CN104540652B - 树脂膜和使用了该树脂膜的平切薄镶板片材以及汽车内装部件 - Google Patents
树脂膜和使用了该树脂膜的平切薄镶板片材以及汽车内装部件 Download PDFInfo
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- CN104540652B CN104540652B CN201380032459.3A CN201380032459A CN104540652B CN 104540652 B CN104540652 B CN 104540652B CN 201380032459 A CN201380032459 A CN 201380032459A CN 104540652 B CN104540652 B CN 104540652B
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- resin
- truncation
- resin molding
- thin
- panelling
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Abstract
本发明提供能够与天然木平切薄镶板牢固地粘接,同时透湿性、氧透过性极低,能够对于该平切薄镶板赋予优异的汽车内装适合性的树脂膜。本发明的树脂膜10,其特征在于,包括熔融粘接填充层12和功能层14,该熔融粘接填充层12由熔体流动速率(MFR;试验条件为170℃、2.1kg载荷)为2.5~33.0g/10分钟的烯烃系树脂形成,该烯烃系树脂含有改性聚烯烃树脂,该功能层14由热塑性树脂形成,层叠于上述熔融粘接填充层12的表面。
Description
技术领域
本发明涉及层叠于天然木平切薄镶板(sliced veneer)的树脂膜、尤其是适合汽车内装用的平切薄镶板片材的制造的树脂膜和使用了该树脂膜的平切薄镶板片材以及汽车内装部件。
背景技术
近年来,着眼于天然木的优异的设计性,在汽车的内装部件、家具、或家电制品等中使用了使用天然木平切薄镶板(以下也简称为“平切薄镶板”。)在表面施以美丽的木花纹(实施了所谓“真木加工”)的树脂成型品。
上述树脂成型品的真木加工,以往采用以下的工序进行。即,首先,最初在成型为规定的形状的树脂成型品的表面使用粘合剂将平切薄镶板贴合。接着,在贴合的平切薄镶板的表面依次实施包含透明树脂等的底涂和中涂,进行研磨/磨光。然后,实施了面涂后,进行研磨/磨光,将表面整饰为镜面状而完成。
这样,在以往的真木加工中,必须反复进行涂装、研磨,因此存在费工夫、制造成本升高的问题。
因此,作为能够解决涂装、研磨的烦杂、与其相伴的制造成本的问题的技术,专利文献1中公开了包含平切薄镶板、填充含浸于该平切薄镶板的导管和木质部、在该平切薄镶板的表里两面熔融粘合的透明的填充用热塑性膜和与该填充用热塑性膜的两面加热压接的伸长率为400%以上的透明的伸展性膜的可三维成型的天然木平切薄镶板,即,使平切薄镶板与树脂膜一体化的“平切薄镶板片材”。如果将这样的平切薄镶板片材固定于规定形状的注射成型模具,将基材树脂注射成型,则能够简单地、高效率地制造对表面实施了真木加工的树脂成型品。
其中,专利文献1中,作为构成填充用热塑性膜、伸展性膜的树脂,公开了聚酰胺系、聚氨酯系、聚酯系和EVA系的热塑性树脂,但这些树脂由于透湿性、氧透过性比较高,因此特别是在湿度、温度大幅变化的环境中长间暴露的汽车内装用途中使用的情况下,担心装饰树脂成型品的表面的平切薄镶板的劣化、褪色容易进行。此外,对于EVA系的热塑性树脂,由于耐热性低,因此不适合汽车内装用途。
因此,作为与平切薄镶板热压接的树脂膜,如果如专利文献2中所示,使用在热塑性树脂中透湿性、氧透过性极低的聚烯烃树脂,能够解决上述劣化、褪色的问题。此外,聚烯烃树脂具有作为汽车内装用途必需的100℃以上的耐热性。
现有技术文献
专利文献
专利文献1:专利第3930491号公报
专利文献2:特开2011-255542号公报
发明内容
发明要解决的课题
但是,聚烯烃树脂是其几乎由碳和氢组成的极性低的化学上稳定的塑料,如上所述,与其他树脂相比,透湿性、氧透过性极低,另一方面,由于表面的润湿性差,因此与其他材料或其他塑料的粘接极其困难,一般认为无法粘接。
即,如专利文献2中记载那样,只是单纯地将平切薄镶板与聚烯烃树脂膜热压接,具有不能制造将平切薄镶板与树脂膜牢固地粘接的耐久性高的平切薄镶板片材的问题。
因此,本发明的主要课题在于提供能够与天然木平切薄镶板牢固地粘接,同时透湿性、氧透过性极低,对于该平切薄镶板能够赋予优异的汽车内装适合性的树脂膜。此外,本发明的另一课题在于提供使用了这样的树脂膜的特别适合汽车内装用途的平切薄镶板片材和汽车内装部件。
用于解决课题的手段
本发明中的第1发明是树脂膜10,其是粘附于天然木平切薄镶板18的表面的树脂膜10,其特征在于,包括熔融粘接填充层12和功能层14,该熔融粘接填充层12由熔体流动速率(MFR;试验条件为170℃、2.1kg载荷)为2.5~33.0g/10分钟的烯烃系树脂形成,该烯烃系树脂含有改性聚烯烃树脂,该功能层14由热塑性树脂形成,层叠于上述熔融粘接填充层12的表面。
本发明中,由于用熔体流动速率(MFR;试验条件为170℃、2.1kg载荷)为2.5~33.0g/10分钟且含有改性聚烯烃树脂的烯烃系树脂形成了树脂膜10的熔融粘接填充层12,因此将树脂膜10与平切薄镶板18热压接时,熔融粘接填充层12侵入到由导管、木质部等构成的平切薄镶板18的深部,主要利用锚定效应,将树脂膜10与平切薄镶板18牢固地粘接。
其中,构成熔融粘接填充层12的烯烃系树脂的熔体流动速率,优选如上所述为2.5~33.0g/10分钟的范围内。这是因为,熔体流动速率不到2.5g/10分钟的情况下,熔融粘接填充层12对于平切薄镶板18的含浸性、粘接性变差,相反比33.0g/10分钟大的情况下,膜制膜性变差,尤其是吹胀成型中的膜制膜显著恶化。
上述的发明中,优选在熔融粘接填充层12与功能层14之间还存在由烯烃系的聚合物合金或聚合物共混物形成的中间层16。通过夹持这样的中间层16,即使如后述那样用烯烃系树脂以外的树脂形成了功能层14的情况下,也能将熔融粘接填充层12与功能层14牢固地接合。
此外,本发明中,优选形成上述功能层14的热塑性树脂为选自由聚甲基丙烯酸甲酯树脂(PMMA)、聚碳酸酯树脂(PC)、聚丙烯树脂(PP)、ABS树脂(ABS)、聚酯系树脂、聚乙烯树脂(PE)、聚苯乙烯树脂(PS)、聚氨酯树脂(PU)组成的组中的至少1种。这种情况下,能够对上述的功能层14赋予各树脂各自具有的功能。
进而,本发明中,优选在上述熔融粘接填充层12或中间层16的至少任一方中配合将波长为380~700nm的电磁波、更优选地波长为380~400nm的紫外线和波长为400~500nm的近似上述紫外线的可见光吸收或扩散的有色材料。
通常,对于配合紫外线吸收剂的一般的塑料的耐光配方,将380nm以下的波长的紫外线吸收或扩散,但通过“配合将波长为380~700nm的电磁波吸收或扩散的有色材料”,与以往的耐光配方并用,从而能够将更宽的波长范围的紫外线、与其近似的可见光等吸收或扩散,能够更有效地防止将树脂膜10粘接的平切薄镶板18的变色、劣化。此外,由于在熔融粘接填充层12或中间层16的至少任一方中配合“将波长为380~700nm的电磁波吸收或扩散的有色材料”,因此将该树脂膜10粘贴于平切薄镶板18时成为最外表面侧的功能层14成为透明、光泽感优异的状态。因此,只是将这样的树脂膜10粘贴于平切薄镶板18的表面,就能够对平切薄镶板18施加耐光性的彩色,而且能够将平切薄镶板18的表面整饰为镜面状。
再有,作为“将波长为380~700nm的电磁波吸收或扩散的有色材料”,能够例示也包含红褐色、栗色、深红色等的茶系的或黑系的染料、颜料、无机系紫外线吸收剂、氧化铁系紫外线吸收剂等。
本发明中的第2发明是汽车内装用的平切薄镶板片材20,是在天然木平切薄镶板18的表里两面将热塑性的树脂膜热压接的平切薄镶板片材20,其特征在于,在上述天然木平切薄镶板18的至少表面侧,将权利要求1~4的任一项所述的树脂膜10在其熔融粘接填充层12的熔点以上的温度下热压接。
其中,本发明(第2发明)中,优选地,在上述天然木平切薄镶板18的里面与在该里面侧热压接的树脂膜11之间、或、与上述天然木平切薄镶板18的里面热压接的树脂膜11的外表面侧,插入或层叠在比该树脂膜11的熔点高的温度下能够维持形状的纤维为主体的非织造布34。
此外,本发明中的第3发明为汽车内装部件32,其特征在于,使用上述第2发明的平切薄镶板片材20,注射成型而得到。
发明的效果
根据本发明,能够提供能够与天然木平切薄镶板牢固地粘接,同时透湿性、氧透过性极低,能够对于该平切薄镶板赋予优异的汽车内装适合性的树脂膜。此外,如果使用本发明的树脂膜,能够提供对于汽车内装用途特别适合的平切薄镶板片材和汽车内装部件。
附图说明
图1为表示本发明中的一实施例的树脂膜的结构的示意图,(a)表示不具有中间层的2层结构的树脂膜,(b)表示具有中间层的3层结构的树脂膜。
图2为表示使用了本发明的树脂膜的平切薄镶板片材制造工序的一例的说明图。
图3为将本发明的第1实施方式的平切薄镶板片材的木口面放大的SEM照片(附图代用照片)。
图4为表示本发明的第2实施方式的平切薄镶板片材的图,(a)为表示其制造工序的一例的说明图,(b)为将该工序中得到的平切薄镶板片材的木口面放大的SEM照片(附图代用照片)。
图5为表示本发明的第3实施方式的平切薄镶板片材的图,(a)为表示其制造工序的一例的说明图,(b)为将该工序中得到的平切薄镶板片材的木口面放大的SEM照片(附图代用照片)。
图6为表示使用了本发明的平切薄镶板片材的汽车内装部件制造工序的一例的说明图。
图7为表示平切薄镶板片材的注射成型时的与模具的追随性评价时作成的树脂成型样品的附图代用照片,(a)表示其表面全体,(b)为将其表面状态部分地放大。
具体实施方式
以下对于本发明的树脂膜和使用了该树脂膜的平切薄镶板片材以及汽车内装部件,参照附图说明。
本发明的树脂膜10粘附于天然木平切薄镶板18(参照图2)的表面,用于保护、装饰该平切薄镶板18,有如图1(a)中所示由熔融粘接填充层12和功能层14构成的结构和如图1(b)中所示在熔融粘接填充层12与功能层14之间存在中间层16的结构。
对树脂膜10的厚度并无特别限定,优选为30~500μm的范围。这是因为,树脂膜10的厚度不到30μm的情况下,维持作为平切薄镶板18表面的保护、装饰用材料必要的足够的强度变得困难,相反,树脂膜10的厚度比500μm大的情况下,该树脂膜10过于变得刚直,损害作为平切薄镶板18表面的保护、装饰用材料必要的柔软性(曲面追随性)。
熔融粘接填充层12是将树脂膜10粘附于天然木平切薄镶板18的表面时热熔融而浸透到平切薄镶板18的内部、在该平切薄镶板18的导管、木质部之间填充的层,由按照JIS K6922-2测定的熔体流动速率(MFR;试验条件为170℃、2.1kg载荷)为2.5~33.0g/10分钟、优选地3.0~10.0g/10分钟、更优选地4.0~7.0g/10分钟的烯烃系树脂形成。如上所述,如果MFR不到2.5g/10分钟,熔融粘接填充层12对于平切薄镶板18的含浸性、粘接性变差,相反,如果MFR超过33.0g/10分钟,膜制膜性变差,尤其是吹胀成型中的膜制膜显著地恶化。
其中,如上所述,聚烯烃树脂是极性低的化学上稳定的塑料,即使提高MFR,提高热熔融时的流动性,由于表面的润湿性差,因此与平切薄镶板18、其他树脂的粘接也极难。因此,本发明的树脂膜10中,为了提高对于平切薄镶板18、其他树脂的粘接性,在构成熔融粘接填充层12的烯烃系树脂中配合了将该烯烃系树脂或烯烃系树脂与其他树脂的共聚物用α、β-不饱和羧酸、其衍生物(例如丙烯酸、丙烯酸甲酯)、或脂环族羧酸、其衍生物(例如马来酸酐)等改性(例如接枝改性)的改性聚烯烃树脂。
该改性聚烯烃树脂,在非极性的聚烯烃树脂中导入极性基,赋予与平切薄镶板18、其他树脂这样的不同材料的粘接性,形成熔融粘接填充层12的烯烃系树脂全体中该改性聚烯烃树脂所占的配合比例优选为2重量%~80重量%的范围,更优选为5重量%~20重量%的范围。这是因为,形成熔融粘接填充层12的烯烃系树脂全体中酸改性聚烯烃树脂所占的配合比例不到2重量%的情况下,与平切薄镶板的亲和性变差,含浸性也降低,相反,超过80重量%的情况下,含浸性变得极好,但在平切薄镶板表面残留的树脂的量变少,有时与功能层14(或中间层16)的粘接强度降低。
功能层14是将树脂膜10粘附于平切薄镶板18而构成平切薄镶板片材20时配置在最表侧(或最里侧)的层。该功能层14是用于使形成其的树脂发挥固有的功能、性质的层。因此,将使用本发明的树脂膜10制造的平切薄镶板片材20在汽车内装用途中使用的情况下,优选用选自由聚甲基丙烯酸甲酯树脂(PMMA)、聚碳酸酯树脂(PC)、聚丙烯树脂(PP)、ABS树脂(ABS)、以聚对苯二甲酸乙二醇酯树脂(PET)、聚对苯二甲酸丁二醇酯作为硬链段的酯弹性体等聚酯系树脂、聚乙烯树脂(PE)、聚苯乙烯树脂(PS)、聚氨酯树脂(PU)组成的组中的至少1种形成该功能层14。例如,用聚氨酯树脂形成功能层14的情况下,表面的触感改善,用ABS树脂形成功能层14的情况下,抗冲击性提高,这样通过该功能层14,能够对树脂膜10的表面(乃至平切薄镶板片材20的表面)赋予上述的各树脂各自固有的功能。
此外,如后所述,将使用本发明的树脂膜10制造的平切薄镶板片材20与基材树脂30接合来制造汽车内装部件32时(参照图6),通过使构成功能层14的树脂与和该功能层14接合的基材树脂30为同一或同种的树脂,能够以高的层间强度使平切薄镶板片材20与基材树脂30牢固地接合一体化。
中间层16,是如图1(b)中所示,根据需要存在于熔融粘接填充层12与功能层14之间的层。如上所述,烯烃系树脂是极性低的化学上稳定的塑料,即使在熔融粘接填充层12中配合了改性聚烯烃树脂,由于构成功能层14的树脂的种类等,有时在熔融粘接填充层12与功能层14之间不能确保足够的层间强度。这种情况下,优选在熔融粘接填充层12与功能层14之间存在由烯烃系的聚合物合金或聚合物共混物形成的中间层16。
其中,作为在烯烃系的聚合物合金或聚合物共混物中与烯烃系树脂一起配合的原料树脂,优选使用与构成功能层14的树脂相同或同种的树脂。这样,能够通过该中间层16,以高的层间强度将熔融粘接填充层12与功能层14牢固地接合。
制造由以上的各层12、14、16构成的树脂膜10时,能够采用吹胀法、T型模头法或管式法等公知的膜制造方法。此外,为了提高制造效率,同时减轻在库管理等的负担,提高制品的处理性,优选将各层12、14、16与制膜同时地层叠、一体化,但也可分别各自地制造各层12、14、16,在平切薄镶板18的表面粘附时,以规定的顺序层叠、热压接。
再有,在形成树脂膜10的各层12、14、16中,除了原料树脂以外,根据需要可添加防粘连剂、润滑剂、紫外线吸收剂、耐候稳定剂、阻燃剂、将波长为380~700nm的电磁波吸收或扩散的有色材料等添加剂。
其中,在树脂膜10中添加将波长为380~700nm的电磁波、即波长为380~400nm的紫外线和波长为400~700nm的可见光吸收或扩散的有色材料,更具体地,也包含红褐色、栗色、深红色等的茶系的或黑系的染料、颜料、无机系紫外线吸收剂、氧化铁系紫外线吸收剂等的情况下,优选在熔融粘接填充层12或中间层16的至少任一方中添加。通过将有色的这些试剂配合于熔融粘接填充层12或中间层16的至少任一方,功能层14成为透明、光泽感优异的状态。因此,只是将这样构成的树脂膜10与平切薄镶板18的表面热压接,就能够对平切薄镶板18施加耐光性的彩色,同时能够将平切薄镶板18的表面整饰为镜面状。
接下来,参照图2对使用如上所述构成的树脂膜10制造“平切薄镶板片材20”的方法进行说明。
本发明的平切薄镶板片材20,在天然木平切薄镶板18的表里的各表面(表里两面)粘附树脂膜的产物中,至少在天然木平切薄镶板18的表面侧粘附上述的树脂膜10而保护、装饰该平切薄镶板18的表面。其中,在天然木平切薄镶板18的表里两面粘附上述本发明的树脂膜10的情况下,能够发挥能够抑制平切薄镶板片材20的翘曲等进一步的效果。
天然木平切薄镶板18是将天然的原木或原木的单板集成而成的集成材料平切加工或旋转加工而得到的厚0.1~2.0mm左右的薄板材。其中,作为制造平切薄镶板18的代表性的原木,可列举日本扁柏、罗汉柏、榉木、日本栎木、梣木、桐木、杉木、桃花心木、胡桃木、栎木、柚木、红木、乌木、紫檀、黑檀、榆树、竹、枫树(枫木)等。
将上述的平切薄镶板18与前述的树脂膜10层叠一体化而制造平切薄镶板片材20时,使用图2中所示的热辊22。具体地,通过在至少平切薄镶板18的单面层叠了树脂膜10后,将该层叠的片材送入加热到构成熔融粘接填充层12的树脂的熔点或其以上的温度的上下一对热辊22之间,边施加规定的压力边热压接,然后冷却,从而如图3中所示,熔融粘接填充层12浸透到平切薄镶板18的内部,将两者牢固地粘接的平切薄镶板片材20完成。
再有,图2中,示出了在平切薄镶板18的上侧层叠不具有中间层16的2层结构的树脂膜10,在下侧层叠具有中间层16的3层结构的树脂膜10的情形,但平切薄镶板18与树脂膜10的组合并不限定于此。
此外,平切薄镶板片材20的制造方法,不仅是如上所述使用上下一对的热辊22连续地制造平切薄镶板片材20的方法,也可以是将裁切成规定的长度的树脂膜10和平切薄镶板18层叠并用平面压机热压接的方法(间歇式)等。
此外,制造平切薄镶板片材20时,根据需要加入如下的改进的方法适合。即,如图4(a)中所示,在平切薄镶板18的表面层叠树脂膜10,同时在平切薄镶板18的里面层叠里面侧用的树脂膜11(当然,该树脂膜11可以是本发明的树脂膜10。),使用热辊22热压接时,在平切薄镶板18的里面与在该里面侧热压接的树脂膜11之间安装在比该树脂膜11的熔点高的温度下能够维持形状的纤维为主体的非织造布34。这样,该非织造布34,如图4(b)中所示,从里面侧用的树脂膜11的内部全体到外表面配置,该树脂膜11恰好成为FRP(FiberReinforced Plastics)这样的结构。其结果,如后述那样采用注射成型制造汽车内装部件32时,防止由于加热、熔融状态的基材树脂30具有的热、压力、或流动,在树脂膜11的外表面侧形成的(与该基材树脂30的)粘接层熔融、流出,能够防止在两者之间发生粘接不良。此外,在树脂膜11的外表面分散的非织造布34与基材树脂30之间发挥锚定效果,能够将两者牢固地接合。此外,如上所述,由于树脂膜11成为了FRP这样的结构,因此也能够对平切薄镶板片材20赋予刚性。
此外,如图5(a)中所示,在平切薄镶板18的表面层叠树脂膜10,同时在平切薄镶板18的里面层叠里面侧用的树脂膜11(当然,该树脂膜11也可以是本发明的树脂膜10。),用热辊22热压接时,在树脂膜11的外表面侧层叠在比该树脂膜11的熔点高的温度下能够维持形状的纤维为主体的非织造布34。这样,该非织造布34,如图5(b)中所示,从树脂膜11外表面侧的内部到外表面配置。其结果,与上述的情形同样地,采用注射成型制造汽车内装部件32时,能够防止由于加热、熔融状态的基材树脂30具有的热、压力、或流动,在树脂膜11的外表面侧形成的(与该基材树脂30的)粘接层熔融、流出,防止在两者之间发生粘接不良,而且由于与上述的情形相比,在树脂膜11的外表面配置了更多的非织造布34,因此在非织造布34与基材树脂30之间发挥更多的锚定效果,能够将两者更牢固地接合。再有,这样将非织造布34在树脂膜11的外表面侧层叠的情况下,不太能够期待提高平切薄镶板片材20的刚性,但不会损害平切薄镶板片材20的柔软性。
再有,在图4(b)和图5(b)中所示的例子中,作为平切薄镶板20,准备了厚200μm的バーズアイメイプル,作为树脂膜10,准备了厚150μm的树脂膜。此外,作为树脂膜11,准备了由平切薄镶板粘接层和中间层和功能层组成的三层结构的树脂膜,在整个层中包含以聚对苯二甲酸丁二醇酯作为硬链段的酯弹性体,厚度为100μm。此外,作为非织造布34,准备了由PET纤维构成的单位面积重量40g/m2的射流喷网法非织造布(シンワ(株)社制造品号7840A)。然后,将它们按照图4(a)或图5(a)的顺序层叠,用170℃的热辊热压接,得到了平切薄镶板片材20。
此外,上述的说明中,将非织造布34限定为“以在比树脂膜11的熔点高的温度下能够维持形状的纤维为主体”,所谓“以在比树脂膜11的熔点高的温度下能够维持形状的纤维”,不只限于比树脂膜11熔点高的热塑性纤维,是也包含例如人造丝、Lyocel l等再生纤维素纤维、棉籽绒等的概念。此外,非织造布34的制造方法能够采用干式和湿式的任何方法。
接下来,参照图6,对使用在平切薄镶板16的表里两面将本发明的树脂膜10热压接的图3的平切薄镶板片材20制造“汽车内装部件32”的方法进行说明。
首先,最初,如图6(a)中所示,将在两面热压接了树脂膜10的平切薄镶板片材20装入注射成型装置24的第1模26(阴模)。再有,该平切薄镶板片材20可预先通过真空成型等成型为沿第1模26的内面的规定的形状。
接着,如图6(b)中所示,从没有图示的注射单元的喷嘴,经由设置在第2模28的浇口28a将加热、熔融的基材树脂30挤出到模腔A内,将第1模26和第2模28锁模。
然后,将由平切薄镶板片材20构成的表面保护·装饰部分和由基材树脂30构成的主体部分冷却、固化,完成了汽车内装部件32后,如图6(c)中所示,将完成的汽车内装部件32从模腔A脱模。
该汽车内装部件32的制造方法中,优选使位于平切薄镶板片材20的与基材树脂30相接的一侧的表面的树脂膜10的功能层14与和该功能层14接合的基材树脂30为同一或同种的树脂。这是因为,由此能够以高的层间强度将平切薄镶板片材20与基材树脂30牢固地接合一体化。
此外,如果已对第1模26的表面进行镜面整饰,则该镜面转印于完成的汽车内装部件32的表面,因此对于汽车内装部件32,能够省略另外实施镜面加工的麻烦。
实施例
以下对于本发明的树脂膜,列举具体的实施例和比较例进行说明,但本发明并不限定于这些实施例。
再有,实施例和比较例的各树脂膜(更具体地,熔融粘接填充层膜)的特性评价采用以下的方法进行。
1.树脂膜的特性评价
(1)熔融粘接填充层膜的制造特性的评价
(a)构成熔融粘接填充层的树脂的MFR:按照JIS K6922-2,在170℃,2.1kg载荷的试验条件下测定。
(b)T型模头加工性:将构成熔融粘接填充层的组成的树脂物混合物,使用螺杆直径35mm的单螺杆挤出机,导入以模头内的熔融树脂的流动变得均匀的方式设计的宽400mm的T型模头,在模头出口的树脂温度170℃的条件下挤出。再有,模唇间隙为1.0mm。然后,将从模头出来的熔融树脂膜用30℃的冷却辊冷却,得到了层厚为50μm的烯烃系膜,同时通过目视观察T型模头加工性,用◎(优)、○(良)、△(合格)、×(不合格)的4等级评价。
(c)吹胀加工性:作为将单层膜成型的情形,将构成熔融粘接填充层的组成的树脂组合物,使用35mm挤出机,在挤出温度200℃、排出量5kg/hr下熔融混炼,从周长157mm(直径50mmφ)、模唇间隙0.5mm的圆形模唇挤出为筒状,边吹空气边冷却,制作厚50μm的吹胀膜。此外,作为成型多层膜的情形,以构成熔融粘接填充层的组成的树脂组合物作为内层,以聚丙烯树脂(无规聚丙烯:日本ポリケム株式会社制造ウインテックWFX4TA)作为中间层和外层,在模头温度190℃下制作三层的共挤出吹胀膜。再有,挤出机口径为内层/中间层/外层=45/45/45(单位:mmφ),层构成比设定为内层/中间层/外层=1/1/1(总厚度=150μm),层叠体成型速度设定为8m/分钟。然后,对于各吹胀膜成型过程,通过目视观察吹胀加工性,用◎(优)、○(良)、△(合格)、×(不合格)的4等级评价。
(2)熔融粘接填充层膜的物性评价
(a)含浸性:在厚0.20mm的天然木平切薄镶板(バーズアイメープル)的上下两面设置成为熔融粘接填充层的厚0.05mm的实施例或比较例的膜,进而在其外侧重叠厚0.10mm的聚丙烯膜(功能层),使用热压机,在180℃、1MPa下热压接30秒。然后,在加压的状态下冷却到常温,得到了平切薄镶板片材。从得到的平切薄镶板片材的大致中央部分切出宽30mm×长100mm的试料,拍摄将木口面放大200倍的SEM照片,通过目视观察熔融粘接填充层对于平切薄镶板内部的浸透情况,用◎(优)、○(良)、△(合格)、×(不合格)的4等级评价。
(b)密合性:使用采用与上述含浸性评价相同的方法作成的试料,将表里两面的聚丙烯膜分别安装于拉伸试验机的夹具,对该聚丙烯膜进行拉伸,测定平切薄镶板与聚丙烯膜的剥离强度。然后,对得到的结果用◎(优)、○(良)、△(合格)、×(不合格)的4等级评价。
[实施例1]
准备作为高透明聚丙烯树脂的日本ポリプロ社制造的ウィンテック(注册商标;品号WFX4TA)、作为分子量调节用高MFR聚丙烯树脂的日泉化学社制造的PP2100以及作为马来酸改性聚丙烯树脂的三洋化成工业社制造的ユーメックス(注册商标;品号1010)。然后,将高透明聚丙烯树脂49重量%、分子量调节用高MFR聚丙烯树脂41重量%和马来酸改性聚丙烯树脂10重量%混合,进而相对于上述树脂混合物100重量份,分别加入0.5重量份的アデカ社制造的紫外线吸收剂アデカスタブ(注册商标;品号1413)、BASF(旧チバ·ジャパン)社制造的抗氧化剂IRGANOX(注册商标;品号1010),将这些混合体使用安装有80目的金属网的35mmφ的带有通气孔的挤出机,在温度170℃下挤出为丝束状,将丝束水冷后切割,调制熔融粘接填充层用的配混物。得到的配混物在90℃下干燥8小时后,将其一部分供于上述的熔融粘接填充层膜的制造特性的评价。
接着,将该配混物投入设定在200℃的制膜温度的35mmφ的空冷吹胀成膜机,成型厚50μm的熔融粘接填充层膜。
将得到的膜的物性评价结果和采用该配方的膜制造特性的评价结果示于表1。
[实施例2]
除了准备作为改性聚烯烃系树脂的三菱化学社制造的モディック(注册商标;品号F534A)、作为分子量调节用高MFR聚丙烯树脂的日泉化学社制造的PP2100,将改性聚烯烃系树脂80重量%和分子量调节用高MFR聚丙烯树脂20重量%混合,调制熔融粘接填充层用的配混物以外,采用与实施例1同样的方法进行了熔融粘接填充层膜的制造特性和得到的膜物性的评价。将得到的结果示于表1。
[比较例1]
除了只使用作为高透明聚丙烯树脂的日本ポリプロ社制造的ウィンテック(注册商标;品号WFX4TA)调制熔融粘接填充层用的配混物以外,采用与实施例1同样的方法进行了熔融粘接填充层膜的制造特性和得到的膜物性的评价。将得到的结果示于表1。
[比较例2]
除了只使用作为分子量调节用高MFR聚丙烯树脂的日泉化学社制造的PP2100调制熔融粘接填充层用的配混物以外,采用与实施例1同样的方法进行了熔融粘接填充层膜的制造特性和得到的膜物性的评价。将得到的结果示于表1。
[比较例3]
除了准备作为分子量调节用高MFR聚丙烯树脂的日泉化学社制造的PP2100、作为马来酸改性聚丙烯树脂的三洋化成工业社制造的ユーメックス(注册商标;品号1010),将分子量调节用高MFR聚丙烯树脂80重量%和马来酸改性聚丙烯树脂20重量%混合,调制熔融粘接填充层用的配混物以外,采用与实施例1同样的方法进行了熔融粘接填充层膜的制造特性和得到的膜物性的评价。将得到的结果示于表1。
[表1]
如表1中所示,对于实施例的熔融粘接填充层膜,可看到制造性和作为熔融粘接填充层的功能都良好。而对于构成熔融粘接填充层的树脂的MFR不到本发明的下限的比较例1,虽然膜的制造性良好,但可看到得到的膜作为熔融粘接填充层完全没有发挥功能。此外,相反地,构成熔融粘接填充层的树脂的MFR大大超过本发明的上限的情况下,可看到主要是膜的制造性显著地恶化。
2.平切薄镶板片材的特性评价
(1)对于平切薄镶板片材的伸长率
在厚0.20mm的天然木平切薄镶板(バーズアイメープル)的表里两面,经由上述实施例1的熔融粘接填充层膜将厚0.05mm的聚丙烯膜热压接,得到了厚0.35mm的平切薄镶板片材。对于该平切薄镶板片材和没有层叠树脂膜的厚0.20mm的天然木平切薄镶板(バーズアイメープル),采用以下的方法测定了伸长率。
即,从各片材切出宽10mm×长200mm的试验试料,使用岛津精密万能试验机オートグラフ,在室温15±5℃、湿度30±5%、速度1mm/分、标点距离100mm的条件下进行拉伸试验,测定了伸长率。
其结果,通过用由熔融粘接填充层膜和聚丙烯膜组成的树脂膜层叠天然木平切薄镶板,可以看到在天然木平切薄镶板的纤维方向上伸长率提高2倍左右,在与该纤维方向正交的方向上伸长率提高4~5倍左右。
(2)对于将平切薄镶板片材用于注射成型时的与模具的追随性
准备与用于上述伸长率的测定同样的平切薄镶板片材,将该平切薄镶板片材放置于在日精树脂工业制造的注射成型机NS-60-9A中安装的试验模具(使用改变了凹凸部的深度、曲率等的数种的模具)。然后,在注射树脂温度200℃、注射压力60MPa的条件下,在平切薄镶板片材的里面侧将聚丙烯树脂注射成型,得到了图7中所示的与模具的追随性评价用的树脂成型样品。再有,作为比较,代替平切薄镶板片材而使用了没有用树脂膜层叠的厚0.20mm的天然木平切薄镶板(バーズアイメープル),也作成了树脂成型样品。然后,确认各树脂成型样品的台阶高差部分以及在凸部平面有无平切薄镶板的开裂,评价与模具的追随性。
其结果,对于用树脂膜层叠的平切薄镶板片材,如上所述伸长率提高,此外,各向异性得到缓和,在平切薄镶板的纤维方向和与其正交的方向之间的伸长率之差几乎不存在,因此与模具的追随性显著提高,可看到也能够应对对于以往(即,只是天然木平切薄镶板)是不可能的曲率高的形状、深的凹凸等。
附图标记的说明
10…树脂膜
11…(在天然木平切薄镶板的里面侧热压接的)树脂膜
12…熔融粘接填充层
14…功能层
16…中间层
18…天然木平切薄镶板(平切薄镶板)
20…平切薄镶板片材
22…热辊
24…注射成型装置
26…第1型(阴模)
28…第2型
30…基材树脂
32…汽车内装部件
34…非织造布
Claims (9)
1.树脂膜(10),是粘附于天然木平切薄镶板(18)的表面的树脂膜(10),其特征在于,包括熔融粘接填充层(12)和功能层(14),该熔融粘接填充层(12)由熔体流动速率MFR为2.5~33.0g/10分钟的烯烃系树脂形成,所述熔体流动速率MFR的试验条件为170℃、2.1kg载荷,该烯烃系树脂含有改性聚烯烃树脂,该功能层(14)由热塑性树脂形成,层叠于所述熔融粘接填充层(12)的表面,并且在上述熔融粘接填充层(12)与上述功能层(14)之间还存在由烯烃系的聚合物共混物形成的中间层(16)。
2.树脂膜(10),是粘附于天然木平切薄镶板(18)的表面的树脂膜(10),其特征在于,包括熔融粘接填充层(12)和功能层(14),该熔融粘接填充层(12)由熔体流动速率MFR为2.5~33.0g/10分钟的烯烃系树脂形成,所述熔体流动速率MFR的试验条件为170℃、2.1kg载荷,该烯烃系树脂含有改性聚烯烃树脂,该功能层(14)由热塑性树脂形成,层叠于所述熔融粘接填充层(12)的表面,并且在上述熔融粘接填充层(12)与上述功能层(14)之间还存在由烯烃系的聚合物合金形成的中间层(16)。
3.权利要求1或2所述的树脂膜(10),其特征在于,形成上述功能层(14)的热塑性树脂是选自由聚甲基丙烯酸甲酯树脂、聚碳酸酯树脂、聚丙烯树脂、ABS树脂、聚酯系树脂、聚乙烯树脂、聚苯乙烯树脂、聚氨酯树脂组成的组中的至少1种。
4.权利要求1或2所述的树脂膜(10),其特征在于,在上述熔融粘接填充层(12)或中间层(16)的至少任一方中配合有将波长为380~700nm的电磁波吸收或扩散的有色材料。
5.权利要求3所述的树脂膜(10),其特征在于,在上述熔融粘接填充层(12)或中间层(16)的至少任一方中配合有将波长为380~700nm的电磁波吸收或扩散的有色材料。
6.汽车内装用的平切薄镶板片材(20),是在天然木平切薄镶板(18)的表里两面将热塑性的树脂膜热压接而成的平切薄镶板片材(20),其特征在于,在上述天然木平切薄镶板(18)的至少表面侧将权利要求1~5任一项所述的树脂膜(10)在其熔融粘接填充层(12)的熔点以上的温度下热压接。
7.权利要求6所述的汽车内装用的平切薄镶板片材(20),其特征在于,在上述天然木平切薄镶板(18)的里面与在该里面侧热压接的里面侧用的树脂膜(11)之间,插入以在比该里面侧用的树脂膜(11)的熔点高的温度下能够维持形状的纤维为主体的非织造布(34)。
8.权利要求6所述的汽车内装用的平切薄镶板片材(20),其特征在于,在与上述天然木平切薄镶板(18)的里面热压接的里面侧用的树脂膜(11)的外表面侧层叠有以在比该里面侧用的树脂膜(11)的熔点高的温度下能够维持形状的纤维为主体的非织造布。
9.汽车内装部件(32),其特征在于,使用权利要求6~8任一项所述的平切薄镶板片材(20)注射成型而得到。
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