JP2014024310A - Synthetic leather/resin laminate-structured housing and apparatus for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a synthetic leather/resin laminate housing devoid of wrinkling and pattern distortions by virtue of an improved adhesiveness of a synthetic leather layer and a base resin layer.SOLUTION: Of a press and an injection molder hereby provided, the press comprises a female mold 10 for receiving a multilayer adhered assembly of a synthetic resin layer 4 wherein a polyester sheet 2 has been adhered to one layer thereof via a PVA-based film layer 3 in a state where the polyester sheet 2 faces the cavity side and a male mold 11 for pressing the multilayer adhered assembly into the fixed mold. The injection molder comprises a female mold 22 for receiving the molded multilayer adhered assembly in a state where the polyester sheet 2 faces the cavity side, an injection-molding male mold 12 mobilized toward the adhered assembly received by the female mold 22, and an injection unit for injecting a raw ingredient of a base resin layer into a space stipulated by the multilayer adhered assembly received by the female mold 22 and the injection-molding male mold 12. After the raw ingredient of the base resin layer has been solidified, the molded artifact is retrieved, and the polyester sheet 2 and PVA-based film layer 3 are peeled from the former.

Description

  The present invention relates to a synthetic leather / resin laminated structure housing and an apparatus for manufacturing the same, and more particularly to a synthetic leather / resin laminated structure housing in which a synthetic leather layer is laminated on a base resin layer and an apparatus for manufacturing the same.

  In the technical field of housings for electronic devices, home appliances, etc. and housings for automobile interior parts, the housings are often made by resin molding in which a decorative material is laminated on the outer surface. Decorative material is an indispensable element for differentiating from other products. In such a situation, some companies can freely select a decorative design of a product by applying various decorative materials to the resin molded housing even for the same product.

  As a method for decorating a resin molded housing, there is a technique for painting, transferring, and gravure printing on a resin sheet (see, for example, Patent Document 1), and a decorative material containing fibers (synthetic leather) having excellent decorative properties. A resin molded body formed on the surface of a resin container by in-mold molding has been proposed (see, for example, Patent Document 2). In this resin molded body, a base material film and a decorative material made of a synthetic leather material bonded to each other are fused to the surface of the object to be decorated. For example, the decorative material is made of a synthetic leather material covered with a base film, and the base film material is made of a polyester resin, a polyamide resin such as nylon, a polyolefin resin, a polystyrene resin, or the like.

  In addition, as a technique for adhering a synthetic leather material as a decoration material to a body to be decorated, a decorative material is prepared by tensioning a synthetic leather material on the mold cavity surface and then injecting molten resin into the cavity under pressure. There is a technique in which molten resin is infiltrated into the two and laminated and pressure-bonded in a thrown state (see, for example, Patent Document 3).

JP 2000-25168 A JP 2010-36366 A JP-A-2005-471161

  However, in the technology of Patent Document 1, the decoration by painting is not only a flat decoration part, but also the volatile organic compound (VOC) used in the painting process causes health damage, In many cases, the paint is easily peeled off from the plastic molded casing, and the decoration by gravure printing is not suitable for individual small-scale production because of the necessity of preparing a cylinder for each pattern.

  In addition, in the technique of Patent Document 2, the base film covering the synthetic leather material is inferior in impact resistance and easily scratched, and has low resistance at high temperature during in-mold molding and is capable of being synthesized for a decorative object. The adhesiveness of the leather material is inferior, and in order to form a product housing, it is necessary to perform a further housing processing step on the object to be decorated to which the decorative material is fused.

  In the technique of Patent Document 3, the adhesiveness of the synthetic leather material to the decoration material is not sufficient, and various low-volume productivity for product diversification and versatility for each product are not necessarily considered. In the technique of Patent Document 3, the synthetic leather material is prone to wrinkles and the pattern is distorted when the molten resin is injected under pressure, and the yield during mass production is poor.

  An object of the present invention is to provide a synthetic leather / resin laminated housing manufacturing apparatus capable of improving the adhesion of a synthetic leather layer to a base resin layer and eliminating wrinkles and pattern distortion of the synthetic leather layer. Another object of the present invention is to provide a synthetic leather / resin laminate housing in which the synthetic leather layer does not adhere to the base resin layer, and the synthetic leather layer has no wrinkles or pattern distortion.

  In order to achieve the above object, the synthetic leather / resin laminated housing manufacturing apparatus according to claim 1 is a polyester sheet PVA which forms a polyvinyl alcohol film layer (hereinafter referred to as PVA film layer) on at least one surface. A fixed mold for receiving a multilayer adhesive body having a synthetic leather layer bonded to the system membrane surface with the polyester sheet facing the cavity, and the received adhesive body for forming the adhesive body of the fixed mold A movable mold that is moved toward the fixed mold so as to be pushed in; another fixed mold that receives the molded adhesive body with the polyester sheet facing the cavity; and the other fixed mold The base resin layer raw material is injected into a space defined by the injection mold that is moved toward the adhesive body received in the mold, the adhesive body that is received in the other fixed mold, and the injection mold. And a injection unit that, the polyester sheet and the PVA-based film layer is characterized in that material of the injected foundation resin layer is peeled off after solidification.

  The synthetic leather / resin laminated housing manufacturing apparatus according to claim 2, wherein the synthetic leather layer is formed on the PVA film surface of the polyester sheet forming a polyvinyl alcohol film layer (hereinafter referred to as PVA film layer) on at least one surface. A fixed mold for receiving the bonded multilayer adhesive with the polyester sheet facing the cavity, and the received multilayer adhesive for pressing the received multilayer adhesive into the fixed mold to form the multilayer adhesive. A movable mold moved toward the fixed mold, an injection mold moved toward the multilayer adhesive received in the fixed mold, a multilayer adhesive received in the fixed mold, and the An injection unit for injecting the raw material of the base resin layer into a space defined by the injection mold, and the polyester sheet and the PVA film layer are solidified by the injected raw material of the base resin layer. Characterized in that it is peeled off later.

  The synthetic leather / resin laminated structure housing according to claim 9 is manufactured by the synthetic leather / resin laminated structure housing manufacturing apparatus.

  According to the synthetic leather / resin laminated housing manufacturing apparatus according to claim 1, the adhesion of the synthetic leather layer to the base resin layer is improved, and the generation of wrinkles and the distortion of the pattern of the synthetic leather layer is eliminated. Can do.

  The synthetic leather / resin laminated housing according to claim 9 is excellent in adhesion of the synthetic leather layer to the base resin layer, and is free from wrinkles and pattern distortion of the synthetic leather layer.

It is an external appearance perspective view of the synthetic leather / resin laminated structure housing which concerns on embodiment of this invention. It is sectional drawing of the synthetic leather / resin laminated structure housing along line II-II of FIG. It is sectional drawing of the synthetic leather / resin laminated structure housing which follows the line III-III of FIG. It is a figure used for demonstrating the manufacturing apparatus of the synthetic leather / resin laminated structure housing which concerns on embodiment of this invention.

  Hereinafter, the present invention will be described in detail with reference to the drawings.

  FIG. 1 is an external perspective view of a synthetic leather / resin laminated structure housing according to an embodiment of the present invention.

  In FIG. 1, a synthetic leather / resin laminated structure housing 40 (hereinafter also referred to simply as “housing 40”) is a casing having an inverted basin structure, and has one protrusion 41 and one opening at the bottom of the inverted basin structure. Part 42.

  The cross section of the protrusion 41 is shown in FIG. 2 as a cross-sectional view along line II-II in FIG. 1, and the cross section of the opening 42 is shown in FIG. 3 as a cross-sectional view along line III-III in FIG. .

  The housing 40 includes the synthetic leather layer 4 and the base resin layer 5 fixed to the synthetic leather layer 4 while infiltrating the gaps between the fibers of the synthetic leather layer 4.

  The synthetic leather layer 4 is made of synthetic leather.

  With this synthetic leather, various designs can be easily obtained, and the three-dimensional effect on the surface of the synthetic leather is displayed as it is. The use of synthetic leather has the effect of increasing the strength of the housing 40 in addition to increasing the degree of freedom in design of the housing 40.

  The base resin layer 5 is made of a thermoplastic synthetic resin, preferably a synthetic resin for injection molding, and specifically selected from the group of ABS (acrylbutyl styrene), PC (polycarbonate), PMMA (acrylic), and ABS + PC. It is made of only one material, preferably ABS or PMMA, more preferably ABS, and the thickness is arbitrarily set according to the product, and in this embodiment is about 1.2 mm. The raw material of the base resin layer 5 is heated and melted by an injection molding machine in FIG. 4 to be described later, and as will be described later, a polyester sheet (details will be described later) passes through a PVA film having a thickness of 0.1 to 100 μm. A multilayer adhesive body of the synthetic leather layer 4 adhered to the surface of the synthetic leather layer 4 is injected into a female mold 22 shown in FIG. It adheres to the synthetic leather layer 4 while infiltrating into the gap (FIG. 4). The base resin layer 5 is more firmly fixed to the synthetic leather layer 4 due to the shrinkage of the synthetic leather layer 4 and the base resin layer 5 during cooling and solidification.

  According to the housing 40 of FIG. 1, since the base resin layer 5 is fixed to the synthetic leather layer 4 while infiltrating the gaps between the fibers on the back of the synthetic leather layer 4, the base resin of the synthetic leather layer 4 is obtained by the anchor effect. While improving the adhesiveness with respect to the layer 5, each fiber of the synthetic leather layer 4 can improve the intensity | strength of the housing 40. FIG. Moreover, according to the housing 40 of FIG. 1, the pattern of the surface of the housing 40 can be variously selected by changing the synthetic leather.

  Although the housing 40 of FIG. 1 has an inverted basin structure with the synthetic leather layer 4 as a front, the housing 40 may have an inverted basin structure with the base resin layer 5 as a front.

  FIG. 4 is a diagram used for explaining the synthetic leather / resin laminated housing manufacturing apparatus according to the embodiment of the present invention.

  In FIG. 4, steps I and II are performed by a press machine, and steps III and IV are performed by an injection molding machine. Finally, step V described later is performed by an appropriate method.

  First, an adhesive body of a synthetic leather layer 4 in which a polyester sheet 2 is bonded to one surface via a PVA film layer is prepared. The polyester sheet 2 is made of polyester. This polyester may be a homopolyester or a copolyester.

  The homopolyester is preferably obtained by cocondensing an aromatic dicarboxylic acid and an aliphatic glycol. Examples of the aromatic dicarboxylic acid include terephthalic acid and 2,6-naphthalenedicarboxylic acid. Examples of the aliphatic glycol include ethylene glycol, diethylene glycol, and 1,4-cyclohexanedimethanol.

  The copolymerized polyester is preferably obtained by copolymerizing dicarboxylic acid and / or glycol as the third component of the homopolyester. Examples of the dicarboxylic acid include isophthalic acid, terephthalic acid, 2,6-naphthalenedicarboxylic acid, adipic acid, and sebacic acid. Examples of the glycol include ethylene glycol, propylene glycol, diethylene glycol, propylene glycol, butanediol, 1,4-cyclohexanedimethanol and the like.

  A typical example of the polyester used in the present embodiment is polyethylene terephthalate (PET).

  The PVA-based membrane is water-soluble, and for example, SOLBRON (registered trademark) manufactured by Aicello Chemical Co., Ltd. can be mentioned. The PVA-based membrane may be unmodified or modified. When the PVA film is modified, one or more of the following monomers may be copolymerized in the PVA main chain.

  The monomer may be an olefin such as ethylene or propylene, maleic acid, a salt or ester thereof, acrylamide or a derivative thereof, methacrylamide or a derivative thereof, acrylic acid, a salt or an ester thereof. It may be methacrylic acid, a salt or ester thereof.

  The degree of polymerization of the PVA film is preferably 500 to 5000, more preferably 500 to 2400. When the degree of polymerization of the PVA-based film is less than 500, the mechanical strength of the film is insufficient and the synthetic leather layer 4 may be damaged by impact or the like.

  The degree of saponification of the PVA-based membrane is preferably 50 to 99.9 mol%, more preferably 80 to 99.9 mol%. When the saponification degree of the PVA-based membrane is less than 50 mol%, there is a possibility that the releasability with the synthetic leather layer 4 may be hindered.

  The PVA film may contain a plasticizer for the purpose of imparting flexibility. In this case, the type of plasticizer used is not particularly limited, but glycerin, diglycerin, propylene glycol, trimethylolpropane, etc. And polyhydric alcohols, sugar alcohols such as sorbitol and xylitol, and polyether compounds such as polyethylene glycol and polypropylene glycol.

  Next, in step I of FIG. 4, the adhesive body of the polyester sheet 2 and the synthetic leather layer 4 is placed on the female die 10 (fixed die) of the press machine with the polyester sheet 2 facing the cavity of the female die 10. Put. This adhesive body may be cut into a predetermined shape in advance.

  Next, in step II, the male die 11 (movable die) of the press machine is moved to the female die so that the adhesive body of the polyester sheet 2 and the synthetic leather layer 4 placed in step I is pushed into the female die 10. Move toward the mold 10. Thereby, the adhesive body of the polyester sheet 2 and the synthetic leather layer 4 is shape | molded in the shape prescribed | regulated with the female metal mold | die 10 and the male metal mold | die 11, and after that, the shape | molded adhesive body is taken out from a press machine. At this time, deburring may be performed by cutting the periphery of the formed adhesive body with a laser cutter or a cutting die (cutting unit).

  Subsequently, in Step III of FIG. 4, an adhesive body of the polyester sheet 2 and the synthetic leather layer 4 formed by a press machine is used as a female mold 22 (other fixed mold) with the polyester sheet 2 as the cavity side of the female mold 10. The injection molding male mold 12 (injection molding mold) is moved toward the adhesive body received in the mold die 22 and the injection hole 20a of the injection molding machine 20 is injected. After pressing against the injection molding hole 12a of the molding male mold 12, the injection screw 21 is rotated clockwise to feed the raw material 31 of the base resin layer 5 in the tank 30 to the adhesive, the injection molding male mold 12, and Inject into the space defined by. At this time, the raw material 31 of the base resin layer 5 infiltrates into the gaps between the respective fibers on the back side of the synthetic leather layer 4, and the synthetic leather layer 4 and the base resin layer 5 contract with each other when the raw material 31 is cooled and solidified. Fixing becomes stronger.

  Next, in Step IV, after the raw material 31 of the injection molded base resin layer 5 is cooled and solidified, the injection machine 20 and the injection molded male mold 12 are separated from the female mold 10 and the molded product is taken out.

  Finally, the polyester sheet 2 and the PVA film layer 3 are peeled off from the molded product taken out (Step V). Thereby, the desired synthetic leather / resin laminated structure housing 40 is obtained. Since the polyester sheet 2 is bonded to the synthetic leather layer 4 through the PVA film layer 3 as a release layer on one surface thereof, the polyester sheet 2 and the PVA film layer 3 are easily peeled off from the synthetic leather layer 4. be able to.

  The female die 10 and the male die 11 constitute a press machine, and the female die 22, the injection molding male die 12, and the injection machine 20 constitute an injection molding machine. The press machine and the injection molding machine constitute an apparatus for manufacturing the housing 40. As a modification, the press machine and the injection molding machine may be integrated, and the female die 10 may be used as the female die 22. In this case, the injection molded male mold 12 is moved toward the multilayer adhesive body of the polyester sheet 2 and the synthetic leather layer 4 molded in the female mold 10.

  According to the synthetic leather / resin laminated housing manufacturing apparatus of FIG. 4, in step III, the raw material 31 of the base resin layer 5 infiltrates into the gaps between the fibers of the synthetic leather layer 4, and the raw material 31 is synthesized at the time of cooling and solidifying. Due to the shrinkage of the leather layer 4 and the base resin layer 5, the adhesion between the synthetic leather layer 4 becomes stronger. Furthermore, polycarbonate that can be molded only at high temperatures can be used as the material of the base resin layer 5.

  Further, according to the synthetic leather / resin laminated housing manufacturing apparatus of FIG. 3, the adhesiveness of the synthetic leather layer 4 excellent in decorativeness to the base resin layer 5 is improved and the polyester sheet 2 is adhered. Since the base resin layer 5 is injection-molded, the generation of wrinkles and the distortion of the pattern can be eliminated in the synthetic leather layer 4 when the base resin layer 5 is injection-molded.

  In the textile / resin laminated structure manufacturing apparatus of FIG. 3, the housing 40 has an inverted basin structure with the synthetic leather layer 4 as a front, and the housing 40 has an inverted basin shape with the base resin layer 5 as a front. It is good also as a structure.

  In the embodiment of the present invention, the synthetic leather / resin structure housing 40 is merely described as a general housing. However, as an application technical field of the embodiment of the present invention, an in-mold having a surface coating layer is used. For decorative items by molding, specifically, miscellaneous goods including containers and stationary, housings for electronic devices and home appliances including mobile phones and laptop computers, housings for interior and exterior products of buildings and automobiles, aircraft Interior housings.

2 Polyester sheet 3 PVA film layer 4 Synthetic leather layer 5 Base resin layer 10 Female mold 11 Male mold 12 Injection molding male mold 20 Injection machine 21 Injection screw 22 Female mold 30 Tank 31 Raw material 40 Synthetic leather / resin lamination Structural housing 41 Protruding part 42 Opening part

Claims (9)

  Fixing a multilayer adhesive body in which a synthetic leather layer is bonded to a PVA film surface of a polyester sheet forming a polyvinyl alcohol film layer (hereinafter referred to as PVA film layer) on at least one surface, with the polyester sheet facing the cavity A mold, a movable mold moved toward the fixed mold so as to push the received adhesive body into the fixed mold to mold the adhesive body, and the molded adhesive body Receiving the polyester sheet with the polyester sheet facing the cavity, an injection mold moved toward the adhesive received in the other fixed mold, and receiving in the other fixed mold An injection unit for injecting the raw material of the base resin layer into a space defined by the adhesive body and the injection mold, and the polyester sheet and the PVA-based film layer are formed on the injected base tree. Apparatus for producing a synthetic leather / resin laminate structure housing, characterized in that the material layer is peeled off after solidification.   Fixing a multilayer adhesive body in which a synthetic leather layer is bonded to a PVA film surface of a polyester sheet forming a polyvinyl alcohol film layer (hereinafter referred to as PVA film layer) on at least one surface, with the polyester sheet facing the cavity A mold, a movable mold moved toward the fixed mold to push the received multilayer adhesive into the fixed mold to mold the multilayer adhesive, and the fixed mold The base resin layer material is injected into a space defined by the injection mold that is moved toward the multilayer adhesive received in the mold, and the multilayer adhesive received in the fixed mold and the injection mold. A synthetic leather / resin laminated structure, wherein the polyester sheet and the PVA film layer are peeled off after the injected base resin layer material is solidified Of manufacturing equipment.   Furthermore, the manufacturing apparatus of the synthetic leather / resin laminated structure housing of Claim 1 or 2 provided with the cutting unit which cut | disconnects the periphery of the shape | molded multilayer adhesive body.   The said base resin layer consists of a thermoplastic synthetic resin, The manufacturing apparatus of the synthetic leather / resin laminated structure housing of any one of Claim 1 to 3 characterized by the above-mentioned.   The apparatus for manufacturing a synthetic leather / resin laminated structure housing according to claim 4, wherein the thermoplastic synthetic resin is made of a synthetic resin for injection molding.   6. The synthetic leather / resin laminated housing manufacturing apparatus according to claim 5, wherein the synthetic resin for injection molding is made of one material selected from the group of ABS, PC, PMMA, and PC + ABS.   7. The synthetic leather / resin laminated housing manufacturing apparatus according to claim 6, wherein the injection molding synthetic resin is made of ABS or PMMA.   The said polyester sheet consists of a polyethylene terephthalate, The manufacturing apparatus of the synthetic leather / resin laminated structure housing of any one of Claim 1 to 7 characterized by the above-mentioned.   A synthetic leather / resin laminated structure housing manufactured by the synthetic leather / resin laminated structure manufacturing apparatus according to claim 1.

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