JP2612731B2 - Manufacturing method of laminated skin material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a method for producing a laminated skin material, wherein the obtained laminated skin material is formed of a highly rigid resin-based shaping base material (hereinafter referred to as a shaping base material). This is a laminated skin material that is used to produce a vehicle interior material with an integrated shape-forming base material and laminated skin material in a single action. The present invention relates to a method for producing a laminated skin material, which has a soft feel and good cushioning properties, and also has excellent bonding properties to a shaped substrate.

[Conventional technology]

2. Description of the Related Art Conventionally, among those used for interior components such as door trims and pillar trims which are required for vehicles, a cushion layer made of a rigid resin foam is used as an intermediate layer on the upper surface of a highly rigid resin molded base material, and the surface soft synthetic resin sheet is used as a skin. A laminate in which a layered body is fixed is used.

The method for manufacturing the vehicle interior member includes (1)
A method in which the laminate and the shaped substrate are separately molded and shaped, and then an adhesive layer is formed on the surface of the shaped substrate, and the two are laminated and joined together, or (2) After forming and shaping only the shaping substrate in advance, an adhesive layer is formed on the shaping substrate, and the laminate is shaped using a shaping method such as vacuum shaping, and simultaneously the shaping is performed. A method of bonding and integrating the upper surface of the base material or (3) a method of forming a three-layer structure by previously laminating an unformed shaping base material and a laminate, and then forming and shaping the three-layer structure. 4) The resin of the shaping base material flows into the shaping mold in a molten state and is shaped, and at the same time, the laminate is placed on the shaping mold and vacuum formed, compressed air formed or press formed. Methods of forming, shaping, joining and integrating are known.

[Problems to be solved by the present invention]

However, when the product is obtained by using the method (1), since the above-described shaped base material and the laminate are separately manufactured as described above, the shrinkage generated at the time of molding the two is different from each other. In addition, the method (2) is a method developed to improve the disadvantage (1), but the method (2) is not suitable for bonding on the shaped substrate. In order to form the agent layer, it is necessary to separately provide a spray device and a drying device for forming the adhesive layer, which causes problems in terms of cost and economy.

The method (3) was developed in order to improve these disadvantages. However, since the above-mentioned three-layer structure is a composite of materials having different moldability, it is difficult to form the three-layer structure at the time of molding. Because there is a restriction on the suitability of the molding conditions of the molded product and the shape of the molded product, etc., and the drawn pattern applied to the surface of the laminated skin material before molding disappears at the heating temperature under the forming conditions of the above-mentioned forming. In order to form a concavo-convex pattern opposite to the drawn pattern on the upper surface of the shaping mold and to form a drawn pattern on the surface of the skin layer simultaneously with the above-mentioned forming, compared to other forming methods There are problems that the cost of manufacturing the mold is high, and that special care is required also for maintenance of the mold. In addition, even if any of the methods (1) to (3) is used, the layer in contact with the shaped substrate is a cushion layer,
This layer has cells which are deformed or crushed by the heating and pressurizing during the formation of the above-mentioned laminate, and in any case, have an undesirably serious structural defect.

Recently, the method (4) has been used as a more advanced method. In this method, the shaped base resin is flowed into a mold in a molten state, and at the same time, the laminate is formed and shaped. The base resin comes into direct contact with the cushion layer of the laminate in a molten state and is molded under a high pressure, and the cushion layer is formed at a high temperature and a high pressure during the molding. In addition, the problem that the foam cell structure collapses and disappears occurs.

For this reason, as a method of preventing this, recently, a method of attaching a base cloth, a nonwoven fabric, a synthetic resin sheet, or the like to the back surface of the cushion layer has been used. The cost is high, the material and the cushion layer have a problem in adhesive bonding, and the material is newly provided.
When the above-mentioned resin for forming base material is melted to form the base material and the laminate is formed at the same time by using the method of the above, the bonding adhesion between the two becomes incomplete, and the basics for obtaining a product are obtained. In addition to causing serious defects, the new material intervenes, and the hand becomes hard, and contains various defects such as generation of wrinkles at the time of molding and tearing, which is an unfavorable defect factor. .

According to the present invention, as a result of intensive studies to solve the problems as described above, as a result, the second crosslinked high-foamed synthetic resin sheet is used as the lower layer, the first crosslinked high-foamed sheet is used as the intermediate layer, and the upper surface thereof is further heated. An object of the present invention is to provide a method for producing a laminated skin material in which plastic synthetic resin sheets are sequentially laminated and integrated as a skin layer.

[Means for solving the problem]

The present invention is a laminated skin material joined and integrated at the time of shaping the base material, the expansion ratio is 10 to 30 times, and the sheet thickness is 0.5 to 3
A second crosslinked highly foamed synthetic resin sheet made of a polyolefin resin having a thickness of 2 mm or a polyurethane resin having an expansion ratio of 20 to 50 times and having the same thickness is used as a lower layer sheet (hereinafter referred to as a lower layer foam sheet). A first crosslinked highly foamed synthetic resin sheet made of a polyvinyl chloride resin having a magnification of 5 to 25 and a sheet thickness of 1 to 4 mm or a polyolefin resin having an expansion ratio of 10 to 40 and having the same thickness is used as an intermediate layer sheet ( A non-foamed thermoplastic synthetic resin sheet having a sheet thickness of 0.2 to 1.5 mm, a surface hardness of 40 to 80 and a surface hardness of 40 to 80 is further provided on the intermediate layer foam sheet. Hereinafter, it is referred to as a skin layer sheet).

[Action]

 Hereinafter, the production method of the present invention will be described in detail.

The laminated skin material of the present invention is obtained by sequentially laminating and integrating a lower-layer foam sheet, an intermediate-layer foam sheet, and a skin layer sheet, and cutting and cutting the same into a certain size. When being melted and shaped, the lower foamed sheet of the cut laminated skin material is placed on the base material so as to be in contact with the base material, and the shaped base material and the laminated skin material are joined together at the same time as molding to form an automobile or the like. To obtain the interior member.

That is, the laminated skin material of the present invention is formed by laminating a shaped base material in a mold and shaping the shaped base material, and the lower layer foamed sheet is formed into an intermediate layer foamed sheet positioned on the shaped base material resin in the mold. On the other hand,
It acts as a buffer for the heat and molding pressure of the molten resin of the shaping substrate, and serves to prevent the collapse of the foam cells of the intermediate foam sheet, while the lower foam sheet itself melts and melts during the in-mold molding. As a result of the role of the adhesive of the shaped base material in the state, the bonding property between the shaped base material and the laminated skin material can be improved. For this reason, as the lower layer foam sheet of the present invention, the expansion ratio of the cross-linked highly foamed polyolefin resin is 10
A foam sheet having a foaming ratio of from 30 to 30 times, preferably from 15 to 25 times, and a polyurethane resin having a foaming ratio of from 20 to 50 times, preferably from 30 to 40 times, and a sheet thickness of from 0.5 to 3 mm, preferably from 1 to 2 mm is used. The polyolefin resin used for the foamed sheet is a polypropylene resin alone or a copolymer of a polypropylene resin and a polyethylene resin or a mixture thereof,
As the polyurethane-based resin, various two-package type urethane resins may be used alone or in a mixture. Even if a foamed sheet of a resin other than the above is used as the lower foamed sheet, the cushioning protection effect on the intermediate layer sheet during the molding cannot be obtained, and the effect on the bonding property with the molded resin base material is also satisfied. Therefore, it is impossible to obtain the laminated skin material intended for the present invention. Also, when the expansion ratio of the lower layer foam sheet is 10 times or less in the case of a polyolefin-based resin or 20 times or less in the case of a polyurethane-based resin, a problem occurs in the bonding property with the shaping substrate, and the sheet becomes hard. When the interior part after molding is used, the feeling becomes hard,
In addition, appearance defects such as generation of wrinkles are unfavorable, and in the case of a polyolefin resin, the expansion ratio is 30 times or more, and in the case of a polyurethane resin, 50 times or more, it is satisfactory in terms of the bonding property at the time of molding, but buffer protection. The effect is insufficient, which is not preferable. Further, if the thickness of the lower layer foam sheet is 0.5 mm or less, a problem occurs in the above-mentioned protective effect and bonding property, and 3 m
Above m, the above points can be solved, but the weight becomes heavy,
The above-described moldability, feeling, and softness are unfavorably caused by defects.

In the present invention, the intermediate layer foam sheet is joined and laminated on the upper surface of the lower layer foam sheet.As the method of the laminate joining, an extruder is used to extrude an adhesive film between the foam sheets using an extruder. Joining using a roll type laminator while forming, or applying an adhesive to the upper surface of the lower foam sheet and joining, or far infrared rays on one of the joining surfaces of the two sheets or both surfaces Use the so-called heat fusion method of joining using a roller type laminator while heating and melting using a heating device,
Alternatively, they are joined and integrated by any method of joining using a frame lamination method.

In particular, when the lower layer foam sheet is a polyurethane resin, it is preferable to use the method of applying an adhesive or the frame laminating method among the above methods. When the intermediate layer foam sheet is used as an interior part for molding automobiles in the laminated skin material of the present invention, the intermediate layer foam sheet plays a role of reducing its weight, maintaining a soft feel and maintaining good cushioning properties. The intermediate layer foam sheet of the present invention has an expansion ratio of 5 to 25 times, preferably 10 to 20 times, and preferably 10 to 40 times, of the crosslinked and highly expanded polyvinyl chloride resin. Double preferably 15
A foam sheet having a thickness of up to 30 times and a sheet thickness of 1 to 4 mm, preferably 2 to 3 mm is used. As the polyvinyl chloride resin used for the foamed sheet, a homopolymer or copolymer of a vinyl chloride resin, or a copolymer of such a resin and a polyvinyl acetate resin or a polyethylene resin, alone or in a mixture, is used. Or a resin obtained by chemically or electron beam crosslinking of the above resin, or a polyvinyl chloride resin having a reactive hydroxyl group in the molecule, which is crosslinked with an isocyanate.

When the intermediate layer foam sheet is a polyvinyl chloride resin, if the expansion ratio is 5 or less, the softness is lacking when used as the interior part for molding, and if it is 25 or more, the cushioning property is incomplete, and the in-mold molding is performed. Undesirably causes problems in the shaping properties of

Also, as the polyolefin resin, a polypropylene resin alone or a copolymer of a polypropylene resin and a polyethylene resin or a crosslinked product of these is used, and when the expansion ratio is 10 times or less, it lacks in softness, and when the expansion ratio is 40 times or more, it has a cushioning property. Is incomplete and is not preferred.

When the thickness of the intermediate layer foam sheet is 1 mm or less, defects in softness and cushioning properties occur, and when it is 4 mm or more, the weight becomes heavy and the shapeability in the above-mentioned in-mold molding is disadvantageously disadvantageous.

Next, a skin layer sheet is formed on the upper surface of the foamed intermediate layer sheet to obtain the laminated skin material of the present invention. The sheet serves as a laminated skin material to improve its surface strength and durability, and to provide a design effect and increase the added value of the product. As the thermoplastic synthetic resin used for the skin layer sheet, polyvinyl chloride, polyvinyl acetate, polyurethane, etc. alone or a mixture thereof or a copolymer thereof, or soft vinyl chloride and AS resin, AAS resin, ABS resin, nitrile rubber Alternatively, a resin made of a mixture such as acrylic rubber is used as the colored sheet. The thickness of the sheet is 0.2-1.5m
m, the surface hardness of which is required to be 40 to 80 in Shore A. If the thickness is 0.2 mm or less and the surface hardness value is 40 or less, problems occur in the scratch resistance, abrasion resistance and the formability of the product, which is not preferable, and the thickness is 1.5 mm or more and the surface hardness value is 80 or more. In this case, the weight is too heavy and too hard, so that the weight reduction and the softness are impaired, and a sharp shape cannot be obtained at the time of molding, and the object of the present invention cannot be achieved in any case. As a method of forming the skin layer sheet, the thermoplastic resin is formed into a sheet by using a calendering method or an extrusion method, and a squeezed pattern or a printed pattern is formed on the surface thereof. Laminating or integrating using a laminating method or an adhesive bonding method, or using a coating method to obtain a sheet-like material having a drawn pattern using a squeezable release paper, and using any of the above-described bonding methods The laminate may be formed by using the same. The squeezed pattern and the printed pattern may be formed on the skin layer sheet after forming the laminate.

〔Example〕

 Hereinafter, a specific configuration of the present invention will be described with reference to examples.

Example 1 A crosslinked high-expansion polypropylene sheet [AP66,15020 (manufactured by Toray Industries, Inc.)] having a thickness of about 1 mm and an expansion ratio of 15 times was used as a lower-layer foam sheet, and an intermediate layer foam sheet having a thickness of about 2 mm and an expansion ratio of 20 times was used. Cross-linked highly foamed polypropylene resin sheet [AP
66,25010 (manufactured by Toray Industries, Inc.)] and extruding an adhesive film (Admer 9F305 (manufactured by Mitsui Petrochemical Industries, Ltd.)) between the two foam sheets using an extruder at an extrusion temperature of about 200 ° C. At a speed of about 15 m / min., The two foam sheets were continuously joined using a roll laminator while the film was still in a molten state, with the film thickness being about 0.05 mm under extrusion conditions of about 15 mm / min. A laminate was obtained. Next, a colored thermoplastic synthetic resin sheet [ethylene-propylene diene monomer-copolymer resin millastomer] was used as a skin layer sheet showing a value of 70 with a Shore A using another extruder on the upper surface of the foamed intermediate layer sheet of the laminate. 7030N (manufactured by Mitsui Petrochemical Industry Co., Ltd.) with an extrusion processing temperature of about 230 ° C and an extrusion speed of about 6 m / min.
Formed and placed on the surface of the skin layer sheet while being continuously joined and integrated with the laminated material using a roll laminator equipped with a squeezing roll while the sheet is still in a molten state. An uneven squeezing pattern was formed. Next, this was cut into a certain size using a cutting machine to obtain a laminated skin material. The obtained product is melt-flowed and molded into a mold in an injection molding machine by injection molding a thermoplastic synthetic resin (polypropylene resin J840G (manufactured by Mitsui Petrochemical Industries, Ltd.)) as a base resin. At this time, the laminated skin material is placed in the mold so as to be positioned on the upper surface of the base resin, and the base resin flows into the mold at the same time as the stamping molding is performed while the resin is still in a molten state. When the above-mentioned base resin and laminated skin material are shaped and joined together by using the method, it has a lightweight, soft feel and good cushioning properties.
In addition, an excellent interior member for automobiles having a high design value and having a sharp shaped shape, being uniformly and firmly joined and integrated with the above-described base material, and having a surface with an uneven pattern, which is rich in design properties.

Example 2 A polypropylene resin sheet [AP66,2520 (manufactured by Toray Industries, Inc.)] having a thickness of about 2 mm and an expansion ratio of 25 was used as the lower layer foam sheet, and an intermediate layer foam sheet having a thickness of about 2 mm and an expansion ratio of 15 was used. Using a cross-linked highly foamed vinyl chloride resin sheet having the following composition, a two-liquid cross-linkable adhesive type urethane-based adhesive is applied to the upper surface of the lower foam sheet, and is bonded and integrated with the intermediate foam sheet to obtain a laminated material. Was. Next, as a skin layer sheet, a composition having the following composition was formed with an extruder to form a colored sheet having a thickness of about 0.8 mm and a surface hardness of 50 with Shore A, and at the same time, an engraved pattern with unevenness was formed on one of the laminate rolls. At the same time as joining to the upper surface of the foamed intermediate layer sheet by using a roll, an uneven pattern was formed on the surface of the skin sheet. Next, this was cut into a fixed size using a cutting machine to obtain a laminated skin material. The obtained product is placed in a metal mold of a blow molding machine for molding a resin substrate so as to be located on the upper surface of the resin substrate, and a thermoplastic synthetic resin (polypropylene resin B200) is used as the resin for the substrate.
(Manufactured by Mitsui Petrochemical Industry Co., Ltd.)] into the mold by melt-injection using a blow molding method, and at the same time, simultaneously molding and shaping the surface material for molding by the molding pressure during the molding. When it is bonded to the resin base material, it is bonded to the base material uniformly and firmly, and has the same excellent quality, performance, and effects as those of the first embodiment, and also has an excellent interior design. Obtained.

(1) [Composition of intermediate layer polyvinyl chloride resin foam sheet] Vinyl chloride-hydroxyacrylate copolymer 100 parts by weight Trimellitic ester plasticizer 50 {Stabilizer for Ba-Zn based foaming material 3} Pigment 2} Azo Dicarbonamide (foaming agent) 12 〃 Block isocyanate (crosslinking agent) 6 〃 (2) [Skin compound] 100 parts by weight of polyvinyl chloride resin (= 1300) 50 parts by weight of ABS resin Nitrile rubber 15 〃 Trimellitic ester 60 〃 Ba-Ca-Zn-based stabilizer 3 顔料 Pigment 2 〃 Filler 20 〃 Example 3 Crosslinked highly foamed polypropylene resin sheet [AP66, 20010 (manufactured by Toray Industries, Inc.)] having a thickness of about 1 mm and an expansion ratio of 20 times Is the lower layer foam sheet and the middle layer foam sheet is about 3m thick
m, foaming ratio 30 times used as a cross-linked high foaming polypropylene resin sheet [AX60,30030 (manufactured by Toray Industries, Inc.)]
While the upper surface of the lower foamed sheet was heated and melted by a heat melting method using a far-infrared heater, the intermediate foamed sheet was continuously supplied and bonded and integrated to obtain a laminate. Next, a colored thermoplastic synthetic resin sheet is used as a skin layer sheet having a value of 50 with Shore A having the same composition as in Example 2 using a two-part crosslinked urethane type adhesive on the upper surface of the intermediate layer foam sheet of this layer. Were laminated and then cut into a predetermined size using a cutting machine to obtain a laminated skin agent.

The obtained product is placed on a lower mold for molding obtained by engraving a concavo-convex pattern of a press molding machine so that the skin layer sheet surface is in contact therewith, and a thermoplastic synthetic resin [ Polypropylene resin J640 (manufactured by Mitsui Petrochemical Industry Co., Ltd.)] is extruded into a sheet shape by a T-die using an extruder, and the sheet is still supplied while being continuously supplied to the upper surface of the lower foamed sheet of the laminated skin material. While in the molten state, the above-mentioned resin base material and the laminated skin material were integrally formed and pressed together by press-molding the surface thereof using a molding upper mold, and were uniformly and strongly bonded to the resin base material. And an interior member for an automobile having the same excellent quality, performance and effect as in Example 1 and having excellent design properties.

Example 4 A cross-linked highly foamed polyurethane resin sheet having a thickness of about 1 mm and a foaming ratio of 40 times [Urethane foam EL62] was used in exactly the same manner as in Example 1 except that the thickness of the lower-layer foamed sheet of Example 1 was about 1 mm and the expansion ratio was 40 times.
(Manufactured by Inoue MTP Co., Ltd.)]
A laminated skin material was obtained using the same material as in Example 1. The obtained product was molded and shaped in the same manner as in Example 1. As a result, the product was uniformly and firmly joined to the resin base material, and had the same excellent quality, performance and effects as in Example 1, and was excellent. Thus, an automobile interior member having a design characteristic was obtained.

〔The invention's effect〕

As described above, the present invention is a laminated skin material obtained by laminating and integrating a skin layer sheet of a thermoplastic synthetic resin on the intermediate layer of the cross-linked high foam synthetic resin on the lower layer foam sheet of the cross-linked high foam synthetic resin, and further on the upper surface thereof, Injection molding base resin
When molding using a blow method or a press method, the lower foamed sheet side of the laminated skin material is brought into contact with the shaping base resin which is melt-filled in the molding die, and the above both are simultaneously formed and joined. At this time, the lower layer foam sheet has a buffering function of preventing collapse of foam cells of the intermediate layer foam sheet of the laminated skin material due to heat of the molten resin of the shape substrate and pressure during molding, and the shape substrate. In addition to having the function of strengthening the uniform and strong adhesive bonding force between the resin and the laminated skin material, the laminated skin material has a lightweight, soft feel, good cushioning properties, and sharp shaping properties. As well as having excellent design properties, it is possible to obtain excellent products for use as interior parts for automobiles.

Further, when used as an interior member for an automobile, the present invention is capable of simultaneously forming a composite laminated skin material at the same time as molding of the molded resin base material, and also capable of firmly and uniformly joining and integrating the two. Can be continuously produced economically, inexpensively, and efficiently.

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Norimichi Hiki 1876 Higashi-cho, Hamamatsu-shi, Shizuoka Kyowa Leather Co., Ltd. (72) Inventor Masayuki Kondo 1876 Higashi-cho, Hamamatsu-shi, Shizuoka Kyowa Leather Co., Ltd. References JP-A-62-212137 (JP, A) JP-A-63-19232 (JP, A) JP-A-60-173447 (JP, U)

Claims (3)

(57) [Claims] 1. A laminated skin material joined and integrated at the time of molding a highly rigid resin shaped base material, wherein a second cross-linking height of a polyolefin resin having an expansion ratio of 10 to 30 and a sheet thickness of 0.5 to 3 mm is provided. A foam synthetic resin sheet as a lower layer, on the lower layer,
A first crosslinked highly foamed synthetic resin sheet made of a polyvinyl chloride resin having an expansion ratio of 5 to 25 and a sheet thickness of 1 to 4 mm is used as an intermediate layer, and a sheet thickness of 0.2 to 1.5 is further formed on the intermediate layer.
A method for producing a laminated skin material, comprising sequentially laminating and integrating a non-foamed thermoplastic synthetic resin sheet having a surface hardness of 40 to 80 mm and a surface hardness of 40 to 80 as a skin layer. 2. The method for producing a laminated skin material according to claim 1, wherein the second crosslinked highly foamed synthetic resin sheet comprises a polyurethane resin sheet having an expansion ratio of 20 to 50 times. 3. The method for producing a laminated skin material according to claim 1, wherein the first crosslinked highly foamed synthetic resin sheet comprises a polyolefin resin sheet having an expansion ratio of 10 to 40 times.