Skin foam-in-place foamed article and production method thereof
AssigneeInoac Corporation
InventorTakayuki Yokota
Life of this patent
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Abstract
There is provided a skin foam-in-place foamed article comprising a pad (15) and a bag-like outer material (20) covering the pad (15). The outer material (20) has a top layer (21) and a liner layer (22) made of a foamed resin. The liner layer (22) has a closed cell structure. A pad-side skin layer (27a) having a density higher than that of a bulk layer (26) is provided on the liner layer (22), on a side of the pad (15). A corona treatment is applied to the pad-side skin layer (27a).
Claims21
A skin foam-in-place foamed article comprising:
- a pad made of a foamed resin;
- a bag-like outer material that is integrated with and covering the pad,
- wherein the bag-like outer material comprises a top layer and a sheet-like liner layer integrated with the top layer and formed into a bag shape such that the liner layer is on an inside;
- the liner layer comprises a bulk layer, a top-side skin layer on a front surface of the bulk layer, and a pad-side skin layer on a rear surface of the bulk layer, wherein the bulk layer and the top-side and pad-side skin layers are provided integrally in a foamed resin having a closed cell structure, the top-side and pad-side skin layers each having a density higher than that of the bulk layer are formed during foam molding of the liner layer such that closed cells of each the top-side and pad-side skin layers are smaller than closed cells formed in the bulk layer,
- wherein the liner layer has a thickness of 1.5 to 3 mm and the top-side and pad-side skin layers each has a thickness of 50 μm to 500 μm;
- and
- a corona treatment applied to enhance a wettability of an outermost surface of the pad-side skin layer in contact with the pad.
A method of producing a skin foam-in-place foamed article comprising a pad made of a foamed resin, and a bag-like outer material integrated with and covering the pad, the method comprising, in this order:
- forming a sheet-like liner layer that comprises a bulk layer and a top-side skin layer formed on a front surface of the bulk layer and a pad-side skin layer formed on a rear surface of the bulk layer, the bulk layer and the top-side and pad-side skin layers are provided integrally in a foamed resin having a closed cell structure, the top-side and pad-side skin layers each having a density higher than that of the bulk layer are formed during foam molding of the liner layer such that closed cells of each the top-side and pad-side skin layers are smaller than closed cells formed in the bulk layer, wherein the foam molding comprises foaming and curing a resin raw material while the front and rear surfaces are contacted,
- wherein the liner layer has a thickness of 1.5 to 3 mm and the top-side and pad-side skin layers each has a thickness of 50 μm to 500 μm;
- subjecting an outermost surface of the pad-side skin layer to a corona treatment to enhance a wettability thereof;
- integrating a top layer and the liner layer to obtain an outer material;
- forming the outer material into a bag shape such that the liner layer is on an inside to obtain the bag-like outer material;
- injecting a liquid foamed resin into the inside of the bag-like outer material and foaming and curing to obtain the pad made of the foamed resin.
Dependencies are inferred from the claim text.