JP3560300B2 - Manufacturing method of patterned nonwoven skin material - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
TECHNICAL FIELD The present invention relates to a method for producing a patterned nonwoven-based skin material capable of forming a patterned nonwoven-based skin material simultaneously with hot-press molding of the skin material without performing post-processing or the like.
[0002]
[Prior art]
For example, nonwoven fabric skin materials made of polyester fiber web are widely used as interior materials for automobiles, and the surface of such nonwoven fabric skin material is further referred to as a skin layer for the purpose of improving the design effect. Usually, a leather-like synthetic resin film layer is formed and used, but recently it has been required to further add a pattern to the skin layer in response to diversification of user preferences. . In this case, as a patterning means, a method of performing printing in a post-process or a method of performing patterning by painting in a post-process is generally adopted.
[0003]
However, when such a method is used, the patterning is performed in a post-process, and the number of processes increases, which complicates the work and deteriorates the moldability, and requires a processing apparatus and workers for the process. There is a problem that the production cost is high due to the necessity. Furthermore, it is difficult to express a subtle shade of color even in a pattern that can be processed, and when combined with embossing, it is technically difficult to completely match the pattern with the embossed pattern. There was a point.
[0004]
[Problems to be solved by the invention]
The present invention solves the conventional problems as described above, and it is possible to integrally form a pattern on a skin layer simultaneously with hot-press molding of a skin material without performing post-processing, etc. It can be easily and inexpensively produced without the need for equipment and processes for production, and when the expression of delicate shades of color or embossing is added, the pattern and embossed pattern are completely matched. The present invention has been completed for the purpose of providing a method for producing a patterned nonwoven-based skin material that can be used.
[0005]
[Means for Solving the Problems]
The present invention made in order to solve the above-mentioned problem, the pattern formation by adding a decorative plate having a hole for pattern formation on the surface of a fiber web in which a high melting point fiber and a binder fiber having a lower melting point than this are mixed. The portion exposed by the hole is a portion where the impregnating force is lower than the other portion due to the melting of the binder fiber, and then a coating material containing a pigment is applied to the surface of the fibrous web, and then a hot pressure is applied. A method for producing a patterned nonwoven-based skin material, characterized in that a portion where the impregnating force is reduced is made into a nonwoven fabric having a pattern with a darker color pattern than other portions having impregnating power, and a high melting point fiber. A decorative plate having a hole for pattern formation is attached to the surface of a fiber web mixed with a binder fiber having a lower melting point than the above, sandwiched by a pressurizing plate having air permeability, and a temperature slightly higher than the melting point of the binder fiber. Hot air The web is passed from the back side to the front side to form a molding material having a raised pattern pattern in which binder fibers are melted on the surface and raised from the pattern forming holes, and then the surface of the molding material is coated with pigment. The material is applied and the coating material on the raised pattern is placed thicker than the other parts without being impregnated, and the pattern is darker than the other parts by hot pressing. A method for producing a patterned nonwoven-based skin material, characterized in that it is a patterned nonwoven fabric.
[0006]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, a preferred embodiment of the present invention will be described with reference to the drawings illustrating a forming process of a nonwoven fabric-based skin material used as an interior material for automobiles.
Reference numeral 1 denotes a fibrous web. The fibrous web 1 according to the present invention is composed mainly of a high-melting fiber such as polyester or polyamide having a fiber thickness of 2 to 6 deniers and a binder having a lower melting point than the high-melting fiber. A fiber having a basis weight of 100 to 300 g / m ² in which fibers (melting point: 120 to 150 ° C.) are mixed at a ratio of 5 to 30% is used.
[0007]
As shown in FIG. 1, the fiber web 1 is heat-set by sandwiching it between a pair of upper and lower pressurizing plates 2a and 2b having air permeability. As the pressure plates 2a and 2b, for example, those having a large number of through holes 3 such as punched metal are used, and between the surface side of the fiber web 1 and the pressure plate 2b, as shown in FIG. A decorative plate 4 having a well-patterned pattern forming hole 4a is interposed. The decorative plate 4 may be a heat-resistant resin sheet or the like in addition to a metal plate such as a punching metal. In the drawing, a large number of circular pattern forming holes 4a are arranged. Although the decorative plate 4 is shown, it goes without saying that any shape and arrangement may be used according to the pattern to be formed.
[0008]
The heat setting process is performed by passing hot air (130 to 160 ° C.) having a temperature about 10 to 20 ° C. higher than the melting point of the binder fiber from the back side to the front side of the fiber web 1. This heating melts the binder fiber and fuses it with the high-melting fiber which is the main material in the web layer, and restricts the passage of hot air by the interposition of the decorative plate 4 so that the surface of the fibrous web 1 has ventilation holes. Only the portion corresponding to 4a is a passage for hot air, the binder fiber of only that portion is melted, the impregnating force is lower than the other portions, and the impregnating force is lower than the other portions. As shown in FIG. 3, a molding material 6 having a raised pattern pattern portion 5 in which binder fibers are melted is formed on the surface by the pressures of the pressure plates 2a and 2b and the static pressure due to ventilation.
[0009]
Next, a coating material containing a pigment is applied to the surface of the obtained molding material 6. As this coating material, a highly durable resin such as urethane resin having poor wettability with the polyester high melting point fiber as the main material may be used, and may be spray-coated at about 100 to 150 g / m ² (WET standard). At this time, since the raised pattern 5 of the molding material 6 has the binder fiber in a molten state as described above, the coating material 7 having poor wettability gathers around the raised pattern 5 as shown in FIG. On the other hand, in other portions, the coating material 7 is impregnated inside. As a result, there is no impregnation of the coating material on the raised pattern 5 and a larger amount of the coating material 7 is placed on the other portions.
[0010]
Next, as shown in FIG. 5, the molding material 6 on which the coating material 7 has been applied is subjected to a hot press (heating at about 150 ° C.) between a pair of upper and lower heating dies 8a and 8b by a conventional method. After cooling, it is taken out of the mold to obtain a nonwoven fabric skin material. As shown in FIGS. 6 and 7, the raised portion 5 is pressed by the hot-press to become a skin material having a smooth surface. Is a state in which a large amount of the coating material 7 is placed, and the amount of the coating material 7 per unit area is large, so that a large amount of pigment as a colorant is also contained, and the whole color is the same color, but is darker than other portions. Will be clearly formed. If a slight clearance is set between the heating dies 8a and 8b during the hot-pressing step, an embossed pattern having an uneven feeling on the surface can be formed. An excellent product completely matching the pattern can be obtained.
[0011]
In the above-described embodiment, the hot air having a temperature slightly higher than the melting point of the binder fiber is passed between the back side and the front side of the fibrous web 1 while being sandwiched between the pressurizing plates 2a and 2b having air permeability. Is melted to form a protruding pattern protruding from the pattern forming holes 4a of the decorative plate 4, and a coating material containing a pigment is applied to the surface thereof to impregnate the coating material on the protruding pattern. It is placed in a state where it is thicker than other parts without being pressed, and this is hot-pressed to make a non-woven fabric with a patterned pattern darker than the other parts, but sandwiched with a pressure plate A high-melting fiber is mixed with a binder fiber having a lower melting point than that of a fiber web, and a decorative plate having a hole for forming a pattern is attached to the surface of the fibrous web. Bye A portion where the impregnating force is reduced by melting the fiber and making the impregnating force lower than the other portions, and then applying a coating material containing a pigment to the surface of the fibrous web and applying heat pressure. May be a non-woven fabric having a pattern with a darker color pattern than other portions having impregnating power.
[0012]
【The invention's effect】
As is clear from the above description, the present invention can integrally form a pattern on a skin layer simultaneously with hot-press molding of a skin material without performing post-processing and the like, and for special pattern processing. It can be easily and inexpensively produced without the need for equipment and processes, and the pattern and embossed pattern can be completely matched when subtle shades of color or embossing are added. Things.
Therefore, the present invention greatly contributes to the development of industry as a method for producing a patterned nonwoven skin material which eliminates the conventional problems.
[Brief description of the drawings]
FIG. 1 is a process diagram of a heat set showing an embodiment of the present invention.
FIG. 2 is a plan view showing a decorative plate.
FIG. 3 is a sectional view showing a molding material.
FIG. 4 is an enlarged cross-sectional view showing an application state of a coating material.
FIG. 5 is a process diagram of a hot press according to the embodiment of the present invention.
FIG. 6 is a cross-sectional view of a nonwoven fabric skin material obtained according to the present invention.
FIG. 7 is a plan view of a nonwoven fabric skin material obtained according to the present invention.
[Explanation of symbols]
REFERENCE SIGNS LIST 1 fibrous web 4 decorative board 5 raised pattern 6 molding material 7 coating material 10 pattern

Claims (3)

A high-melting fiber is mixed with a binder fiber having a lower melting point than that of the fiber web, and a decorative plate having a pattern forming hole is attached to the surface of the fibrous web. A portion having a lower impregnating force than the portion of the above, and then applying a coating material mixed with a pigment on the surface of the fibrous web, and applying the hot pressure to the portion having a lower impregnating force by another impregnating force A method for producing a patterned nonwoven skin material, characterized in that the nonwoven fabric is patterned with a darker colored pattern than the part. A high-melting fiber is mixed with a binder web having a lower melting point than the binder fiber, and a decorative plate having a hole for pattern formation is attached to the surface of the fibrous web and sandwiched by a pressurized pressure plate, and the melting point of the binder fiber is lower than the melting point of the binder fiber. Hot air at a slightly higher temperature is passed from the back side to the front side of the fibrous web, and the binder fiber is melted on the surface to form a molding material having a raised pattern that is raised from the pattern forming holes. A coating material mixed with a pigment is applied so that the coating material on the raised pattern is placed thicker than other parts without being impregnated, and the pattern is hot-pressed to make the pattern more dense than other parts. A method for producing a patterned nonwoven-based skin material, wherein the nonwoven fabric is a patterned nonwoven fabric. The method for producing a patterned nonwoven skin material according to claim 1 or 2, wherein the coating material is a highly durable resin having poor wettability to high melting point fibers mixed with the fiber web.

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