JP2008119997A - Sheet material for thermoforming - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a sheet material for thermoforming which can easily be thermoformed, and at the same time, hardly spoils the air permeability of a base material at the time of thermoforming, and in addition, scarcely contaminating the working environment. <P>SOLUTION: This sheet material 10 for thermoforming is made by depositing at least a thermoplastic synthetic resin 21a consisting of a fiber foam having a thickness of 10 to 100 μm on one surface of the base material 11 made of a synthetic resin foamed body such as a polyurethane foam in a deposition quantity of 5 to 80 g/m<SP>2</SP>to the base material 11, laminating the sheet material 10 for thermoforming with a skin material or the like, and heat-pressing the resulting laminated product so that the thermoplastic synthetic resin 21a consisting of the fiber form is re-activated and is bonded to the skin material or the like. At the same time, the sheet material 10 for thermoforming and the skin material or the like can be shaped. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a thermoforming sheet material, and more particularly, to a thermoforming sheet material that is bonded and integrated with a flexible material such as a cloth material by thermoforming (hot press molding) using a mold.

  Conventionally, a laminated material made of a base material made of a cushioning material such as a nonwoven fabric or a synthetic resin foam and a flexible material such as a cloth material has been widely used as a member of a clothing product or the like. For example, for the inner material to be attached to the cup part of a brassiere in clothing, a laminated material obtained by bonding a base material and a flexible material as a surface material with an adhesive is formed into a cup shape by thermoforming (hot press molding). Shaped laminated molded products are used. The bonding of the base material and the flexible material is performed by an adhesive applied to at least one of the base material and the flexible material, or a non-woven fabric called a web disposed between the base material and the flexible material. This is done with a hot melt adhesive. In addition, when using a web for bonding a base material and a flexible material, the case where a base material and a flexible material are bonded together before thermoforming, and a web and a base material are flexible at the time of thermoforming. In some cases, the materials are bonded together at the same time as shaping.

  However, when an adhesive is used, if the amount of adhesive applied is too large, the feel of the clothing product may be impaired. Moreover, when the base material is a synthetic resin foam, air bubbles on the surface of the synthetic resin foam may be blocked with an adhesive, and the air permeability of the clothing product may be impaired. Further, when a solvent-based adhesive is used, the solvent may scatter when the adhesive is applied, contaminating the work environment and possibly harming the health of the worker. In addition, when a base material and a flexible material are continuously supplied and pasted together with an adhesive, since they are wound up after being pasted together, the solvent and water volatilization contained in the adhesive are removed. However, the curing time has to be lengthened and there is a problem of taking a storage place.

  On the other hand, when thermoforming after pasting a base material and a flexible material together using a web, the hot melt adhesive of the web is softened again during thermoforming. There is a risk of slipping. In addition, when the web is sandwiched between the base material and the flexible material at the time of thermoforming, if the positional relationship between the web, the base material and the flexible material is shifted, problems such as the web protruding may occur. Therefore, it is necessary to carefully position the base material and the flexible material.

JP 2001-234402 A

  The present invention has been made in view of the above points, and can easily perform thermoforming, hardly impair the air permeability of the base material during thermoforming, and has little risk of contamination of the work environment, particularly for clothing. An object of the present invention is to provide a thermoforming sheet material suitable for the above.

  The invention according to claim 1 relates to a thermoforming sheet material, characterized in that a fibrous thermoplastic synthetic resin having a thickness of 10 to 100 μm is attached to at least one surface of a base material made of a cushioning material.

The invention of claim 2 is characterized in that, in claim 1, the amount of the fibrous thermoplastic synthetic resin attached to the substrate is 5 to 80 g / m ² .

  A third aspect of the invention is characterized in that, in the first or second aspect, the fibrous thermoplastic synthetic resin is made of a fibrous polyethylene terephthalate resin.

  According to a fourth aspect of the present invention, in any one of the first to third aspects, the cushioning material is made of polyurethane foam.

  In the thermoforming sheet material of the present invention, a fibrous thermoplastic synthetic resin having a thickness of 10 to 100 μm is attached to at least one surface of a base material made of a cushioning material, so that the fibrous thermoplastic synthetic resin is attached. By laminating a flexible material on the surface, and performing thermoforming using a mold, the fibrous thermoplastic synthetic resin is reactivated (melted) and bonded to the flexible material. Can be shaped. Therefore, the thermoforming sheet material of the present invention does not require application of an adhesive or web arrangement at the time of thermoforming, and can be easily thermoformed. In addition, there is no risk of work environment contamination due to solvent volatilization during application of the adhesive. Furthermore, even when the cushioning material constituting the base material is made of a synthetic resin foam, it is not necessary to apply an adhesive to the synthetic resin foam of the base material. There is no risk of impairing air permeability by blocking.

  Hereinafter, embodiments of the present invention will be described in detail. 1 is a cross-sectional view of a thermoforming sheet material according to an embodiment of the present invention, FIG. 2 is a perspective view of the thermoforming sheet material according to the embodiment, and FIG. 3 is a fibrous thermoplastic composite in the embodiment. FIG. 4 is a perspective view of a coating device for fibrous thermoplastic synthetic resin, FIG. 5 is an exploded perspective view of the coating device, and FIG. 6 is a diagram for thermoforming according to an embodiment of the present invention. FIG. 7 is a schematic cross-sectional view showing a heat-molding die at the time of thermoforming using a sheet material, and FIG.

  The thermoforming sheet material 10 shown in FIGS. 1 and 2 is formed by being laminated with a flexible material such as a cloth material and thermoformed to adhere to the flexible material and be shaped. It is suitable as a thermoforming sheet material for clothing. The sheet material 10 for thermoforming has a configuration in which a fibrous thermoplastic synthetic resin 21 a is attached to at least one surface of a base material 11. In the illustrated example, a fibrous thermoplastic synthetic resin 21 a is attached to one side of the substrate 11.

  The base material 11 is made of a cushioning material. As the cushioning material, a cushioning material such as a nonwoven fabric or a synthetic resin foam is used. Examples of the synthetic resin foam include polyurethane foam, polyethylene foam, polypropylene foam, EVA foam and the like. In the case where the thermoforming sheet material 10 is for clothing, the cushioning material constituting the base material 11 preferably has a soft feel, good air permeability, recoverability after compression, and the like. As the buffer material, a synthetic resin foam is preferable. Among the synthetic resin foams, polyurethane foam is generally superior to other synthetic resin foams in terms of flexible feel, good breathability, and recoverability after compression. Is more preferable as a cushioning material. Furthermore, a polyurethane foam having an open cell structure is preferable, for example, a flexible polyurethane foam is more preferable. The thickness of the base material 11 is 2.0 to 15.0 mm as an example, although it varies depending on the material and hardness of the base material 11.

  The fibrous thermoplastic synthetic resin 21a is reversibly melted (activated) and solidified by heating and cooling, and is bonded by solidification. Examples of the thermoplastic synthetic resin include polyester, polyamide, EVA, polyvinyl alcohol, polyolefin (polyethylene, polypropylene, etc.), and the like. In addition, when the thermoforming sheet material 10 is used for clothing, the base material 11 and the fibrous thermoplastic synthetic resin 21a are preferably difficult to discolor because there is a risk of discoloration being observed through a thin fabric. Furthermore, in the case of apparel use, the fibrous thermoplastic synthetic resin 21a is particularly preferably a polyester-based resin since it is preferable to have good water resistance and heat resistance with little decrease in adhesive strength even after washing and drying. . Further, when the base material 11 is made of polyurethane foam, the temperature at the time of thermoforming is increased to about 200 ° C., and therefore the fibrous thermoplastic synthetic resin 21a is greatly reduced in viscosity at the time of thermoforming. In such a case, the air permeability of the laminated molded product obtained by thermoforming is impaired, and the touch is also lowered. Therefore, the fibrous thermoplastic synthetic resin 21a is preferably a polyester system having a high melting temperature so that it does not penetrate as much as possible into the polyurethane foam of the base material 11 during thermoforming, and among them, a polyethylene terephthalate (PET) resin is preferable. It is particularly preferable from the viewpoints of availability and cost.

  As is understood from FIGS. 2 and 3, the fibrous thermoplastic synthetic resin 21 a becomes a thin film adhesive layer 21 in which the fibrous thermoplastic synthetic resin 21 a intersects, and the surface of the substrate 11. Adhering to Between the fibrous thermoplastic synthetic resins 21a, there are gaps 22 due to the intersection of the fibrous thermoplastic synthetic resins 21a. Due to the presence of the gap 22 between the fibrous thermoplastic synthetic resin 21a, for example, in the case where the base material 11 has air permeability such as a flexible polyurethane foam, the air is passed through the thermoforming sheet 10. Sex can be imparted.

  The thickness of the fibrous thermoplastic synthetic resin 21a is preferably 10 to 100 μm. If the thickness of the fibrous thermoplastic synthetic resin 21a is less than 10 μm, the adhesiveness during thermoforming is inferior. On the other hand, if the thickness exceeds 100 μm, the flexibility and feel of the laminated molded product obtained by thermoforming. Will be damaged. On the other hand, by setting the thickness within the above range, it becomes easy to form the gap 22 between the fibrous thermoplastic synthetic resins 21a, and the adhesiveness by the fibrous thermoplastic synthetic resin 21a is improved during thermoforming. Moreover, the softness | flexibility and feel of a laminated molded product obtained by thermoforming can be made favorable.

The adhesion amount of the fibrous thermoplastic synthetic resin 21a to the substrate 11 is preferably 5 to 80 g / m ² with respect to the fibrous thermoplastic synthetic resin adhesion surface of the substrate 11. When the adhesion amount is less than 5 g / m ^2, the interval between the fibrous thermoplastic synthetic resins 21a on the surface of the substrate 11 is partially increased (the adhesion amount of the thermoplastic synthetic resin is small), and thermoforming is performed. On the other hand, poor adhesion occurs, and on the other hand, when the adhesion amount exceeds 80 g / m ² , the flexibility and feel of the laminated molded product obtained by thermoforming are impaired. On the other hand, by setting the amount of adhesion within the above range, it becomes easy to form the gap 22 between the fibrous thermoplastic synthetic resins 21a, and the adhesiveness by the fibrous thermoplastic synthetic resin 21a is good at the time of thermoforming. Furthermore, the flexibility and feel of the laminated molded product obtained by thermoforming can be prevented from being impaired. In addition, the adhesion amount of the said fibrous thermoplastic synthetic resin 21a is 10-30 g / m < ² > from points, such as the said adhesive strength, a softness | flexibility, a touch property, cost, among the range of 5-80 g / m < ² >. More preferred.

  The fibrous thermoplastic synthetic resin 21a can be attached to the surface of the substrate 11 by, for example, a fibrous thermoplastic synthetic resin coating apparatus 40 shown in FIGS. In the fibrous thermoplastic synthetic resin coating apparatus 40, a pair of base plates 47 and 48 are fixed to the lower surface of a support plate 46. A base 49 is formed on the base plates 47 and 48, and a resin supply port 50 and air supply ports 51 and 52 are formed on the opposing surface of the base 49. The support plate 46 and the base plates 47 and 48 are formed with a plurality of resin injection holes 53 that communicate with the resin supply port 50 and a plurality of air introduction holes 54 and 55 that communicate with the air supply ports 51 and 52. Has been. A nozzle plate 56 is disposed between the opposing surfaces of the base 49. A plurality of nozzle grooves 57 are formed in the nozzle plate 56 at predetermined intervals so as to correspond to the resin supply port 50 and the air supply ports 51 and 52. The nozzle groove 57 is formed in the vertical direction with a groove width of about 0.4 mm.

  In order to attach the fibrous thermoplastic synthetic resin 21 a to the surface of the base material 11 by the fibrous thermoplastic synthetic resin coating device 40, the base material 11 is positioned at a predetermined distance from the base 49. The nozzle plate 56 is supplied at a predetermined speed in a direction orthogonal to the arrangement direction of the nozzle grooves 57 in the nozzle plate 56. In this state, a molten thermoplastic synthetic resin is extruded from the plurality of nozzle grooves 57 to the surface of the substrate 11 and applied from the resin injection hole 53 to the resin supply port 50. The resin injection hole 53 is supplied with a molten thermoplastic synthetic resin through a supply path (not shown).

  When the molten thermoplastic synthetic resin is extruded onto the surface of the substrate 11, the air supplied from the air introduction holes 54 and 55 to the air supply ports 51 and 52 together with the molten thermoplastic synthetic resin. It blows out from the nozzle groove 57. As a result, the molten thermoplastic synthetic resin pushed out from the nozzle groove 57 is drawn into a fiber having a predetermined thickness to form a molten fibrous thermoplastic synthetic resin 21b. In addition, since the air blown out from the nozzle groove 57 becomes a turbulent flow and hits the molten fibrous thermoplastic synthetic resin 21b, the molten fibrous thermoplastic synthetic resin 21b oscillates irregularly while It is applied to and adhered to the surface of the base material 11, and then cured by natural cooling to become the fibrous thermoplastic synthetic resin 21a. Further, since the molten fibrous thermoplastic synthetic resin applied and adhered to the surface of the base material 11 has a certain degree of viscosity, it is difficult to impregnate the base material 11 from the surface of the base material 11. It can be adhered to the surface of the material 11 in a raised state.

  Thermoforming using the thermoforming sheet material 10 is performed as follows. First, the thermoforming sheet material 10 is appropriately cut into a predetermined shape and dimensions as necessary, and then, as shown in FIG. 6, an adhesive layer 21 made of the fibrous thermoplastic synthetic resin 21a is applied as a cloth material. The flexible material 31 is placed on the flexible material 31 so as to face the flexible material 31, and is placed between the press die 71 and the receiving die 72 of the hot press die 70 and hot pressed. The mold surfaces of the press die 71 and the receiving die 72 are adapted to the shaping shape of a laminated molded product obtained by thermoforming, for example, the cup shape of a brassiere. The temperature of the hot press die 70 at the time of thermoforming is a temperature at which the fibrous thermoplastic synthetic resin 21a is melted (activated). Then, after hot pressing for a predetermined time, the heating by the hot press die 70 is stopped, whereby the fibrous thermoplastic synthetic resin 21a is cured in the thermoforming sheet material 10 and the flexible material 31 is cured. And are integrated with the flexible material 31. At the same time, the thermoforming sheet material 10 and the flexible material 31 are formed into a shape pressed between the press die 71 and the receiving die 72 by curing the fibrous thermoplastic synthetic resin 21a. Fixed and shaped.

  Thereafter, when the laminated molded product is taken out from the hot press die 70, as shown in FIG. 7, the thermoformed sheet material 10 and the flexible material 31 are bonded and integrated, and the molded laminated molded product 30 is formed. can get. The laminated molded product 30 thus obtained is further appropriately trimmed and covered with a surface material according to the application. For example, when the laminated molded product 30 is used as an inner member of a brassiere cup, the laminated molded product 30 shaped into a cup shape by the thermoforming is appropriately trimmed and then covered with a surface material. To make a brassiere cup. The thermoforming sheet material 10 may have a fibrous thermoplastic synthetic resin 21a attached to both surfaces of the base material 11. In that case, both surfaces of the thermoforming sheet material 10 are formed during the thermoforming. The flexible material 31 is laminated and disposed. The sheet material 10 for thermoforming is not limited to the inner member of the brassiere cup, but is suitable for other clothing, for example, a pad member for clothing.

As the substrate 11, a sheet of flexible polyurethane foam (product number: EL-61, manufactured by Inoac Corporation, density 30 kg / m ³ ) having a thickness of 12 mm was used, and a conveyance roller conveyor set at a conveyance speed of 30 m / min. The base material 11 is placed thereon, and the fibrous thermoplastic synthetic resin coating apparatus 40 is operated to change the thermoplastic synthetic resin (PET resin, product number: D-1655E, manufactured by Ms Chemie Japan Co., Ltd.) to 180. It was heated to ° C., discharged in a fiber form from the nozzle groove 57 together with 200 ° C. heated air, and adhered to the surface of the substrate 11 being conveyed. Then, the fibrous thermoplastic synthetic resin was cured by subsequent natural cooling to obtain the thermoforming sheet material 10. In addition, the thickness of the fibrous thermoplastic synthetic resin 21a adhering to the surface of the base material 11 was set to 20 μm, and the adhesion amount was set to 20 g / m ² with respect to the surface of the base material 11. The nozzle groove 57 is not in contact with the surface of the base material 11 and adheres the fibrous thermoplastic synthetic resin 21a to the surface of the base material 11 with a constant width.

  Thereafter, the flexible material 31 made of a tricot (nylon tricot half 30 denier) cut into 200 mm × 200 mm and cut into 200 mm × 200 mm is prepared as shown in FIG. Further, the thermoforming sheet material 10 is overlapped with the flexible material 31 so that the adhesion surface of the fibrous thermoplastic synthetic resin 21a is on the flexible material 31 side. Thermoformed by hot pressing at 170 ° C. for 170 seconds to obtain a laminated molded product 30. Since there is no need to perform adhesive application work or web placement work at the time of thermoforming, there is no risk of environmental deterioration due to scattering of the adhesive, and the work is easy, and the obtained laminated molded product In No. 30, there was no web displacement, and neither a decrease in touch due to excessive application of adhesive nor a decrease in breathability was observed.

It is sectional drawing of the sheet material for thermoforming which concerns on one Embodiment of this invention. It is a perspective view of the sheet material for thermoforming in the embodiment. It is a perspective view of the contact bonding layer which consists of a fibrous thermoplastic synthetic resin in the embodiment. It is a perspective view of the coating device of a fibrous thermoplastic synthetic resin. It is a disassembled perspective view of the coating device. It is a schematic sectional drawing of the hot press type | mold at the time of the thermoforming using the sheet material for thermoforming which concerns on one Embodiment of this invention. It is a schematic sectional drawing which shows the time of taking out the laminated molded product after thermoforming in the same embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Thermoforming sheet material 11 Base material 21 Adhesive layer 21a Fibrous thermoplastic synthetic resin 22 Gap between fibrous thermoplastic synthetic resins

Claims (4)

  A sheet material for thermoforming, wherein a fibrous thermoplastic synthetic resin having a thickness of 10 to 100 µm is attached to at least one surface of a base material made of a buffer material. The thermoforming sheet material according to claim 1, wherein an adhesion amount of the fibrous thermoplastic synthetic resin to the base material is 5 to 80 g / m ² .   The sheet material for thermoforming according to claim 1 or 2, wherein the fibrous thermoplastic synthetic resin comprises a fibrous polyethylene terephthalate resin.   The thermoforming sheet material according to any one of claims 1 to 3, wherein the cushioning material is made of polyurethane foam.

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