JP3054262B2 - Sheet material excellent in design effect and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet-like material having an excellent effect of forming designs such as characters and designs, and more particularly to the use of a heating mold when pressing a heating mold to form a design. The present invention relates to a sheet material excellent in design effect over a wide temperature range.

[0002]

2. Description of the Related Art Conventionally, as a sheet-like material for forming a design such as a character or a design by pressing a heated mold,
It is known that a wet silver surface layer made of polyurethane is formed on a sheet substrate obtained by adding a polymer elastic body to a fibrous substrate.

[0003] The sheet-like material as described above is, for example, 160 to
By pressing the mold heated to 210 ° C., an uneven design is formed on the surface, and the temperature of the mold used here needs to be appropriately set according to the softening temperature of the wet silver surface layer. is there. That is, when the softening temperature of the wet-type silver surface layer is high, the unevenness is not sufficiently imparted unless the temperature of the mold is also increased accordingly. vice versa,
If the softening temperature of the wet-grain surface layer is low, the mold should not be too hot, and if it is too hot, the sheet may stick to the mold surface.

In general, in shaping a design into a sheet having excellent design effects, a method in which a high-temperature mold is pressed for a short time is advantageous in terms of working efficiency, and therefore, the softening temperature of the wet silver surface layer is reduced. Of resin having a temperature of 180 ° C. or higher is generally used.

However, when shaping is performed on a sheet having a wet silver surface layer having a high softening temperature, it is necessary to keep the mold temperature at a high temperature within a certain range. When a large number of shaping processes are performed, it is difficult to precisely control the temperature to a fixed temperature, such as a temporary decrease in the temperature of the mold. For this reason, a favorable uneven shape cannot be given to the sheet-like material with a change in the temperature of the mold, and stable quality cannot be obtained.

Further, there is a problem that short-time shaping processing results in insufficient surface smoothness of the shaped part.

[0007]

DISCLOSURE OF THE INVENTION The present inventors have completed the present invention as a result of intensive studies in view of the above-mentioned problems, and an object of the present invention is to form a good shape by pressing a heating mold. In processing, even if the temperature of the heating mold fluctuates to some extent, shaping can be performed with stable quality, and a shaping surface with good surface smoothness can be obtained even by short shaping. An object of the present invention is to provide a sheet-like material excellent in design effect and a method for producing the same.

[0008] An object of the present invention is to form a wet silver surface layer mainly composed of a polymer alloy composed of polyurethane and polyester on a sheet substrate obtained by providing a polymer elastic material to a fibrous substrate. This is achieved by a sheet-like article having an excellent design effect, wherein the polyester has a softening temperature lower than that of the polyurethane by 30 ° C. or more.

Another object of the present invention is to apply a resin solution to a sheet substrate comprising a fibrous substrate and a polymer elastic body, and to wet-solidify the resin solution to form a wet silver surface on the sheet substrate. A method for producing a sheet-like material comprising forming a layer, wherein the resin solution is obtained by dissolving a mixture of a polyurethane and a polyester having a softening temperature lower than that of the polyurethane by 30 ° C. or more with an organic solvent. This is achieved by a method for manufacturing a sheet-like material having an excellent design effect.

In the present invention, the term "sheet base material" means a fibrous base material such as a nonwoven fabric, a woven fabric, or a knitted fabric, which is provided with an organic solvent solution or an emulsion of a polymer elastic material, solidified, and solidified. Is filled with a polymer elastic body, or a coating layer of the same polymer elastic body is formed on this surface,
The production may be performed by a known appropriate method.

Examples of the above-mentioned polymer elastic body include polymers such as polyurethane resin, vinyl chloride resin, acrylate / styrene copolymer, styrene / butadiene copolymer, urethane / vinyl chloride copolymer, and mixtures thereof. Preferred are polyurethane resins and mixtures of polyurethane resins with urethane / vinyl chloride copolymers.

In the present invention, a wet silver surface layer having a porous structure is formed on the surface of the sheet substrate. The wet silver surface layer is mainly composed of a polymer alloy in which a polyurethane and a polyester are mixed, and usually contains a pigment or dye dispersed therein for coloring into a desired color.

In the present invention, the mixed polyurethane and polyester have different softening temperatures. That is, the softening temperature of the polyester is at least 30 ° C., preferably 30 to 100 ° C., higher than the softening temperature of the polyurethane.
° C, more preferably 50-80 ° C. If the difference in the softening temperature is smaller than 30 ° C., the optimal use temperature range of the mold in shaping is narrowed. As a combination of the polyurethane and the polyester, for example, a polyurethane having a softening temperature of 180 to 220 ° C. and a softening temperature of 100 to 220 ° C.
Combinations with 150 ° C. polyesters can be mentioned.

The mixing ratio of the polyurethane and the polyester to be mixed is preferably a weight ratio of 9: 1 to 4: 6,
More preferably, it is 8: 2 to 6: 4. If the proportion of the polyester is too large, a favorable porous structure tends to be hardly obtained by wet coagulation.

In the wet silver surface layer according to the present invention, the polyurethane and polyester mixed in the above-mentioned combination are dissolved in an appropriate organic solvent, and if necessary, an appropriate amount of a desired color pigment or dye is added. After forming an organic solvent solution, the solution can be formed by applying the solution to the sheet substrate, wet coagulation, washing with water and drying. The thickness of the wet silver surface layer is preferably about 0.1 to 0.6 mm, and more preferably about 0.2 to 0.5 mm.

The organic solvent dissolves both the polyurethane and the polyester. Specifically, for example, dimethylformamide, ethyl acetate, toluene and MEK
And dimethylformamide is preferred.

In the method of the present invention, the method of dissolving the polyurethane and the polyester in the organic solvent is not particularly limited. For example, a method in which one resin is dissolved and then the other resin is dissolved, or both resins are dissolved. At the same time, a method of dissolving in an organic solvent, a method of mixing solutions in which respective resins are dissolved in advance, and the like can be given. Incidentally, polyester having a high softening temperature tends to be hardly dissolved in a solvent.

The steps of applying the solution adjusted to the composition as described above on the surface of the sheet substrate, treating with a water-based coagulating liquid to form a wet silver surface layer, and washing and drying are carried out in a conventional manner. Can be.

That is, if necessary, a surfactant, a colorant, an antioxidant and the like are added, and the solid content is adjusted to 10 to 40% by weight, preferably 15 to 35% by weight. The solvent solution is generally applied to the surface of the sheet substrate using a suitable coating means such as a roll coater, a knife coater or the like at a rate of 150 to 1,500 g /
m ² , preferably 300 to 1,200 g / m ² (as a solution), then immersed in water or a mixture of water and an organic solvent for wet coagulation, followed by removal. By washing with water for the solvent and drying, a sheet-like material having a wet silver surface layer having a porous structure can be obtained.

In the present invention, the wet silver surface layer has a denser porous structure than a conventional product formed using only polyurethane as a resin. For this reason, compared with the conventional product, the surface shape is finer, the mechanical strength is excellent, and the abrasion resistance is good.

In the present invention, in place of the wet grain surface layer,
When the porous resin layer obtained by the dry foaming method is formed,
When a design is formed by a heating mold, the color change is poor, which is not preferable.

[0022]

The present invention will be described below in detail with reference to examples. In the examples and comparative examples, “parts” means “parts by weight”.

Example 1 Ester staple fiber (denier 1.5 denier, length 50 mm)
Nonwoven fabric (basis weight 240 g / m ² , thickness 1.6 m
m), 100 parts of a polyurethane elastomer (solid content: 30%, DMF solution) synthesized from polybutylene adipate glycol, diphenylmethane-4,4'-diisocyanate and ethylene glycol, 1.5 parts of iron oxide brown, 100 parts of dimethylformamide The resulting solution was impregnated with a solution consisting of 1 part and wet coagulated, washed sufficiently with water and dried to obtain a sheet base material having a thickness of 1.5 mm and an apparent density of 0.34 g / cm ³ .

Next, on one surface of the obtained sheet substrate,
A polyurethane elastomer having a softening temperature of 190 ° C. (solid content: 30%, DMF solution) 80 synthesized in the same manner as described above
Part and a polyester having a softening temperature of 110 ° C. (solid content 30
%, DMF solution), a solution consisting of 20 parts of iron oxide brown as a coloring agent, 30 parts of dimethylformamide, and 3 parts of a surfactant is applied at 800 g / m ² , and then dipped in water to coagulate the polyurethane. I was sorry. This was washed with warm water to completely remove dimethylformamide, followed by drying to form a brown wet silver surface layer and obtain a sheet.

<Shaping> A mold having an uneven pattern formed on the surface of the obtained sheet is placed at 170 ° C. and 200 ° C.
And heated under pressure for 1 second to perform shaping.

The results are as shown in Table 1, and a good three-dimensional design was formed at any heating temperature. The shaping surface had extremely good surface smoothness.

Example 2 The procedure of Example 1 was repeated, except that 20 parts of a polyester having a softening temperature of 130 ° C. was used instead of the polyester having a softening temperature of 110 ° C., which was added to the solution used for forming the wet grain surface layer. A sheet was obtained in the same manner as in Example 1.

The obtained sheet was shaped in the same manner as in Example 1. The results were as shown in Table 1.

Example 3 The procedure of Example 1 was repeated, except that 20 parts of a polyester having a softening temperature of 150 ° C. was used instead of the polyester having a softening temperature of 110 ° C., which was added to the solution used for forming the wet grain surface layer. A sheet was obtained in the same manner as in Example 1.

The obtained sheet was shaped in the same manner as in Example 1. The results were as shown in Table 1.

Example 4 The amount of the polyurethane elastomer having a softening temperature of 190 ° C. mixed with the solution used for forming the wet grain surface layer in Example 1 was changed to 50 parts instead of 80 parts, and the softening temperature was changed to 1 part.
A sheet was obtained in the same manner as in Example 1 except that the blending amount of the polyester at 10 ° C. was changed to 50 parts instead of 20 parts.

The obtained sheet was shaped in the same manner as in Example 1. The results were as shown in Table 1.

Comparative Example 1 The procedure of Example 1 was repeated, except that 20 parts of a polyester having a softening temperature of 170 ° C. was used instead of the polyester having a softening temperature of 110 ° C., which was added to the solution used for forming the wet grain surface layer. A sheet was obtained in the same manner as in Example 1.

The obtained sheet was shaped in the same manner as in Example 1. The results were as shown in Table 1.

COMPARATIVE EXAMPLE 2 A softening temperature of 160.degree. C. was used in place of the two resins blended in the solution used for forming the wet silver surface layer in Example 1.
A sheet was obtained in the same manner as in Example 1 except that 100 parts of the polyurethane elastomer was used.

The obtained sheet was shaped in the same manner as in Example 1. The results were as shown in Table 1.

[0037]

[Table 1]

[0038]

As described above, in the sheet-like material of the present invention, since the wet grain surface layer is formed by a polymer alloy of polyurethane having a high softening temperature and polyester having a low softening temperature, good shaping processing is performed. The temperature range of the mold has been greatly expanded compared to conventional products. For this reason, even if the temperature of the mold slightly changes, shaping processing of stable quality can be performed, which is extremely suitable in the case of shaping a large amount or when the temperature control of the mold is not precise.

Further, the wet silver surface layer of the sheet-like material of the present invention has a denser porous structure than the conventional product because the mixed solution of polyurethane and polyester is wet-solidified. Therefore, even when the heated mold is pressed for a short time, a processed surface having excellent surface smoothness can be obtained. Further, a product having excellent mechanical strength and good abrasion resistance as compared with conventional products can be obtained.

Claims (2)

(57) [Claims] 1. A sheet-like material obtained by forming a wet silver surface layer mainly composed of a polymer alloy composed of polyurethane and polyester on a sheet substrate obtained by providing a polymer elastic material to a fibrous substrate. A sheet-like article having an excellent design effect, wherein the polyester has a softening temperature lower than that of the polyurethane by 30 ° C. or more. 2. A method comprising applying a resin solution to a sheet base obtained by providing a polymer base material to a fibrous base and wet-solidifying the resin solution to form a wet silver surface layer on the sheet base. In the method for producing a sheet-like material, the resin solution,
A method for producing a sheet having excellent design effects, comprising a mixture of a polyurethane and a polyester having a softening temperature lower than that of the polyurethane by 30 ° C. or more dissolved in an organic solvent.