JP2021041667A - Composite molding and method for producing composite molding - Google Patents

Abstract

To provide a composite molding that can maintain and emphasize the original texture and feel of woody material.SOLUTION: A composite molding has: a material sheet that has an adhesive layer and a thin film protective layer in this order on one side of a material while having a thermoplastic shape following layer and a nonwoven fabric layer in this order on the other side of the material, not the one side with the thin film protective layer thereon; and a reinforcement layer provided on the nonwoven fabric layer at the side opposite the material side.SELECTED DRAWING: Figure 1b

Description

The present invention relates to a composite molded product using a material such as a wood material and a method for producing the same.

Conventionally, composite molded products of wood and resin with natural wood grain have been used in a wide range of fields such as home appliance exteriors, automobile interior materials, and building materials. The surface of such a composite molded product of wood grain is generally coated with a surface protective coating using a coating process such as open pore coating or closed pore coating to impart antifouling property and scratch resistance.

Patent Document 1 discloses a wood decorative surface material having a coating treatment on the outermost surface. This configuration is shown in FIG.

The wood decorative surface material 100 of FIG. 2 is composed of a wood single plate 102, a metal thin plate 103, and a porous material 105 whose surfaces have been painted. It is also possible to select the resin thin plate 104 for the metal thin plate 103 and the fibrous material 106 for the porous material 105. The wood single plate 102 facing the outermost surface of the wood decorative surface material 100 is subjected to general coating coatings such as fabric finish, coloring, undercoating, intermediate coating, and topcoating to emphasize the design of the appearance. Not only is it protected from dirt and scratches.

Japanese Unexamined Patent Publication No. 5-131488

In this conventional example, since the surface of the wood single plate 102 is coated with a thick film, even if the treatment method emphasizes the conduit portion such as open pore coating, at least the uneven shape of the surface of the wood single plate 102 is formed. It will be buried in the paint and the original texture will be impaired. Further, since the painting process requires a plurality of steps and a polishing step for making the surface uniform, the tact time and cost increase, and the productivity is lowered.

Therefore, an object of the present invention is to provide a composite molded product capable of maintaining and emphasizing the original texture and tactile sensation of a wood material.

The composite molded product according to the present invention has an adhesive layer and a thin film protective layer on one surface of the material in this order, and is provided on the other surface of the material on the opposite side to the one surface provided with the thin film protective layer. , A material sheet having a thermoplastic shape-following layer and a non-woven fabric layer in this order,
A reinforcing layer provided on the surface of the non-woven fabric layer opposite to the material side,
To be equipped.

In the method for producing a composite molded product according to the present invention, a thin film protective layer is formed on one surface of a material by a transfer method.
A thermoplastic shape-following layer and a non-woven fabric layer are sequentially laminated on one surface of the material provided with the thin film protective layer and the other surface on the opposite side, and thermocompression bonded to form a laminated material sheet.
The material sheet is placed in a molding die, and a resin is injection-molded from the side of the non-woven fabric layer of the material sheet to form an initial composite molded product.
By irradiating a certain amount of ultraviolet rays from the side of the thin film protective layer of the initial composite molded product, the thin film protective layer is shrunk and cured so as to follow the uneven shape of the surface of the material, and the thin film protective layer is formed. The thermoplastic shape-following layer and the non-woven fabric layer are deformed in accordance with the shape deformation due to shrinkage curing to form a composite molded product.

According to the structure of the composite molded product according to the present invention, it is possible to maintain and emphasize the original texture and texture of the material.

According to the method for producing a composite molded product according to the present invention, by transferring the thin film protective layer to the surface of the material, the protective layer can be formed on the surface of the material without using the coating process.
Further, by irradiating a certain amount of ultraviolet rays, the thin film protective layer shrinks and hardens along the surface uneven shape of the material, and the thermoplastic shape-following layer and the non-woven fabric layer are linked to the shape change of the thin film protective layer. Transforms. Therefore, the followability of the thin film protective layer in the uneven shape of the material surface is improved. Therefore, even after the thin film protective layer is formed on the surface, the original texture of the material can be maintained and emphasized.

It is a top view of the composite molded article which concerns on Embodiment 1. FIG. It is a schematic cross-sectional view which shows the cross-sectional structure seen in the AA direction of the composite molded article of FIG. 1a. It is a schematic cross-sectional view which shows the cross-sectional structure of the initial composite molded article before ultraviolet irradiation. It is a schematic cross-sectional view which shows the cross-sectional structure at the time of ultraviolet irradiation of an initial composite molded article. It is a schematic cross-sectional view which shows the cross-sectional structure of the composite molded article after ultraviolet irradiation. It is sectional drawing of the composite molded article of Patent Document 1. FIG.

The composite molded product according to the first aspect has an adhesive layer and a thin film protective layer on one surface of the material in this order, and the other surface of the material provided with the thin film protective layer and the other side opposite to the one surface. A material sheet having a thermoplastic shape-following layer and a non-woven fabric layer on the surface in this order,
A reinforcing layer provided on the surface of the non-woven fabric layer opposite to the material side,
To be equipped.

In the composite molded product according to the second aspect, in the first aspect, the valley portion is thicker than the mountain portion in terms of the thickness of the thin film protective layer at the peaks and valleys of the surface uneven shape of the material sheet. May be thick.

In the first or second aspect of the composite molded product according to the third aspect, the material is selected from wood materials, stones, corks, cloths, natural leathers, and artificial leathers formed using natural wood. At least one of the materials may be used.

The composite molded product according to the fourth aspect is a wood material in which the material is formed by using natural wood in any one of the first to third aspects.
The material sheet may be composed of the thin film protective layer, the adhesive layer, the wood material, the thermoplastic shape-following layer, and the non-woven fabric layer in this order.

In the composite molded product according to the fifth aspect, in the fourth aspect, the thin film protective layer has a hard coat layer, and at least one kind of nanoparticles of silica, alumina, and zirconia are contained therein. The above may be contained, and a part of the nanoparticles may be crosslinked with a part of the resin material constituting the hard coat layer.

In the composite molded product according to the sixth aspect, in the fourth or fifth aspect, the thermoplastic shape-following layer may have a thickness of 29 μm or more and 201 μm or less.

In the composite molded product according to the seventh aspect, in any of the fourth to sixth aspects, at least one or more functional layers selected from an ultraviolet ray blocking layer and an antibacterial layer are provided on the back surface of the thin film protective layer. May have.

According to the above configuration, functions such as an ultraviolet ray blocking layer and an antibacterial layer can be imparted.

In the method for producing a composite molded product according to the eighth aspect, a thin film protective layer is formed on one surface of the material by a transfer method via an adhesive layer.
A thermoplastic shape-following layer and a non-woven fabric layer are sequentially laminated on one surface of the material provided with the thin film protective layer and the other surface on the opposite side, and thermocompression bonded to form a laminated material sheet.
The material sheet is placed in a molding die, and a resin is injection-molded from the side of the non-woven fabric layer of the material sheet to form an initial composite molded product.
By irradiating a certain amount of ultraviolet rays from the side of the thin film protective layer of the initial composite molded product, the thin film protective layer is shrunk and cured so as to follow the uneven shape of the surface of the material, and the thin film protective layer is formed. The thermoplastic shape-following layer and the non-woven fabric layer are deformed in accordance with the shape deformation due to shrinkage curing to form a composite molded product.

According to the above configuration, the followability of the thin film protective layer to the uneven shape of the surface of the material is improved, and a composite molded product in which the arithmetic average roughness Ra value of the material is larger than that before irradiation with ultraviolet rays can be obtained.

In the method for producing a composite molded product according to a ninth aspect, in the eighth aspect, the laminated material sheets are preformed into an arbitrary shape by using a crimping device before the injection molding. The preformed material sheet may be placed in the molding die.

Hereinafter, the composite molded product according to each embodiment of the present disclosure will be described with reference to the drawings. In the drawings, substantially the same members are designated by the same reference numerals.

(Embodiment 1)
FIG. 1a is a plan view of the composite molded product 51 according to the first embodiment. FIG. 1b is a schematic cross-sectional view showing a cross-sectional structure of the composite molded product 51 of FIG. 1a as viewed in the AA direction.
This composite molded product is composed of a composite molded product 51 having a wood material sheet 31 as a constituent requirement. The wood material sheet 31 and the composite molded product 51 are configured as follows.
In the wood material sheet 31, the adhesive layer 3 and the thin film protective layer 2 are formed in this order on the front surface side of the wood material 1 derived from natural wood, and the thermoplastic shape following layer 4 and the non-woven fabric layer 5 are formed on the back surface side of the wood material 1. Are formed in order. The wood material sheet 31 can be used as a single sheet by undergoing a thermocompression bonding step such as a press or a laminator. Further, a reinforcing layer 6 is formed on the back surface of the non-woven fabric layer 5 by injection molding, and a composite molded product 51 in which a wood material sheet 31 and an injection molding resin are fused is formed.

According to this composite molded product, by forming the thin film protective layer 2 on the surface of the wood material 1, the surface can be protected without impairing the appearance such as the original texture and glossiness of the wood material 1.

Hereinafter, each member constituting the composite molded product 51 will be described.

<Material>
The material may be, for example, at least one of materials selected from wood, stone, cork, cloth, natural leather, and artificial leather formed using natural wood. As shown in FIGS. 1a to 1e, in the following description, a case where "wood material" is selected as the material will be described. In this case, the material sheet is a "wood sheet". The material is not limited to wood.

<Wood material>
The wood material 1 refers to a sheet-like plate material obtained by thinly slicing wood derived from natural wood, and the plate thickness thereof is 0.1 mm or more and 2 mm or less. If the plate thickness of the wood material 1 is less than 0.1 mm, it is too thin to be easily torn and difficult to handle. On the other hand, if it exceeds 2 mm, it is too thick, and it becomes difficult to sufficiently shape the product shape by preliminary shaping before injection molding. Further, the inside of the wood material 1 may be impregnated with an organic resin such as polyethylene glycol or a phenol resin, although it depends on the intended use. The impregnation treatment increases the mechanical strength of the wood material 1 and makes it resistant to cracks and the like. Further, by arbitrarily adding a pigment, a phosphorescent paint, a dye, a flame retardant, or the like to the wood material 1 in addition to the organic resin, the appearance or functionality of the wood material 1 is improved in addition to the mechanical strength. It is also possible. In addition to the impregnation treatment, it is also possible to decolorize the wood material 1 or to impart a color or pattern to one side or both sides of the wood material 1. The "wood material" 1 referred to here is not limited to one sheet of natural wood, but for example, a plurality of sheets of natural wood are laminated and sliced to a plate thickness of 0.1 mm or more and 2 mm or less. Also includes processed sheet-shaped wood boards.

<Thin film protective layer>
The thin film protective layer 2 is formed by forming a release layer on a film containing a polymer as a main component and using a general printing technique such as screen printing or coater coating on the surface of the release layer. The thin film protective layer 2 has a structure including a hard coat layer at least on the outermost surface. The thickness of the hard coat layer is within the range of 1 μm or more and 50 μm or less, and the hard coat layer has a property of shrinking and curing when irradiated with ultraviolet rays. For example, the hard coat layer may be made of an ultraviolet curable resin. Further, on the back surface of the hard coat layer, that is, on the adhesive layer side instead of the resurface side, if it is a layer that can be formed by using a general printing technique, a layer to which additives such as an ultraviolet ray blocking layer and a filler are added. It is also possible to stack arbitrary functional layers such as a colored layer and a pattern layer together. The total film thickness of the thin film protective layer 2 is 3 μm or more and 100 μm or less, and has transparency. For this reason, the distance from the wood material 1 becomes short, and the original texture of the wood material 1 can be felt without feeling the depth and glossiness when a thick protective layer is applied by a general painting process. it can.

By using a film containing a polymer as a main component, which can impart irregularities to the surface of the hard coat layer, the appearance, feel, glossiness, etc. of the wood material sheet 31 and the composite molded product 51 can be freely changed. it can. As a method for imparting unevenness to the surface of the hard coat layer, there are embossing on the film, addition of a filler to the peeling layer, etc.

<Adhesive layer>
For the adhesive layer 3, for example, a transparent thermoplastic component such as olefin-based, polyolefin-based, urethane-based, or acrylic-based can be used. The film thickness of the adhesive layer 3 can be set arbitrarily. The thickness of the thin film protective layer 2 is preferably 3 μm or more and 50 μm or less in order to improve the followability of the wood material 1 to the surface. Further, in order to enhance the adhesiveness between the wood material 1 and the thin film protective layer 2, two or more kinds of adhesive components can be mixed or laminated in a film thickness range of 3 μm or more and 50 μm or less. ..

<Thermoplastic shape following layer>
As the thermoplastic shape-following layer 4, for example, a transparent resin having thermoplasticity such as olefin-based, polyolefin-based, urethane-based, acrylic-based, and rubber-based can be used. The thermoplastic shape-following layer 4 has a thickness of more than 29 μm and a film thickness of less than 201 μm. If the film thickness is 29 μm or less, the adhesion to the wood material 1 deteriorates. On the other hand, if the film thickness is 201 μm or more, when the wood material sheet 31 is injection-molded, it may flow extremely due to its resin pressure and high temperature, and defects such as gate flow may occur.

<Non-woven fabric layer>
As the non-woven fabric layer 5, for example, a non-woven fabric containing a polymer such as polyethylene terephthalate or acrylic as a main component can be used, but the non-woven fabric layer 5 is not limited to these, and the material, thickness, and the like can be selected according to the intended use. At the time of injection molding, the injection molding resin penetrates into the gaps between the non-woven fabric layers, so that the non-woven fabric layer 5 and the reinforcing layer 6 can be adhered by the anchor effect.

Further, by laminating the thermoplastic shape following layer 4 and the non-woven fabric layer 5 in combination, when the wood material sheet 31 is preformed or injection-molded, it is deformed so as to follow the deformation of the wood material 1 and is made of wood. Since the stress applied to the material 1 is relaxed, it plays a role of alleviating appearance defects such as cracks. Further, when the surface of the initial composite molded product 50 after injection molding is irradiated with a certain amount of ultraviolet rays and the thin film protective layer 2 shrinks and hardens along the surface uneven shape of the wood material 1, the thermoplastic shape following layer 4 And the non-woven fabric layer 5 are deformed in conjunction with the shape change of the thin film protective layer 2. Therefore, the thin film protective layer 2 can easily follow the uneven shape of the surface of the wood material 1, and the original surface uneven shape of the wood material 1 can be maintained and emphasized even after the protective layer is formed on the surface. ..

<Reinforcing layer>
As the reinforcing layer 6, for example, a commercially available general-purpose molding resin such as PMMA resin, ABS resin, PS resin, or PC resin can be used. In addition, it is also possible to handle resins that require molding at high temperatures, such as resins for optical applications and super engineering resins.

<Manufacturing method of composite molded products>
A method for manufacturing a composite molded product using a wood material as a material will be described below.
(1) A thin film protective layer 2 is formed on one of both sides of a wood material 1 formed of natural wood via an adhesive layer 3 by a transfer method.
(2) Next, the thermoplastic shape-following layer 4 and the non-woven fabric layer 5 are laminated in this order on the surface of the wood material 1 opposite to the surface on which the thin film protective layer 2 is provided, and then thermocompression bonded to laminate the wood material 1. The wood sheet 31 is formed.
(3) Next, the wood material sheet 31 is placed in a molding die (not shown), and the resin is injection-molded from the non-woven fabric layer 5 side of the wood material sheet 31 to form the initial composite molded product 50.
(4) A certain amount of ultraviolet rays is irradiated from the side of the thin film protective layer 2 of the initial composite molded product 50 to shrink and cure the thin film protective layer 2 so as to follow the uneven shape of the surface of the wood material 1. At the same time, the thermoplastic shape-following layer 4 and the non-woven fabric layer 5 are deformed in accordance with the shape deformation of the thin film protective layer 2 due to shrinkage and hardening to form the composite molded product 51.
From the above, the composite molded product 51 can be obtained.

1c, 1d, and 1e are schematic cross sections showing the cross-sectional structures of the composite molded product 51 before the initial composite molded product 50 is irradiated with ultraviolet rays, when the initial composite molded product 50 is irradiated with ultraviolet rays, and after the initial composite molded product 50 is irradiated with ultraviolet rays. It is a figure.
As shown in FIG. 1c, the thin film protective layer 2 is formed on the surface of the wood material 1 via the adhesive layer 3 before the irradiation with ultraviolet rays. Since the thin film protective layer 2 is a thin film, it follows the surface uneven shape of the wood material 1.
FIG. 1d shows how the hard coat layer in the thin film protective layer 2 is shrunk and cured by being irradiated with ultraviolet rays when the initial composite molded product 50 is irradiated with ultraviolet rays. For example, ultraviolet rays having a wavelength in the range of 150 nm to 400 nm are irradiated for about 0.1 to 60 seconds. The hard coat layer irradiated with ultraviolet rays shrinks and hardens along the surface uneven shape of the wood material 1, and when the film thickness d1 of the peak portion and the film thickness d2 of the valley portion of the surface uneven shape are compared. In addition, the film thickness d1 at the peak is deformed to be thinner than the film thickness d2 at the valley. As a result, the surface uneven shape derived from the wood material 1 is emphasized. At this time, as described above, the thermoplastic shape-following layer 4 and the non-woven fabric layer 5 are deformed in conjunction with the shape change of the thin film protective layer 2, so that the followability of the thin film protective layer 2 is improved.

As shown in FIG. 1e, the hard coat layer in the thin film protective layer 2 that has shrunk and hardened by irradiation with ultraviolet rays emphasizes the surface uneven shape of the wood material 1 as compared with the initial composite molded product 50 before irradiation with ultraviolet rays. The composite molded product 51 can be obtained.
Even if an arbitrary functional layer is formed on the back surface of the hard coat layer in the thin film protective layer 2, the shape is deformed in accordance with the hard coat layer that shrinks when irradiated with ultraviolet rays, so that the same effect is obtained. Is obtained. Further, the hard coat layer component in the thin film protective layer 2 may be an electron beam curing type. By doing so, the surface uneven shape of the wood material 1 can be maintained by irradiating the initial composite molded product 50 with an electron beam instead of ultraviolet rays, as described above. The reason why the initial composite molded product 50 after injection molding is irradiated with ultraviolet rays instead of the wood material sheet 31 is to further emphasize the surface uneven shape of the wood material 1. That is, even if the surface uneven shape of the wood material 1 is emphasized by irradiating with ultraviolet rays at the stage of the wood material sheet 31, the emphasized surface uneven shape is crushed by the high pressure by being sandwiched between the molds at the time of injection molding. It ends up.

As an example of the first embodiment, the Ra value of the surface of the composite molded product of the wood material subjected to the closed pore coating treatment was 0.87 μm. On the other hand, the Ra value on the surface of the initial composite molded product 50 before irradiation with ultraviolet rays was 2.94 μm. Then, the Ra value on the surface of the composite molded product 51 after the ultraviolet irradiation was 3.39 μm, and the result was obtained that the Ra value was improved by about 15% before and after the ultraviolet irradiation. Although the measured value varies depending on the type of the wood material 1, the same effect of improving the surface roughness value before and after the irradiation with ultraviolet rays can be obtained. The Ra value in the first embodiment is "arithmetic mean roughness". Specifically, it is defined by the Japanese Industrial Standards (JIS B 0601, JIS B 0031), a part of the roughness curve is extracted with the reference length, and the uneven state of the section is expressed as an average value in micrometers. It is a representation.
Due to these configurations in the composite molded product according to the first embodiment, the followability of the thin film protective layer 2 to the surface of the wood material 1 is enhanced, and the surface uneven shape of the wood material 1 can be emphasized.

From the above, it is possible to obtain a composite molded product 51 having a surface protective layer formed while maintaining the texture, tactile sensation, and the like of the wood material 1. Further, in the formation of the surface protective layer, the thin film protective layer 2 is formed on the polymer film on which the release layer is formed by using printing technology, and is transferred to the surface of the wood material 1. As a result, the surface protective layer can be formed in a small number of steps without using the conventional coating process that requires a multi-step step. That is, according to this method for producing a composite molded product, it is possible to reduce multiple steps in the coating process and coating material loss, and it is possible to obtain a composite molded product in which a surface protective layer is formed with high productivity.

Further, by irradiating the surface of the initial composite molded product 50 obtained by injection molding the wood material sheet 31 on which the thin film protective layer 2 is formed with ultraviolet rays, the thin film protective layer 2 shrinks and hardens along the surface uneven shape of the wood material 1. To do. Therefore, in the composite molded product 51, it is possible to emphasize uneven portions such as conduits of the wood material 1.

In the first embodiment, a wood material is used as the material of the composite molded product, but by appropriately selecting the adhesive layer 3 and the thermoplastic shape following layer 4, for example, stone, etc. can be used instead of the wood material. It is possible to use materials such as cork, cloth, natural leather and artificial leather.

It should be noted that the present disclosure includes appropriately combining any of the various embodiments and / or examples described above, and the respective embodiments and / or embodiments. The effects of the examples can be achieved.

The composite molded product according to the present invention contributes to high design in fields that require decoration such as exteriors of various home appliances and in-vehicle interiors.

1 Wood material 2 Thin film protective layer 3 Adhesive layer 4 Thermoplastic shape-following layer 5 Non-woven fabric layer 6 Reinforcing layer 31 Wood material sheet 50 Initial composite molded product 51 Composite molded product

Claims (9)

An adhesive layer and a thin film protective layer are provided on one surface of the material in this order, and a thermoplastic shape-following layer and a non-woven fabric layer are provided on the other surface opposite to one surface of the material provided with the thin film protective layer. Material sheets that have in this order, and
A reinforcing layer provided on the surface of the non-woven fabric layer opposite to the material side,
A composite molded product. The composite molded product according to claim 1, wherein the valley portion is thicker than the peak portion in terms of the thickness of the thin film protective layer in the peaks and valleys of the surface uneven shape of the material sheet. The material according to claim 1 or 2, wherein the material uses at least one of a material selected from a wood material formed from natural wood, stone, cork, cloth, natural leather, and artificial leather. Composite molded product. The material is a wood material formed from natural wood,
The composite according to any one of claims 1 to 3, wherein the material sheet is composed of the thin film protective layer, the adhesive layer, the wood material, the thermoplastic shape following layer, and the non-woven fabric layer in this order. Molding. The thin film protective layer has a hard coat layer, and at least one kind of nano-sized nanoparticles of silica, alumina, and zirconia is contained therein, and a part of the nanoparticles is the hard coat. The composite molded product according to claim 4, wherein the composite molded product is crosslinked with a part of the resin material constituting the layer. The composite molded product according to claim 4 or 5, wherein the thermoplastic shape-following layer has a thickness of 29 μm or more and 201 μm or less. The composite molded product according to any one of claims 4 to 6, wherein the back surface of the thin film protective layer has at least one or more functional layers selected from an ultraviolet ray blocking layer and an antibacterial layer. A thin film protective layer is formed on one surface of the material by a transfer method.
A thermoplastic shape-following layer and a non-woven fabric layer are sequentially laminated on one surface of the material provided with the thin film protective layer and the other surface on the opposite side, and thermocompression bonded to form a laminated material sheet.
The material sheet is placed in a molding die, and a resin is injection-molded from the side of the non-woven fabric layer of the material sheet to form an initial composite molded product.
By irradiating a certain amount of ultraviolet rays from the side of the thin film protective layer of the initial composite molded product, the thin film protective layer is shrunk and cured so as to follow the uneven shape of the surface of the material, and the thin film protective layer is formed. The thermoplastic shape-following layer and the non-woven fabric layer are deformed in accordance with the shape deformation due to shrinkage curing to form a composite molded product.
A method for manufacturing a composite molded product. The eighth aspect of the present invention, wherein the laminated material sheets are preformed into an arbitrary shape by using a crimping device before the injection molding, and the preformed material sheets are placed in the molding die. Manufacturing method of composite molded products.