JP2008012799A - Resin sheet with nonwoven fabric, manufacturing method of the same and molding method of molded product using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin sheet with a nonwoven fabric and a manufacturing method of the same which can soften the resin sheet main body while not spoiling the quality of the nonwoven fabric even by the heating in the heating/pressure molding and while retaining its quality and in addition prevent the resin sheet from sticking to the heater, and to provide a molding method of a molded product using the resin sheet with the nonwoven fabric. <P>SOLUTION: The resin sheet 1 with the nonwoven fabric comprises the sheet-like nonwoven fabric 3, which is formed of a PET resin having a melting point higher than that of a PP resin that makes the base material of the resin sheet main body 2, pasted on almost the whole of one surface of the resin sheet main body 2. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a resin sheet material that can be heated and pressed.

  Conventionally, molding by heating and pressure molding has been performed as one method for molding a resin sheet material.

  In heating and pressure molding, before performing pressure molding by a press machine, the resin sheet material is heated in advance by a heater or the like and softened until deformation by pressurization of the press machine becomes possible.

  As a method for heating the resin sheet material, for example, a method in which the resin sheet material is directly placed on a panel heater and heated is employed.

In addition to this method, Patent Document 1 discloses a method in which a non-woven fabric of synthetic fibers is interposed between a resin sheet material and a panel heater in order to uniformly heat the resin sheet material. ing.
JP 2005-88508 A

  However, in the method of directly placing the resin sheet material on the panel heater and heating, the surface portion of the resin sheet material is slightly melted by heating, so the melted surface portion is adhered to the surface of the heater, There was a problem that the resin sheet material stuck to the heater.

  Moreover, in the method of heating by interposing the nonwoven fabric between the resin sheet material and the panel heater, the nonwoven fabric itself may be melted by the heat of the heater depending on the selection of the synthetic fiber used for the nonwoven fabric.

  Therefore, in the present invention, the quality of the nonwoven fabric is not impaired even by heating in heating and pressure molding, the resin sheet body can be softened while maintaining the quality of the nonwoven fabric, and stick to the heater. It aims at providing the manufacturing method of the resin sheet with a nonwoven fabric which does not have, the manufacturing method of the resin sheet with a nonwoven fabric, and the molded article using the resin sheet with a nonwoven fabric.

  In order to achieve the above object, the invention described in claim 1 is characterized in that a sheet-like non-woven fabric made of a resin having a melting point higher than the melting point of the resin serving as the base material of the resin sheet body is at least the resin sheet body. It is characterized by a non-woven fabric-attached resin sheet that is affixed to substantially the entire surface of one side.

And the invention described in Claim 2 is a manufacturing method of the resin sheet with a nonwoven fabric described in Claim 1,
Immediately after heating and melting the base material to form the resin sheet main body by extrusion, only the surface portion is in a molten state by pressing the sheet-like nonwoven fabric to the resin sheet main body in a semi-molten state, It is characterized by a method for producing a resin sheet with a nonwoven fabric, in which the sheet-like nonwoven fabric is pasted on substantially the entire surface of at least one surface of the resin sheet main body by heat fusion.

The invention described in claim 3 is a molding method of a molded article using the resin sheet with a nonwoven fabric described in claim 1,
A heating device having a heating section for heating and softening the resin sheet body;
Using a press machine for pressure forming the resin sheet with nonwoven fabric,
An arrangement heating step of arranging and heating the resin sheet with the nonwoven fabric on the heating portion with the surface on which the non-woven fabric is pasted corresponding to the heating portion,
After heating and softening the resin sheet with nonwoven fabric by the heating device, inserting the resin sheet with nonwoven fabric between one mold of the pressing machine and the other mold of the pressing machine,
A pressing step in which the one mold and the other mold are closed in a state where the resin sheet with nonwoven fabric is spread between the two molds, and the resin sheet with nonwoven fabric is molded into a molded product having a desired shape; Including
The heating temperature by the heating device is set to be higher than the melting point temperature of the resin serving as the base material of the resin sheet main body and lower than the melting point temperature of the resin constituting the nonwoven fabric, and the heating device sets the resin. The sheet body is heated from the side on which the nonwoven fabric is pasted, and is characterized by a method for forming a molded article using a resin sheet with a nonwoven fabric.

  Since the nonwoven fabric is pasted on the resin sheet body, the adhesive according to the first aspect of the present invention configured as described above is used when bonding other members to the surface on which the nonwoven fabric is pasted. Entangles well with non-woven fabric, has high anchoring properties and good adhesion.

  And since the nonwoven fabric is affixed on the substantially whole surface of the resin sheet main body, an adhesive surface can be largely and firmly adhere | attached, for example in the case of adhesion | attachment with the sheet-like other member.

  Moreover, since the nonwoven fabric is affixed beforehand to the resin sheet main body, the process of affixing a nonwoven fabric separately is abbreviate | omitted and the increase in the number of work processes can be suppressed.

  Furthermore, since the non-woven fabric is preliminarily pasted on the resin sheet main body, the surface on which the non-woven fabric is pasted is good without any additional surface processing.

  And the thing of Claim 2 sticks a nonwoven fabric to a resin sheet main body by heat sealing | fusion by pressing a nonwoven fabric to the resin sheet main body in which only the surface part is a molten state immediately after forming by extrusion molding. Therefore, since the nonwoven fabric is stuck at the same time as the extrusion, the production efficiency is good, and it is not necessary to prepare an adhesive for bonding the resin sheet main body and the nonwoven fabric separately, so that the manufacturing cost can be suppressed.

  Moreover, since melting | fusing point temperature of resin which comprises a nonwoven fabric is higher than melting | fusing point temperature of resin used as the base material of a resin sheet main body, a nonwoven fabric does not melt at the time of heat-fusion, and the quality of a nonwoven fabric can be maintained.

  Furthermore, since the thing of Claim 3 sets the heating temperature by a heating part to the temperature lower than melting | fusing point temperature of resin which comprises a nonwoven fabric, since a nonwoven fabric itself does not melt by the heating of a heating part. It is possible to leave the fuzz necessary for securing the anchor property at the time of adhesion, and to maintain the surface quality of the nonwoven fabric.

  And since the heating temperature by a heating part is set to the temperature higher than melting | fusing point temperature of resin used as the base material of the resin sheet main body, and lower than melting | fusing point temperature of resin which comprises the nonwoven fabric, it is nonwoven fabric by a heating part. When the resin sheet with a nonwoven fabric is heated from the side, the nonwoven fabric itself does not melt, and only the resin sheet main body can be softened by heating while maintaining the quality of the nonwoven fabric.

  Furthermore, since the resin sheet main body is heated from the side where the nonwoven fabric is pasted by the heating section, the resin sheet main body does not directly touch the heating section, and the resin sheet main body does not melt and stick to the heating section.

  Moreover, since the heating temperature of the heating unit is set to a temperature lower than the melting point temperature of the resin constituting the nonwoven fabric, the nonwoven fabric itself does not melt by heating by the heating unit, and the nonwoven fabric melts and is attached to the heating device. Since it does not wear, the resin sheet with the nonwoven fabric does not stick to the heating device.

  Hereinafter, the present invention will be described based on examples of embodiments according to the present invention.

<Constitution>
FIG. 1 is a partially broken perspective view of a resin sheet with a nonwoven fabric according to this embodiment, and FIG. 2 is a cross-sectional view taken along the line AA of FIG.

  1 and 2, 1 is a resin sheet with a nonwoven fabric, 2 is a resin sheet body, and 3 is a nonwoven fabric.

  The resin sheet 1 with a nonwoven fabric of a present Example is mainly used as a raw material of the components used with the interior member of a vehicle and the interior member of a vehicle.

  For example, it is used as a material for a rear heater duct used as a part of a molded carpet module for a vehicle, a material for a luggage trim, a reinforcing material for a carpet, and the like.

  The molded carpet module for a vehicle is configured by integrally mounting an in-vehicle component such as a rear heater duct on the back side of a molded carpet provided with a heat-meltable resin layer by heat-fusion of a heat-meltable resin. .

  The resin sheet main body 2 is mainly composed of polypropylene resin (hereinafter referred to as PP resin). Since the PP resin has thermoplasticity, the resin sheet body 2 itself has thermoplasticity.

  As shown in FIGS. 1 and 2, the non-woven fabric 3 is stuck on substantially the entire surface of one side of the resin sheet main body 2.

  The nonwoven fabric 3 is mainly composed of polyethylene terephthalate resin (hereinafter referred to as PET resin), and is a needle punched nonwoven fabric manufactured by a needle punch manufacturing method.

  For example, when a molded product such as a rear heater duct is formed using the resin sheet 1 with a nonwoven fabric, the resin sheet body 2 softened by heating at the time of heating and pressure molding is formed between a press machine mold and a mold. Therefore, the nonwoven fabric 3 needs to extend following the extension of the resin sheet main body 2, and the nonwoven fabric 3 is required to have elasticity equal to or higher than that of the resin sheet main body 2.

  Since the needle punched nonwoven fabric has a lot of fuzz, it is entangled well with, for example, an adhesive or a fusing material, has high anchoring properties, and is well attached to the back side of the above-described molded carpet.

  In addition, it has good stretchability and expands and contracts sufficiently following the extension of the resin sheet main body 2 during heating and pressure molding.

In the resin sheet 1 with a nonwoven fabric of a present Example, the fabric weight of the nonwoven fabric 3 uses 60 g / m < ² > with respect to the adhesive surface of the resin sheet main body 2. FIG.

  When the basis weight of the nonwoven fabric 3 is small, the anchoring property at the time of fusion is impaired, and when too large, the heating efficiency of the resin sheet main body 2 is lowered due to the heat insulating property of the nonwoven fabric 3 itself at the time of heating and pressure forming.

Although the basis weight of the nonwoven fabric 3 can be set in a range of ^{30g / m 2 ~100g / m 2} , minimum and ensure anchoring of necessary heating efficiency of the resin sheet body 2, and reduction and material cost Considering about 60 g / m ² is appropriate.

  The melting point temperature of the PP resin that is the base material of the resin sheet body 2 is about 160 ° C., and the melting point temperature of the PET resin that is the base material of the nonwoven fabric 3 is about 240 ° C.

  Thus, in the resin sheet 1 with a nonwoven fabric of a present Example, melting | fusing point temperature of PET resin used as the base material of the nonwoven fabric 3 is higher than melting | fusing point temperature of PP resin used as the base material of the resin sheet main body 2. It has become.

<Method for producing resin sheet 1 with nonwoven fabric>
FIG. 3 is a schematic view of an extrusion molding machine for explaining a method for producing the nonwoven fabric-attached resin sheet 1 according to this example.

  In FIG. 3, reference numeral 4 denotes an extrusion molding machine, and the extrusion molding machine 4 includes an extruder 5, a take-up device 6, a nonwoven fabric raw roll 7, a fixed size cutting machine 8, and a stacker 9. .

  The resin sheet main body 2 immediately after being extruded from the extruder 5 and molded is softened entirely by heat, and is in a semi-molten state in which only the surface portion is slightly melted.

  The take-up device 6 is provided with take-up rolls 6a and 6b and a pressure roll 6c.

  The pressure roll 6c takes in the nonwoven fabric 3 from the nonwoven fabric raw roll 7 wound in a roll shape, and simultaneously presses the nonwoven fabric 3 against the resin sheet main body 2 in a semi-molten state.

  In this way, the nonwoven fabric 3 is pressed against the semi-molten resin sheet main body 2 so that the non-woven fabric 3 is bonded to the surface portion of the resin sheet main body 2 in a semi-molten state. Affix to almost the entire surface of one side.

  The non-woven fabric-attached resin sheet 1 obtained by pasting the non-woven fabric 3 is further taken up by the take-up roll 6b, sent to the sizing cutter 8 and cut to a standard size, and then stacked on the stacker 9.

<Molding method of molded product using resin sheet 1 with nonwoven fabric>
FIG. 4 is a schematic diagram for explaining a molding method of a molded article using the resin sheet with nonwoven fabric according to the present embodiment, wherein (a) represents a process of placing the resin sheet with nonwoven fabric on the heating device; ) Represents the step of lowering and heating the upper heater portion, and (c) represents the step of lifting the upper heater portion and taking out the resin sheet with nonwoven fabric.

  FIG. 5 is a schematic diagram for explaining the pressing process, wherein (a) represents a process of inserting a resin sheet with a nonwoven fabric between the upper mold and the lower mold of the press machine, and (b) represents the upper mold and the lower mold. A state in which the mold is closed is represented by a mold, and (c) represents a state in which the upper mold and the lower mold are opened, and represents a state in which a resin sheet with a nonwoven fabric is molded.

  As shown in FIG. 4 or 5, for molding a molded product using the resin sheet 1 with nonwoven fabric, a heating device 10 for heating and softening the resin sheet body 2 and the resin sheet 1 with nonwoven fabric are pressurized. A press machine 15 for molding is used.

  As shown in FIG. 4, the heating device 10 is provided with a pair of a lower heater unit 11 and an upper heater unit 12 in the vertical direction and is configured to be opened and closed by hinges 13 and 13.

  The heating device 10 used in the present embodiment is a direct heating heater, and the lower heater panel 11a and the upper heater panel 12a are heated by electric heat.

  When heating the non-woven fabric-attached resin sheet 1 of the present embodiment, first, as shown in FIG. Directly on the heater panel 11a.

  And the handle 14 is grasped and the upper heater part 12 is lowered. At this time, as shown in FIG. 4B, a gap of about 1 cm is left between the upper surface of the resin sheet 1 with nonwoven fabric and the upper heater panel 12a, and the upper heater is placed in the resin sheet main body 2. The surface of the panel 12a should not be in direct contact.

  Thus, the resin sheet 1 with a nonwoven fabric is heated so that it may be pinched | interposed between the lower heater part 11 and the upper heater part 12 of the heating apparatus 10. FIG.

  At this time, it is necessary to raise the heating temperature of the resin sheet 1 with the nonwoven fabric to about 160 ° C. or higher at which the PP resin as the base material of the resin sheet body 2 is softened.

  Therefore, the heating temperature by the heating device 10 is higher than about 160 ° C. that is the melting point temperature of the PP resin that is the base material of the resin sheet body 2, and about 240 ° C. that is the melting point temperature of the PET resin constituting the nonwoven fabric 3. Set lower between 210 ° C and 215 ° C.

  Since the heating temperature at this time is higher than the melting point temperature (about 160 ° C.) of the resin sheet main body 2, the resin sheet main body 2 becomes soft and can be molded.

  On the other hand, the PET resin constituting the nonwoven fabric 3 does not melt because the melting point is about 240 ° C., and the nonwoven fabric 3 does not melt and therefore does not stick to the lower heater panel 11a.

  Moreover, since the nonwoven fabric 3 does not melt, the surface quality is not impaired.

  As described above, since the heating is performed with a gap of about 1 cm between the resin sheet 1 with nonwoven fabric and the upper heater panel 12a, the resin sheet 1 with nonwoven fabric sticks to the upper heater panel 12a. Nor.

  And after heating the resin sheet 1 with a nonwoven fabric with the heating apparatus 10 and softening the resin sheet main body 2, the handle | steering-wheel 14 is grasped and the upper heater part 12 is lifted, as shown in FIG.4 (c). The resin sheet 1 with a nonwoven fabric is taken out.

  As shown in FIG. 5, the press machine 15 has a lower die 16 and an upper die 17, and water-cooled piping (illustrated) is provided inside the lower die 16 and the upper die 17 in order to prevent a temperature rise of the die during pressing. Is omitted) to cool the mold and the object to be molded.

  Next, as shown in FIG. 5A, the nonwoven fabric-attached resin sheet 1 taken out from the heating device 10 is inserted between the lower mold 16 and the upper mold 17.

  And as shown in FIG.5 (b), with the state which inserted the resin sheet 1 with a nonwoven fabric between the lower mold | type 16 and the upper mold | type 17, the lower mold | type 16 and the upper mold | type 17 are closed, and a nonwoven fabric is obtained. The attached resin sheet 1 is formed into a desired shape.

  After pressurizing and cooling, as shown in FIG. 5 (c), the lower mold 16 and the upper mold 17 are opened, and the resin sheet 1 with the nonwoven fabric formed from between the lower mold 16 and the upper mold 17. Take out.

  And the periphery of the resin sheet 1 with a nonwoven fabric shape | molded is trimmed and finished.

<Function and effect>
Since the nonwoven fabric 3 is affixed to the resin sheet main body 2, when adhering another member to the surface where the nonwoven fabric 3 is affixed, an adhesive etc. are entangled with the nonwoven fabric 3 well, anchor property is high, and adhesiveness is high. Good.

  And since the nonwoven fabric 3 is affixed on the substantially whole surface of the resin sheet main body 2, when bonding | bonding with the sheet-like other member, an adhesion surface can be adhere | attached largely and firmly, for example.

  Moreover, since the nonwoven fabric 3 is affixed beforehand to the resin sheet main body 2, the process of affixing the nonwoven fabric 3 separately is abbreviate | omitted, and the increase in the number of work processes can be suppressed.

  Furthermore, since the nonwoven fabric 3 is affixed to the resin sheet main body 2 in advance, the surface on which the nonwoven fabric 3 is affixed does not have to be surface-treated separately.

  And just after forming by extrusion molding, the nonwoven fabric 3 is affixed to the resin sheet main body 2 by heat sealing | bonding by pressing the nonwoven fabric 3 to the resin sheet main body 2 in which only the surface part is a molten state. At the same time, since the nonwoven fabric 3 is attached, the production efficiency is good, and it is not necessary to prepare an adhesive for bonding the resin sheet main body 2 and the nonwoven fabric 3 separately, so that the manufacturing cost can be suppressed.

  Moreover, since the melting point temperature of the PET resin constituting the nonwoven fabric 3 is higher than the melting point temperature of the PP resin that is the base material of the resin sheet body 2, the nonwoven fabric 3 does not melt at the time of heat-sealing, and the quality of the nonwoven fabric 3 is improved. Can keep.

  Furthermore, since the heating temperature by the heating device 10 is set to a temperature lower than the melting point temperature of the PET resin constituting the nonwoven fabric 3, the nonwoven fabric 3 itself is not melted by the heating of the heating device 10, so that at the time of bonding It is possible to leave the fuzz necessary for securing the anchor property of the fabric and to maintain the surface quality of the nonwoven fabric 3.

  And since the heating temperature by the heating apparatus 10 is set to a temperature higher than the melting point temperature of the PP resin that is the base material of the resin sheet main body 2 and lower than the melting point temperature of the PET resin constituting the nonwoven fabric 3. When the resin sheet 1 with a nonwoven fabric is heated from the nonwoven fabric 3 side by the heater panel 11a, the nonwoven fabric 3 itself is not melted, and only the resin sheet body 2 can be softened by heating while maintaining the quality of the nonwoven fabric 3. .

  Further, since the resin sheet main body 2 is heated by the heater panel 11a from the side where the nonwoven fabric 3 is attached, the resin sheet main body 2 does not directly touch the heater panel 11a, and the resin sheet main body 2 melts and the heater panel 11a is heated. There is no sticking to.

  And since the heating temperature of the heating apparatus 10 is set to the temperature lower than the melting point temperature of PET resin which comprises the nonwoven fabric 3, the nonwoven fabric 3 itself does not melt | dissolve by the heating by the heating apparatus 10, and the nonwoven fabric 3 is Since it melts and does not stick to the heating device 10, the resin sheet 1 with a nonwoven fabric does not stick to the heating device 10.

  In addition, when the molded article using the resin sheet 1 with nonwoven fabric is pressure-molded, the surface of the resin sheet 1 with nonwoven fabric on which the nonwoven fabric 3 is stuck does not stick to the mold of the press machine 15.

  Although the best embodiment of the present invention has been described in detail with reference to the drawings, the specific configuration is not limited to this embodiment, and design changes that do not depart from the gist of the present invention are possible. Are included in the present invention.

  In this example, PP resin was used for the resin sheet main body 2 and PET resin was used for the non-woven fabric 3, but the non-woven fabric base material was higher than the melting point temperature of the resin used as the base material of the resin sheet main body. As long as the melting point temperature of the resin is made of a resin having a higher melting point temperature, it is not always necessary to be a PP resin or a PET resin.

  Moreover, in the present Example, although the nonwoven fabric 3 was melt | fused to the single side | surface of the resin sheet main body 2, the nonwoven fabric 3 may be affixed on both surfaces of the resin sheet main body 2. FIG.

It is a partial fracture perspective view of a resin sheet with a nonwoven fabric concerning this example. It is sectional drawing of the AA cross section of FIG. It is a schematic diagram of the extrusion machine explaining the manufacturing method of the resin sheet with a nonwoven fabric which concerns on a present Example. It is the schematic explaining the shaping | molding method of the molded article using the resin sheet with a nonwoven fabric which concerns on a present Example. (A) represents the process of disposing the resin sheet with nonwoven fabric on the heating device, (b) represents the process of lowering and heating the upper heater part, and (c) lifting the upper heater part and resin with nonwoven fabric The process of taking out the sheet is shown. It is a schematic diagram explaining the press process of the shaping | molding method of the molded article using the resin sheet with a nonwoven fabric which concerns on a present Example. (A) represents the process of inserting a resin sheet with a nonwoven fabric between the upper mold and the lower mold of the press machine, (b) represents a state in which the upper mold and the lower mold are closed, and (c) represents the upper mold. The mold and the lower mold represent a state in which the mold is opened, and a state in which the resin sheet with the nonwoven fabric is molded is illustrated.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Resin sheet with nonwoven fabric 2 Resin sheet body 3 Nonwoven fabric 10 Heating device 11a, 12a Heater panel (heating unit)
15 Press 16 Lower mold (mold)
17 Upper mold (mold)

Claims (3)

  A sheet-like nonwoven fabric composed of a resin having a melting point higher than the melting point of the resin serving as the base material of the resin sheet body is pasted on substantially the entire surface of at least one surface of the resin sheet body. Non-woven fabric resin sheet. It is a manufacturing method of the resin sheet with a nonwoven fabric described in Claim 1,
Immediately after heating and melting the base material to form the resin sheet main body by extrusion, only the surface portion is in a molten state by pressing the sheet-like nonwoven fabric to the resin sheet main body in a semi-molten state, A method for producing a resin sheet with a nonwoven fabric, characterized in that the sheet-like nonwoven fabric is stuck on substantially the entire surface of at least one surface of the resin sheet main body by heat sealing. A molding method for a molded article using the resin sheet with a nonwoven fabric according to claim 1,
A heating device having a heating section for heating and softening the resin sheet body;
Using a press machine for pressure forming the resin sheet with nonwoven fabric,
An arrangement heating step of arranging and heating the resin sheet with the nonwoven fabric on the heating portion with the surface on which the non-woven fabric is pasted corresponding to the heating portion,
After heating and softening the resin sheet with nonwoven fabric by the heating device, inserting the resin sheet with nonwoven fabric between one mold of the pressing machine and the other mold of the pressing machine,
A pressing step in which the one mold and the other mold are closed in a state where the resin sheet with nonwoven fabric is spread between the two molds, and the resin sheet with nonwoven fabric is molded into a molded product having a desired shape; Including
The heating temperature by the heating device is set to be higher than the melting point temperature of the resin serving as the base material of the resin sheet main body and lower than the melting point temperature of the resin constituting the nonwoven fabric, and the heating device sets the resin. A method of forming a molded article using a resin sheet with a nonwoven fabric, wherein the sheet body is heated from the side where the nonwoven fabric is affixed.

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