Laminating apparatus and method for manufacturing vehicle seat using eco-friendly water-based adhesive
11504957 · 2022-11-22
Assignee
Inventors
- Seong Jee Lee (Gyeongsangbuk-do, KR)
- Jae Keun Sung (Ulsan, KR)
- Jong Hee Park (Gyeongsangbuk-do, KR)
- Chong Mi Lee (Ulsan, KR)
- Jae Kwang Lee (Gyeonggi-do, KR)
- Seong Jun Park (Gyeonggi-do, KR)
Cpc classification
B32B37/0053
PERFORMING OPERATIONS; TRANSPORTING
B32B37/10
PERFORMING OPERATIONS; TRANSPORTING
B32B37/12
PERFORMING OPERATIONS; TRANSPORTING
International classification
B32B37/00
PERFORMING OPERATIONS; TRANSPORTING
B32B37/10
PERFORMING OPERATIONS; TRANSPORTING
B32B37/12
PERFORMING OPERATIONS; TRANSPORTING
Abstract
Proposed are a laminating apparatus and a method for manufacturing a vehicle seat. The laminating apparatus includes a first lamination part (100); a second lamination part (200); and a drying part (300), wherein the first lamination part (100) includes: a polyurethane foam feeding roll (110); a first bonding part (120); a fabric feeding roll (130) mounted on a side of the first lamination part (100); and a first pressing part (140), the second lamination part (200) includes: a second application part (210); a backing cloth feeding roll (220); and a second pressing part (230), and the drying part (300) includes: a feed part (310); and a chamber part (320).
Claims
1. A method of manufacturing a laminate vehicle seat, the method comprising: (S1) applying a first water-based adhesive to a first surface of a polyurethane foam fed from a polyurethane foam feeding roll (110); (S2) primarily pressing fabric fed from a fabric feeding roll (130) and the polyurethane foam applied with the first water-based adhesive to manufacture a pressed polyurethane foam; (S3) applying a second water-based adhesive to a second surface of the pressed polyurethane foam; (S4) secondarily pressing a backing cloth fed from a backing cloth feeding roll (220) and the pressed polyurethane foam applied with the second water-based adhesive to manufacture a pressed backing cloth; (S5) feeding the pressed backing cloth at a predetermined angle with respect to a moving direction; and (S6) drying the fed pressed backing cloth, wherein said method further comprises any one of the following conditions (A)-(D): (A) wherein in step (S1), the first water-based adhesive is applied to the first surface of the polyurethane foam fed from the polyurethane foam feeding roll (110) using a pair of application rolls (121), and a ratio of driving speed between the polyurethane foam feeding roll (110) and the pair of first application rolls (121) is 1:1 (B) wherein in step (S2), the fabric fed from the fabric feeding roll (130) and the polyurethane foam applied with the first water-based adhesive are primarily pressed using a pair of first pressing rolls (141), and a driving speed of the fabric feeding roll (130) is slower by 0.3 to 1.5 RPM than that of the pair of first pressing rolls (141); (C) wherein in step (S4), the backing cloth fed from the backing cloth feeding roll (220) and the pressed polyurethane foam applied with the second water-based adhesive are secondarily pressed using a pair of second pressing rolls (231), and a driving speed of the backing cloth feeding roll (220) is slower by 0.3 to 1.5 RPM than that of the pair of second pressing rolls (231); and (D) wherein in step (S6), in order to remove moisture from the first water-based adhesive and the second water-based adhesive and leave only solids, the pressed backing cloth is dried by means of hot air under conditions of an airflow velocity of 50 to 200 CMM (m.sup.3/min), an air pressure of 30 to 80 mmAQ, and a temperature of 90 to 180° C.
2. The method of claim 1, wherein in step (S1), the first water-based adhesive is applied to the first surface of the polyurethane foam fed from the polyurethane foam feeding roll (110) using a pair of application rolls (121), and a ratio of driving speed between the polyurethane foam feeding roll (110) and the pair of first application rolls (121) is 1:1.
3. The method of claim 1, wherein in step (S2), the fabric fed from the fabric feeding roll (130) and the polyurethane foam applied with the first water-based adhesive are primarily pressed using a pair of first pressing rolls (141), and a driving speed of the fabric feeding roll (130) is slower by 0.3 to 1.5 RPM than that of the pair of first pressing rolls (141).
4. The method of claim 1, wherein in step (S4), the backing cloth fed from the backing cloth feeding roll (220) and the pressed polyurethane foam applied with the second water-based adhesive are secondarily pressed using a pair of second pressing rolls (231), and a driving speed of the backing cloth feeding roll (220) is slower by 0.3 to 1.5 RPM than that of the pair of second pressing rolls (231).
5. The method of claim 1, wherein in step (S6), in order to remove moisture from the first water-based adhesive and the second water-based adhesive and leave only solids, the pressed backing cloth is dried by means of hot air under conditions of an airflow velocity of 50 to 200 CMM (m.sup.3/min), an air pressure of 30 to 80 mmAQ, and a temperature of 90 to 180° C.
6. The method of claim 1, wherein in step (S6), after the drying of the pressed backing cloth, final pressing is performed using a final pressing roll (330), and final pressing conditions are controlled so that peel strength is equal to or greater than 0.5 kgf on the basis of HKMC Spec. of the Hyundai-Kia Motor Company (HKMC) standards.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The above and other objectives, features, and other advantages of the present disclosure will be more clearly understood from the following detailed description when taken in conjunction with the accompanying drawings, in which:
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DETAILED DESCRIPTION OF THE INVENTION
(14) Hereinbelow, exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Throughout the drawings, the same reference numerals will refer to the same or like parts.
(15)
(16) Referring to
(17) In the present disclosure, through two lamination and drying processes using an eco-friendly water-based adhesive, it is possible to manufacture a laminate vehicle seat that has excellent probe tack properties, maintains soft properties even after curing thus causing no wrinkles, and is excellent in properties of cold resistance, heat shrinkage resistance, shear adhesion failure temperature, and durability.
(18) In this regard, a laminating apparatus according to the present disclosure is configured by sequentially connecting a first lamination part 100, a second lamination part 200, and a drying part 300.
(19)
(20) Referring to
(21) a polyurethane foam feeding roll 110 configured to feed the polyurethane foam;
(22) a first bonding part 120 configured to apply a first water-based adhesive to a first or first and second surfaces of the fed polyurethane foam;
(23) a fabric feeding roll 130 mounted on a side of the first lamination part 100 at a position spaced apart from the polyurethane foam feeding roll 110, and configured to feed fabric; and
(24) a first pressing part 140 configured to primarily press the fed fabric and the polyurethane foam applied with the first water-based adhesive to manufacture a pressed polyurethane foam.
(25) The first bonding part 120 may include:
(26) a pair of first application rolls 121 composed of a fixed roll 121a and a gap roll 121b that are configured to be equally controlled and are spaced apart from each other at a predetermined distance;
(27) a comma knife 122 configured to control the amount of application of the first water-based adhesive; and
(28) an application width automatic control guide 123 configured to control an application width of the first water-based adhesive.
(29) Specifically, in the first bonding part 120, the pair of first application rolls 121 is composed of the fixed roll 121a and the gap roll 121b. The comma knife 122 and a solvent tank 124 may be provided in the vicinity of the fixed roll 121a so that the adhesive may be applied to the first surface of the polyurethane foam, and a pressing process may be performed on the second surface of the polyurethane foam using the gap roll 121b.
(30) The pair of first application rolls 121 are required to be controlled in the gap therebetween according to the thickness of the polyurethane foam. Specifically, a distance d11 between the pair of first application rolls 121, i.e., between the fixed roll 121a and the gap roll 121b, may be 80 to 95% of the thickness of the polyurethane foam. The distance d11 between the fixed roll 121a and the gap roll 121b may be controlled by controlling the position of the gap roll 121b.
(31) When the distance d11 therebetween is smaller than the above range, there is a concern that the polyurethane foam may be damaged. On the other hand, when distance d11 therebetween is larger than the above range, as the amount of the adhesive penetrating into the polyurethane foam during the first pressing process increases, the thickness of the polyurethane foam may decrease after adhesion and curing, which is not desirable. Specifically, the distance d11 may be 85 to 95% of the thickness of the polyurethane foam.
(32) In the present disclosure, the comma knife 122 may be mounted on the fixed roll 121a at a distance dcl of 0.5 to 2 mm to control the amount of application of the first water-based adhesive. When the distance dcl of the comma knife 122 is too small beyond the above range, adhesion strength is weakened. On the other hand, when the distance dcl thereof is too large, the thickness of the polyurethane foam may decrease regardless of the distance between the pair of first application rolls 121. Specifically, the distance dc1 may be 1 to 1.5 mm.
(33) In the present disclosure, when an adhesive application width of the polyurethane foam is larger or smaller than a fabric width, the adhesive may stain the fabric and thus cause fabric contamination. Therefore, the application width of the first water-based adhesive may be controlled through the application width automatic control guide 123.
(34) Specifically, the application width automatic control guide 123 may be operated in conjunction with a fabric width detection sensor 150 so that the application width of the first water-based adhesive may become the same as the fabric width and the adhesive application width of the polyurethane foam.
(35) The first pressing part 140 includes a pair of first pressing rolls 141 configured to be equally controlled and spaced apart from each other at a predetermined distance. The pair of first pressing rolls 141 is composed of a gap roll 141a and a fixed roll 141b. A distance d12 between the pair of first pressing rolls 141, i.e., between the gap roll 141a and the fixed roll 141b, may be 1.5 to 5 mm regardless of the thicknesses of the fabric and the polyurethane foam. The distance d12 between the gap roll 141a and the fixed roll 141b may be controlled by controlling the position of the gap roll 141a.
(36) The degree of pressing is determined according to the distance d12, so that a difference may occur in peel strength. Therefore, when the distance d12 is smaller than the above range, there is a concern that the fabric and the polyurethane foam may be damaged. On the other hand, when the distance d12 is larger than the above range, pressing is not properly performed, which is not desirable. Specifically, the distance d12 may be 2 to 4 mm.
(37) As described above, the application width automatic control guide 123 may be operated in conjunction with a fabric width detection sensor 150 so that the application width of the first water-based adhesive may become the same as the fabric width and the adhesive application width of the polyurethane foam.
(38) When the fabric width and the adhesive application width of the polyurethane foam are the same, the first water-based adhesive does not stain the gap roll 141a during pressing by the fixed roll 141b. On the other hand, when the adhesive application width of the polyurethane foam is larger or smaller than the fabric width, the adhesive may stain the fabric and thus cause fabric contamination.
(39)
(40) Referring to
(41) a second application part 210 configured to apply a second water-based adhesive to the first or first and second surfaces of the pressed polyurethane foam;
(42) a backing cloth feeding roll 220 configured to feed a backing cloth; and
(43) a second pressing part 230 configured to secondarily press the fed backing cloth and the pressed polyurethane foam applied with the second water-based adhesive to manufacture a pressed backing cloth.
(44) The second application part 210 may include:
(45) a pair of second application rolls 211 composed of a gap roll 211a and a fixed roll 211b that are configured to be equally controlled and are spaced apart from each other at a predetermined distance.
(46) Specifically, in the second application part 210, the pair of second application rolls 211 is composed of the gap roll 211a and the fixed roll 211b. A comma knife 212 and a solvent tank 213 may be provided in the vicinity of the fixed roll 211b so that the adhesive may be applied to the first surface of the pressed polyurethane foam, and a pressing process may be performed on the second surface of the pressed polyurethane foam using the gap roll 211a.
(47) The pair of second application rolls 211 are required to be controlled in the gap therebetween according to the thickness of the polyurethane foam. Specifically, a distance d21 between the pair of second application rolls 211, i.e., between the gap roll 211a and the fixed roll 211b, may be 80 to 95% of the thickness of the pressed polyurethane foam. When the distance d21 therebetween is smaller than the above range, there is a concern that the polyurethane foam may be damaged. On the other hand, when distance d21 therebetween is larger than the above range, as the amount of the adhesive penetrating into the polyurethane foam during the first pressing process increases, the thickness of the polyurethane foam may decrease after adhesion and curing, which is not desirable.
(48) Specifically, the distance d21 may be 85 to 95% of the thickness of the pressed polyurethane foam.
(49) In the present disclosure, the comma knife 212 may be mounted on the fixed roll 211b at a distance dc2 of 0.1 to 2 mm to control the amount of application of the second water-based adhesive. When the distance dc2 of the comma knife 212 is too small beyond the above range, adhesion strength is weakened. On the other hand, when the distance dc2 thereof is too large, the thickness of the polyurethane foam may decrease regardless of the distance between the pair of second application rolls 211. Specifically, the distance dc2 may be 1 to 1.5 mm.
(50) The second pressing part 230 includes a pair of second pressing rolls 231 configured to be equally controlled and spaced apart from each other at a predetermined distance. The pair of second pressing rolls 231 is composed of a fixed roll 231a and a gap roll 231b. A distance d22 between the pair of second pressing rolls 231, i.e., between the fixed roll 231a and the gap roll 231b, may be 80 to 95% of the thicknesses of the fabric and the polyurethane foam. That is, the distance d22 may be 80 to 95% of the sum of the thickness of the fabric and the thickness of the polyurethane foam. The degree of pressing is determined according to the distance d22, so that a difference may occur in peel strength. Therefore, when the distance d22 is smaller than the above range, there is a concern that the fabric and the polyurethane foam may be damaged. On the other hand, when the distance d22 is larger than the above range, the second water-based adhesive oozes out on the surface of the backing cloth, and thus the second water-based adhesive stains the surface of the gap roll 231b, which may cause contamination and peeling of the backing cloth, which is not desirable. Specifically, the distance d22 may be 85 to 95% of the thicknesses of the fabric and the polyurethane foam.
(51) In the present disclosure, as the first water-based adhesive and the second water-based adhesive, water-based adhesives that have no odor and in which no VOCs are detected in a solvent itself may be used, and may be the same or different from each other.
(52) Each of the water-based adhesives may be formed by using, for example, at least one selected from the group consisting of acrylic emulsion resin, chloroprene rubber, urethane emulsion resin, ethylene-vinyl acetate emulsion resin, epoxy emulsion resin, vinyl acetate emulsion resin, aqueous polymer-isocyanate-based resin, styrene-butadiene rubber solution-based resin, styrene-butadiene rubber-based latex, nitrile rubber-based resin, and nitrocellulose-based resin.
(53) In an example, each of the water-based adhesives may be obtained by using a composition including the chloroprene rubber and the acrylic emulsion resin, and may have a solid content of 30 to 40%, a viscosity of 1000 to 3000 mpa.Math.s/20° C., and a pH of 7 to 11.
(54) In another example, each of the water-based adhesives may be obtained by using a composition including the urethane emulsion resin, and may have a solid content of 30 to 40%, a viscosity of equal to or greater than 10,000, a PH of 6 to 9, and a density of 0.5 to 3 g/cm.sup.3.
(55) The drying part 300 includes:
(56) a feed part 310 configured to feed the pressed backing cloth at a predetermined angle with respect to a moving direction; and
(57) a chamber part 320 configured to dry the fed pressed backing cloth.
(58) The present disclosure can effectively remove organic compounds such as CO.sub.2, TDI, and amine contained in the polyurethane foam through drying, thereby manufacturing a vehicle seat that is harmless to the human body.
(59) Specifically, the drying part 300 may include: the feed part 310 configured to feed the pressed backing cloth at an angle of 20 to 60° with respect to the moving direction;
(60) the chamber part 320 including at least one hot air nozzle 321 and a suction ventilation fan 322 that are configured to dry the fed pressed backing cloth by means of hot air; and
(61) a final pressing roll 330.
(62) In the present disclosure, for effective drying, the pressed backing cloth may be fed at an angle of 20 to 60° with respect to the moving direction. When the angle thereof is smaller than the above range, fold wrinkles may occur on the surface of the fabric (woven fabric, synthetic fabric) depending on the thickness of the polyurethane foam and the elongation of the backing cloth. On the other hand, when the angle thereof is larger than the above range, frictional slip against the fabric may occur, which is not desirable.
(63) The number of hot air nozzles 321 is not limited, but may be 5 to 15, for example.
(64) The suction ventilation fan 322 may be configured to suck organic compounds and odors discharged from the polyurethane foam and discharge the same to a dust collection facility to perform related processes in an eco-friendly manner.
(65) In some cases, the backing cloth may be moved on a mesh belt 323 in the chamber part 320 to increase the drying effect, and final pressing may be performed on the final pressing roll 330 to solve the problem of backing cloth peeling and adhesive ooze.
(66) On the other hand, the present disclosure provides a method of manufacturing a laminate vehicle seat using the laminating apparatus for manufacturing the vehicle seat.
(67) Specifically, the method of manufacturing the laminate vehicle seat may include:
(68) a first application step (S1) of applying a first water-based adhesive to a first surface of a polyurethane foam fed from a polyurethane foam feeding roll 110;
(69) a first pressing step (S2) of first pressing fabric fed from a fabric feeding roll 130 and the polyurethane foam applied with the first water-based adhesive to manufacture a pressed polyurethane foam;
(70) a second application step (S3) of applying a second water-based adhesive to the first surface of the pressed polyurethane foam;
(71) a second pressing step (S4) of second pressing a backing cloth fed from a backing cloth feeding roll 220 and the pressed polyurethane foam applied with the second water-based adhesive to manufacture a pressed backing cloth;
(72) a feed step (S5) of feeding the pressed backing cloth at a predetermined angle with respect to a moving direction; and
(73) a drying step (S6) of drying the fed pressed backing cloth.
(74) In step (S1),
(75) the first water-based adhesive is applied to the first surface of the polyurethane foam fed from the polyurethane foam feeding roll 110 using a pair of first application rolls 121, and in order to prevent the polyurethane foam from rolling during lamination according to the thickness, density, and hardness, and elongation of each specification, the ratio of driving speed between the polyurethane foam feeding roll 110 and the pair of first application rolls 121 may be 1:1.
(76) In step (S2),
(77) the fabric fed from the fabric feeding roll 130 and the polyurethane foam applied with the first water-based adhesive are primarily pressed using a pair of first pressing rolls 141.
(78) In this case, the driving speed of the fabric feeding roll 130 may be slower by 0.5 to 1 RPM than that of the pair of first pressing rolls 141. When the driving speed thereof is out of the above range, the fabric may be pushed or wrinkled during pressing.
(79) In step (S4),
(80) the backing cloth fed from the backing cloth feeding roll 220 and the pressed polyurethane foam applied with the second water-based adhesive are secondarily pressed using a pair of second pressing rolls 231. In this case, the driving speed of the backing cloth feeding roll 220 may be slower by 0.3 to 1.5 RPM than that of the pair of second pressing rolls 231. When the driving speed thereof is out of the above range, the fabric may be pushed or wrinkled during pressing. Specifically, the driving speed of the backing cloth feeding roll 220 may be slower by 0.5 to 1 RPM than that of the pair of second pressing rolls 231.
(81) In step (S5),
(82) the pressed backing cloth may be fed at an angle of 20 to 60° with respect to the moving direction. When the angle thereof is smaller than the above range, fold wrinkles may occur on the surface of the fabric (woven fabric, synthetic fabric) depending on the thickness of the polyurethane foam and the elongation of the backing cloth. On the other hand, when the angle thereof is larger than the above range, frictional slip against driving rollers may occur, which is not desirable. Specifically, the backing cloth may be fed at an angle of 30 to 50° with respect to the moving direction.
(83) In step (S6),
(84) in order to remove moisture from the first water-based adhesive and the second water-based adhesive and leave only solids, the pressed backing cloth may be dried by means of hot air using hot air nozzles 321 under conditions of an airflow velocity of 50 to 200 CMM (m.sup.3/min), an air pressure of 30 to 80 mmAQ, and a temperature of 90 to 180° C. Thereafter, using a suction ventilation fan 322, organic compounds such as CO.sub.2, TDI, and amine, and odors contained in the polyurethane foam may be sucked and discharged to a dust collection facility, so that the process can be performed in an eco-friendly manner. With such hot air drying, a water-based adhesive solvent, etc. oozing out of the backing cloth during second backing cloth pressing is quickly dried so that only solids remain on an application surface of the polyurethane foam, thereby improving adhesion performance.
(85) The above process may be performed in a chamber part 320, and the backing cloth is moved therein using a mesh belt 323, so that organic compounds and other odors contained in the polyurethane foam can be effectively discharged.
(86) Thereafter, an additional pressing step may be performed using a final pressing roll 330, so that backing cloth peeling due to a decrease in adhesive force and adhesive ooze appearing on the surface of the backing cloth can be prevented. Specifically, after the drying of the pressed backing cloth, final pressing is performed using the final pressing roll 330, and final pressing conditions may be controlled so that peel strength is equal to or greater than 0.5 kgf on the basis of HKMC Spec. of the Hyundai-Kia Motor Company (HKMC) standards, and specifically, the peel strength is equal to or greater than 0.6 kgf.
(87) Hereinafter, the present disclosure will be described in detail through examples, but the following example and experimental example are only illustrative of one embodiment of the present disclosure. Thus, the scope of the present disclosure is not limited by the following example and experimental example.
EXAMPLE
(88) In the present disclosure, a first water-based adhesive and a second water-based adhesive having the following compositions were used.
(89) A liquid water-based adhesive (appearance: colored viscous liquid, solid content: about 34%, viscosity: about 2,000 mpa.Math.s/20° C., pH: 7 to 11) based on a chloroprene rubber (CR) and an acrylic emulsion resin, and a water-based PU adhesive (main raw material: polyurethane, appearance: milky white liquid, solid content: 40±1%, viscosity: equal to or greater than 10,000, PH: 6 to 9, density: 1.062 g/cm.sup.3) were used.
Experimental Example
(90)
(91) Referring back to
(92) In addition,
(93) A comparative test on adhesion strength (peel strength) between related-art flame lamination and PUR lamination, and lamination of the laminate vehicle seat according to the present disclosure is illustrated in
(94) Referring to
(95) Although the exemplary embodiments of the present disclosure have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the present disclosure as disclosed in the accompanying claims.