JP2016124156A - Method for producing decorative molding, and method for producing artificial leather with protective film - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative molding having an artificial leather on a surface layer, which suppresses disappearance of three-dimensional embossed unevenness of a grained artificial leather and reduction of the depth of a recessed portion, and has embossed unevenness that keeps three-dimensional touch feeling.SOLUTION: A method for producing a decorative molding includes: a first step of arranging a preform molding obtained by shaped into an artificial leather with a protective film in a cavity of a mold; a second step of injecting a molten resin to a rear face side with respect to a surface where the protective film of the preform molding is arranged, and thereby molding an in-mold molding; and a third step of peeling a protective layer from the in-mold molding, and thereby obtaining a decorative molding. The artificial leather with the protective film contains an artificial leather containing a nonwoven fabric formed of ultrafine fibers having a thickness of 250 μm or more and a resin layer having and an embossed uneven surface as a three-dimensional decorative surface, and a protective film formed by applying a resin so as to fill a recessed portion of the embossed uneven surface.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for producing a decorative molded body having an artificial leather-like appearance, and more specifically, a preform molded body provided with artificial leather is placed in a cavity of a mold and in-mold injection molding is performed. It is related with the method of manufacturing the decorative molded object which has the external appearance.

  BACKGROUND ART A decorative molded body having artificial leather on the surface is known as an exterior member for interior parts such as vehicles and aircraft, mobile phones, mobile devices, housings for home appliances, building materials, and furniture. The decorative molded body with artificial leather on the surface is known to have a decorative surface with silver-coated artificial leather that has a cushioning property by a fiber base material and is laminated with a resin layer resembling the silver surface of leather. It has been.

  For example, in Patent Document 1 below, a reinforcing sheet having a thickness of 0.1 to 0.6 mm is bonded 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. The insert material having a feeling of feeling with silver is made into a three-dimensional shape by pre-molding, punched into the required shape and stored in the cavity in the injection mold, and then molded resin in the molten state from the reinforcing sheet side of the insert material A method for producing a molded product in which artificial leather obtained by integrating a insert material on the surface of a resin molded product having a thickness of at least 0.2 mm by molding is molded on the surface is disclosed.

By the way, although not related to artificial leather, Patent Document 2 below is a resin decorative film for imparting a concavo-convex pattern to the surface of a molded product in film insert molding,
Disclosed is a decorative film for film insert molding comprising a shaping layer film provided with a concavo-convex pattern and a protective layer film in close contact with the concavo-convex pattern, wherein the shaping layer film and the protective layer film are weakly bonded.

Japanese Patent Application Laid-Open No. 2006-281592 JP 2013-43417 A

  Three-dimensional embossing unevenness may be formed on the resin layer of the surface layer of silver-finished artificial leather by embossing embossing or embossing paper to improve decoration. It was. When a decorative molded body having a three-dimensional embossed unevenness on the surface is manufactured by a method as disclosed in Patent Document 1, heat transmitted from a molten resin at the time of injection molding or a mold Due to the mold temperature, the decorative surface softens and the surface resin layer stretches and the three-dimensional embossed unevenness disappears, or the depth of the recessed portion becomes shallow, and the three-dimensional tactile sensation is lost or lowered. There was a problem of doing.

  The present invention suppresses the disappearance of the three-dimensional embossing unevenness of the silver-tone artificial leather or the reduction of the depth of the recess by in-mold injection molding, and the embossing unevenness in which the three-dimensional tactile sensation is maintained An object of the present invention is to provide a decorative molded body having an artificial leather having a surface layer.

  One aspect of the present invention is a first method in which a preform molded body obtained by shaping an artificial leather with a protective film having a three-dimensional decorative surface protected by a protective film is disposed in a cavity of a mold. A second step of forming an in-mold molded body by injecting a molten resin to the back side of the surface on which the protective film of the preform molded body in the mold is disposed, and a protective layer from the in-mold molded body And a third step of obtaining a decorative molded body by peeling off, and the artificial leather with a protective film has a three-dimensional embossed uneven surface laminated on one surface of a nonwoven fabric of nonwoven fabric and a nonwoven fabric having a thickness of 250 μm or more. It is a manufacturing method of the decoration molded object containing the artificial leather containing the resin layer used as a decorative surface, and the protective film formed by coating resin so that the recessed part of an embossing uneven surface may be filled. In such a manufacturing method, the three-dimensional embossed unevenness of the silver-finished artificial leather is lost or the depth of the recessed portion is reduced by heat transmitted from the mold surface during injection molding during in-mold injection molding. It is suppressed. As a result, a decorative molded body having artificial leather having embossed irregularities with excellent three-dimensional tactile sensation on the surface layer is obtained.

  Moreover, it is preferable that the ratio of the depth of the recessed part with respect to the thickness of the artificial leather is 30% or less from the point that the embossed unevenness is less likely to be crushed when the nonwoven fabric becomes a cushion.

  Moreover, as a protective film, it is preferable that it is resin which has polyolefin resin as a main component from the point which can be easily peeled even if the fine embossing unevenness | corrugation is formed.

Further, ultrafine fibers preferably comprises a glass transition temperature (T _g) 100~130 ℃ polyester. Since such ultrafine fibers are softened at a relatively low temperature and are easily stretched when softened, they can be molded without applying a high injection pressure during injection molding. Therefore, it is preferable from the viewpoint that molding can be performed without applying too much pressure to the embossed concavities and convexities formed on the silver-tone resin layer.

In addition, since the nonwoven fabric has an apparent density of 0.45 g / cm ³ or more, it is difficult for the molten resin to reach the decorative surface in injection molding, so the influence of the heat of the molten resin on the decorative surface is reduced. In addition, since the voids of the nonwoven fabric can be sufficiently left in the obtained decorative molded body, the nonwoven fabric contained in the artificial leather is completely filled with the injected resin and does not become hard. It is preferable from the point that the texture which has cushioning properties can be maintained.

  Another aspect of the present invention is a method for manufacturing artificial leather with a protective film used in the method for manufacturing a decorative molded body described above, and forms a molten protective film on the embossed uneven surface of the artificial leather. It is the manufacturing method of artificial leather with a protective film provided with the process of apply | coating resin for making it form a coating film, and the process of pressing a coating film toward an embossed uneven | corrugated surface.

  ADVANTAGE OF THE INVENTION According to this invention, the decorative molded body which has the artificial leather which has the embossing unevenness | corrugation excellent in three-dimensional tactile sense in the surface layer is obtained.

FIG. 1 is a schematic cross-sectional view of an artificial leather 10 with a protective film according to this embodiment. FIG. 2 is a schematic cross-sectional view illustrating each step of preform molding. FIG. 3 is a schematic cross-sectional view illustrating each process of in-mold molding. FIG. 4 is a schematic cross-sectional view of the decorative molded body 40 whose decorative surface is exposed.

  The method for producing a decorative molded body of the present embodiment is obtained by molding a preform molded body obtained by shaping a synthetic leather with a protective film having a three-dimensional decorative surface protected by a protective film into a cavity of a mold. A second step of forming an in-mold molded body by injecting a molten resin to the back side of the surface on which the protective film of the preform molded body in the mold is disposed; A third step of obtaining a decorative molded body by peeling the protective layer from the molded body, and the artificial leather with a protective film is laminated on one surface of the nonwoven fabric and the nonwoven fabric having a thickness of 250 μm or more. A decorative molded body including an artificial leather including a resin layer having an embossed uneven surface as a three-dimensional decorative surface, and a protective film formed by coating a resin so as to fill the concave portion of the embossed uneven surface. Manufacturing method A.

  First, the method for producing artificial leather with a protective film used in the method for producing a decorative molded body of the present embodiment will be described in detail.

  As shown in FIG. 1, the artificial leather 10 with a protective film has an embossed uneven surface 2 a laminated on one surface of the nonwoven fabric 1 and the nonwoven fabric 1 having a thickness of 250 μm or more as a three-dimensional decorative surface. An artificial leather 3 including a silver-tone resin layer 2 and a protective film 4 formed by applying and forming a resin so as to fill the recess 2c of the embossed uneven surface 2a.

  Artificial leather includes a nonwoven fabric of ultrafine fibers having a fineness of 1 dtex or less and a resin layer having an embossed uneven surface laminated on one surface of the nonwoven fabric as a three-dimensional decorative surface.

  The non-woven fabric of ultrafine fibers contains ultrafine fibers having a fineness of 1 dtex or less, further 0.01 to 0.8 dtex, particularly 0.05 to 0.5 dtex, and particularly 0.07 to 0.1 dtex. Is preferred. When the fineness of the ultrafine fibers is too high, when preforming the artificial leather with a protective film, the stretchability at the time of softening by heating is lowered, and the formability tends to be lowered. Moreover, when the fineness is too low, the industrial productivity of the nonwoven fabric tends to decrease.

The apparent density of the ultrafine fiber nonwoven fabric is 0.45 g / cm ³ or more, more preferably 0.45 to 0.70 g / cm ³ , and particularly preferably 0.50 to 0.65 g / cm ³ . When the nonwoven fabric has such a high apparent density, it is difficult to make the molten resin reach the decorative surface in the in-mold molding, and it is easy to obtain a decorative molded body that retains the voids in the nonwoven fabric. As a result, the influence of heat on the embossed uneven surface is suppressed, and the disappearance of the three-dimensional embossed unevenness and the reduction of the depth of the recessed portion are suppressed. The apparent density of the nonwoven fabric is, for example, the value of the basis weight measured by the method described in JIS L 1096 8.4.2 (1999) as the thickness value measured at a load of 240 gf / cm ² according to JIS L1096. It can be calculated by dividing.

  In order to make the nonwoven fabric have such a high apparent density, the ultrafine fibers are fibers formed by converging a plurality of ultrafine single fibers that are formed through ultrafine fiber-forming fibers such as sea-island type composite fibers. It is preferably present as a bundle. Specifically, for example, it is preferable that 5 to 1000, more preferably 5 to 200, particularly preferably 10 to 50, and most preferably 10 to 30 ultrafine fibers are present as a fiber bundle. Thus, when the ultrafine fibers are present in the form of fiber bundles, the apparent density of the nonwoven fabric can be increased.

Specific examples of the resin component forming the ultrafine fiber include, for example, polyethylene terephthalate (PET), modified polyethylene terephthalate, polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polytriethylene terephthalate, polyhexamethylene terephthalate, Aromatic polyester resins such as polypropylene terephthalate and polyethylene naphthalate; aliphatic polyesters such as polylactic acid, polyethylene succinate, polybutylene succinate, polybutylene succinate adipate, and polyhydroxybutyrate-polyhydroxyvalerate copolymer Resins such as polyamide 6, polyamide 66, polyamide 610, polyamide 10, polyamide 11, polyamide 12, polyamide 6-12 -Based resins; polyolefin resins such as polypropylene, polyethylene, polybutene, polymethylpentene, chlorinated polyolefin, ethylene vinyl acetate copolymer, styrene ethylene copolymer; modified polyvinyl alcohol containing 25 to 70 mol% of ethylene units, etc. And modified elastomers such as polyurethane elastomers, polyamide elastomers, and polyester elastomers. Among these, polyesters having a glass transition temperature (T _g ) of 100 to 120 ° C., more preferably 105 to 115 ° C. are preferred from the viewpoint of excellent shapeability during preform molding. In the case of preform molding, if the _Tg is too high, the stretchability of the fiber tends to decrease and the formability tends to decrease. If the _Tg is too low, it becomes too soft and solidifies. There is a tendency to take. As the polyester a T _g is 100 to 120 ° C., aromatic polyethylene terephthalate disturb the structure of the linear to the structural unit copolymerizable component modified polyethylene terephthalate containing, as a constituent unit, in particular, isophthalic acid, phthalic acid, 5 A modified polyethylene terephthalate containing an asymmetric aromatic carboxylic acid such as sodium sulfoisophthalic acid or an aliphatic dicarboxylic acid such as adipic acid as a copolymerization component in a predetermined ratio is preferable. More specifically, modified polyethylene terephthalate containing 2 to 12 mol% of isophthalic acid unit as a monomer component is preferable. T _g is measured by fixing a test piece having a width of 5 mm and a length of 30 mm between chucks with a spacing of 20 mm using, for example, a dynamic viscoelasticity measuring apparatus (for example, FT Leospectra DDVIV manufactured by Rheology). It can be obtained by measuring the dynamic viscoelastic behavior under conditions of a region of 30 to 250 ° C., a temperature rising rate of 3 ° C./min, a strain of 5 μm / 20 mm, and a measurement frequency of 10 Hz.

  The fiber length of the ultrafine fiber is not particularly limited, but a long fiber is particularly preferable from the viewpoint of easily increasing the apparent density. Here, the long fiber means that it is not a short fiber cut by a predetermined length. The length of the long fibers is preferably 100 mm or more, and more preferably 200 mm or more from the viewpoint that the fiber density of the ultrafine fibers can be sufficiently increased. When the length of the ultrafine fiber is too short, it tends to be difficult to increase the density of the fiber. Although an upper limit is not specifically limited, For example, the fiber length of several m, several hundreds m, several km or more spun continuously may be sufficient. Further, these fibers may be mixed with several kinds of fibers instead of single.

  Moreover, it is preferable that the nonwoven fabric containing an ultrafine fiber contains the polymer elastic body impregnated. Such a polymer elastic body improves the shape stability of the preform molded body. Specific examples of such a polymer elastic body include polyurethane, acrylonitrile elastomer, olefin elastomer, polyester elastomer, polyamide elastomer, acrylic elastomer, and the like. Of these, polyurethane, particularly crosslinked non-foamed polyurethane is preferred. The cross-linked non-foamed polyurethane suppresses deformation due to elastic recovery after release from the mold when preforming. As a result, when forming a deep-drawn preform, it is preferable because a sharp and sharp corner can be formed.

  The crosslinked non-foamed polyurethane is preferably formed using an aqueous emulsion of a crosslinkable polyurethane. Specific examples of the water-based emulsion of the crosslinkable polyurethane include water-based emulsions of polycarbonate-based polyurethane, polyester-based polyurethane, polyether-based polyurethane, and polycarbonate / ether-based polyurethane that form a crosslinked structure after drying.

The crosslinked non-foamed polyurethane is a cross-linked non-foamed polyurethane having a mass reduction rate of 5% by mass or less, preferably 3% by mass or less with respect to DMF immersion. It is preferable from the point that the deformation due to the elastic recovery is suppressed. In addition, the mass reduction | decrease rate with respect to DMF immersion of the bridge | crosslinking non-foaming polyurethane is after immersing in DMF 100 times the mass of polyurethane for 24 hours at normal temperature, DMF is filtered, the obtained filtrate is dried, and the mass Measure. And the following formula:
Mass reduction rate (%) = (1-weight after DMF immersion / weight before DMF immersion) × 100.

  Preform molding in which the content of the polymer elastic body in the nonwoven fabric is in the range of 5 to 40% by mass, more preferably 8 to 35% by mass, and particularly 12 to 30% by mass with respect to the total amount of the nonwoven fabric. From the point which is excellent in the formability of.

  The thickness of the nonwoven fabric is 250 μm or more, preferably 250 to 750 μm, particularly preferably about 300 to 550 μm. When the thickness of the nonwoven fabric is less than 250 μm, the cushioning property is lowered, heat from the injection resin is easily transmitted to the resin layer, and the three-dimensional embossed unevenness disappears or the depth of the recessed portion becomes shallow. When the nonwoven fabric is too thick, the decorative molded body tends to be too thick.

  By forming a resin layer having three-dimensional embossed unevenness on the surface of such a nonwoven fabric, an artificial leather having an embossed uneven surface which is a three-dimensional decorative surface can be obtained. As a method of forming artificial leather having an embossed uneven surface, there is a method of forming a resin layer containing a polymer elastic body such as polyurethane on the surface of a non-woven fabric of ultrafine fibers by a method such as a dry surface forming method or a direct coating method. Can be mentioned. In the dry surface-forming method, a resin film containing a polymer elastic body is formed on a supporting substrate such as a release paper having an embossed pattern, and then an adhesive is applied to the surface of the resin film to form a fiber substrate. It is a method of forming a resin layer having an embossed concavo-convex surface by laminating on the surface, pressing and adhering if necessary, and releasing the release paper. In addition, the direct coating method uses a embossing roll or the like after a liquid resin or resin liquid containing a polymer elastic body is directly applied to the surface of a fiber substrate and then cured to form a silver-tone resin layer. This is a method of forming a resin layer having an embossed uneven surface by forming an embossed uneven surface.

  As the polymer elastic body for forming the resin layer, polyurethane, an acrylic elastic body, a silicone elastic body, and the like conventionally used for forming a silver-tone resin layer can be used. The thickness of the silver-tone resin layer is not particularly limited, but is preferably about 60 to 200 μm from the viewpoint that the balance between mechanical properties and texture can be maintained.

  The three-dimensional decorative surface, which is an embossed uneven surface, is protected by a protective film formed by coating a resin so as to fill the recesses of the embossed uneven surface. By protecting the three-dimensional decorative surface, which is an embossed uneven surface, with such a protective film, it is possible to suppress the disappearance of the three-dimensional embossed unevenness and the reduction of the depth of the recessed portion during in-mold molding. . That is, since the protective film is formed so as to fill the concave portion of the embossed concave / convex surface, the concave portion is fixed by the protective film and is not easily deformed by heat.

  The protective film is not particularly limited as long as it is a thermoplastic easily peelable resin film that is easily deformed by in-mold molding while being deformed to conform to the shape of the mold in preform molding. As a specific example of such a resin film, a polyolefin film mainly composed of polyethylene or polypropylene is particularly preferably used.

  The protective film is formed by coating a resin so as to fill the concave portions on the embossed uneven surface. By forming the protective film by coating as described above, the details of the concave portions of the embossed uneven surface are sufficiently filled with the protective film, and the concave portions are not easily deformed even during in-mold molding.

  The protective film is formed by, for example, applying a molten resin such as polyolefin resin for forming a molten protective film on the embossed uneven surface of the artificial leather using a resin melt extruder equipped with a T die. A method is used in which the coating film is pressed against the embossed uneven surface with a roll and then cooled.

  The thickness of the protective film is preferably 50 to 1000 μm, more preferably 150 to 800 μm, and particularly preferably about 250 to 650 μm. If the protective film is too thick, the moldability of the preform molding tends to decrease, and if the protective film is too thin, the effect tends not to be sufficiently obtained.

  In this way, an artificial leather with a protective film is obtained. The total thickness of the artificial leather with a protective film in the present embodiment is preferably 360 to 1350 μm, more preferably 500 to 1200 μm, and particularly preferably about 650 to 1100 μm. If the overall thickness is too thin, the recesses tend to disappear or become shallow.

  The total thickness of the artificial leather with the protective film peeled off in this embodiment is preferably 310 to 1200 μm, more preferably 400 to 1100 μm, and particularly preferably about 650 to 800 μm. If the overall thickness is too thin, the recesses tend to disappear or become shallow. In addition, the ratio of the depth of the recess to the thickness of the artificial leather is 30% or less, and further 20% or less. Heat and pressure are absorbed by the thickness, and the recess is not easily lost or shallow. It is preferable from the point which tends to become.

  And the preform molded object used with the manufacturing method of the decorative molded object of this embodiment is manufactured by hot press-molding the artificial leather with a protective film as mentioned above to a three-dimensional shape.

  With reference to FIG. 2, the process of preforming artificial leather with a protective film will be described. In preform molding, first, as shown in FIG. 2 (a), an artificial film with a protective film is provided so that the protective film 4 faces the lower mold 7b between the upper mold 7a and the lower mold 7b. The leather 10 is disposed, and the artificial leather 10 with the protective film is softened by heating. And as shown in FIG.2 (b), the upper metal mold | die 7a and the lower metal mold | die 7b are clamped, and it shapes in the artificial leather 10 with a protective film. And the intermediate molded object 21 of a preform molded object is formed by cooling.

  Then, as shown in FIG. 2 (c), the intermediate mold 21 is released by opening the upper mold 7a and the lower mold 7b. In this way, the intermediate molded body 21 is taken out.

  Although such an intermediate molded body 21 may be used as a preform molded body as it is, it is preferable to finish the preform molded body 20 that has been trimmed in advance by trimming and removing unnecessary portions. When the preform molded body is trimmed in advance and molded so as to form the contour of the decorative molded body, the contour of the decorative molded body obtained is obtained as in the case of trimming after injection molding. A cut surface is not formed on the end face, and a highly wear-resistant resin formed by injection molding is preferable from the viewpoint of forming the end face. In addition, when the decorative molded body is trimmed after injection molding, a cut surface of artificial leather usually appears on the end surface. In such a case, since the material having low wear resistance such as the fibers forming the artificial leather and the polymer elastic body appears on the end face, the wear resistance of the end face tends to be lowered. As shown in FIG. 2D, by trimming and removing unnecessary portions, a preform 20 that has been trimmed in advance is obtained.

  Next, referring to FIG. 3, the decoration is provided with a silver-finished artificial leather having a decorative surface including three-dimensional embossed irregularities on the surface layer by in-mold molding by injection molding using a preform molded body. A process of forming the formed body will be described.

  As shown in FIG. 3A, the mold 17 includes a movable mold 17a including a cavity C and a fixed mold 17b. A stripper plate 17c is disposed between the movable mold 17a and the fixed mold 17b. First, the preform molded body 20 of the artificial leather with protective film 10 having the embossed uneven surface 2a protected by the protective film 4 is faced to the surface of the movable mold 17a in which the protective film 4 forms the cavity C. Deploy.

  The method for disposing the preform molded body inside the cavity is not particularly limited, but it is preferable that the preform molded body is fixed inside the cavity for positioning. When the preform molded body is not fixed inside the cavity, the preform molded body may be displaced in the cavity due to the flow of the injection resin at the time of injection molding in the next step. Specific examples of the method of fixing the preform molded body inside the cavity include, for example, a method of fixing to the surface of the movable mold with an adhesive, a hole or a recess included in the shape of the preform molded body. Can be fixed by fitting it in the core of the movable mold that matches the shape.

  And as shown in FIG.3 (b), the preform molded body is inject | emitted by injecting the molten resin 31a to the back surface side with respect to the surface where the protective film of the preform molded body 20 in the metal mold | die 17 was arrange | positioned by injection molding. An in-mold molded body in which 20 is integrated on the surface is molded. Specifically, the movable mold 17a and the fixed mold 17b are clamped, and the cylinder 18 of the injection molding machine 15 is advanced until the nozzle 16 contacts the sprue bush 17f of the fixed mold 17b. The molten resin 31a melted in the cylinder 18 is injected with the screw 19, whereby the molten resin 31a is injected into the mold 17 and injection molded. The injected molten resin 31a flows through the resin flow path R in the mold 17 and flows into the cavity C to be filled. At this time, since the molten resin 31a permeates moderately into the non-woven fabric of the ultrafine fibers forming the artificial leather 1, the preform molding is performed so that the injection molded body 31 molded by injection molding maintains high adhesion due to the anchoring effect. It is integrated with the body 20.

  Examples of the resin for molding an injection molded body that is injected by in-mold injection molding include polyolefin resins such as ABS resin, polycarbonate resin, and polypropylene, polyethylene terephthalate (PET), and polybutylene terephthalate (PBT). Various thermoplastic resins such as polyester resins and various polyamide resins are used without particular limitation, and are appropriately selected according to applications. For example, as a resin used for a casing of a mobile phone, a mobile device, a home appliance, etc., a resin having excellent impact resistance such as an ABS resin, a polycarbonate resin, and a polyolefin resin such as polypropylene is preferably used.

  The injection molding conditions are such that the resin can flow to the flow end depending on the melting point and melt viscosity of the resin to be injected, the shape of the molded body, and the resin thickness (resin temperature, mold temperature, injection pressure, injection speed, injection) The subsequent holding pressure and cooling time) are appropriately selected.

  And after completion | finish of injection, as shown in FIG.3 (c), the molten resin 31a is cooled, the injection molded body 31 is formed, and the in-mold molded body 30 with which the preform molded body 20 was integrated is shape | molded. . Then, as shown in FIG. 3D, by opening the mold 17, the movable mold 17a and the fixed mold 17b are isolated, and the runner 32 and the decorative molded body 30 are taken out. . Thus, the in-mold molded object 30 which has the embossed uneven | corrugated surface 2a protected by the protective film 4 is obtained.

  Then, as shown in FIG. 4, the decorative molded body 40 in which the artificial leather-like embossed uneven surface 2 a is exposed by peeling off the protective film 4 from the in-mold molded body 30 protected by the protective film 4. can get. The peeling method of a protective film is not specifically limited, It does not specifically limit, such as peeling by hand or peeling using exclusive peeling equipment.

Hereinafter, the present invention will be described more specifically with reference to examples. In addition, this invention is not limited at all by the Example.
[Example 1]

An apparent density of 0.53 g obtained by entanglement of fiber bundles (average 25 fibers / bundle) of ultrafine fibers having a single fiber fineness of 0.08 dtex obtained by removing sea components from a nonwoven fabric of long sea-island composite fibers A non-woven fabric having a thickness of 500 μm was prepared by impregnating a crosslinked non-foamed polyurethane having a mass reduction rate of 0.5% by mass with respect to DMF immersion into a / cm ³ non-woven fabric. The ultrafine fiber was made of an isophthalic acid-modified polyester having a Tg of 110 ° C., and the mass ratio of non-foamed polyurethane / nonwoven fabric was 15/85.

  On the other hand, a polycarbonate non-yellowing type polyurethane resin solution is applied to the surface of a 300 μm-thick textured release paper having an uneven texture pattern with a depth of about 20 μm, and dried at 80 ° C. for 10 minutes to a thickness of 30 μm. A polyurethane film was formed. Then, a polycarbonate non-yellowing type two-part curable polyurethane solution containing a colorant was further applied to the surface of the formed polyurethane film, and dried at 50 ° C. for 3 minutes to form a 120 μm-thick polyurethane film. In this way, a silver-tone resin layer having a total thickness of 150 μm was formed.

  Then, a silver surface-like resin layer formed on the embossed release paper was bonded to one surface of the nonwoven fabric, heated at 80 ° C. for 2 minutes, and then aged at 40 ° C. for 3 days, and then the release paper was peeled off. Thus, an artificial leather provided with a silver-tone resin layer having an embossed uneven surface was obtained.

  Then, using a melt extruder equipped with a T-die, the melted polyethylene resin is applied to the embossed uneven surface of the obtained artificial leather, and a protective film having a thickness of 450 μm is formed on the embossed uneven surface by cooling. did. In this way, an artificial leather with a protective film was obtained.

  Using the obtained artificial leather with protective film, a preform molded body was molded using a mold having a cavity in the shape of a remote control casing. The preform molding was performed by placing artificial leather with a protective film on a lower mold of a pair of molds heated to a temperature of 150 ° C., and pressing it with a pressure of 0.4 MPa. A preform molded body was thus obtained.

  And, in the cavity having a shape along the shape of the preform molded body of the in-mold mold of the injection in-mold molding machine so that the protective film is in contact with the mold surface. The ABS resin was injection molded under the conditions of a resin temperature of 235 ° C. and a mold temperature of 30 to 50 ° C. In this way, an in-mold molded body having the shape of the remote control casing was obtained. And the decorative molded object which has an embossed uneven surface of the artificial leather tone was obtained by peeling the protective film of the surface layer of an in-mold molded object by hand. When the depth of the obtained embossed uneven surface was measured, the depth was about 20 μm. Moreover, the tactile sensation of the surface of the obtained decorative molded body had a texture of artificial leather, and a cushion feeling was felt on the embossed uneven surface.

[Comparative Example 1]
In Example 1, instead of using an artificial leather with a protective film in which a protective film having a thickness of 450 μm is formed on an embossed uneven surface, an artificial leather having a resin layer having an embossed uneven surface on which no protective film is formed is used. The decorative molded body was obtained and evaluated in the same manner as in Example 1 except that the step of peeling off the protective film was omitted. When the depth of the embossed uneven surface obtained was measured, the depth was about 2 μm. Moreover, although the tactile sensation on the surface of the obtained decorative molded body had a texture of artificial leather, the cushion feeling and the uneven feeling were not clearly felt on the embossed uneven surface.

[Comparative Example 1]
In Example 1, instead of using an artificial leather with a protective film formed by coating a resin with a protective film having a thickness of 450 μm on the embossed uneven surface, an amorphous film having a thickness of 70 μm was used as the protective film on the embossed uneven surface. A decorative molded body was obtained and evaluated in the same manner as in Example 1 except that the conductive PET film was bonded through a PVA adhesive layer having a thickness of 30 μm. When the depth of the obtained embossed uneven surface was measured, the depth was about 4 μm. Moreover, although the tactile sensation on the surface of the obtained decorative molded body had a texture of artificial leather, the cushion feeling and the uneven feeling were not clearly felt on the embossed uneven surface.

  INDUSTRIAL APPLICABILITY The present invention can decorate the surface of an injection molded body such as a vehicle interior material, a portable terminal main body (smartphone, tablet PC) and accessories thereof such as a case and a cover, a casing of an electronic device, and a cosmetic case in a textile style.

DESCRIPTION OF SYMBOLS 1 Non-woven fabric of extra fine fiber 2 Resin layer with silver tone 2a Embossed uneven surface 2c Concavity 3 Artificial leather 4 Protective film 7 Preform mold 7a Upper mold 7b Lower mold 10 Artificial leather with protective film 15 Injection molding machine 16 Nozzle 17 (Injection molding) Mold 17a Movable side mold 17b Fixed side mold 17c Stripper plate 17f Sprue bush 18 Cylinder 19 Screw 20 (Trimmed) preform molded body 21 Intermediate molded body of preform molded body 31 Injection molding Body 31a Molten resin 32 Runner 30 In-mold molded body 40 Decorated molded body

Claims (7)

A first step of placing a preform molded body obtained by shaping the artificial leather with a protective film having a three-dimensional decorative surface protected by a protective film in the cavity of the mold;
A second step of molding an in-mold molded body by injecting a molten resin on the back side of the preform molded body in the mold with respect to the surface on which the protective film is disposed;
A third step of obtaining a decorative molded body by peeling the protective layer from the in-mold molded body,
The artificial leather with protective film is
An artificial leather including a non-woven fabric of ultrafine fibers having a thickness of 250 μm or more and a resin layer having an embossed uneven surface laminated on one surface of the nonwoven fabric as the three-dimensional decorative surface, and a recess in the embossed uneven surface are filled. And a protective film formed by coating a resin as described above.   The method for producing a decorative molded body according to claim 1, wherein a ratio of the depth of the concave portion to the thickness of the artificial leather is 30% or less.   The said protective film is a manufacturing method of the decorative molded body of Claim 1 or 2 which has polyolefin resin as a main component. The ultrafine fibers, method of manufacturing the decorative molded article according to claim 1 comprising a glass transition temperature (T _g) 100~130 ℃ polyester. The nonwoven fabric manufacturing method of the decorative molded body according to any one of claims 1 to 4, an apparent density of 0.45 g / cm ³ or more. It is a manufacturing method of the artificial leather with a protective film used for the manufacturing method of the decorative molded object of any one of Claims 1-5,
A step of applying a resin for forming the melted protective film on the embossed uneven surface of the artificial leather to form a coating film;
And a step of pressing the coating film against the embossed uneven surface, and a method for producing artificial leather with a protective film.   The method for producing artificial leather with a protective film according to claim 6, wherein the resin for forming the protective film contains a polyolefin-based resin as a main component.

Images