheet, usually, the molded body and the adhesive sheet are laminated, heated, and the contact surface is integrated to realize the adhesion. At this time, if there is a repaired portion on the surface to be joined of the molded body, there is a problem that the portion cannot be sufficiently integrated with the adhesive sheet. In other words, when bonding an adherend using an adhesive sheet on a molded body having a repair location, simply laminating and heating the adhesive sheet results in insufficient bonding of the adherend at the repair location. There was a problem that the adhesiveness was lowered in the laminate.
[0008]
Therefore, even if the object of the present invention is to apply an adhesive sheet to a surface to be bonded having a repaired part, the adhesion of the adhesive sheet onto the surface to be bonded and the object to be bonded via the adhesive sheet It is an object of the present invention to provide a laminate and a method for manufacturing the laminate that can achieve excellent adhesion in the resulting laminate.
[0009]
[Means for Solving the Problems]
As a result of intensive studies to elucidate the cause of adhesion failure of the adhesive sheet at the repaired portion of the bonded surface, the present inventor has found that the surface of the repaired portion is rougher than the non-repaired portion. In addition, by additionally improving the adhesiveness of the rough surface at such a repair location, the adhesiveness of the entire surface to be bonded can be appropriately secured, and the object to be bonded can be satisfactorily bonded onto the surface to be bonded. The present invention was completed by finding out what can be done.
[0012]
The laminate-forming member of the present invention is characterized in that a heat-fusing adhesive sheet is fused on the surface to be joined of the laminate-forming base member.
[0013]
In particular, the laminate-forming member of the present invention can be suitably used as a vehicle seat pad.
[0014]
Furthermore, the laminate of the present invention is characterized in that an adherend is bonded onto the heat-fusing adhesive sheet of the laminate-forming member.
[0015]
The method for producing a laminate-forming member of the present invention is a method for producing a laminate-forming member mainly comprising a substrate made of polyurethane foam and a heat-fusion-type adhesive sheet, wherein the surface to be joined of the substrate On the manufacturing method of the member for forming a laminate including a fusing step of fusing the heat-fusing adhesive sheet by heating,
As the substrate, the surface to be bonded includes a rough surface portion that is a repaired portion of the substrate,
Prior to the fusing step, an adhesive is attached to the repair site, and at that time, the adhesive is mixed with a repair material and attached to the repair site.
[0016]
The method for producing a laminate of the present invention is mainly a method for producing a laminate comprising a substrate made of polyurethane foam, a heat-fusion-type adhesive sheet, and an adherend, and the bonded surface of the substrate On top of that, a fusion step of fusing the heat-fusing adhesive sheet by heating, and fusing the fused heat-fusing adhesive sheet by heating, and through the melted heat-fusing adhesive sheet In the method for manufacturing a laminate including a bonding step of bonding the adherend to the bonded surface,
As the substrate, the surface to be bonded includes a rough surface portion that is a repaired portion of the substrate,
Prior to the fusing step, an adhesive is attached to the repair site, and at that time, the adhesive is mixed with a repair material and attached to the repair site.
[0017]
In the manufacturing method of the present invention, in the case where a substrate including a rough surface portion is used as the base, the adhesive is attached to at least a part of the rough surface portion. Moreover, when the said rough surface part is a repair location of the said base | substrate, it is preferable to mix the said adhesive agent with the material for repair, and to make it adhere to this repair location.
[0018]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail.
In FIG. 1, the schematic sectional drawing of the laminated body of this invention is shown. As shown in the figure, the laminate 10 of the present invention is mainly composed of a substrate 1, a heat-sealing adhesive sheet 4, and an adherend 2. The illustrated laminate 10 is manufactured through the laminate-forming base member and laminate-forming member of the present invention (hereinafter also referred to as “foundation member” and “forming member”, respectively).
[0019]
In FIG. 2, the process drawing which concerns on the manufacturing method of the laminated body of this invention is shown. FIG. 2 (a) is a schematic cross-sectional view of the laminate-forming base member 100 of the present invention. As shown in the drawing, the base member 100 includes a base body 1 having a bonded surface A including a rough surface portion 5 and an adhesive 3 that adheres to at least a part of the rough surface portion 5. In the method for producing a laminate of the present invention, first, as shown in FIG. 2 (b), a heat-fusing adhesive sheet 4 is fused on the surface to be joined A of the base member 100 by heating (melting). Attachment step), a laminate-forming member 200 shown in FIG.
[0020]
Here, as described above, the heat-sealable adhesive sheet can be fused on the surface to be bonded of the substrate 1 by being melted by heating, and in particular, on the surface to be bonded A of the substrate 1. In the case where the rough surface portion 5 as shown in FIG. 1 exists, the formation of the adherend may be insufficient in the rough surface portion 5. In the present invention, by adhering the adhesive 3 in advance to such a site that is incompatible with the adhesive sheet on the bonded surface A of the substrate 1, the adhesiveness of this site can be improved satisfactorily. In this way, it is possible to obtain the forming member 200 in which the adhesive sheet 4 is well fused, and thus the laminate 10.
[0021]
Next, the adhesive sheet 4 of the forming member 200 shown in FIG. 2C is melted by heating, and the adherend 2 is joined onto the joined surface A via the melted adhesive sheet 4 (joining step). The laminated body 10 shown in FIG. 2 (d) can be obtained. In the laminated body 10 obtained in this way, a good adhesion state is realized for both the base 1 and the adhesive sheet 4 and between the adhesive sheet 4 and the adherend 2. It is possible to obtain a strong laminate 10 that is unlikely to peel off.
[0022]
The base member 100, the forming member 200, and the laminate 10 of the present invention are used as intermediate products for forming a new member or a final product as a final product by appropriately selecting the materials of the base 1 and the adherend 2. Can be used. For example, the laminated body 10 can be suitably used as a vehicle seat by applying a seat cover as the adherend 2 to the base body 1 having a cushioning property. In this case, the base member 100 and the forming member 200 can be used as a vehicle seat pad of the intermediate product. Specifically, by applying the present invention to a vehicle seat pad having a specification in which a seat cover is directly bonded to the surface, even if there is a repair location on the base body 1, the adhesive strength is maintained, It is possible to reduce and improve the yield. In particular, the vehicle seat pad as the forming member 200 of the present invention adheres the sheet cover onto the substrate 1 by pressing the sheet cover as the adherend 2 onto the adhesive sheet 4 previously melted by heating. It is suitably used in a method for obtaining a vehicle seat as the laminate 10.
[0023]
In the method for manufacturing a laminate and the method for manufacturing a forming member according to the present invention, the bonding surface A is adhered to at least a part of the bonding surface A of the substrate 1 prior to the fusing step. It is important only to improve the adhesiveness in the case, and the specific conditions such as the material of the substrate 1, the adherend 2 and the adhesive sheet 4, the kind of the adhesive 3, the fusion and joining technique in the manufacturing process, It is not restricted and can be appropriately selected according to a conventional method. For example, although it depends on the material of the adhesive sheet 4 as a condition of the fusion process, for example, a sufficient adhesion state is ensured by setting the temperature to about 100 to 190 ° C. for about 30 seconds to 2 minutes. be able to.
[0024]
The substrate 1 to which the present invention can be applied is not particularly limited as long as it is made of a material that can be bonded by the adhesive sheet 4 such as various plastics. However, the laminated body having cushioning properties such as the vehicle seat described above. In the case of 10, it is possible to list plastic foam, especially soft / hard polyurethane foam, palm lock (palm fiber), curl lock (cushion material formed by intertwining polyester fibers), fabric foam, etc. For this, a flexible polyurethane foam is used.
[0025]
As the adhesive 3, various adhesives that are usually used can be appropriately selected and used depending on the material of the base 1, and is not particularly limited. For example, the base 1 is made of polyurethane foam. In the case of using one, a high-viscosity adhesive such as a synthetic rubber adhesive, for example, trade name G762 (toluene) manufactured by Konishi Bond Co., Ltd., in consideration of the permeability of the adhesive 3 into the open cell skeleton. 40 to 50%) or the like is preferably used. By using a high-viscosity adhesive, the surface irregularities formed by the open cells can be filled appropriately. Various hot melt adhesives such as a heat-fusing adhesive sheet can also be suitably used, and two or more of various adhesives can be used in combination as desired.
[0026]
As long as the adhesive 3 can adequately ensure the adhesiveness of the adhesive sheet 4 over the entire bonded surface A of the substrate 1 in the subsequent fusion process (see FIG. 2B), If at least a part of the surface A to be bonded, particularly the surface A to be bonded includes the rough surface part 5, it may be attached to at least a part of the rough surface part 5 as shown. Moreover, as shown in FIG. 3, it can also be made to adhere over the whole rough surface part 5 among the to-be-joined surfaces A. FIG. Specifically, the rough surface portion 5 includes, for example, a portion in which a molding defect generated in the molding process of the substrate 1 or a damage generated during the handling thereof is repaired. In addition to the rough surface portion 5, for example, if there is a portion on the surface of the substrate 1 where a solvent having poor compatibility with the adhesive sheet 4 is attached, the effect of the present invention can be obtained by attaching the adhesive 3 to the portion. Can do.
[0027]
Here, in the case of the substrate 1 made of polyurethane foam, since the skin surface is formed on the molding surface, it is considered that the molding surface is very smooth and excellent in compatibility with the adhesive sheet 4. On the other hand, the repaired parts are formed by embedding polyurethane foam as a repair material and then cutting (buffing) according to the surface shape of the surrounding area, so the cell structure with the foam structure destroyed pops out randomly. It is considered that the surface state is very rough as compared with the non-repaired portion and has a fuzzy surface state that is not suitable for adhesion. Accordingly, by attaching the adhesive 3 to the repaired portion, the rough surface structure of the repaired portion is leveled with the adhesive 3, and the synergistic effect of the adhesive of the adhesive 3 and the adhesive of the adhesive sheet 4 is achieved. Can be obtained, and the adhesive strength of the repaired portion can be improved to be equal to or higher than that of the normal surface.
[0028]
A technique for attaching the adhesive 3 to the surface of the substrate 1 is not particularly limited, but usually a technique in which the adhesive 3 is directly applied to the surface of the substrate 1 as shown in FIG. Can be used. In particular, when the adhesive 3 is attached to the repair location, a method is used in which the adhesive 3 is mixed in advance with a repair material used for repair, and the repair work and the adhesive 3 are simultaneously applied. You can also. For example, in the case of the base body 1 made of the above-mentioned polyurethane foam, when the repair material such as the foam material is again packed in the uneven portion or the hole portion caused by the molding failure or the like, the adhesive material according to the present invention is repaired. The repair material may be fixed using
[0029]
As the heat-sealable adhesive sheet 4, a commercially available one can be appropriately selected and used according to the material of the substrate 1, and is not particularly limited. Specifically, for example, a sheet-like hot melt agent, a net-like hot melt agent, a film-like hot melt agent, a powder-like hot melt agent, and the like can be given, and a sheet-like hot melt agent is particularly preferable. Specifically, hot melt adhesives manufactured by Nitto Boseki Co., Ltd., trade name span fab series (materials: polyamide, polyester, polyolefin, polyurethane, etc.) can be suitably used.
[0030]
In addition, the adherend 2 can be appropriately selected according to its use, such as the vehicle seat cover described above, and is not particularly limited. For example, flexible polyurethane foam, fabric foam, fabric, Examples include polypropylene (PP) fiber.
[0031]
【Example】
Hereinafter, the present invention will be described specifically by way of examples.
(Conventional example 1)
A molded polyurethane foam pad having a skin layer uniformly formed on the surface is used as the substrate 1, and an adhesive sheet 4 (sheet-like hot melt adhesive manufactured by Nitto Boseki Co., Ltd., trade name Spunfab PE2900) is laminated on the surface. And fused to form a member. For heating, a laminating hot press machine 20 as shown in FIG. 4 was used. The press plate temperature was about 170 ° C. (set temperature 220 ° C.), and the distance from the upper press plate to the surface of the adhesive sheet 4 laminated on the substrate 1 was about 3 to 5 mm. The heat irradiation time was 90 seconds.
[0032]
(Conventional example 2)
The same procedure as in Conventional Example 1 was performed except that a molded polyurethane foam pad having a repair location was used as the substrate 1.
[0033]
Cross-sectional photographic views of the vicinity of the surface of the substrate 1 in the above-described conventional example 1 and conventional example 2 are shown in FIGS. 5 and 6 before and after the adhesive sheet is fused. FIG. 6 is an enlarged view of only the vicinity of the repaired portion of the base 1.
[0034]
As shown in FIG. 5 (a), the mold skin surface of the substrate 1 having no repaired portion is smooth, and after fusion, the molten adhesive sheet 4 is firmly attached to the surface as shown in FIG. 5 (b). Are tied together. In the state shown in FIG. 5B, the adhesive sheet 4 was not removed at all even if it was peeled off with a fingertip, and was in an ideal adhesive state.
[0035]
On the other hand, as shown in FIG. 6 (a), the surface of the base body 1 having repaired portions is such that the broken cell skeleton protrudes outward and is rougher and fluffier than the non-repaired portions. Met. Therefore, after fusion, as shown in FIG. 6B, the cell skeleton from which the molten adhesive sheet 4 protrudes is agglomerated, and in particular, the dense portion of the adhesive sheet and the remarkable protruding portion of the cell skeleton. It was found that agglomeration is likely to occur at the place where the two overlap. The aggregated portions were scattered in the spots. Further, since the aggregated adherends are connected to only some of the cell skeletons at points, they easily fall off when traced with a fingertip.
[0036]
As a result of the above examination, the surface of the repaired part is rougher than the non-repaired part, and the compatibility between the surface of the repaired part and the adhesive sheet is deteriorated. It was confirmed that the material was not uniformly spread but agglomerated in the form of particles, and as a result, an insufficiently fused part of the adhesive sheet was generated, and the adhesion in the resulting member was impaired.
[0037]
(Examples 1 to 10)
As shown in FIGS. 7 (a) to 7 (f), various adhesives shown in Table 1 below were attached to the repaired portion of the base 1 using a molded polyurethane foam pad having a repaired portion as the base 1. After that, members of each example were manufactured in the same manner as in the conventional example 1 except that the adhesive sheet 4 was fused.
[0038]
As shown in the drawing, the various urethane foam adhesives 11 of Examples 1 to 5 were applied by brush ((A) in the figure), and the mousse hot melt agent 12 of Example 6 was applied by spraying ( The solid hot melt agent 13 of Example 7 is rubbed into the surface ((c) in the figure), and the creamy hot melt agent 14 of Example 8 is applied directly (((b) in the figure) ((in the figure)). D)), each was adhered to the repaired part and dried. In addition, for the sheet-like hot melt agent (heat-bonding adhesive sheet) 17 of Example 9, the hot press machine 16 and the sheet-like hot melt agent 17 are used so that the hot melt agent does not adhere to the hot press machine 16 during pressing. With the release sheet 15 sandwiched between them, it was attached by pressing at a surface temperature of 180 ° C. and a pressing time of 4 seconds of a hot press machine, and then cooled ((e) in the figure). Furthermore, for Example 10, the same urethane foam adhesive 11 as in Example 4 was applied by brush and dried, and then the same sheet-like hot melt agent (heat-bonding adhesive sheet) 17 as in Example 9 was used. Were attached by pressing at a surface temperature of 180 ° C. and a press time of 4 seconds of the hot press machine 16 with the release sheet 15 sandwiched therebetween, and then cooled ((f) in the figure) ).
[0039]
For each member obtained in Conventional Examples 1 and 2 and Examples 1 to 10, a peel test for confirming the adhesion state of the adhesive sheet 4 was performed as shown in FIGS. Specifically, first, as shown in FIG. 8, a hot melt sheet (web) 32 is placed on a polyurethane foam 31 having a smooth surface, and this is performed by heat irradiation so that the surface temperature becomes about 150 ° C. After melting ((A) in the figure), this and each member 30 were overlapped and pressed ((B) in the figure), and both were bonded ((C) in the figure). Next, a test piece (L: 100 mm × W: 20 mm × H: 30 (= 15 + 15) mm) as shown in FIG. 9 (a) was cut out, and one end of each test piece was peeled off from the adhesive surface A by several centimeters. A grip portion was provided, and the peel strength was measured at a tensile speed of 200 mm / min using a 180 ° tensile tester as shown in FIG. The maximum tensile load is taken as the peel strength, and measurement is performed on 5 test pieces for each example. The case where the adhesion state is very good and the peel strength is high is ◎, the case where the adhesion state is good is ○, and the case where the adhesion state is bad. A sample having a low peel strength was evaluated as x. The evaluation results are also shown in Table 1 below.
[0040]
[Table 1]

[0041]
From the results of Table 1 above, in the members of Examples 1 to 10 in which the adhesive was adhered to the repaired portion of the base 1, the adhesive state of the adhesive sheet 4 was compared to the member of Conventional Example 2 that did not use an adhesive. It was confirmed that it can be improved well.
[0042]
【The invention's effect】
As described above, according to the present invention, even when an adhesive sheet is applied to a surface to be joined having a repaired portion, the adhesion of the adhesive sheet on the surface to be joined, and Therefore, it is possible to realize a laminated body capable of realizing excellent adhesion in the obtained laminated body and a method for manufacturing the laminated body.
[Brief description of the drawings]
FIG. 1 is a schematic view showing a laminate of the present invention.
FIGS. 2A to 2D are process diagrams showing an outline of a method for producing a laminate according to the present invention.
FIG. 3 is a schematic view showing an example of an adhesive state.
FIG. 4 is a schematic view showing a laminating hot press machine.
5 (a) is a cross-sectional photographic view showing the vicinity of the surface of a molded polyurethane foam pad having no repair site, and (b) is a cross-sectional photographic view showing a state where an adhesive sheet is fused on the surface. It is.
6A is a cross-sectional photographic view showing the vicinity of the surface of a repaired portion of a molded polyurethane foam pad, and FIG. 6B is a cross-sectional photographic view showing a state where an adhesive sheet is fused on the surface. .
FIGS. 7A to 7F are explanatory views showing a method for manufacturing the members of Examples 1 to 10. FIGS.
FIG. 8 is a first explanatory diagram showing an outline of a peel test in Examples.
FIG. 9 is a second explanatory diagram showing an outline of a peel test in Examples.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Substrate 2 To-be-adhered body 3 Adhesive 4 Adhesive sheet 5 Rough surface part 10 Laminated body 11 Adhesive for urethane foam 12 Moose hot melt agent 13 Solid hot melt agent 14 Cream hot melt agent 15 Release sheet 16, 20 Hot press Machine 17 Sheet-like hot melt agent 30 Member 31 Polyurethane foam 32 Hot melt sheet 100 Laminate-forming base member 200 Laminate-forming member

Claims (2)

A method for producing a laminate-forming member mainly comprising a base made of polyurethane foam and a heat-sealable adhesive sheet, wherein the heat-sealable adhesive sheet is melted by heating on the surface to be joined of the base. In the manufacturing method of the member for forming a laminated body including the fusion process to be worn,
As the substrate, the surface to be bonded includes a rough surface portion that is a repaired portion of the substrate,
Prior to the fusing step, an adhesive is attached to the repair site, and at that time, the adhesive is mixed with a repair material and attached to the repair site . Production method. A method of manufacturing a laminate mainly comprising a base made of polyurethane foam, a heat-sealable adhesive sheet, and an adherend, wherein the heat-sealable adhesive sheet is heated on a surface to be joined of the base. A fusing step of fusing by the above-mentioned method, and fusing the fused heat-fusing adhesive sheet by heating, and joining the adherend onto the joined surface through the fused fusing adhesive sheet In the manufacturing method of a laminated body including the joining process to do,
As the substrate, the surface to be bonded includes a rough surface portion that is a repaired portion of the substrate,
Prior to the fusing step, an adhesive is attached to the repair site, and at that time, the adhesive is mixed with a repair material and attached to the repair site . Production method.

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