JP2006281592A - Method for producing molding with artificial leather integrated with surface and insert material having suede tone or silver attachment tone tactile feeling used in the method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a molding with artificial leather excellent in appearance integrated with its surface and an insert material having a suede tone or silver attachment tone tactile feeling used in the method. <P>SOLUTION: On the back of the artificial leather 1 which is made of fibers at least 0.05 denier in size and has a thickness of 0.4-1.0 mm, the insert material 3 which is laminated with a rigid reinforcing sheet 2 of thickness 0.1-0.6 mm and has the suede tone or silver attachment tone tactile feeling is formed in a three-dimensional shape by preliminary molding, punched in a necessary shape, and housed in the cavity of an injection molding mold, and then a molten molding resin 8 is injected from the reinforcing sheet 2 side of the insert material 3, so that the resin molding 5 of thickness 0.2 mm or above is molded, and simultaneously the insert material 3 is integrated with the surface of the molding 5. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for producing a molded product in which artificial leather that can be used for interiors of vehicles, airplanes, ships, etc., and exteriors such as furniture and display stands, and a suede tone or silvered tone used in this method. The present invention relates to an insert material having a tactile sensation.

  As industrial products having a suede-like or silver-like feel, those using artificial leather 1 have been put to practical use in various places (see Patent Document 1). There are a wide variety of items such as clothing, bags, shoes, etc. that are frequently touched by human hands, and many of them are manufactured by applying shapes to the artificial leather 1 and then bonding and sewing. There are also products that are formed by integrally molding artificial leather 1 and resin molded products, but they are often found on palm rests (such as palms and pads for placing wrists and cushions to keep the wrists horizontal). These are limited to those in which the shape of the suede-tone or silver-tone portion is substantially flat.

  The reason why the example in which the shape of the suede-like or silver-tone part is three-dimensional for a product obtained by integrally molding the artificial leather 1 and the resin molded product is not found is considered to be the difficulty in handling the artificial leather 1.

In order to integrally form the resin molded product so that the shape of the suede-tone or silver-tone portion is three-dimensional, the artificial leather 1 provided with a desired three-dimensional shape (hereinafter referred to as pre-molding) is injection molded. After being inserted into the mold, so-called insert molding is performed in which the artificial leather 1 and the resin molded product are integrally formed by injection-filling molten resin into the injection mold.
JP-A-7-173778

  Examples of the preforming method include a method using a vacuum or high-pressure gas, and a method using a press die made of metal or resin. However, the artificial leather 1 can be formed into a desired three-dimensional shape by any method. However, since the artificial leather 1 is soft, it is difficult to maintain the shape as it is, and the shape of the artificial leather 1 is lost. The meaning of molding disappears.

  Still, since the artificial leather 1 is stretched by the pressure of the injection resin, it can be given a three-dimensional shape. In this case, the artificial leather 1 is sandwiched between the parting surfaces outside the cavity of the injection mold. Need to hold in. This is because if the suede-like artificial leather 1 is not held outside the cavity, the suede-like or silver-tone part may be misaligned, or it may be wrinkled without following the three-dimensional shape. This is because an appearance defect occurs.

  On the other hand, even when the artificial leather 1 is held outside the cavity, the insert molded product immediately after molding is in a state in which the artificial leather 1 protrudes more than the resin molded product. It is necessary to cut excess artificial leather 1. The cutting of the surplus portion of the artificial leather 1 can be performed by male-female cutting, but has the following problems.

In other words, clearance is an important factor in male-female cutting, and clearance needs to be designed according to the target product, but if at least clearance less than the thickness of the object to be cut cannot be realized, You can't get a product without it. That is, when cutting the artificial leather 1, at least clearance equal to or less than the diameter of the fiber is necessary. For example, if the artificial leather 1 is made of 0.1 denier fiber made of polyester having a density of 1,4 g / cm ^2. Since the fiber diameter is about 0.5 μm, the required male-female clearance is at least as narrow as 0.5 μm or less. However, if the resin molded product is cut at the same time as cutting the surplus portion of the artificial leather 1, the backlash of the mold at the time of operation becomes large, and it becomes impossible to cut off the fiber with such a narrow clearance.

  Of course, if the resin molded product is not cut at the same time as the artificial leather 1, it is possible to obtain a product without burrs, but in that case, it is impossible to eliminate the positional deviation at all. It must be slightly larger than the product.

  Therefore, the present invention eliminates the above-mentioned problems, and a method for producing a molded product in which artificial leather having an excellent appearance is integrated on the surface, and an insert material having a suede-like or silver-like feel used in this method. The purpose is to provide.

  In order to achieve the above object, the insert material of the present invention having a suede-like or silver-like feel has a thickness of 0.4 to 1.0 mm on the back of an artificial leather made of fibers having a fineness of 0.05 denier or more. A reinforcing sheet having a rigidity of 0.1 to 0.6 mm was bonded.

  Moreover, in the structure of the said insert material, you may form an adhesive layer in the surface opposite to the surface which bonded the artificial leather of the reinforcement sheet.

  Further, in the method for producing a molded product in which the artificial leather of the present invention is integrated on the surface, the insert material having the above-described configuration is made into a three-dimensional shape by preforming, and is punched into a required shape to be in a cavity in an injection mold. After molding, the molten resin is injected from the reinforcing sheet side of the insert material, thereby forming a resin molded product having a thickness of at least 0.2 mm and simultaneously integrating the insert material on the surface. .

   In the present invention, since a reinforcing sheet bonded to artificial leather is used as an insert material, even if preforming is performed so as to give a desired three-dimensional shape, the reinforcing sheet serves as a support material and loses its shape. Absent. Therefore, it is not wrinkled at the time of injection molding, and the suede tone or silvered tone portion is not displaced and formed.

  In addition, this pre-molded insert material that does not lose its shape can be punched into the required shape and stored in the cavity in the injection mold, so that the surplus part of the artificial leather is removed in the post-injection molding process. There is no need to remove it. Therefore, burr is not generated and the artificial leather is not made larger than the resin molded product.

  Embodiments of the present invention will be described in detail with reference to the drawings.

  FIG. 1 is a schematic cross-sectional view showing an embodiment of an insert material having a suede-like or silvery feel according to the present invention. In the figure, 1 is artificial leather, 2 is a reinforcing sheet, 3 is an insert material, and 4 is a laminate adhesive.

  Artificial leather refers to a base material (nonwoven fabric) mainly composed of a fiber layer having a random three-dimensional solid structure impregnated with polyurethane or a similar high molecular weight material, and is referred to as 0.2 denier or less. A leather-like feel can be obtained by using extra fine fibers (see FIG. 2a). As a material of the fiber, there is a material using nylon or polyester, and may be appropriately selected according to a desired tactile feeling and texture. From the viewpoint of physical properties, it is preferable to select a polyester product that is less stretched by desorption. The thickness of the fiber is an important factor that affects the feel and texture. When the fibers become thicker, the texture becomes rougher, and when the fibers become thinner, the texture becomes smoother. In terms of physical properties, if it is too thin, it tends to be cut, and problems such as reduced wear resistance occur. In addition, there are two types of artificial leather: suede or silver-tone type and silver-tone type (skin tone) depending on the surface finish. Artificial leather 1 has a surface finish and the former is coated, colored gravure, mold The latter is brushed (see FIG. 2b), dyeing, etc., such as pressing and dyeing.

As a requirement in the present invention, it is necessary to maintain softness even after the pressure during injection molding (about 50 to 200 kgf / cm ² ) is applied. For this purpose, a material using fibers having a fineness of 0.05 denier or more It is necessary to choose.

  The thicker the artificial leather 1, the greater the texture. However, if the thickness is too large as a requirement in the present invention, it is necessary to increase the thickness of the support material, resulting in an increase in the thickness of the molded product. Therefore, in this case, 0.4 to 1.0 mm is set as an appropriate thickness.

  Moreover, you may provide arbitrary patterns, such as a character and a symbol, by silk screen printing, gravure printing, offset printing, etc. in the artificial leather 1 surface layer. The material of the ink used in this case is not defined in the present invention, but in order to satisfy durability including abrasion resistance, a curable type that causes an irreversible reaction by heat, ultraviolet rays, electron beams, etc. What used resin as the binder is used suitably. For example, a white ink in which a titanium oxide pigment having a particle diameter of 0.5 to 5 μm is kneaded using a polyester resin as a main component and an isocyanate as a curing agent.

  As the reinforcing sheet 2, sheets of polycarbonate (PC) resin, ABS resin, urethane resin, olefin resin, polyethylene terephthalate (PET) resin, polybutylene terephthalate (PBT) resin, nylon resin, etc. can be used. 2 requires rigidity as a support. If the thickness is too thin, the rigidity becomes insufficient and the shape of the film cannot be maintained. If the thickness is too thick, the thickness of the product increases and the cost increases. As a result of the experiment, good results were obtained by using the reinforcing sheet 2 of 0.1 to 0.6 mm.

  There are dry lamination, thermal lamination, etc. as a method of bonding the artificial leather 1 and the reinforcing sheet 2 to the insert material 3, but in order not to impair the touch of the artificial leather 1, high temperature during processing should be avoided. From that viewpoint, dry laminate is more preferably used. The material of the laminating adhesive 4 used at this time needs to be appropriately selected depending on the materials of the artificial leather 1 and the reinforcing sheet 2.

  In addition, the structure of the insert material 3 is not limited to an above-described aspect. For example, you may provide the contact bonding layer 6 in order to improve the adhesiveness with the resin molded product 5 on the surface opposite to the surface which bonded the artificial leather 1 of the reinforcement sheet 2 (refer FIG. 3). As the adhesive layer 6, a heat-sensitive or pressure-sensitive resin suitable for the material of the resin molded product 5 is appropriately used. For example, when the material of the resin molded product 5 is an acrylic resin, an acrylic resin may be used. Further, when the material of the resin molded product 5 is a polyphenylene oxide / polystyrene resin, a polycarbonate resin, a styrene copolymer resin, or a polystyrene blend resin, an acrylic resin, a polystyrene resin, A polyamide resin or the like may be used. Furthermore, when the material of the resin molded product 5 is a polypropylene resin, a chlorinated polyolefin resin, a chlorinated ethylene-vinyl acetate copolymer resin, a deepened rubber, and a coumarone indene resin can be used. Examples of the method for forming the adhesive layer 6 include a coating method such as a gravure code method, a roll coating method and a comma coating method, a printing method such as a gravure printing method and a screen printing method.

  Below, the manufacturing method of the molded article which integrated the artificial leather of this invention on the surface using the said insert material is demonstrated (refer FIG. 4).

  First, the insert material 3 which is a bonding sheet of the artificial leather 1 and the reinforcing sheet 2 is formed into a three-dimensional shape by preforming (see FIG. 4a). Examples of the preforming method include a method using a vacuum or high-pressure gas, and a method using a press die made of metal or resin.

  Next, the preformed insert material 3 is punched into a desired shape using male and female dies (see FIG. 4b). At this time, the operation accuracy of the male and female dies can be improved by making the reinforcing sheet 2 sufficiently thin. However, if the reinforced sheet 2 is too thin, the function as a support material is insufficient, so that the shape loss cannot be prevented. It is necessary to set the thickness appropriately in accordance with the shape of the molded product in the range of 1 to 0.6 mm.

  Finally, the insert material 3 cut into a desired shape is placed in a cavity in an injection mold, and a molten molding resin is injected from the reinforcing sheet 2 side of the insert material 3 (see FIG. 4c). At the same time as molding the resin molded product, the insert material is integrated on the surface.

  The molded resin needs to be appropriately selected in order to satisfy the physical properties required for the product. If impact resistance is important in parts such as a housing, polycarbonate, an alloy product thereof, ABS, and the like are preferable. In addition to the softness of the artificial leather 1, when it is desired to obtain a soft texture as a whole product, an elastomer may be used. These molding resins need to be molded to a thickness of at least 0.2 mm in order to satisfy the required properties and to complete the filling of the cavity when the molding resin is injected.

Suede feel by sticking a 0.17mm thick ABS sheet to a 0.6mm thick suede-like artificial leather (Kuraray Co., Ltd. "Kurarino") made of polyester and 0.1 denier fiber. An insert material having was obtained. At this time, urethane resin was used as an adhesive, and after applying 18 g / m ² (wet) to the ABS sheet side, artificial leather was laminated at a pressure of 7 kgf / cm ² .

  The above insert material is placed on a drawing die having the same shape as the mold cavity shape with the artificial leather facing down, heated to about 90 ° C., and then subjected to a high pressure of 70 HPa from the ABS sheet side, then cooled. As a result, it was preformed into a desired three-dimensional shape.

  This pre-molded insert material is set in a male-male male mold with a maximum clearance of 1.8 μm, punched out with a press, and placed in a cavity in an injection mold so that the artificial leather is in contact with the cavity surface. After that, by injection-filling molten polycarbonate and ABS alloy resin from the reinforcing sheet side of the insert material, a resin molded product is molded with a thickness of 0.4 mm or more, and at the same time, the insert material is integrated on the surface. .

It is a schematic cross section which shows one Example of the insert material which has a suede tone or the feeling with silver according to this invention. It is a photograph explaining the structure of artificial leather. It is a schematic cross section which shows one Example of the insert material which has a suede tone or the feeling with silver according to this invention. It is sectional drawing which shows one Example of manufacture of the molded article with which the artificial leather which concerns on this invention was integrated on the surface.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Artificial leather 2 Reinforcement sheet 3 Insert material 4 Laminate adhesive 5 Resin molded product 6 Adhesive layer 7 Injection mold 8 Molding resin

Claims (3)

  Suede tone characterized by bonding a reinforcing sheet having a thickness of 0.1 to 0.6 mm to the back of an artificial leather made of fibers having a fineness of 0.05 denier or more and having a thickness of 0.4 to 1.0 mm Or an insert material with a feeling of touch with silver.   The insert material having a suede-like or silver-like touch feeling according to claim 1, wherein an adhesive layer is formed on the surface of the reinforcing sheet opposite to the surface on which the artificial leather is bonded.   The insert material according to claim 1 or 2 is made into a three-dimensional shape by preforming, punched into a necessary shape and stored in a cavity in an injection mold, and then melted from the reinforcing sheet side of the insert material. Injecting the molding resin, the molded article having a thickness of at least 0.2 mm is molded at the same time and the insert material is integrated on the surface thereof. Production method.

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