WO2022153751A1 - 加飾成形体およびその製造方法 - Google Patents
加飾成形体およびその製造方法 Download PDFInfo
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- WO2022153751A1 WO2022153751A1 PCT/JP2021/045597 JP2021045597W WO2022153751A1 WO 2022153751 A1 WO2022153751 A1 WO 2022153751A1 JP 2021045597 W JP2021045597 W JP 2021045597W WO 2022153751 A1 WO2022153751 A1 WO 2022153751A1
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- WO
- WIPO (PCT)
- Prior art keywords
- decorative
- layer
- thermoplastic resin
- fiber
- woven fabric
- Prior art date
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- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
- D04H1/4242—Carbon fibres
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
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- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
- B29C51/145—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets having at least one layer of textile or fibrous material combined with at least one plastics layer
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- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0854—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns in the form of a non-woven mat
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- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0037—Other properties
- B29K2995/0091—Damping, energy absorption
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
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- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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- B29L2031/58—Upholstery or cushions, e.g. vehicle upholstery or interior padding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/722—Decorative or ornamental articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
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- B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
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- B32B2255/20—Inorganic coating
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/26—Polymeric coating
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- B32B2255/00—Coating on the layer surface
- B32B2255/28—Multiple coating on one surface
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
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- B32B2262/02—Synthetic macromolecular fibres
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- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
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- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/14—Mixture of at least two fibres made of different materials
- B32B2262/144—Non-woven fabric
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- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/10—Fibres of continuous length
- B32B2305/20—Fibres of continuous length in the form of a non-woven mat
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- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/402—Coloured
- B32B2307/4023—Coloured on the layer surface, e.g. ink
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- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/402—Coloured
- B32B2307/4026—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
Definitions
- the present invention relates to a decorative molded body having high designability, being lightweight, and having excellent followability during deep drawing molding, and a method for molding the decorative molded body by a relatively simple method.
- Nonwoven fabrics that are lightweight and have excellent followability during deep drawing are suitable for industrial materials, building materials, automobiles, and the like.
- a lightweight non-woven fabric with excellent rigidity after molding is used as a material for a molded body for an automobile undercover or dash silencer, it follows the shape of the molding mold such as sound absorption performance, cushioning performance, and uneven protrusions.
- Cheap since the molded body is lightweight, it is possible to significantly improve energy saving and workability by reducing the weight of the interior and exterior materials of the automobile.
- a non-woven fabric in which fibers made of an inorganic fiber and a thermoplastic resin are mixed can be expected to have excellent high rigidity by molding, and a part of a metal material can be replaced. Further, when the recycled carbon fiber extracted from the carbon fiber reinforced resin using the heat-curable resin is used as the material of the support layer A, it can contribute to the reduction of the environmental load.
- Patent Document 1 and Patent Document 2 describe a fiber web of composite fibers made of a specific copolymerized polyester whose core component is polyethylene terephthalate and whose sheath component is ethylene glycol, adipic acid, terephthalic acid, isophthalic acid, or the like.
- a method for manufacturing a precise semi-finished product for automobile equipment, which has been needle-punched and three-dimensionally entangled, has been proposed.
- the range of the heating temperature is widened during heating and compression molding, but there is no description about the design. Further, since it is necessary to use a special component, the cost advantage is lowered as compared with the case where a general-purpose resin is used. Further, it is expected that there is a problem that the adhesiveness with polypropylene, which is widely used for automobile members, is insufficient.
- the surface of the moldable non-woven fabric has unevenness in the distribution of fibers in the non-woven fabric and irregularities due to the morphology of the fibers themselves, and there is a problem in designability because light is diffusely reflected and the gloss is insufficient or the smoothness is poor. ..
- thermosetting resin a fiber-reinforced composite material using a thermosetting resin is also used as a moldable material.
- a method of impregnating glass fibers or carbon fibers made of continuous fibers called UD, which are arranged in advance, with an epoxy resin or the like and performing thermosetting is usually used.
- continuous fibers high strength can be expected, but there is a problem that the followability to deep drawing molding is inferior.
- Fiber reinforced composite materials that use thermosetting resins are often used as interior / exterior members of automobiles where design is important.
- design is important.
- the smoothness is given by applying multiple layers of paint by spray painting or the like, and finally the coating that gives the design is applied. There were many.
- Patent Document 4 instead of laminating such coatings, a thermoplastic resin film containing reinforcing fibers such as potassium titanate and wallastonite and spherical particles is used to impart surface smoothness. There is. However, in the present invention, it is possible to obtain a molded product having a design without using such a specific member.
- Patent Document 5 discloses a composite decorative film composed of a releasable film and a transfer film. However, it is difficult to obtain a non-woven fabric composite molding material having a high design property required by the present invention. Further, insert molding accompanied by injection molding is used for the composite with the molded body, and it is not provided as a lightweight molded body based on the non-woven fabric, which is the object of the present invention.
- Patent Documents 6 and 7 disclose a metallic laminated film and a decorative molded product thereof.
- This molding technology assumes vacuum forming, and since this film requires an adhesive processing layer, it is necessary to peel off the inner film and perform composite processing.
- vacuum forming since vacuum forming is assumed, the heat resistance of the film for maintaining the vacuum is insufficient in the temperature range for molding the thermoplastic resin, and the film can be substantially molded at 120 to 130 ° C. It is difficult to apply only with a thermosetting resin. Further, in a normal vacuum forming machine, there is a problem that the forming pressure is insufficient in the deep drawing molding process of the thermoplastic resin material.
- Patent Documents 8 and 9 disclose decorative molded products in which a decorative film is compounded with a fiber-reinforced plastic molded body using inorganic fibers and super engineering plastic fibers.
- a vacuum forming method instead of press forming in the step of laminating a decorative film having a special texture, and a high pressure is applied to the plastic molded body during vacuum forming.
- inorganic fibers and thermoplastic super engineering plastic fibers are required.
- the scope of application of thermoplastic super engineering plastic fibers is limited because they are very expensive.
- a non-woven fabric using fibers made of a general-purpose thermoplastic resin such as polyolefin, polyester, and polyamide is used as the main constituent material of the support layer, and one type of molding mold is used without using vacuum forming. Only by itself, it is possible to provide a molded body that is lightweight and has excellent followability during deep draw molding, and has a different purpose from the inventions described in Patent Documents 8 and 9.
- the present invention has been made against the background of the above-mentioned problems of the prior art, and is a decorative molded body having excellent design and lightness, and excellent followability during deep draw molding, and the addition by a relatively simple method. Provided is a method for producing a decorative molded article.
- the decorative molded article of the present invention and the method for producing the same, which can solve the above problems, are as follows.
- 1. A decorative molded body in which the decorative layer B and the support layer A are laminated in this order from the surface side.
- the support layer A is a non-woven fabric (a) containing at least two types of thermoplastic resin fibers, a non-woven fabric (b) containing thermoplastic resin fibers and inorganic fibers, and a thermoplastic resin composition layer containing inorganic fibers in the thermoplastic resin.
- the decorative layer B is an easily molded polyester film (d) containing a thermoplastic resin capable of thermoforming and having a thermoplastic resin composition containing a pigment or dye laminated on the surface side, and at least two types of heat having different melting points. It is either a non-woven fabric (e) containing a composite fiber made of a plastic resin and having irregularities formed on the surface by embossing, or a synthetic leather (f) using an organic fiber as a base material.
- the decorative layer B and the support layer A are compositely integrated with each other via a heat-adhesive resin.
- a decorative molded body characterized by this. 2.
- the decorative layer B is further laminated with a transparent protective layer on the surface side, and the protective layer is any one of a transparent ink, a weather-resistant paint, and a weather-resistant film in which an alumina white pigment is dispersed in a vehicle.
- the decorative layer B is a non-woven fabric (e) containing a composite fiber made of at least two types of thermoplastic resins having different melting points and having irregularities formed on the surface by embossing, and the composite fiber has a sheath component.
- the decorative molded body according to 1 above which is a heat-adhesive resin having a melting point of 20 ° C.
- the decorative molded product of the present invention is excellent in design and light weight, and is also excellent in followability during deep drawing molding. Further, the method for producing a decorative molded body of the present invention has a relatively simple production process and uses a general-purpose thermoplastic resin as a material, so that it can be produced at low cost.
- the non-woven fabric before molding has a high porosity. Therefore, it takes time for the heat required for molding to be sufficiently transferred.
- the basis weight of the non-woven fabric is preferably 4000 g / m 2 or less.
- the support layer A is preferably 40% or more, more preferably 50% or more, and particularly preferably 70% or more based on the mass of the molded body. On the other hand, if the ratio of the support layer A to the molded body is 80% or more on a mass basis, the effect of improving the rigidity may be small.
- the fibers constituting the non-woven fabric may be short fibers or long fibers.
- the staple fiber nonwoven fabric has good thermoformability, and among them, a staple fiber nonwoven fabric in which at least a part of the constituent fibers is a core-sheath type composite fiber is preferable.
- long fibers without crimping are often arranged in a non-woven fabric with few bending points without loosening or bending. Therefore, high rigidity can be expected because the strength of each fiber directly contributes to the strength of the non-woven fabric.
- the fibers are mainly arranged not in the thickness direction but in the two-dimensional in-plane direction, so that it is considered that it becomes easy to increase the bending rigidity and the initial modulus.
- the non-woven fabric may be used as a single layer, but two or more layers of the non-woven fabric may be composited. Further, since the number of restraint points of the fibers may increase in the single layer and the moldability may decrease, it is also one of the preferable embodiments to integrate the fibers by a needle punch method or the like.
- the same non-woven fabric may be simply laminated, but the strength of the molded product can also be increased by changing the composition on the front and back to increase the proportion of high-strength fibers near the surface. It is one of the preferable embodiments for enhancing the above.
- the non-woven fabric is composed of only the same fibers, it is preferable to use a non-woven fabric made of core-sheath type fibers made of two or more kinds of thermoplastic resins in order to improve morphological stability.
- fibers of different thermoplastic resins may be mixed.
- a mixed fiber of a long-fiber non-woven fabric can be produced by discharging different types of thermoplastic resins from adjacent spinning holes.
- polyester, polyolefin and polyamide are preferable, and polyester and polyolefin which are general-purpose thermoplastic resins and inexpensive are particularly preferable.
- polyesters include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polybutylene terephthalate (PBN), polyethylene naphthalate (PEN), polycyclohexylene methylene terephthalate (PCT), and polytrimethylene terephthalate (PTT).
- PBT polybutylene terephthalate
- PET polyethylene terephthalate
- PBN polybutylene terephthalate
- PEN polyethylene naphthalate
- PCT polycyclohexylene methylene terephthalate
- PTT polytrimethylene terephthalate
- polyolefin polyethylene (PE), polypropylene (PP) and the like can be exemplified.
- Polyamide-based fibers such as nylon 6 (NY6) and nylon 66 (NY66
- a core-sheath type or side-by-side type composite fiber it is preferable to use a core-sheath type or side-by-side type composite fiber.
- a combination of PP / PET, copolymerized PET / PET, PBT / PET, and PE / PP is preferable.
- composite fibers such as PP / PET-based, NY6 / PET-based, and copolymerized PET / PET is also particularly suitable.
- the fineness of the thermoplastic resin fibers constituting the non-woven fabric is not particularly limited, but the average fiber diameter is preferably 10 to 25 ⁇ m, preferably 12 to 25 ⁇ m, because it is easy to obtain mechanical strength when the fibers are deformed and adhered. 20 ⁇ m is particularly preferable. It is also one of the preferable embodiments that the thermoplastic resin fiber has a birefringence of 100 ⁇ 10 -3 or less in order to improve moldability.
- the fiber length of the inorganic fiber is preferably 7 to 100 mm, more preferably 10 to 80 mm, and particularly preferably 15 to 75 mm.
- Inorganic fibers are mainly used to improve rigidity, and longer fibers tend to provide higher mechanical properties. However, even if the fiber length of the inorganic fiber exceeds 100 mm, the improvement effect is small. Further, since the inorganic fiber is a straight fiber without crimping, it becomes difficult to manufacture a mixed fiber non-woven fabric using a card machine. Further, even if an inorganic fiber having a long fiber length is used, the inorganic fiber is often broken in the manufacturing process (particularly, the mixed fiber process). Further, when the fiber length is shortened, the fall of the fiber in the carding process often becomes a problem. In addition, the yield of dry non-woven fabric may be poor.
- thermoplastic resin fiber polypropylene fiber, polyester fiber, polyamide fiber, polyphenylene sulfide fiber, PTFE fiber and the like are suitable.
- thermoplastic resin composition layer (c) containing inorganic fibers in the thermoplastic resin As the support layer A used in the present invention, a thermoplastic resin composition layer containing inorganic fibers in the thermoplastic resin is one of the preferred embodiments.
- a thermoplastic resin that melts during hot pressing in the nonwoven fabric (b) a thermoplastic resin composition layer containing inorganic fibers in the thermoplastic resin can be obtained.
- a polyolefin resin, a polyester resin, and a polyamide resin are preferable.
- the decorative layer B is an easily molded polyester film (d) containing a thermoplastic resin capable of thermoforming and having a thermoplastic resin composition containing a pigment or dye laminated on the surface side, and at least two types of heat having different melting points. It is either a non-woven fabric (e) containing a composite fiber made of a plastic resin and having irregularities formed on the surface by embossing, or a synthetic leather (f) using an organic fiber as a base material.
- the thickness of the decorative layer B is preferably 50 to 2000 ⁇ m.
- the thickness of the decorative layer B is preferably 50 ⁇ m or more, and particularly preferably 80 ⁇ m or more in order to suppress tearing during molding.
- the thickness of the decorative layer B is preferably 2000 ⁇ m or less, and particularly preferably 1200 ⁇ m or less, from the viewpoint of heat conduction during thermoforming. If the heat conduction during thermoforming becomes poor, the time required for molding becomes long.
- the easily-molded polyester film preferably has an elongation of 100% or more in both the longitudinal direction and the lateral direction, and is particularly preferably 200% or more.
- the draw ratio in both directions is preferably 2.5 or less, more preferably 2.0 or less, and particularly preferably 1.5. If the draw ratio is high, it may not be able to follow the deformation when it is molded in a state of being laminated with the support layer A, and breakage or wrinkles may occur. Further, it is preferable to set the heat at a temperature slightly higher than the thermoforming temperature (for example, about 3 to 20 ° C.) because it is possible to prevent the film from shrinking and wrinkling due to the heat during molding.
- the decorative layer B can be obtained by laminating a thermoplastic resin composition containing a pigment or dye on the surface side of the easily molded film.
- the pigment or dye may be selected from commercially available products and from the desired design.
- As a method of laminating a thermoplastic resin composition containing a pigment or a dye on a film printing by coating, inkjet printer, gravure printing, or other transfer method is preferable.
- Non-woven fabric (e) containing composite fibers made of at least two types of thermoplastic resins having different melting points and having irregularities formed on the surface by embossing.
- the nonwoven fabric (e) contains composite fibers made of at least two types of thermoplastic resins having different melting points.
- the non-woven fabric (e) is preferably composed of the composite fiber and the thermoplastic resin fiber.
- the composite fiber is preferably a core-sheath type composite fiber in which the sheath component has a melting point lower than that of the core component by 20 ° C. or more. More preferably, it is a heat-adhesive resin in which the sheath component has a melting point lower than that of the core component by 30 ° C. or more.
- any one of a copolymerized polyester resin, a polyolefin-based resin, and a polyamide-based resin is preferable.
- it is a core-sheath type composite fiber in which the core component is polyethylene terephthalate resin and the sheath component is a copolymerized polyester resin.
- the thermoplastic resin fiber used together with the composite fiber is preferably polyethylene terephthalate fiber.
- the surface side of the non-woven fabric (e) is embossed to form dots, continuous patterns, or patterns.
- the embossing may be performed on the non-woven fabric (e) before molding, or may be performed at the time of molding or after molding.
- Synthetic leather based on organic fibers (f)
- the decorative layer B is synthetic leather (including artificial leather)
- a non-woven fabric material or a knitting material produced by impregnating a thermoplastic fiber with a resin such as urethane is preferable.
- a wet method or a dry method may be used as the skin resin impregnated layer of the synthetic leather.
- the thickness of the synthetic leather is preferably in the range of 600 to 1100 ⁇ m.
- polyester fibers or polyamide fibers it is preferable to mainly use polyester fibers or polyamide fibers.
- the decoration layer B and the support layer A are compositely integrated via the heat-adhesive resin.
- the composite integration referred to in the present invention almost the entire contact surface where the support layer A and the decorative layer B are joined via a heat-adhesive resin is adhered, and an interface having a width of about 3 mm or more is bonded. It means that there is no part that is not joined due to floating or large wrinkles.
- the heat-adhesive resin is a constituent material of a low melting point thermoplastic resin fiber constituting the non-woven fabric, or the decorative layer B and the support layer A. It is a constituent material of a layer in which a heat-adhesive resin is applied to a heat-adhesive sheet or an easy-to-mold film laminated between the two. These heat-adhesive resins are melted during hot pressing, and the decorative layer B and the support layer A can be compositely integrated via the heat-adhesive resin.
- the heat-adhesive resin is a thermoplastic resin that can be melted during hot pressing, and a polyamide-based resin, a polyolefin-based resin, or a copolymerized polyester is preferable.
- the heat-adhesive non-woven fabric preferably uses a core-sheath type composite fiber whose sheath component has a lower melting point than the core component, and particularly preferably, the core component is polyethylene terephthalate resin and the sheath component is a copolymerized polyester resin or It is a modified polyolefin resin.
- the non-woven fabric Since the non-woven fabric has minute irregularities on the surface, strong adhesive force can be expected when a heat-adhesive non-woven fabric is used for the support layer A or the decorative layer B. If the air permeability of the heat-adhesive non-woven fabric is 10 cc / cm for 2 seconds or less, the air in the heat-adhesive non-woven fabric may not escape. In that case, floating may occur between the support layer A and the decorative layer B. In that case, it is preferable to provide a heat-adhesive sheet between the support layer A and the decorative layer B. When the thickness of the heat-adhesive film or the heat-adhesive non-woven fabric is 10 to 60 ⁇ m, it is possible to obtain an appropriate adhesive force.
- the heat-adhesive resin layer may be laminated on the surface opposite to the surface on which the thermoplastic resin composition containing the pigment or dye is laminated.
- the same adhesive strength improving effect can be expected even if a coating liquid of an amorphous copolymer polyester resin (manufactured by Toyobo Co., Ltd., Byron RV-200, EV-103) is applied to a thickness of 3 to 5 ⁇ m.
- the decorative layer B of the decorative molded product of the present invention has a transparent protective layer on the surface side (opposite to the support layer A) of the decorative layer B in order to protect the decorative layer. It is preferable that they are laminated.
- the protective layer is preferably any of a transparent ink in which an alumina white pigment is dispersed in a vehicle, a weather-resistant paint, and a weather-resistant film.
- medium which is a transparent ink in which an alumina white pigment is dispersed in a vehicle, a paint or resin layer containing a coloring pigment, a weather-resistant fluororesin paint, a weather-resistant film (vinyl chloride, acrylic, high-density polyethylene, polyester, etc.), etc.
- overcoat varnish for a shrink film or the like can also be preferably used in consideration of the combination with the thermoplastic resin used for the decorative layer B.
- overcoat medium manufactured by Osaka Printing Ink Mfg. Co., Ltd., EXP14008
- EXP14008 overcoat medium
- the molding method of the decorative molded article of the present invention will be described.
- any of the usual heat pressing methods can be used, but the hot pressing method is recommended rather than the cold pressing.
- it may be press-molded into a single plate, passed between heated metal press rolls capable of producing long rolls, or a high-temperature metal belt press machine may be used. Requires special processing.
- the flat plate is once prepared by a preliminary press and then three-dimensionally molded by a press machine again to form a three-dimensional structure.
- a high-temperature metal belt press machine is used as the pre-pressing process, the conditions are set according to the thermoplastic resin material, but the packing density is controlled by pressing under the conditions of a temperature of 140 to 330 ° C. and a pressure of 0.3 to 5 MPa. It is also preferable to do so. By lowering the pressure, it is possible to maintain the voids between the fibers, and sound absorption performance is expected.
- thermoplastic resin composition layer (c) containing the inorganic fibers in the thermoplastic resin is used as the support layer A used in the present invention
- the thermoplastic resin fibers and the non-woven fabric containing the inorganic fibers are thermoformed and then air. It is also one of the preferable forms that the resin is almost removed and there are almost no voids.
- the decorative molded product of the present invention is hot press-molded in a pressure range of 1.5 to 10 MPa and a temperature of 120 to 180 ° C. using only a pair of heating mold sets.
- an adhesive layer or performing processing in which stress is often applied to the object to be molded such as vacuum forming and TOM forming
- the process can be simplified and the manufacturing cost of the mold can be suppressed.
- vacuum forming it is possible to reduce the rigidity required to counter the stress received during the molding process.
- a resin layer (decorative layer B) having a design property can be bonded to a non-woven fabric (support layer A) having a relatively low rigidity and integrally pressed.
- the decorative layer B having moldability may be denatured by the influence of heat, or wrinkles may easily occur during deep drawing molding.
- thermoforming when a non-woven fabric is used for the support layer A, if the basis weight of the non-woven fabric A is higher than 300 g / m 2 , only the non-woven fabric is molded in advance, and the decorative layer B is overlaid on the non-woven fabric. Performing a second press with a mold is also one of the preferred forms. By molding in advance, the surface becomes smooth and the surface of the decorative layer B can be finished more beautifully.
- one of the preferable forms is to engrave dots, continuous patterns, or patterns on the inner surface of the mold in advance with an NC processing machine or the like, and make the patterns emerge on the surface of the molded body after molding.
- the molding pressure becomes high, unevenness such as an embossed pattern imparted in advance may become unclear by hot pressing, and in such a case, it can be improved by the above method.
- a trimming blade is attached to the mold, labor saving in the process can be achieved.
- ⁇ Thickness and apparent density> The thickness was measured under a load of 20 g / cm 2 .
- Card non-woven fabric (grain: 500 g / m 2 ) made of short fibers with a core component of polyethylene terephthalate, a sheath component of polypropylene modified with maleic acid (mass ratio (core / sheath): 50/50), and a fineness of 3.3 dtex. ) was obtained.
- a support layer A was prepared by needle punching this card non-woven fabric using an organ FPD220 (40SM) with a penetrating number of 50 and a needle depth of 10 mm. The apparent density of the support layer A after conversion was 0.18 g / cm 3 .
- a coating liquid in which a blue pigment is dispersed in a polyurethane resin is applied to one side of an easily moldable polyester film (a low draw ratio film treated at a heat setting temperature of 150 ° C.) having a thickness of 100 ⁇ m. , A freshly dried coating layer was formed.
- overcoat medium manufactured by Osaka Printing Ink Mfg. Co., Ltd., EXP14008
- EXP14008 overcoat medium
- the protective layer was arranged so as to be the outermost layer.
- a heat-adhesive sheet having a thickness of 30 ⁇ m (byron GK-680 manufactured by Toyobo Co., Ltd.) is placed between the support layer A and the decorative layer B, and the mold temperature is 160 ° C. (both above and below the mold) and the pressure is 3 MPa.
- Hot press molding was performed in. Table 1 shows the conditions for press molding. The apparent density of the obtained decorative molded product was 0.98 g / cm 3 .
- Example 2 shows the composition and evaluation results of the obtained decorative molded product.
- Example 2 A core-sheath type composite fiber consisting of a core component of polyethylene terephthalate and a sheath component of a low melting point copolymer polyester (melting point 135 ° C.) (mass ratio (core / sheath): 50/50) and a fineness of 5.5 dtex.
- a long-fiber non-woven fabric having a texture of 250 g / m 2 was prepared. Three layers of this long fiber non-woven fabric were laminated, and needle punching was performed using an organ FPD220 (40SM) with a penetrating number of 80 and a needle depth of 13 mm to prepare a support layer A.
- the apparent density of the obtained long fiber web after conversion was 0.20 g / cm 3 .
- the carding method it is composed of polyethylene terephthalate fiber having a fineness of 2.2 dtex and a fiber length of 51 mm, a core component of polyethylene terephthalate, and a sheath component of low melting point polyester (melting point 150 ° C.) (mass ratio (core / core / core /). Sheath): 50/50), heat-adhesive fibers with a fineness of 3.3 dtex and a fiber length of 51 mm are mixed so that the mass ratio is 50/50%, and a non-woven fabric having a grain size of 300 g / m 2 is obtained. Created.
- the decorative molded body obtained in Example 3 was compositely integrated, had an excellent appearance, had a sharp and good fine molded portion, and had excellent followability after deep drawing molding. In addition, the decorative part was good without any stains or spots.
- Table 2 shows the composition and evaluation results of the obtained decorative molded product.
- Example 4 Carbon fiber having an average fiber length of 5 cm and a diameter of 5 ⁇ m and nylon 6 fiber having a fiber length of 51 mm and a fineness of 3.3 dtex are mixed at a volume ratio of 40% / 60%.
- Five non-woven fabrics having a grain size of 250 g / m 2 were prepared by fiber. Then, using a metal belt press machine (manufactured by KBK Steel Products Co., Ltd.), press working was performed at a temperature of 190 ° C. and a pressure of 0.1 MPa. The apparent density was 0.83 g / cm 3 .
- hot press molding was performed at a mold temperature of 160 ° C. and a pressure of 7 MPa.
- the apparent density was 0.78 g / cm 3 .
- hot press molding was performed at a mold temperature of 260 ° C. and a pressure of 7 MPa.
- the apparent density was 1.27 g / cm 3 .
- the obtained laminated non-woven fabric was used as a support layer A.
- the heat-adhesive sheet used in Example 1 and the decorative layer B were superposed on the support layer A in this order, and heat press molding was performed at a mold temperature of 160 ° C. and a pressure of 3.5 MPa.
- Table 1 shows the conditions for press molding.
- the apparent density was 1.3 g / cm 3 .
- the decorative molded product obtained in Example 4 was compositely integrated, had an excellent appearance, had a sharp and good fine molded portion, and had excellent followability after deep drawing molding. In addition, the decorative part was good without cloudiness or floating. Table 2 shows the composition and evaluation results of the obtained decorative molded product.
- Comparative Examples 2 to 5 The test was carried out using the same material as in Example 1 and changing the molding conditions. Table 1 shows the conditions for press molding. In the decorative molded products obtained in Comparative Examples 2 to 5, it was not possible to obtain a composite and integrated decorative molded product. Therefore, the appearance was inferior, and at least one of the molding state after deep drawing molding and the state of the decorative portion was poor. Table 3 shows the structure and evaluation results of the obtained molded product. Further, in the decorative molded product of Comparative Example 4, floating occurred in the decorative layer B as shown in the photograph of FIG. Further, the decorative molded body of Comparative Example 5 is a photograph showing a state in which the decorative layer B is cracked at the edge portion of the molded body, as shown in the photograph of FIG.
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Abstract
Description
軽量で、深い絞り成型時の追随性に優れる不織布は、工業資材用途、建材用途、自動車用途などに好適である。特に、自動車のアンダーカバーやダッシュサイレンサーなどに、軽量かつ成形後の剛性に優れる不織布を成形体の材料として使用する場合、吸音性能、クッション性能、凸凹状の突起などの成形型の形状に追随しやすい。また、成型体が軽量であるため、自動車の内外装材の軽量化による省エネや作業性を大幅に改善することが可能である。また、無機繊維と熱可塑性樹脂よりなる繊維が混繊された不織布は、成形により優れた高い剛性が期待でき、金属材料の一部を代替することも可能となる。
また、熱硬化樹脂を使用した炭素繊維強化樹脂より取り出されたリサイクル炭素繊維を支持層Aの材料として使用する場合には、環境負荷の低減に寄与できる。
例えば、特許文献1や特許文献2には、芯成分がポリエチレンテレフタレート、鞘成分がエチレングリコール、アジピン酸、テレフタル酸、イソフタル酸などを原料とする特定の共重合ポリエステルからなる複合繊維の繊維ウェブを、ニードルパンチ処理して三次元交絡させた緻密な自動車装備材用半製品の製造法が提案されている。この方法によれば、加熱及び圧縮成型する際に加熱温度の範囲が広くなることが開示されているが、意匠性については記載がない。また、特殊な成分を用いることが必要となるため、汎用樹脂を用いた場合と比べ、コスト優位性が低下する。また、自動車用部材に広く用いられているポリプロピレンとの接着性が不十分という問題も予想される。
1.表面側から、加飾層B、支持層Aの順に積層されてなる加飾成形体であって、
支持層Aは、少なくとも2種類の熱可塑性樹脂繊維を含む不織布(a)、熱可塑性樹脂繊維と無機繊維を含む不織布(b)、熱可塑性樹脂中に無機繊維を含有する熱可塑性樹脂組成物層(c)、のいずれかであり、
加飾層Bは、熱成形が可能な熱可塑性樹脂を含み、表面側に顔料又は染料を含む熱可塑性樹脂組成物が積層された易成形ポリエステルフィルム(d)、融点の異なる少なくとも2種類の熱可塑性樹脂からなる複合繊維を含み、かつエンボス加工により表面に凹凸が形成された不織布(e)、有機繊維を基材とする合成皮革(f)のいずれかであり、
加飾層B及び支持層Aは熱接着性樹脂を介して複合一体化されてなる、
ことを特徴とする加飾成形体。
2.前記加飾層Bは、表面側にさらに透明な保護層が積層され、前記保護層は、アルミナ白色顔料をビヒクルに分散した透明インキ、耐候性塗料、耐候性フィルムのいずれかである、前記1に記載の加飾成形体。
3.前記加飾層Bが、融点の異なる少なくとも2種類の熱可塑性樹脂からなる複合繊維を含み、かつエンボス加工により表面に凹凸が形成された不織布(e)であり、前記複合繊維は、鞘成分が芯成分より融点が20℃以上低い熱接着性樹脂であり、共重合ポリエステル樹脂、ポリオレフィン系樹脂、またはポリアミド系樹脂のいずれかである、前記1に記載の加飾成形体。
4.前記加飾層Bが、表面側に顔料又は染料を含む熱可塑性樹脂組成物が積層された易成形ポリエステルフィルム(d)、または有機繊維を基材とする合成皮革(f)であり、加飾層Bと支持層Aの間に熱接着性樹脂層を有し、熱接着性樹脂が共重合ポリエステルである、前記1に記載の加飾成形体。
5.支持層Aが、熱可塑性樹脂繊維と無機繊維を含む不織布(b)であり、熱可塑性樹脂繊維は繊維径が10~25μmであり、無機繊維は繊維径が5~25μmで、かつ繊維長が7~100mmである、前記1に記載の加飾成形体。
6.前記1~5のいずれかに記載の加飾成形体を、1対の加熱金型セットのみを用いて、圧力が1.5~10MPa、温度が120~180℃の範囲で熱プレス成形することを特徴とする加飾成形体の製造方法。
7.金型内面にドット、連続模様、または図柄を予め彫刻し、その柄を成形後の成形体表面に浮かび上がらせることを特徴とする前記6に記載の加飾成形体の製造方法。
(1)支持層A
本発明の加飾積層体を構成する支持層Aは、下記(a)~(c)の3つの構成材料のいずれかを用いる。
1)少なくとも2種類の熱可塑性樹脂繊維を含む不織布(a)
2)熱可塑性樹脂繊維と無機繊維を含む不織布(b)
3)熱可塑性樹脂中に無機繊維を含有する熱可塑性樹脂組成物層(c)
本発明で用いられる支持層Aは、少なくとも2種類の熱可塑性樹脂繊維を含む不織布が好ましい実施形態の一つである。
支持層Aで用いる不織布の目付は、成型体に必要な機械強度特性を考慮し適宜設定することができる。好ましくは80~4000g/m2である。剛性や機械特性の点から、不織布の目付は80g/m2以上が好ましい。一方、成型体の軽量性及び設置スペースの点から、不織布の目付は4000g/m2以下が好ましい。
また、成形前の不織布は、高い空隙率を有する。そのため、成形に必要とされる熱が十分に伝わるのに時間がかかる。この観点からも、不織布の目付は4000g/m2以下が好ましい。
また、前記不織布は単層で用いても良いが、2層以上の不織布が複合化されていてもよい。また、単層では繊維の拘束点の数が多くなり成形性が低下する可能性があるため、ニードルパンチ法などで一体化しておくことも好ましい実施形態の一つである。
不織布が同一繊維のみで構成される場合は、形態安定性を高めるために、2種類以上の熱可塑性樹脂よりなる芯鞘型繊維からなる不織布を用いることが好ましい。あるいは異なる熱可塑性樹脂の繊維を混繊してもよい。長繊維不織布の混繊は、隣接する紡糸孔より異種の熱可塑性樹脂を吐出して製造することができる。
本発明で用いられる支持層Aは、無機繊維と熱可塑性樹脂よりなる繊維が混繊されている不織布も好ましい実施形態の一つである。
繊維径が10~25μm、繊維長が28~100mmである熱可塑性繊維、及び繊維径が5~25μmで、かつ繊維長が7~100mmである無機繊維を主成分とすることが望ましい。前記不織布の製造法としては、カーディング法を用いて繊維長が長い無機繊維を用いることが好ましい。
無機繊維は不織布の補強効果を高める目的で使用する場合が多く、できるだけプレス加工により空隙を減らすことにより機械強度を高めることが好ましい。
本発明で用いられる支持層Aは、熱可塑性樹脂中に無機繊維を含有する熱可塑性樹脂組成物層が好ましい実施形態の一つである。
前記不織布(b)において、熱プレス時に溶融する熱可塑性樹脂を使用することで、熱可塑性樹脂中に無機繊維を含有する熱可塑性樹脂組成物層が得られる。
熱プレス時に溶融する熱可塑性樹脂としては、ポリオレフィン系樹脂、ポリエステル系樹脂、ポリアミド系樹脂が好ましい。
加飾層Bは、熱成形が可能な熱可塑性樹脂を含み、表面側に顔料又は染料を含む熱可塑性樹脂組成物が積層された易成形ポリエステルフィルム(d)、融点の異なる少なくとも2種類の熱可塑性樹脂からなる複合繊維を含み、かつエンボス加工により表面に凹凸が形成された不織布(e)、有機繊維を基材とする合成皮革(f)のいずれかである。加飾層Bの厚みは50~2000μmであることが好ましい。加飾層Bの厚みは、成形時に破れを抑制するために、50μm以上が好ましく、80μm以上が特に好ましい。
一方、加飾層Bの厚みは、熱成形時の熱伝導の点から、2000μm以下が好ましく、1200μm以下が特に好ましい。熱成形時の熱伝導が悪くなると、成形に要する時間が長くなる。
前記の易成形ポリエステルフィルムは、縦方向及び横方向の伸度が共に100%以上が好ましく、特に好ましくは200%以上である。伸度の高いフィルムを得るためには、両方向の延伸倍率を2.5以下とすることが好ましく、さらに好ましくは2.0以下、特に好ましくは1.5である。延伸倍率が高いと、支持層Aと積層した状態で成形するときに変形に追従できなくなって、破断や皺を生じることがある。また、熱成形温度より少し高め(例えば、3~20℃程度)の温度で熱セットしておくと、成形時の熱でフィルムが収縮して皺が発生することを防止できるため好ましい。
前記不織布(e)は、融点の異なる少なくとも2種類の熱可塑性樹脂からなる複合繊維を含む。さらに、前記不織布(e)は、前記の複合繊維及び熱可塑性樹脂繊維から構成されていることが好ましい。前記の複合繊維は、鞘成分が芯成分よりも融点が20℃以上低い芯鞘型の複合繊維が好ましい。さらに好ましくは、鞘成分が芯成分より融点が30℃以上低い熱接着性樹脂である。前記熱接着性樹脂としては、共重合ポリエステル樹脂、ポリオレフィン系樹脂、またはポリアミド系樹脂のいずれかが好ましい。特に好ましくは、芯成分がポリエチレンテレフタレート樹脂で、鞘成分が共重合ポリエステル樹脂である芯鞘型複合繊維である。また、前記複合繊維とともに使用する前記熱可塑性樹脂繊維はポリエチレンテレフタレート繊維が好ましい。
加飾層Bが合成皮革(人工皮革も含む)の場合、熱可塑性繊維にウレタンなどの樹脂を含侵して製造した不織布系材料あるいは編み物系材料が好ましい。合成皮革の表皮樹脂含浸層は、湿式法でも乾式法のいずれを使っても良い。合成皮革の厚みは600~1100μmの範囲が好ましい。
意匠性の高い不織布を用いる場合には、ポリエステル系繊維あるいはポリアミド系繊維を主体とすることが好ましい。
本発明の加飾成形体は、加飾層B及び支持層Aが熱接着性樹脂を介して複合一体化されている。本発明でいう複合一体化は、支持層Aと加飾層Bが熱接着性樹脂を介して接合する接触面のほぼ全体が接着されているものであって、おおよそ3mm以上の幅の界面の浮きや大きな皺で接合されていない部分が無いものをいう。
前記熱接着性樹脂は、加飾層B又は支持層Aが熱接着性不織布の場合は、不織布を構成する低融点の熱可塑性樹脂繊維の構成材料であり、あるいは加飾層Bと支持層Aの間に積層される熱接着性シートや易成形フィルムに熱接着性樹脂を塗布した層の構成材料である。これらの熱接着性樹脂は熱プレス時に溶融し、熱接着性樹脂を介して加飾層B及び支持層Aを複合一体化することができる。
前記の熱接着性不織布は、鞘成分が芯成分よりも融点の低い芯鞘型の複合繊維を用いることが好ましく、特に好ましくは、芯成分がポリエチレンテレフタレート樹脂で、鞘成分が共重合ポリエステル樹脂又は変性ポリオレフィン樹脂である。
また、支持層A又は加飾層Bが前記の芯鞘型の複合繊維からなる熱接着性不織布の場合、成形後に金型を外す際に加飾層Bが浮き上がりを抑制することが必要な場合がある。不織布は表面に微小な凹凸がある事から、支持層A又は加飾層Bに熱接着性不織布を用いると強固な接着力が期待できる。熱接着性不織布の通気度が10cc/cm2秒以下であると、熱接着性不織布内の空気が抜けない場合がある。その際には、支持層Aと加飾層Bの間に浮き上がりを生じることがあるので、その場合には支持層Aと加飾層Bの間に熱接着シートを設けることが好ましい。
熱接着性フィルムや熱接着性不織布の厚みが10~60μmであると、適正な接着力を得ることが可能となる。
本発明の加飾成形体の加飾層Bは、加飾層の保護のために、加飾層Bの表面側(支持層Aとは反対面)に透明な保護層が積層されていることが好ましい。前記保護層は、アルミナ白色顔料をビヒクルに分散した透明インキ、耐候性塗料、耐候性フィルムのいずれかが好ましい。例えば、アルミナ白色顔料をビヒクルに分散した透明インキであるメジウム、着色顔料を含む塗料又は樹脂層、耐候性フッ素樹脂塗料、耐候性フィルム(塩化ビニル、アクリル、高密度ポリエチレン、ポリエステル系など)などが挙げられる。特に好ましくは、アルミナ白色顔料をビヒクルに分散した透明インキであるメジウム、耐候性フッ素樹脂塗料、塩化ビニルや高密度ポリエチレンなどの耐候性フィルムのいずれかである。
また、保護層には、必要に応じて紫外線吸収剤などの耐候剤を使用することも好ましい。シュリンクフィルム用のオーバーコートニスなども、加飾層Bに使用する熱可塑性樹脂との組み合わせを考慮して好適に使用できる。例えば、オーバーコートメジウム(大阪印刷インキ製造株式会社製、EXP14008)などが市販されている。
次に、本発明の加飾成形体の成形方法について説明する。
本発明の加飾成形体の成形方法は、通常の加熱プレス方法のいずれをも用いることができるが、コールドプレスより熱プレス工法が推奨される。例えば単板のプレス成型でもよいし、長尺反の製造が可能な加熱金属プレスロールの間を通したり、高温メタルベルトプレス機を用いたりすることも可能であるが、3次元成形を行うには特殊な加工が必要である。
真空成型、TOM成形などのように、粘着層を用いたり、被成形体に応力がかかることが多い加工を行なったりしないことで、プロセスの簡素化や金型の製造コストを抑えることができる。真空成形を行わないことで、成形加工時に受ける応力に対抗するための必要な剛性を小さくすることが可能となる。また、比較的剛性が低い不織布(支持層A)に意匠性のある樹脂層(加飾層B)を貼り合わせて一体プレスすることが可能となる。また、射出成形やインサート成形では、成形性のある加飾層Bが熱の影響で変性する場合や、深い絞り成型をする際に皺を生じやすくなる場合がある。
熱成形において、支持層Aに不織布を用いる場合、不織布Aの目付が300g/m2より高い場合には、予め不織布のみを成形しておいて、その上に加飾層Bを重ねて、同じ金型で2度目のプレスを行うことも好ましい形態の一つである。予め成形しておくことで表面が平滑になり加飾層Bの表面がよりきれいに仕上げることができる。
また、必要に応じて、金型にトリミング用の刃をとりつけておけば、工程の省力化を図ることができる。
不織布を20cm角に切り出して、その重量(g)を測定した値を1m2あたりに換算して目付とした。単位はg/m2である。
厚みは、20g/cm2の荷重下で測定した。見掛け密度は不織布の目付を厚みで割った値を求めた。JIS L1913(2010)に準拠して測定を行う。
充填密度=A/B(g/cm3)
A:目付(g/m2)
B:厚み(cm)
加飾成形体の外観を目視により3段階で評価した。1を特に良好とし、3は表面平滑性が悪かったり、成形面のエッジ部のシャープな成形ができなかったりして意匠性に問題がある場合とした。2はその中間である。
芯成分がポリエチレンテレフタレート、鞘成分がマレイン酸変性したポリプロピレンからなり(質量比(芯/鞘):50/50)、繊度が3.3dtexである短繊維からなるカード不織布(目付:500g/m2)を得た。このカード不織布に、オルガンFPD220(40SM)を用いてペネ数50、針深10mmでニードルパンチ加工をして支持層Aを作成した。換算後の支持層Aの見かけ密度は0.18g/cm3であった。
次に、加飾層Bとして、厚みが100μmの易成形性ポリエステルフィルム(熱セット温度150℃で処理した低延伸倍率フィルム)の片面に、ポリウレタン系樹脂に青色顔料を分散させた塗布液を塗布、乾燥させたて塗布層を形成させた。
さらに、厚みが30μmの熱接着性シート(東洋紡株式会社製、バイロンGK-680)を支持層Aと加飾層Bの中間に重ね、金型温度160℃(金型の上下とも)、圧力3MPaで熱プレス成形を行った。プレス成型時の条件を表1に示す。得られた加飾成形体の見かけ密度は0.98g/cm3であった。
芯成分がポリエチレンテレフタレート、鞘成分が低融点の共重合ポリエステル(融点135℃)からなり(質量比(芯/鞘):50/50)、繊度が5.5dtexである芯鞘型の複合繊維を用い、目付が250g/m2の長繊維不織布を作成した。この長繊維不織布を3層積層して、オルガンFPD220(40SM)を用いペネ数80、針深13mmでニードルパンチ加工を行い、支持層Aを作成した。得られた長繊維ウエッブの、換算後の見かけ密度は0.20g/cm3であった。
支持層Aの上に加飾層Bを載せ、実施例1と同じ金型で金型温度160℃、圧力3MPaで熱プレス成形を行った。プレス成型時の条件を表1に示す。得られた加飾成形体の見かけ密度は0.85g/cm3であった。
実施例1で用いた支持層Aに、合成皮革(東洋クロス株式会社製、パーミアBOOCOC(目付125g/m2、厚み650μm))を加飾層Bとして、支持層Aと加飾層Bの中間に実施例1で用いた熱接着性シートを積層して、金型温度(金型の上下とも)が160℃、圧力が3MPaで熱プレス成形を行った。プレス成型時の条件を表1に示す。得られた加飾成形体の見かけ密度は0.86g/cm3であった。
カーディング法により、平均繊維長が5cmで、直径が5μmの炭素繊維、及び繊維長が51mmで、繊度が3.3dtexであるナイロン6繊維を、体積比が40%/60%の割合で混繊して、目付250g/m2の不織布を5枚作成した。
その後、メタルベルトプレス機(KBKスチールプロダクツ株式会社製)を用いて、温度190℃、圧力0.1MPaでプレス加工を行った。見かけ密度は0.83g/cm3であった。
前記の支持層Aに、実施例1で使用した熱接着性シートと加飾層Bをこの順に重ね、金型温度160℃、圧力3.5MPaで熱プレス成形を行った。プレス成型時の条件を表1に示す。見かけ密度は1.3g/cm3であった。
熱接着性シートを使用しないこと以外は、実施例4と同様にして成形を行った。プレス成型時の条件を表1に示す。成形形状には問題が無かったものの、成形金型を外す際に、加飾層Bが上部の金型にひっついて浮き上がり、複合一体化された加飾成形体を得ることができなかった。
実施例1と同じ材料を使用し、成形条件を変えて試験を実施した。プレス成型時の条件を表1に示す。
比較例2~5で得られた加飾成形体は、複合一体化された加飾成形体を得ることができなかった。そのため、外観に劣っており、深絞り成型後の成型状態、加飾部の状態の少なくともいずれかが不良であった。得られた成形体の構造と評価結果を表3に示す。また、比較例4の加飾成形体は、図3の写真に示す通り、加飾層Bに浮きが発生した。さらに、比較例5の加飾成形体は、図4の写真に示す通り、成形体のエッジ部で加飾層Bに亀裂が生じた状態を示す写真である。
Claims (7)
- 表面側から、加飾層B、支持層Aの順に積層されてなる加飾成形体であって、
支持層Aは、少なくとも2種類の熱可塑性樹脂繊維を含む不織布(a)、熱可塑性樹脂繊維と無機繊維を含む不織布(b)、熱可塑性樹脂中に無機繊維を含有する熱可塑性樹脂組成物層(c)、のいずれかであり、
加飾層Bは、熱成形が可能な熱可塑性樹脂を含み、表面側に顔料又は染料を含む熱可塑性樹脂組成物が積層された易成形ポリエステルフィルム(d)、融点の異なる少なくとも2種類の熱可塑性樹脂からなる複合繊維を含み、かつエンボス加工により表面に凹凸が形成された不織布(e)、有機繊維を基材とする合成皮革(f)のいずれかであり、
加飾層B及び支持層Aは熱接着性樹脂を介して複合一体化されてなる、
ことを特徴とする加飾成形体。 - 前記加飾層Bは、表面側にさらに透明な保護層が積層され、前記保護層は、アルミナ白色顔料をビヒクルに分散した透明インキ、耐候性塗料、耐候性フィルムのいずれかである、請求項1に記載の加飾成形体。
- 前記加飾層Bが、融点の異なる少なくとも2種類の熱可塑性樹脂からなる複合繊維を含み、かつエンボス加工により表面に凹凸が形成された不織布(e)であり、前記複合繊維は、鞘成分が芯成分より融点が20℃以上低い熱接着性樹脂であり、共重合ポリエステル樹脂、ポリオレフィン系樹脂、またはポリアミド系樹脂のいずれかである、請求項1に記載の加飾成形体。
- 前記加飾層Bが、表面側に顔料又は染料を含む熱可塑性樹脂組成物が積層された易成形ポリエステルフィルム(d)、または有機繊維を基材とする合成皮革(f)であり、加飾層Bと支持層Aの間に熱接着性樹脂層を有し、熱接着性樹脂が共重合ポリエステルである、請求項1に記載の加飾成形体。
- 支持層Aが、熱可塑性樹脂繊維と無機繊維を含む不織布(b)であり、熱可塑性樹脂繊維は繊維径が10~25μmであり、無機繊維は繊維径が5~25μmで、かつ繊維長が7~100mmである、請求項1に記載の加飾成形体。
- 請求項1~5のいずれかに記載の加飾成形体を、1対の加熱金型セットのみを用いて、圧力が1.5~10MPa、温度が120~180℃の範囲で熱プレス成形することを特徴とする加飾成形体の製造方法。
- 金型内面にドット、連続模様、または図柄を予め彫刻し、その柄を成形後の成形体表面に浮かび上がらせることを特徴とする請求項6に記載の加飾成形体の製造方法。
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US20240051260A1 (en) | 2024-02-15 |
JP7160231B1 (ja) | 2022-10-25 |
JP2022186805A (ja) | 2022-12-15 |
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