JP2004291637A - Synthetic resin molding and its manufacturing process - Google Patents

Synthetic resin molding and its manufacturing process Download PDF

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JP2004291637A
JP2004291637A JP2004068616A JP2004068616A JP2004291637A JP 2004291637 A JP2004291637 A JP 2004291637A JP 2004068616 A JP2004068616 A JP 2004068616A JP 2004068616 A JP2004068616 A JP 2004068616A JP 2004291637 A JP2004291637 A JP 2004291637A
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synthetic resin
artificial leather
resin molded
molded product
fibers
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JP4595355B2 (en
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Shunichiro Nakai
俊一郎 中井
Makoto Nishimura
誠 西村
Akira Karasawa
明 唐沢
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Toray Industries Inc
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Toray Industries Inc
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2711/00—Use of natural products or their composites, not provided for in groups B29K2601/00 - B29K2709/00, for preformed parts, e.g. for inserts
    • B29K2711/08—Leather

Abstract

<P>PROBLEM TO BE SOLVED: To provide a synthetic resin molding laminated with artificial leather, which allows a luxurious surface quality and enhances color fastness, and a manufacturing process thereof. <P>SOLUTION: The synthetic resin molding is manufactured; by uniting the artificial leather, of which at least one side is fluffed, on the surface of the synthetic resin mold and binding with its fluffed surface. The manufacturing process is carried out, by injecting a melt of a synthetic resin having a melting point of 250°C or lower on the fluffed surface of the artificial leather fluffed at least on one side and cooling the reverse side to the fluffed surface of the artificial leather while compression molding. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

本発明は、高級感のある表面品位を有する人工皮革貼着合成樹脂成形物およびそれを簡単、容易に提供する製造方法に関するものである。   TECHNICAL FIELD The present invention relates to an artificial leather-attached synthetic resin molded article having a high-grade surface quality and a production method for providing the molded article simply and easily.

従来より合成樹脂成形物の表面に皮革シートを張設することで、質感や触感を高めた製品やその製造方法が提案されている。これらを成形するには合成樹脂容器を成形した後に所定形状に裁断された人工皮革を接着剤や両面テープなどで貼着する方法、基体層と合成樹脂の一体成形により張りあわせる方法がとられている。   2. Description of the Related Art Hitherto, products in which a leather sheet is stretched on the surface of a synthetic resin molded product to enhance the texture and touch and a method for manufacturing the same have been proposed. In order to mold them, a synthetic resin container is molded, and then artificial leather cut into a predetermined shape is adhered with an adhesive or a double-sided tape, or a method of laminating the base layer and the synthetic resin by integral molding. I have.

例えば合成皮革を張設する場合には、人工皮革と合成樹脂との相溶性を利用して人工皮革シートの一面を合成樹脂に融着させることで一体的に成形する方法（特許文献１、２参照）ある。しかしながら、これら一体成形による人工皮革を張設する場合には、成形時に人工皮革表面の品位や物性、染色堅牢度が著しく低下し、高級感が損なわれてしまうという問題があった。これらを解決するに当たり金型への基材層の張り付け方法など工夫が提案されているが特に表面に毛羽を有する人工皮革には成形時の温度により表面感が大きく変化してしまうため問題であった（特許文献３、４参照）。   For example, when synthetic leather is stretched, a method of integrally molding the synthetic leather sheet by fusing one surface of the artificial leather sheet to the synthetic resin utilizing the compatibility between the artificial leather and the synthetic resin (Patent Documents 1 and 2) See). However, when artificial leather is stretched by integral molding, there is a problem that the quality, physical properties, and color fastness of the surface of the artificial leather are significantly reduced at the time of molding, and the sense of quality is impaired. In order to solve these problems, a method such as a method of attaching a base material layer to a mold has been proposed. However, in particular, artificial leather having a fluff on the surface has a problem because the surface feel changes greatly depending on the temperature at the time of molding. (See Patent Documents 3 and 4).

これらの問題を解決するためには、人工皮革シートに布地等の中間材を裏打ちし、人工皮革シートの合成樹脂材料接着側の耐熱温度を高める方法（特許文献５，６参照）があるが、これらの方法を採用した場合、中間材の必要性や中間材裏打ち工程の増加を余儀なくされ、厚みも厚くなりデザイン的な制約を受ける原因となっていたし、さらにかかる人工皮革シートは容易に剥離し易いという致命的欠陥があった。
特開昭５９−１４２９３７号公報 特開平２−５９３１４号公報 特開平６−３４４３７７号公報 特開平７−３０４０６１号公報 特開昭６０−２１２３１３号公報 特開昭６１−１４９４４号公報 In order to solve these problems, there is a method in which an artificial leather sheet is lined with an intermediate material such as cloth to increase the heat-resistant temperature of the synthetic leather material bonding side of the artificial leather sheet (see Patent Documents 5 and 6). When these methods are adopted, the necessity of an intermediate material and an increase in an intermediate material backing process are inevitably increased, and the thickness becomes thick, which causes a design restriction.In addition, such an artificial leather sheet is easily peeled off. There was a fatal defect that it was easy.
JP-A-59-142937 JP-A-2-59314 JP-A-6-344377 JP-A-7-304061 JP-A-60-212313 JP-A-61-14944

このように人工皮革と合成樹脂を一工程で一体的に成形し、且つ人工皮革表面の品位を損なわずに行うことは非常に困難な状況にあった。   As described above, it was very difficult to integrally mold the artificial leather and the synthetic resin in one step and to perform the molding without deteriorating the quality of the artificial leather surface.

本発明は、かかる従来技術の背景に鑑み、高級感のある表面品位に優れ、かつ、染色堅牢度にも優れた人工皮革が貼着された合成樹脂成形物およびそれを簡単、容易に提供する製造方法を提供せんとするものである。   In view of the background of the related art, the present invention provides a synthetic resin molded article to which artificial leather having excellent luxurious surface quality and excellent dyeing fastness is stuck, and a simple and easy product thereof. It does not provide a manufacturing method.

本発明は、かかる課題を解決するために、次のような手段を採用するものである。すなわち、本発明の合成樹脂成形物は、少なくとも片面が立毛化された人工皮革が合成樹脂成形物の表面に一体化されてなる合成樹脂成形物であって、該人工皮革の立毛面で合成樹脂と結合していることを特徴とするものである。   The present invention employs the following means in order to solve such a problem. That is, the synthetic resin molded product of the present invention is a synthetic resin molded product in which artificial leather having at least one surface raised is integrated on the surface of the synthetic resin molded product, and the synthetic resin is formed on the raised surface of the artificial leather. It is characterized by being combined with

また、かかる合成樹脂成形物の製造方法は、少なくとも片面が立毛化された人工皮革の立毛面に、２５０℃以下の融点を有する合成樹脂の溶融液を射出して、圧縮成形する際に、該人工皮革の該立毛面の反対面が冷却されていることを特徴とするものである。   Further, in the method of manufacturing a synthetic resin molded product, a synthetic resin melt having a melting point of 250 ° C. or less is injected onto the raised surface of artificial leather having at least one surface raised, and compression molding is performed. The artificial leather is characterized in that the opposite side of the raised surface is cooled.

本発明によれば、立毛人工皮革を合成樹脂成形品表面に立毛を損なうことなく、極めて容易に且つ確実に、中間層を介さずに一つの工程によって張設することができ、製造コストのダウン並びに工程のスリム化を可能にすることができる。   ADVANTAGE OF THE INVENTION According to this invention, the raised hair artificial leather can be stretched very easily and reliably in one process without interposing an intermediate layer, without damaging the raised hair on the surface of a synthetic resin molded product, and the manufacturing cost can be reduced. In addition, the process can be made slim.


本発明の合成樹脂成形物は、少なくとも片面が立毛化された人工皮革の立毛面が合成樹脂成形物の表面に結合、一体化されていることが重要である。かかる結合部分には、かかる立毛のみならず、人工皮革の反対側（外側表面＝合成樹脂接触面の反対側）に合成樹脂溶融液の温度が伝達されない程度であれば、立毛長さを越えて、人工皮革を構成する不織布まで合成樹脂が及んでもよい。立毛は、合成樹脂溶融液の熱と、成形のためのプレス圧力によって、不織布基材に押し付けられたり、熱変形したり、熱変質したりして、屈曲したり、縮んだりするものであるが、この変形が剥離強力を大きくする要因である。
In the synthetic resin molded product of the present invention, it is important that the raised surface of artificial leather having at least one surface raised is bonded to and integrated with the surface of the synthetic resin molded product. Not only the nap but also the nap length beyond the nap length as long as the temperature of the synthetic resin melt is not transmitted to the opposite side of the artificial leather (outer surface = opposite to the synthetic resin contact surface). The synthetic resin may extend to the nonwoven fabric forming the artificial leather. The napped hair is one that is pressed, thermally deformed, or thermally deteriorated by heat of synthetic resin melt and press pressure for molding, and is bent or shrunk. This deformation is a factor that increases the peel strength.

また、かかる立毛結合構造を採用することによって、人工皮革表面の熱変形や変質を来すことなく、高級感のある表面品位に優れた形で提供することができる。   In addition, by employing such a napped structure, the artificial leather surface can be provided in a high-quality and excellent surface quality without causing thermal deformation or deterioration of the surface.

かかる手段によって、人工皮革の毛羽立たせた立毛部分内に、合成樹脂を効果的に浸透させ、かつ、人工皮革と合成樹脂成形物の表面とを結合、一体化させることにより、強力な固着力効果を生むものである。しかも、かかる特定な固着手段によれば、従来よりも低い温度での合成樹脂成形が可能となり、結果として成形後の人工皮革の表面の品位が損なわれることがない。   By such means, the synthetic resin is effectively penetrated into the fluffy nap portions of the artificial leather, and the artificial leather and the surface of the synthetic resin molded product are combined and integrated to provide a strong fixing effect. It produces. Moreover, according to the specific fixing means, it is possible to mold the synthetic resin at a lower temperature than before, and as a result, the quality of the surface of the artificial leather after molding is not impaired.

本発明で用いる人工皮革は、極細繊維で構成される３次元絡合体不織布と高分子弾性体とで構成される。   The artificial leather used in the present invention is composed of a three-dimensional entangled nonwoven fabric composed of ultrafine fibers and a polymer elastic body.

かかる極細繊維としては、特に限定しないが、海成分を抽出除去する海島型多成分複合繊維、または、後工程で剥離分割することによって極細繊維化される分割型多成分複合繊維などの極細繊維発生型繊維から得られるもので、単繊維繊度が、０．８〜０．００５デシテックスの極細繊維が１０〜数千本束になったものが、柔軟性の高い人工皮革を得る上で好ましく使用される。しかし、成形時に発生する熱の影響を回避する観点から、単繊維繊度があまり細すぎると、熱により融着して十分な投錨効果が得られない。一般的に太デシテックス繊維絡合体は細デシテックス絡合体に比べ、不織布形成時に密度が低く抜けやすく、表面がごわごわして緻密な構造のものが得られない傾向がある。すなわち、前記複合繊維の島繊維のデシテックスが０．８デシテックスを越えると、人工皮革特有の高級感を失う。従って極細繊維は、好ましくは０．５デシテックスから０．０１デシテックス、さらに好ましくは０．２デシテックスから０．０３デシテックスの範囲内のものであるのがよい。   Examples of such ultrafine fibers include, but are not particularly limited to, generation of ultrafine fibers such as sea-island multicomponent composite fibers for extracting and removing sea components, or split-type multicomponent composite fibers that are formed into ultrafine fibers by separation in a subsequent step. What is obtained from the mold fiber, the single fiber fineness is a bundle of 10 to several thousand ultrafine fibers of 0.8 to 0.005 decitex is preferably used for obtaining a highly flexible artificial leather. You. However, from the viewpoint of avoiding the influence of heat generated during molding, if the single fiber fineness is too small, the fibers are fused by heat and a sufficient anchoring effect cannot be obtained. In general, a thick decitex fiber entangled body has a lower density when forming a nonwoven fabric than a fine decitex entangled body, and tends to come off, and the surface tends to be rough and a dense structure cannot be obtained. That is, if the decitex of the island fiber of the composite fiber exceeds 0.8 decitex, the high-class feeling peculiar to artificial leather is lost. Therefore, the ultrafine fibers are preferably in the range of 0.5 to 0.01 dtex, more preferably 0.2 to 0.03 dtex.

本発明において極細繊維の単繊維繊度は、人工皮革を厚み方向にカットした断面を観察面として走査型電子顕微鏡（ＳＥＭ）により観察し、任意の３００カ所の極細繊維の繊維径を測定し、これの平均値を算出するという方法により求める。   In the present invention, the single fiber fineness of the ultrafine fibers is determined by observing the cross section of the artificial leather cut in the thickness direction with a scanning electron microscope (SEM) as an observation surface, and measuring the fiber diameter of any 300 microfine fibers. Is calculated by a method of calculating the average value of.

かかる極細繊維としては、ポリエチレンテレフタレート、ポリエチレンテレフタレート共重合体、ポリブチレンテレフタレート、ポリブチレンテレフタレート共重合体、ポリプロピレンテレフタレートおよびその共重合体等のポリエステル類、ナイロン６、ナイロン６６、ナイロン１２、共重合ナイロン等のポリアミド類から選ばれた少なくとも１種類を素材として使用することができるが、貼り合わせる合成樹脂の溶融温度に耐えられるものであることが必要であり、かつ、染色堅牢度を維持する上から、ポリエチレンテレフタレートおよびその共重合体を用いるのが望ましい。   Examples of such ultrafine fibers include polyesters such as polyethylene terephthalate, polyethylene terephthalate copolymer, polybutylene terephthalate, polybutylene terephthalate copolymer, polypropylene terephthalate and copolymers thereof, nylon 6, nylon 66, nylon 12, and copolymerized nylon. At least one kind selected from polyamides can be used as the material, but it is necessary that the material be able to withstand the melting temperature of the synthetic resin to be bonded, and from the viewpoint of maintaining the color fastness. It is preferable to use polyethylene terephthalate and its copolymer.

なお、ここでいうポリマー（重合体、共重合体）とは、いずれも繊維形成性あるいはフィルム形成性を有する程度の分子量（数平均分子量または重量平均分子量）を少なくとも有するものである。   Here, the polymer (polymer, copolymer) has at least a molecular weight (number-average molecular weight or weight-average molecular weight) enough to have a fiber-forming property or a film-forming property.

本発明の３次元絡合体不織布を得るためには、まず先に述べた極細繊維発生繊維を通常の方法で、ランダムウェッバー、あるいは、クロスラッパーにて、積層ウェブを作成し、ニードルパンチングあるいはウオータージェットパンチにより三次元絡合させて不織布にしたものである。この際不織布の厚み方向にできるだけ多くの繊維を縦方向（シート面に対して直角方向）に配列させるのが好ましい。すなわち、見掛け密度が０．０５〜０．６ｇ／ｃｍ3、より好ましくは０．１〜０．５ｇ／ｃｍ3であり、これら縦配列繊維はバフ研削された際に立毛（起毛）を形成し、立毛面に向けて合成樹脂の溶融液を射出して一体成形したときに、合成樹脂内部に繊維が入り込み投錨効果が発生する。 In order to obtain the three-dimensionally entangled nonwoven fabric of the present invention, first, a laminated web is formed from the above-described ultrafine fiber-generating fibers by a random webber or a cross wrapper, and needle punching or water jetting is performed. It is made into a non-woven fabric by three-dimensionally entangled with a punch. At this time, it is preferable to arrange as many fibers as possible in the thickness direction of the nonwoven fabric in the longitudinal direction (the direction perpendicular to the sheet surface). That is, the apparent density is 0.05 to 0.6 g / cm 3 , more preferably 0.1 to 0.5 g / cm 3 , and these longitudinally arranged fibers form nap (nap) when buffed. When a synthetic resin melt is injected toward the nap surface and integrally molded, fibers enter the synthetic resin and an anchoring effect occurs.

なお、かかる不織布の見掛密度は、ＪＩＳ Ｋ−６５０５に基づいて測定したものである。   The apparent density of the nonwoven fabric is measured based on JIS K-6505.

ニードルパンチング等による絡合付与はニードルの形状や不織布の特性によって異なるが、一般に１００〜３０００パンチ／ｃｍ2の範囲で与えられる。少ないと、立毛が発生せず、多くすぎても不織布を構成する繊維が切れ、物性が低下する。ＪＩＳ Ｌ−１９１３に基づいて測定される不織布の目付は、好ましくは８０〜６００ｇ／ｍ2、より好ましくは１００〜５００ｇ／ｍ2の範囲内であることがよい。かかる目付が８０ｇ／ｍ2未満では、成形時に皺が発生する傾向があり、また、かかる目付が６００ｇ／ｍ2を越えると、シートの剛性が高くなり、複雑な形状の成形に適応しにくくなるので好ましくない。 Entangling by needle punching or the like varies depending on the shape of the needle and the characteristics of the nonwoven fabric, but is generally given in the range of 100 to 3000 punches / cm 2 . If the amount is too small, the nap does not occur, and if the amount is too large, the fibers constituting the nonwoven fabric are cut and the physical properties are reduced. The basis weight of the nonwoven fabric measured based on JIS L-1913 is preferably in the range of 80 to 600 g / m 2 , more preferably 100 to 500 g / m 2 . If the basis weight is less than 80 g / m 2 , wrinkles tend to occur during molding, and if the basis weight exceeds 600 g / m 2 , the rigidity of the sheet increases, making it difficult to adapt to molding of complicated shapes. It is not preferred.

かかる不織布に付与する高分子弾性体とその付与方法は、通常の合成樹脂および付与の方法が採用できる。かかる高分子弾性体としては、例えばポリウレタン系合成樹脂、ポリ塩化ビニル系合成樹脂、ポリアクリル系合成樹脂、ポリアミノ系合成樹脂、シリコーン系合成樹脂、およびこれらの共重合体並びにこれらの混合物等の中から目的や用途によって選択して使用されるが、成形性が良好な柔軟性と柔軟な立毛を得るにはポリウレタンが好ましく採用される。かかる高分子弾性体の不織布への付与方法としては、たとえばポリウレタンのジメチルフォルムアミド溶液中に不織布を含浸した後、水とジメチルフォルムアミド水溶液から成る凝固液の中で、ポリウレタンを凝固させる湿式凝固法、あるいは、水と溶媒混合液から成るウレタン水溶液を含浸させた後、加熱乾燥させてポリウレタンを凝固させる乾式凝固法などを用いることができる。   As a polymer elastic body to be applied to such a nonwoven fabric and a method of applying the same, an ordinary synthetic resin and a method of application can be adopted. Examples of such a polymer elastic body include polyurethane synthetic resin, polyvinyl chloride synthetic resin, polyacrylic synthetic resin, polyamino synthetic resin, silicone synthetic resin, copolymers thereof, and mixtures thereof. Is used depending on the purpose and application, but polyurethane is preferably employed in order to obtain softness and soft nap with good moldability. As a method of applying such a polymer elastic body to a nonwoven fabric, for example, a wet coagulation method of impregnating the nonwoven fabric in a dimethylformamide solution of polyurethane and then coagulating the polyurethane in a coagulation liquid composed of water and an aqueous solution of dimethylformamide is used. Alternatively, a dry coagulation method or the like in which a polyurethane solution is coagulated by impregnating with a urethane aqueous solution composed of water and a solvent mixture, followed by heating and drying can be used.

本発明で使用される高分子弾性体が、例えばポリウレタン系合成樹脂である場合、ポリウレタンの高分子ジオール成分の分子量としては、好ましくは５００〜５０００、より好ましくは１０００〜３０００であるのがよく、その原料であるジオール成分としては、ポリカーボネートジオール、ポリエーテルジオール、ポリエステルジオールあるいはこれらの混合物が好ましく使用される。また、ジイソシアネート成分としては、芳香族系イソシアネート、脂環系イソシアネート、脂肪族系イソシアネートなどを使用することができるが、成形時の耐熱特性に優れた芳香族系イソシアネートが好ましく、特にメチルジイソシアネート（ＭＤＩ）が好ましく使用される。かかる４，４’ジフェニルメタンジイソシアネートからなるポリウレタンは、ジオールの種類にかかわらず、成形時の熱の影響を受けにくいという特徴を有する。また、かかる成形時の熱の影響を受けにくくする上で、鎖伸長剤として、分子量５００以下のグリコール伸長剤や水添ＭＤＩ、ジアミン伸長剤が好ましく使用される。これらの鎖伸長剤の中でも、メチレンビスアニリン（ＭＢＡ）のような耐熱性に優れたジアミン伸長剤を使用することがより好ましい。   When the polymer elastic body used in the present invention is, for example, a polyurethane-based synthetic resin, the molecular weight of the polymer diol component of the polyurethane is preferably 500 to 5000, more preferably 1000 to 3000, As the diol component as a raw material, polycarbonate diol, polyether diol, polyester diol or a mixture thereof is preferably used. As the diisocyanate component, an aromatic isocyanate, an alicyclic isocyanate, an aliphatic isocyanate, or the like can be used. An aromatic isocyanate having excellent heat resistance during molding is preferable, and methyl diisocyanate (MDI ) Are preferably used. Polyurethanes composed of such 4,4'-diphenylmethane diisocyanate are characterized by being less susceptible to heat during molding, regardless of the type of diol. In order to reduce the influence of heat during molding, glycol extenders having a molecular weight of 500 or less, hydrogenated MDI, and diamine extenders are preferably used as chain extenders. Among these chain extenders, it is more preferable to use a diamine extender having excellent heat resistance, such as methylenebisaniline (MBA).

本発明の人工皮革では、極細繊維製不織布と高分子弾性体の重量比は、好ましくは８０／１０〜３０／７０の範囲で設定される。本発明では立毛性を確保する上で、最終的に不織布と高分子重合体の重量比が、好ましくは８０／１０〜５０／５０、より好ましくは７０／３０〜６０／４０の範囲内に調整するのが好ましい。すなわち、高分子弾性体の重量比が７０重量％を越えると、ゴム状の性質が顕著になり、表面硬さが増加するためサンドペーパーでバフィングしたときに毛羽が短く、十分な投錨効果を発生することができない。風合いも硬く曲面を有する成形物には剥離、浮きといった欠点が発生し、表面にしわが発生しやすくなる。また、高分子弾性体の重量比が１０重量％未満になると、成形性は良好となるが、極細繊維と高分子弾性体との結束点が少ないために、成形品の摩耗による繊維の脱落が発生しやすくなる。   In the artificial leather of the present invention, the weight ratio between the nonwoven fabric made of ultrafine fibers and the elastic polymer is preferably set in the range of 80/10 to 30/70. In the present invention, in order to secure the napped property, the weight ratio of the nonwoven fabric and the high-molecular polymer is finally adjusted within the range of preferably 80/10 to 50/50, more preferably 70/30 to 60/40. Is preferred. That is, when the weight ratio of the polymer elastic body exceeds 70% by weight, the rubber-like property becomes remarkable and the surface hardness increases, so that the fluff is short when buffed with sandpaper, and a sufficient anchoring effect is generated. Can not do it. Defects such as peeling and floating occur in a molded product having a hard texture and a curved surface, and wrinkles are likely to be generated on the surface. Further, when the weight ratio of the polymer elastic body is less than 10% by weight, the moldability is good, but since the binding points between the ultrafine fibers and the polymer elastic body are small, the fibers fall off due to wear of the molded article. More likely to occur.

本発明の人工皮革を構成する不織布は極細繊維で構成されているものであるが、かかる極細繊維は、不織布を海島型複合繊維または分割型複合繊維を用いて形成した後、該複合繊維を極細繊維化処理して形成されるものである。   The nonwoven fabric constituting the artificial leather of the present invention is formed of ultrafine fibers.These ultrafine fibers are formed by forming the nonwoven fabric using sea-island composite fibers or split composite fibers, and then converting the composite fibers to ultrafine fibers. It is formed by a fiberizing treatment.

すなわち、不織布に高分子弾性体を付与する前あるいは後に、該不織布を構成している複合繊維の極細繊維化処理を行い極細繊維を発生させるのである。かかる極細化処理の方法については、海島型複合繊維であれば、海部分をトリクレン、トルエン等の溶剤や、アルカリ処理により、溶出させ取り除き、分割型複合繊維の場合は、水流等による機械的処理、あるいは溶剤処理により、剥離分割を行い極細繊維発現させる方法によって得られる。   That is, before or after the elastic polymer is applied to the nonwoven fabric, the conjugate fiber constituting the nonwoven fabric is subjected to ultrafine fiber treatment to generate ultrafine fibers. Regarding the method of such ultrafine treatment, if the sea-island type composite fiber, the sea portion is eluted and removed by a solvent such as trichlene or toluene, or alkali treatment, and in the case of the split type composite fiber, a mechanical treatment such as a water flow is used. Alternatively, it can be obtained by a method in which separation and separation are carried out by solvent treatment to produce ultrafine fibers.

次いで、極細繊維からなる不織布の少なくとも片面を起毛処理する。起毛処理は、針布やサンドペーパーを使用して行うことができる。とりわけ、高分子弾性体付与後、表面をサンドペーパーを使用して、不織布の厚み方向に、好ましくは０．０２〜０．４ｍｍ、より好ましくは０．１５〜０．２ｍｍの範囲で研削処理して起毛することによって、より均一で良好な立毛を形成することができる。かかる起毛部分には、１０〜２００μｍの長さから成る立毛が形成される。かくして最終的に見掛密度が、好ましくは０．１〜０．５ｇ／ｃｍ3、より好ましくは０．２〜０．４ｇ／ｃｍ3の範囲にある不織布を形成する。かかる見掛密度範囲にある不織布とすることが良好な成形性を達成する上からよい。 Next, at least one surface of the nonwoven fabric made of the ultrafine fibers is subjected to a raising treatment. The raising process can be performed using a needle cloth or sandpaper. In particular, after the elastic polymer is applied, the surface is ground using sandpaper in the thickness direction of the nonwoven fabric, preferably in the range of 0.02 to 0.4 mm, more preferably in the range of 0.15 to 0.2 mm. By raising the nap, more uniform and good nap can be formed. Napped hair having a length of 10 to 200 μm is formed on the raised portion. Thus, a non-woven fabric having an apparent density in the range of preferably 0.1 to 0.5 g / cm 3 , more preferably 0.2 to 0.4 g / cm 3 is finally formed. A nonwoven fabric having such an apparent density range is preferable from the viewpoint of achieving good moldability.

本発明の人工皮革の不織布は極細繊維から構成されるが、非成形面（結合しない側の面）は同様にバフィングによってスエード調に仕上げられていてもよく、表面が銀面に形成されたものでもよい。高級な表面に仕上げるには、成形前に高圧液流染色機により染色加工を付与するのが望ましく、高圧液流染色機内には熱水流とともに狭いノズルを通過させることで揉み効果が加わり、かくすることにより不織布層は成形に都合がよい柔軟性を得ることができる。   The non-woven fabric of the artificial leather of the present invention is composed of ultrafine fibers, but the non-molded surface (the surface on the unbonded side) may be similarly finished to a suede tone by buffing, and the surface is formed on a silver surface. May be. In order to finish to a high-grade surface, it is desirable to apply a dyeing process with a high-pressure liquid jet dyeing machine before molding, and in the high-pressure liquid jet dyeing machine, a kneading effect is added by passing through a narrow nozzle together with a hot water flow. Thereby, the nonwoven fabric layer can obtain flexibility which is convenient for molding.

本発明に用いる成形物用の合成樹脂としては、加工性等を考慮して、例えばＡＢＳ合成樹脂、ポリスチレン合成樹脂、ポリウレタン合成樹脂、ポリエチレン合成樹脂、アクリル合成樹脂、ナイロン合成樹脂等の群から、その用途によって自由に選択されるが、成形時に基材に与える熱的影響の関係から言えば、低温で溶解する合成樹脂が望ましく、たとえばＡＢＳ合成樹脂などは好適な合成樹脂である。かかる合成樹脂の成形方法としては、真空成形や一般射出成形等の手段が採用されるが、本発明の基材を取り付け、その裏面に熱可塑性合成樹脂を供給して成形する方法としては、射出成形の中でも、特に射出圧縮成形が採用される。すなわち、この射出圧縮成形法によれば、簡単、容易に、かつ、確実に目的の成形物を提供することができる。   As the synthetic resin for the molded article used in the present invention, in consideration of workability and the like, for example, from the group of ABS synthetic resin, polystyrene synthetic resin, polyurethane synthetic resin, polyethylene synthetic resin, acrylic synthetic resin, nylon synthetic resin, Although it is freely selected depending on its use, a synthetic resin that dissolves at a low temperature is desirable in view of the thermal effect on the base material during molding. For example, an ABS synthetic resin is a suitable synthetic resin. As a method for molding such a synthetic resin, means such as vacuum molding and general injection molding are employed. As a method for attaching the base material of the present invention and supplying a thermoplastic synthetic resin to the back surface thereof, injection molding is used. Among the moldings, injection compression molding is particularly employed. That is, according to this injection compression molding method, a desired molded product can be provided simply, easily, and reliably.

かかる射出圧縮成形によって、合成樹脂を、人工皮革と一体成形する際の加工条件は、成形する合成樹脂の加工条件に依存させて適宜調整すればよいが、その際、少なくとも片面が立毛された人工皮革を載置した金型を予め冷却しておくことが好ましい。すなわち、立毛面とは反対側の、つまり合成樹脂溶融液に接触させない人工皮革面は、冷却された金型に接触させておくのである。こうすることで、合成樹脂溶融液の熱の伝達を防止するものである。つまり、型締めした金型内に合成樹脂を注入し、プレスを行う工程中に、人工皮革を載置した側の金型を冷却しながら加工を行うのである。   The processing conditions for integrally molding the synthetic resin with the artificial leather by such injection compression molding may be appropriately adjusted depending on the processing conditions of the synthetic resin to be molded. It is preferable to cool the mold on which the leather is placed in advance. That is, the artificial leather surface on the opposite side to the napped surface, that is, the artificial leather surface that is not brought into contact with the synthetic resin melt, is kept in contact with the cooled mold. By doing so, the transfer of heat of the synthetic resin melt is prevented. In other words, during the process of injecting the synthetic resin into the clamped mold and performing the pressing, the processing is performed while cooling the mold on which the artificial leather is placed.

かかる人工皮革は、金型成形面上に載置するだけでもよいが、金型本体やこれらの周囲に設けた、例えば人工皮革固定枠にピンやテープ等を用いて固定してもよい。金型を型締めする時、型締め方向は縦方向であっても、横方向であってもよい。   Such artificial leather may be simply placed on the molding surface of the mold, or may be fixed to the mold main body or its surrounding, for example, an artificial leather fixing frame using a pin or a tape. When clamping the mold, the clamping direction may be vertical or horizontal.

射出圧縮成形する際には、合成樹脂射出完了後にプレスを開始しても良いが、加工性の観点から、所定量の合成樹脂が金型に注入された時点からプレスを開始し、その後も連続的に合成樹脂を供給し続け、金型内の合成樹脂を展延させる方法がより好ましい。使用する合成樹脂の種類にも関係するが、合成樹脂溶融温度で溶解した熱可塑性合成樹脂を金型に注入する際の金型成形温度は、人工皮革が熱によりダメージを受けるのを回避するためには、低い方が望ましいが、金型成形温度があまり低すぎると、熱可塑性合成樹脂の金型内への均一充填を阻害するので、好ましくは２５０℃以下、より望ましくは１９０℃〜２４０℃、特に望ましくは２０５℃から２２０℃に設定するのがよい。。   When performing the injection compression molding, the press may be started after the completion of the injection of the synthetic resin, but from the viewpoint of workability, the press is started when a predetermined amount of the synthetic resin is injected into the mold, and then continuously. It is more preferable to continuously supply the synthetic resin and spread the synthetic resin in the mold. Although it depends on the type of synthetic resin used, the mold molding temperature when injecting the thermoplastic synthetic resin melted at the synthetic resin melting temperature into the mold is to prevent the artificial leather from being damaged by heat. Is preferably lower, but if the mold molding temperature is too low, uniform filling of the thermoplastic synthetic resin into the mold is hindered, so that the temperature is preferably 250 ° C or less, more preferably 190 ° C to 240 ° C. It is particularly desirable to set the temperature between 205 ° C and 220 ° C. .

かかる成形時に使用される合成樹脂の粘度は、射出せん断速度にも依存するが、ＪＩＳ Ｋ−６８２８に基づいて測定される粘度が、好ましくは１００〜１００００Ｐａ・ｓ、より好ましくは５００〜５０００Ｐａ・ｓ、特に好ましくは１０００〜３０００Ｐａ・ｓであるのがよい。すなわち、かかる合成樹脂粘度が高すぎると、立毛繊維内部に入り込むことができず、合成樹脂成形物表面の人工皮革の剥離強力が低下する。一方、合成樹脂粘度が低すぎると、立毛繊維内部に入り込み易くなるが、入り込みすぎて、結局、合成樹脂溶融液の熱により、人工皮革の外側（結合する側の反対面）の表面品位を著しく低下させることとなる。かかる合成樹脂粘度が適度にコントロールされていることで、人工皮革の立毛内部に合成樹脂が入り込んだ形で結合、一体化された堅固な構造を形成するのである。   The viscosity of the synthetic resin used at the time of such molding depends on the injection shear rate, but the viscosity measured based on JIS K-6828 is preferably 100 to 10,000 Pa · s, more preferably 500 to 5000 Pa · s. Particularly preferably, the pressure is 1000 to 3000 Pa · s. That is, if the viscosity of the synthetic resin is too high, the synthetic resin cannot penetrate into the nap fibers, and the peel strength of the artificial leather on the surface of the synthetic resin molded product decreases. On the other hand, if the synthetic resin viscosity is too low, it is easy to penetrate into the nap fibers, but too much, and eventually the heat of the synthetic resin melt significantly lowers the surface quality of the outside of the artificial leather (opposite the side to be bonded). Will be reduced. By appropriately controlling the viscosity of the synthetic resin, the synthetic resin is bonded and integrated into the nap of artificial leather to form a solid structure that is integrated.

かかる一体成形時の人工皮革の立毛と熱可塑性合成樹脂とが、接触された状態で保持される保持時間は、好ましくは１０秒以内、より好ましくは１〜５秒以内であるのがよい。すなわち、この保持時間が短すぎると、一体成形後、十分な剥離強力として、好ましくは０．５ｋｇ／ｃｍ幅以上、より好ましくは０．７５〜１．５ｋｇ／ｃｍ幅以上を満足させることができない。しかし、この保持時間が長すぎると、人工皮革の外側（結合する側の反対面）表面の変質や、人工皮革の不織布繊維と高分子弾性体とが、熱により変質硬化したり、さらに人工皮革の全体的な風合いや表面品位を著しく劣化させることとなる。   The holding time during which the raised hairs of the artificial leather and the thermoplastic synthetic resin are kept in contact with each other during the integral molding is preferably within 10 seconds, more preferably within 1 to 5 seconds. That is, if the holding time is too short, it is not possible to satisfy, as a sufficient peel strength, preferably 0.5 kg / cm width or more, more preferably 0.75 to 1.5 kg / cm width or more after integral molding. . However, if the holding time is too long, the outer surface of the artificial leather (the surface opposite to the side to be bonded) is deteriorated, and the nonwoven fabric fiber and the polymer elastic body of the artificial leather are hardened by heat due to heat, and furthermore, the artificial leather Will significantly degrade the overall feel and surface quality.

かかる人工皮革の剥離強力測定方法は、長さ１０ｃｍ、幅２．０ｃｍ試験片の基体層の一部を剥離し一方のチャックに挟み、試験片の合成樹脂層を他方のチャックに挟んで引張試験機で引張速度１００ｍｍ／分で剥離強力を測定、記録し、得られたＳＳ曲線から剥離強力の平坦な部分の平均値を３点求め平均値を出し、得られた値を、幅１cm当たりの値に換算して表したものである。   The method for measuring the peeling strength of artificial leather is such that a tensile test is performed by peeling a part of the base layer of a test piece having a length of 10 cm and a width of 2.0 cm and sandwiching the synthetic resin layer of the test piece between the other chucks. The peel strength was measured and recorded at a tensile speed of 100 mm / min with a machine, and the average value of the flat part of the peel strength was determined at three points from the obtained SS curve to obtain an average value. It is expressed as a value.

本発明は、かかる少なくとも片面に立毛を有する人工皮革を採用したことで、立毛繊維が合成樹脂内部に入り込み、不織布自体が熱による変質を起こす前に、成形処理を完了させることが可能になったものである。すなわち、この立毛繊維の熱による軟化、溶融などによる変形を含めた投錨効果により、熱を十分かけて得られた場合と同様の剥離強力が得られるので、長時間の成形加工時間を必要としないのである。すなわち、本発明は、まさにかかる立毛繊維を利用した加工方法に特徴を有するものである。   The present invention employs such artificial leather having naps on at least one side, so that nap fibers can enter the interior of the synthetic resin and complete the molding process before the nonwoven fabric itself undergoes deterioration due to heat. Things. That is, since the anchoring effect including the softening of the nap fibers by heat and the deformation due to melting, etc., the same peel strength as that obtained by sufficiently applying heat is obtained, so that a long molding processing time is not required. It is. That is, the present invention has a feature in the processing method using the nap fiber.

以下、図面に従って本発明における合成樹脂成形物およびその製造方法を説明する。   Hereinafter, a synthetic resin molded product and a method for producing the same according to the present invention will be described with reference to the drawings.

まず、図１は、本発明の合成樹脂成形物の一例を示す断面図である。この図で、人工皮革（１）の立毛部（２）が、合成樹脂成形物（３）によって結合している状態を示す。   First, FIG. 1 is a sectional view showing an example of the synthetic resin molded product of the present invention. This figure shows a state in which the napped portions (2) of the artificial leather (1) are joined by a synthetic resin molded product (3).

図２は、合成樹脂成形物の製造工程での金型部分の概略断面図を示したものである。すなわち、解放状態にある雌雄一対（４、５）からなる金型間に、雄型（４）の金型成形面側に接するように人工皮革（１）を供給する。このとき、後から射出される合成樹脂と接する面が立毛されている人工皮革（１）を使用することが重要である。また、人工皮革（１）が接触している雄型（４）は、冷却されているのが好ましい。かかる冷却の程度は、溶融合成樹脂（６）の熱が人工皮革の反対側表面に、できるだけ伝達しないような、つまり熱変質しないような冷却状態を維持するのが好ましい。次に、合成樹脂を射出するのに最適な圧縮ストローク位置まで、雌型（５）を作動させて、型締めし、次いで溶融合成樹脂（６）を金型内に設けた合成樹脂供給通路（７）を介して、合成樹脂供給口（８）から金型内（４、５）に直接供給し、所定量の合成樹脂が金型内に注入された時点で、プレスを開始して、人工皮革の立毛面と合成樹脂成形物（３）の表面とを一体化する。次いで金型を開放して成形品を取り出して、本発明の合成樹脂成形物（３）を得るものである。   FIG. 2 is a schematic cross-sectional view of a mold portion in a manufacturing process of a synthetic resin molded product. That is, the artificial leather (1) is supplied between the molds composed of a pair of male and female (4, 5) in the released state so as to be in contact with the mold forming surface side of the male mold (4). At this time, it is important to use an artificial leather (1) whose surface in contact with a synthetic resin to be injected later is raised. The male mold (4) in contact with the artificial leather (1) is preferably cooled. It is preferable that the degree of the cooling is maintained such that the heat of the molten synthetic resin (6) is not transmitted to the opposite surface of the artificial leather as much as possible, that is, is not thermally deteriorated. Next, the female mold (5) is operated and clamped to a compression stroke position optimal for injecting the synthetic resin, and then a synthetic resin supply passage (6) provided with the molten synthetic resin (6) in the mold is provided. 7), the resin is directly supplied from the synthetic resin supply port (8) into the mold (4, 5), and when a predetermined amount of the synthetic resin is injected into the mold, the press is started and the artificial resin is formed. The raised surface of the leather and the surface of the synthetic resin molded product (3) are integrated. Next, the mold is opened and the molded product is taken out to obtain the synthetic resin molded product (3) of the present invention.

本発明によれば、優美な表面品位を保ったまま人工皮革を合成樹脂成形物表面に極めて容易にかつ確実に、中間層を介さずに、一つの工程によって張設することができる。得られる合成樹脂と人工皮革とが一体的に成形されてなる合成樹脂成形物は、その用途として、例えば携帯電話機の筐体やモバイルコンピューター、ＰＤＡ等の電子機器の筐体、ＣＤプレーヤー、ＤＶＤプレーヤー、ｍｐ３プレーヤー等のＡＶ機器の筐体、家庭用浄水器、ポット等の日用品の筐体等に用いるのに好適である。   ADVANTAGE OF THE INVENTION According to this invention, artificial leather can be extended | stretched by one process very easily and reliably, without an intermediate | middle layer, on an synthetic resin molding surface, maintaining an elegant surface quality. The synthetic resin molded product obtained by integrally molding the obtained synthetic resin and artificial leather is used as, for example, a case of a mobile phone, a case of a mobile computer, a case of an electronic device such as a PDA, a CD player, a DVD player. It is suitable for use in housings of AV equipment such as mp3 players, household water purifiers, housings of daily necessities such as pots, and the like.

以下、本発明を実施例により、さらに詳細に説明する。   Hereinafter, the present invention will be described in more detail with reference to Examples.

なお、実施例中の％は断りのない限り重量に関するものである。以下の実施例および、比較例において機械的物性の評価は以下の方法に従った。   The percentages in the examples relate to weight unless otherwise specified. In the following Examples and Comparative Examples, evaluation of mechanical properties was performed according to the following methods.

［目付］
ＪＩＳ Ｌ−１９１３ 一般短繊維不織布試験方法により測定した。 [Eye weight]
It was measured by JIS L-1913 general short fiber nonwoven fabric test method.

［見掛密度］
ＪＩＳ Ｋ−６５０５ 靴甲用人工皮革試験方法によって測定した。 [Apparent density]
JIS K-6505 Measured according to the artificial leather test method for shoe uppers.

［人工皮革の剥離強力測定方法］
長さ１０ｃｍ、幅２．０ｃｍ試験片の基体層の一部を剥離し一方のチャックに挟み、試験片の合成樹脂層を他方のチャックに挟んで引張試験機で引張速度１００ｍｍ／分で剥離強力を測定、記録する。得られたＳＳ曲線から剥離強力の平坦な部分の平均値を３点求め平均値を出す。得られた値は幅１ｃｍ当たりの値に換算して表す。 [Method of measuring peeling strength of artificial leather]
A part of the base layer of the test piece having a length of 10 cm and a width of 2.0 cm was peeled off and sandwiched between one chuck, and the synthetic resin layer of the test piece was sandwiched between the other chucks. Measure and record From the obtained SS curve, three average values of the flat portion of the peel strength are obtained and the average value is obtained. The obtained value is expressed in terms of a value per 1 cm width.

［接着面から合成樹脂層への繊維進入長さ測定方法］
合成樹脂成形物をカミソリで割断し、その断面で、かつ、立毛繊維が進入している面を露出させて、そこを電子顕微鏡にて１５０倍に拡大して写真撮影し、繊維長さを測定する。任意に５点を抽出しその長さの平均値で表す。 [Measurement method of fiber penetration length from adhesive surface to synthetic resin layer]
The synthetic resin molded product is cut with a razor, the cross-section and the surface on which the nap fiber has entered are exposed, and a 150-magnification photograph is taken with an electron microscope to measure the fiber length. I do. Five points are arbitrarily extracted and represented by the average value of the length.

［立毛繊維の平均長さの測定方法］
立毛人工皮革をカミソリで割断し、その断面を電子顕微鏡にて５０倍に拡大して写真撮影し、不織布基材と立毛繊維のそれぞれの境界の平均箇所に定規で直線を引き、その立毛部分の長さを測定する。測定は、任意に５箇所を抽出して測定して、その長さの平均値で表す。 [Method of measuring average length of nap fiber]
The raised hair artificial leather is cut with a razor, its cross section is enlarged by 50 times with an electron microscope, and a photograph is taken. A straight line is drawn with a ruler at the average point of each boundary between the nonwoven fabric base material and the raised fiber, Measure the length. In the measurement, five points are arbitrarily extracted and measured, and the average value of the length is expressed.

［極細繊維の平均デシテックス測定方法］
人工皮革を厚み方向にカットした断面を観察面として走査型電子顕微鏡（ＳＥＭ）により観察し、任意の３００カ所の極細繊維の繊維径を測定し、これの平均値を算出するという方法により求めた。 [Method of measuring average decitex of microfiber]
The cross section of the artificial leather cut in the thickness direction was observed as a surface to be observed using a scanning electron microscope (SEM), and the fiber diameters of arbitrary 300 microfine fibers were measured, and the average value was calculated. .

［染色堅牢度試験方法］
ＪＩＳ Ｌ−０８６１の有機溶剤に対する染色堅牢度試験により求めた。使用した有機溶剤はトリクロロエチレンを使用した。 [Dyeing fastness test method]
It was determined by a color fastness test for an organic solvent according to JIS L-0861. The organic solvent used was trichloroethylene.

［摩耗試験方法］
ＪＩＳ Ｌ−１０９６のマーチンデール試験により求めた。 [Wear test method]
It was determined by the Martindale test of JIS L-1096.

実施例１
島成分としてポリエチレンテレフタレート、海成分としてポリスチレンからなる成分比６０／４０、島数１６、複合繊度４．０ｄｔｅｘ、島繊度０．２ｄｔｅｘ、繊維長５１ｍｍの海島型複合繊維の原綿を用い、カーディングおよびラッピングにより繊維積層ウェブとしたものに、２５００本／ｃｍ2のニードルパンチにより織物が絡合一体化した目付５００ｇ／ｍ2で見掛密度０．１８０ｇ／ｃｍ3の不織布シートを作製した。 Example 1
Using a raw cotton of sea-island type composite fiber having a component ratio of 60/40 composed of polyethylene terephthalate as an island component and polystyrene as a sea component, 16 islands, a composite fineness of 4.0 dtex, an island fineness of 0.2 dtex and a fiber length of 51 mm, A nonwoven fabric sheet having an apparent density of 0.180 g / cm 3 with a basis weight of 500 g / m 2 , in which the woven fabric was entangled and integrated by needle punching at 2500 fibers / cm 2 , was prepared on a fiber laminated web obtained by lapping.

かくして得られたシートを極細化し、アミン伸長から成るポリエーテル系ポリウレタンをシート重量に対し約４０％付与したものを半裁し、バフ機で起毛処理した。研削は厚み方向に対して０．１０ｍｍ分研削し表面に極細繊維から成る、平均毛羽長約１００μｍの立毛を形成した。   The sheet thus obtained was ultrafine, and a sheet to which about 40% of a polyether-based polyurethane composed of amine elongation was added to the sheet weight was cut in half and brushed with a buffing machine. Grinding was performed by 0.10 mm in the thickness direction to form nap with an average fluff length of about 100 μm made of ultrafine fibers on the surface.

仕上げ厚みは０．７５ｍｍで見掛密度は０．３００ｇ／ｃｍ3の生機を得た。その後、分散染料で染色し、厚さ０．８０ｍｍ、目付１９０ｇ／ｍ2で見掛密度は０．２３０ｇ／ｃｍ3であるスエード調人工皮革を得た。 A green sheet having a finished thickness of 0.75 mm and an apparent density of 0.300 g / cm 3 was obtained. Then, it was dyed with a disperse dye to obtain a suede-like artificial leather having a thickness of 0.80 mm, a basis weight of 190 g / m 2 and an apparent density of 0.230 g / cm 3 .

得られた人工皮革に東レ製ＡＢＳ合成樹脂「トヨラック（Ｒ）２５０」（樹脂溶融温度：２１０℃）を用い射出成形を行った。平面板状物金型を用い成形を行った。   Injection molding was performed on the obtained artificial leather using an ABS synthetic resin “Toyolac (R) 250” manufactured by Toray (resin melting temperature: 210 ° C.). Molding was performed using a flat plate-shaped mold.

まず、上記で得た人工皮革の立毛面を上側に向けて常温の雄型金型に張り付けて設定した。このとき該雄型金型に冷媒（常温の水）を通して、冷却を開始した。その後、雌型金型を作動させて、型締めし、該ＡＢＳ合成樹脂の溶融液を注入し、プレスを開始して射出圧縮させて、２秒間保持した後、形成された合成樹脂成形物を取り外し、さらに４０秒、該合成樹脂成形物を冷却した。   First, the artificial leather obtained above was stuck on a male mold at room temperature with the napped surface facing upward and set. At this time, cooling was started by passing a coolant (normal temperature water) through the male mold. Then, the female mold is operated, the mold is clamped, the melt of the ABS synthetic resin is injected, the press is started, the injection is compressed, and the compressed resin is held for 2 seconds. After removing, the synthetic resin molded product was cooled for 40 seconds.

この合成樹脂成形物の断面を電子顕微鏡により観察すると、曲がったり、縮んだりした立毛繊維の全体が合成樹脂内部に埋没していることが観察された。該立毛繊維の埋没深さは、平均７０μｍであった。また、剥離強力は１．５ｋｇ／ｃｍであった。   When the cross section of this synthetic resin molded product was observed with an electron microscope, it was observed that the whole of the bent or shrunk nap fibers was buried inside the synthetic resin. The buried depth of the nap fibers was 70 μm on average. The peel strength was 1.5 kg / cm.

この合成樹脂成形物の表面品位は、張り合わせ前に比べ遜色なく、染色堅牢度は、成形前が４．５級であったものが３．５級に低下したものの、十分実用に耐えるものであった。摩耗試験では、成形前が３．５級であったものが、成形後も変化がなかった。   The surface quality of this synthetic resin molded product was comparable to that before lamination, and the color fastness was 4.5 grade before molding, but dropped to 3.5 grade, but was sufficiently practical. Was. In the abrasion test, there was no change after molding, although the grade was 3.5 before molding.

比較例１
東レ製ＡＢＳ合成樹脂「トヨラック２５０（Ｒ）」のみを用い、射出圧縮成形により得た合成樹脂成形物の表面に、実施例１にて得たスエード調人工皮革を、ニチバン紙両面粘着テープＮＷ−１０Ｓ（Ｒ）を用いて張り付けて合成樹脂成形物を得た。 Comparative Example 1
Using only Toray's ABS synthetic resin "Toyolac 250 (R)", the suede-like artificial leather obtained in Example 1 was applied to the surface of a synthetic resin molded product obtained by injection compression molding, using Nichiban paper double-sided adhesive tape NW-. A synthetic resin molded product was obtained by bonding using 10S (R).

この合成樹脂成形物は、作業性の悪さに加え、張設した人工皮革の剥離強力が０．３ｋｇ／ｃｍと実用に耐え得ないものであった。   In addition to poor workability, the synthetic resin molded article had a peeling strength of 0.3 kg / cm of the stretched artificial leather and was not practically usable.

比較例２
東レ製ＡＢＳ合成樹脂「トヨラック２５０（Ｒ）」のみを用い、射出圧縮成形により得た合成樹脂成形物の表面を、２１０℃のホットプレートで熱し、軟化させた後に、実施例１にて得たスエード調人工皮革を載置し加圧接着させて合成樹脂成形物を得た。 Comparative Example 2
The surface of a synthetic resin molded product obtained by injection compression molding was heated on a hot plate at 210 ° C. and softened using only the Toray ABS synthetic resin “Toyolac 250 (R)”, and then obtained in Example 1. A suede-like artificial leather was placed and adhered under pressure to obtain a synthetic resin molded product.

この合成樹脂成形物の断面を電子顕微鏡により観察すると、接着面から合成樹脂内部に入り込んでいる様子が観察されず、張設した人工皮革の剥離強力も０．３ｋｇ／ｃｍと実用に耐え得ないものであった。   When the cross section of this synthetic resin molded product is observed with an electron microscope, no appearance of penetrating into the synthetic resin from the bonding surface is observed, and the peeling strength of the artificial leather stretched is 0.3 kg / cm, which cannot be put to practical use. Was something.

比較例３
実施例１にて得たスエード調人工皮革の起毛されていない面と合成樹脂とが接するように金型に設定した他は実施例１と同様の方法を用いて人工皮革と合成樹脂との一体成形を行った。 Comparative Example 3
The integrated method of artificial leather and synthetic resin was performed using the same method as in Example 1 except that the mold was set so that the unbrushed surface of the suede-like artificial leather obtained in Example 1 was in contact with the synthetic resin. Molding was performed.

この合成樹脂成形物の断面を電子顕微鏡により観察すると、合成樹脂は人工皮革の内部に入りこんいる様子が観察されず、張設した人工皮革の剥離強力も０．３ｋｇ／ｃｍと実用に耐え得ないものであった。   When the cross section of this synthetic resin molded product is observed with an electron microscope, no appearance of the synthetic resin penetrating into the artificial leather is observed, and the peeling strength of the stretched artificial leather is 0.3 kg / cm, which cannot be put to practical use. Was something.

本発明の合成樹脂成形物の一例を示す断面図である。It is sectional drawing which shows an example of the synthetic resin molding of this invention. 本発明の合成樹脂成形物の製造工程における金型部分の一例を示す概略断面図である。It is an outline sectional view showing an example of a metallic mold part in a manufacturing process of a synthetic resin cast of the present invention.

符号の説明Explanation of reference numerals

１：人工皮革
２：立毛部
３：合成樹脂成形物
４：金型（雄）
５：金型（雌）
６：溶融合成樹脂
７：合成樹脂供給通路
８：合成樹脂供給口 1: artificial leather 2: raised hair 3: synthetic resin molding 4: mold (male)
5: Mold (female)
6: molten synthetic resin 7: synthetic resin supply passage 8: synthetic resin supply port

Claims (11)

少なくとも片面が立毛化された人工皮革が合成樹脂成形物の表面に一体化されてなる合成樹脂成形物であって、該人工皮革の立毛面で合成樹脂と結合していることを特徴とする合成樹脂成形物。 A synthetic resin molded article in which artificial leather having at least one surface raised is integrated with the surface of the synthetic resin molded article, wherein the synthetic leather is bonded to the synthetic resin on the raised surface of the artificial leather. Resin molding. 該人工皮革が、０．８デシテックス以下の極細繊維で構成される３次元絡合体不織布と高分子弾性体とで構成されたものである請求項１に記載の合成樹脂成形物。 The synthetic resin molded product according to claim 1, wherein the artificial leather is formed of a three-dimensional entangled nonwoven fabric composed of ultrafine fibers of 0.8 decitex or less and an elastic polymer. 該人工皮革の見掛密度が、ＪＩＳ Ｋ−６５０５に基づいて測定されたときの見掛け密度で０．１〜０．５ｇ／ｃｍ3である請求項１または２に記載の合成樹脂成形物。 Apparent density of the artificial leather, synthetic resin molded article according to claim 1 or 2 is 0.1 to 0.5 g / cm 3 in apparent density, as measured based on JIS K-6505. 該人工皮革と該合成樹脂成形物の剥離強力が０．５ｋｇ／ｃｍ以上である請求項１〜３のいずれかに記載の合成樹脂成形物。 The synthetic resin molded product according to any one of claims 1 to 3, wherein the peel strength between the artificial leather and the synthetic resin molded product is 0.5 kg / cm or more. 該立毛が、起毛されたものである請求項１〜４のいずれかに記載の合成樹脂成形物。 The synthetic resin molded product according to any one of claims 1 to 4, wherein the nap is raised. 少なくとも片面が立毛化された人工皮革の該立毛面に、２５０℃以下の融点を有する合成樹脂の溶融液を射出して、圧縮成形する際に、該人工皮革の該立毛面の反対面が冷却されていることを特徴とする合成樹脂成形物の製造方法。 At the time of injecting a melt of a synthetic resin having a melting point of 250 ° C. or less onto the raised surface of the artificial leather having at least one surface raised, the surface opposite to the raised surface of the artificial leather is cooled during compression molding. A method for producing a synthetic resin molded product, characterized in that: 該射出圧縮成形する際に、該人工皮革表面と合成樹脂溶融液とが、金型内で接している時間が１０秒以下である請求項６に記載の合成樹脂成形物の製造方法。 The method for producing a synthetic resin molded product according to claim 6, wherein a time during which the surface of the artificial leather and the synthetic resin melt are in contact with each other in the mold during the injection compression molding is 10 seconds or less. 該人工皮革が、０．８デシテックス以下の極細繊維を発生する極細繊維発生型繊維からなり、かつ、ＪＩＳ Ｋ−６５０５に基づいて測定されたときの見掛け密度が０．０５〜０．６ｇ／ｃｍ3である３次元不織布に、高分子弾性体を含浸凝固させた後、極細繊維を発生させたものである請求項６または７に記載の合成樹脂成形物の製造方法。 The artificial leather is made of ultrafine fiber-generating fibers that generate ultrafine fibers of 0.8 decitex or less, and has an apparent density of 0.05 to 0.6 g / cm when measured according to JIS K-6505. The method for producing a synthetic resin molded product according to claim 6 or 7, wherein the three-dimensional nonwoven fabric ( 3 ) is obtained by impregnating and solidifying a polymer elastic material and then generating ultrafine fibers. 該人工皮革が、０．８デシテックス以下の極細繊維を発生する極細繊維発生型繊維からなり、かつ、ＪＩＳ Ｋ−６５０５に基づいて測定されたときの見掛け密度が０．０５〜０．６ｇ／ｃｍ3である３次元不織布から極細繊維を発生させた後に、高分子弾性体を含浸凝固させたものである請求項６または７に記載の合成樹脂成形物の製造方法。 The artificial leather is made of ultrafine fiber-generating fibers that generate ultrafine fibers of 0.8 decitex or less, and has an apparent density of 0.05 to 0.6 g / cm when measured according to JIS K-6505. The method for producing a synthetic resin molded product according to claim 6 or 7, wherein the ultrafine fibers are generated from the three-dimensional nonwoven fabric ( 3) and then the polymer elastic body is impregnated and solidified. 請求項８または９において、該高分子弾性体の含浸量が、該極細繊維と該高分子弾性体の重量比で８０／１０〜３０／７０の範囲内である合成樹脂成形物の製造方法。 The method for producing a synthetic resin molded product according to claim 8 or 9, wherein the amount of impregnation of the elastic polymer is in a range of 80/10 to 30/70 by weight ratio of the ultrafine fiber and the elastic polymer. 該人工皮革の立毛化が、極細繊維発生型繊維の極細繊維化処理後、サンドペーパーにより起毛したものであり、かつ、起毛後の該人工皮革の見掛密度が、ＪＩＳ Ｋ−６５０５に基づいて測定されたときの見掛け密度で０．１〜０．５ｇ／ｃｍ3の範囲内である請求項６〜１０のいずれかに記載の合成樹脂成形物の製造方法。 The raising of the artificial leather is obtained by raising the hair with a sandpaper after the processing for forming the ultrafine fibers into the ultrafine fibers, and the apparent density of the artificial leather after raising is based on JIS K-6505. method for producing a synthetic resin molded product according to any one of claims 6-10 is in the range of 0.1 to 0.5 g / cm 3 in apparent density, as measured.
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