JP4958033B2 - Method for producing flocking for automobile interior - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a trimming flocked product for an automobile having the soft feel, high abrasion strength and product stability. <P>SOLUTION: The trimming flocked product is constituted by flocking piles with a thickness of 0.1-0.9 dT and a length of 0.1-0.6 mm, which are treated with an electrodepositing treatment agent containing synthetic tannin and an inorganic silicon compound and a smoothing agent, on a base material by fiber coating. The coefficient of dynamic friction of the flocked product is the thickness (dT value) of the piles/2+0.7 or below and the coefficient of static friction of the flocked product is the thickness (dT value) of the piles/2+0.9 or below. <P>COPYRIGHT: (C)2008,JPO&amp;INPIT

Description

  The present invention relates to a flocking article for automobile interior having a soft tactile sensation and having high wear strength and product stability, and more specifically, an electrodeposition treatment containing a synthetic tannin and an inorganic silicon compound. The surface of the electrodeposition treatment is flattened by treating the pile, and further treated with a smoothing agent to reduce the frictional force of the flocked product in which the ultra fine pile is flocked, thereby having a soft touch and high It is possible to provide a flocking product for automobile interior that exhibits wear strength and product stability.

BACKGROUND ART So-called flocked products in which piles (hairy fibers) are attached to the surface of a substrate such as a plastic plate via an adhesive are used for the interior of automobiles.
Conventionally, when a pile is attached to the surface of a hair transplant object to which an adhesive has been applied, a lower pile is applied by applying a high voltage to the electrodes installed in the vicinity of the object to be transplanted and on the top of a pile supply container containing the pile. The so-called electrostatic flocking method is generally used, in which the pile in the supply container is floated by electric lines of force and attached to the object to be transplanted, or the pile is attached to the object to be transplanted by dropping it from above. Has been done.

However, electrostatic flocking methods tend to have uneven pile deposits when planting flocks with irregularities and complex shapes, or flocks with large areas, and the density of piles to be flocked When the value is low, it is difficult to lower the pile density because the amount of pile attached becomes uneven.
Furthermore, in the electrostatic flocking method, since the pile is flocked substantially perpendicular to the object to be transplanted, the feel of the obtained flocked product tends to be hard.

On the other hand, a fiber coating method has been developed in which a powder coating method is applied, and a pile is sprayed from a spray gun onto a target object to be transplanted (see, for example, Patent Document 1).
In the fiber coating, the pile is planted in a state of being tilted with respect to the object to be transplanted, so that it is possible to produce a flocking product with a soft touch, and it is possible to uniformly plant even at a low pile density. It has a feature that a large device such as electrostatic flocking is not required.
In addition, electrostatic spraying has been developed in which fiber coating is performed with a high voltage applied (see, for example, Patent Document 2).
Japanese Patent Laid-Open No. 08-117646 JP 2004-16966 A

A flocking product for automobile interiors needs to satisfy high wear strength and product stability, but on the other hand, high quality and high touch feeling have been demanded year by year.
In particular, a flock for interior decoration of a luxury car requires a high-class feeling in addition to the above, but a soft touch is an important requirement for a high-class feeling.
In order to achieve a soft touch, it is necessary to use an extra fine pile. However, in the case of a flocked product manufactured by a conventional flocking method using an extra fine pile, the high wear strength required as an automobile interior material is obtained. Could not be achieved. In order to cope with this, for example, it was examined to increase the wear strength by increasing the density of the pile or applying a texture to the substrate. However, when the pile density is high, there is a problem that it becomes difficult to obtain a soft touch and the cost is high. In addition, although it is easy to obtain the required wear strength when the base material is provided with a texture, there is a problem that the difference in the degree of wear between the protruding portion and the retracted portion is likely to cause unevenness and the appearance is deteriorated. It was.

  An object of the present invention is to provide a flocking product for an automobile interior that can solve the above-described problems, that is, has a soft touch and has high wear strength and product stability.

  As a result of intensive studies to solve the above-mentioned problems, the inventors of the present invention have a thickness of 0.1 to 0.1 treated with an electrodeposition treatment agent and a smoothing agent containing synthetic tannin and an inorganic silicon compound on a base material. When a pile having a length of 0.9 dT and a length of 0.1 to 0.6 mm is planted by fiber coating, the dynamic friction coefficient of the obtained hair transplant product is less than the pile thickness (dT value) /2+0.7 and / or the static friction coefficient. When the thickness of the pile (dT value) /2+0.9 or less was found, the flocked product had a soft tactile sensation and exhibited high wear strength and product stability, thereby completing the present invention.

That is, the present invention
The adhesive layer of the base material was treated with an electrodeposition treatment containing synthetic tannin and colloidal silica and an alkyl sulfate as a smoothing agent. The thickness was 0.1 to 0.55 dT, and the length was 0.1 to 0.00. This is a method for producing a flocked product for automobile interiors by filing a 6 mm nylon fiber pile at a spraying amount of 30 g / min to 60 g / min by fiber coating by electrostatic spraying using an electrostatic spray gun. The dynamic friction coefficient of the flocked product is related to a pile thickness (dT value) /2+0.7 or less and / or a static friction coefficient is a pile thickness (dT value) /2+0.9 or less.

  The present invention has a soft tactile sensation as well as high wear strength and product stability as long as it can be manufactured so that the dynamic friction coefficient and static friction coefficient of the flocked product are within a specific range. It has been found for the first time that it is a flocking product having the above, and this makes it possible to provide an excellent flocking product for automobile interiors.

  The material used for the flocked product of the present invention may be ABS resin, polyolefin, synthetic resin such as polypropylene (PP) or polyethylene (PE), wood, woven fabric or the like. In addition, a recycled product that has been attracting attention in recent years, mainly a recycled polypropylene product, can also be used as a base material. The base material may be formed into a required shape.

  The above-mentioned base material can be used as an automobile interior member as an automobile door trim, pillar cover, trunk side, trunk rear, seat back panel, seat rear panel, rear parcel, headlining, console box, instrument panel, etc. It is particularly suitable for use in pillar covers, console boxes and the like.

An adhesive layer is formed on the surface of the substrate before planting the pile on the substrate.
Examples of the adhesive used for forming the adhesive layer include adhesives based on highly concealing paints such as epoxy, melamine, acrylic, polyester, urethane, and chlorinated polyolefin. The adhesive is selected from various resins as a vehicle in consideration of elongation, softness, adhesion, light resistance, curability, etc., and suitable for the intended planned adhesive performance. The solvent for the adhesive may be selected from those that dissolve well the resin selected as the vehicle, for example, aromatic, aliphatic, ester, and ketone. In addition to the vehicle and solvent described above, a colorant, a drying agent, a color separation preventing agent, a thickening agent, a flattening agent, an anti-sagging agent, an ultraviolet absorber, a curing agent, and the like can be arbitrarily selected as the adhesive. Can be used.

  Also, when using an adhesive containing a flexible component, the adhesive itself has softness and great elasticity, and the pile is implanted into the flexible adhesive layer, so the processed surface coated with the pile is soft, You can get an excellent tactile feel like suede. Such an adhesive is, for example, a urethane-based or polyol-modified chlorinated polyolefin-based adhesive. For example, as the urethane-based adhesive, an acrylic-modified urethane-based, polyester-modified urethane-based, silicon-modified urethane-based adhesive, or the like can be used. Yet another advantage of using a urethane-based adhesive is that the resulting processed surface has excellent wear resistance, solvent resistance and light resistance, and is less susceptible to scratching. Among these, it is considered that the wear resistance is improved because the pile is hard to come off against friction because the adhesive has softness and great elasticity. The thickness of the adhesive layer is usually 10 to 100 μm, preferably 20 to 30 μm in a dry state. The method for forming the adhesive layer is appropriately selected from brush coating, flow coating, roll coating, spray coating, and the like.

  The material of the pile used in the flocked product of the present invention may be natural, regenerated (semi-synthetic) or synthetic fiber. Preferred pile materials include aromatic polyamide fibers (trade names Kevlar, Nomex, Conex, etc.), other polyamide fibers (6-nylon, 6-6 nylon, 4,6-nylon, etc.), regular polyester fibers, basic Examples thereof include dye-dyeable polyester fiber, acrylic fiber, vinylon fiber, regenerated cellulose fiber (rayon), wool fiber, cotton fiber, hemp fiber, polyolefin fiber, collagen fiber, ceramic fiber, carbon fiber, and potassium titanate fiber. Particularly preferred among them are polyester fibers and polyamide fibers.

Moreover, the pile to be used for flocking article of the present invention, soft microfine pile for tactile is used, its size is 0.1 thickness to 0.55 dT (dtex), from 0.1 to zero length. 6 mm.

The pile used for the hair transplant product of the present invention is treated with an electrodeposition treatment agent and a smoothing agent before hair transplantation.
As this electrodeposition treatment, the surface of the cut short fiber is treated with a tannin compound, tartar, etc. to produce a tannin compound or the like on the fiber surface, thereby utilizing the water retention of the tannin compound or the like. , A method of maintaining good electrical conductivity on the surface of the flock, an inorganic salt, an inorganic silicon compound, a surfactant or a mixture thereof is attached to the surface of the cut short fiber, thereby utilizing their crystal water, There are two methods of maintaining good electrical conductivity on the flock surface, and there is also a method of simultaneously using the two methods.
In the present invention, the above two methods are used simultaneously.

Examples of the tannin compound include natural tannin and synthetic tannin. Inorganic salts include sodium chloride (NaCl), barium chloride (BaCl ₂ ), magnesium chloride (MgCl ₂ ), magnesium sulfate (MgSO ₄ ), sodium silicate (Na ₂ SiO ₃ ), sodium carbonate (Na ₂ CO ₃ ), Examples thereof include sodium sulfate (Na ₂ SO ₄ ). Colloidal silica etc. are mentioned as an inorganic silicon compound. Furthermore, examples of the surfactant include an anionic surfactant, a nonionic surfactant, an amphoteric surfactant, and a cationic surfactant.
Examples of the electrodeposition treatment agent include an electrodeposition treatment agent containing a tannin compound and an inorganic silicon compound, and an electrodeposition treatment agent containing a synthetic tannin and an inorganic silicon compound. Also, synthetic tannin and colloidal silica can be used. The electrodeposition processing agent to contain is mentioned.
The treatment with the electrodeposition treatment agent can be performed by immersing the pile in a tannin compound, an inorganic salt, a surfactant or an inorganic silicon compound solution, or a mixed solution thereof. In addition, the thickness of the electrodeposition treatment film formed by the treatment is basically arbitrary as long as the required conductivity and appropriate separability are exhibited.

In addition to the electrodeposition treatment, the pile used for the flocked product of the present invention is treated with a smoothing agent in order to keep the dynamic friction coefficient and the static friction coefficient low. Examples of the smoothing agent include paraffin-based, silicon-based, wax-based, and alkyl sulfate, and preferably include alkyl sulfate.
The alkyl sulfate preferably includes a monoalkyl sulfate having 12 to 18 carbon atoms or a mixture thereof. As the salt, sodium salt, potassium salt, ammonium salt and the like are preferable, and sodium salt is preferable.

The pile used in the present invention preferably has an electric leakage resistance value of 10 ⁶ Ω / cm to 10 ⁹ Ω / cm. By using a pile with an electric leakage resistance value in this range, when the pile is sprayed with an electrostatic spray gun, etc., the pile can be dispersed and sprayed appropriately without agglomeration, and the feel and texture of the flocked product is better. It becomes a thing.
Further, the pile may have a linear shape, but may be a curved shape, for example, a crimped or curled shape by crimping short fibers.

The pile planting is performed by fiber coating, and the fiber coating is not particularly limited as long as it is a method of planting the pile by spraying, and any of normal spraying without applying voltage and electrostatic spraying with applying voltage can be used. Including.
A preferred method for flocking is electrostatic spraying.

The fiber coating can transfer the pile to the charging chamber in the spray gun with air pressure, charge the pile, and then spray it from the gun outlet to the paint surface of the substrate with air pressure. Are used as appropriate. The spray gun is used with the carrier air pressure set larger than the spray pressure. As a result, the pile can be sprayed smoothly and uniformly without interruption.
In the case of electrostatic spraying, for example, it is achieved by performing the above operation using an electrostatic spray gun.

  The time from the formation of the adhesive layer on the substrate surface to the spraying of the pile by the spray gun is preferably set within 3 minutes. The time until the spraying of the pile after the formation of the adhesive layer is not completely cured, the adhesive on the surface of the base material fully exerts the fixing action of the pile, and further considers the production efficiency of the flocked product This is the value set. In particular, when using a conveyor type flocking device, the adhesive layer formation process and the pile spraying process are separated and separate processes, so the time until the pile spraying after the adhesive layer is formed is managed. It is important to spray the pile within 3 minutes after the formation of the adhesive layer, in order to obtain a flocked product with a good feel and texture with high production efficiency.

  Furthermore, the spraying of the pile is preferably performed in an amount of 30 to 60 g / min. When the pile is sprayed onto the adhesive layer on the substrate in an amount within this range, the dispersion of the pile can be made moderate and the pile can be sprayed on the surface of the substrate efficiently. In particular, in the conveyor type flocking apparatus, since the base material is sequentially sent from the adhesive layer forming process to the pile spraying process, setting the amount of pile sprayed per unit time from the viewpoint of the production efficiency of the flocked product Is important.

In the fiber coating method, for example, the pile is discharged by a screw feeder provided at the lower part of the stored pile tank, sent to an injector connected to the discharge port, and air is supplied from the injector to the charging chamber of the electrostatic spray gun. The gun is transported, charged in the heating chamber, and sprayed onto the surface of the base material having an adhesive layer on the surface from the spraying port of the gun by the transporting air and the spraying air introduced into the charging chamber.

The static friction coefficient of the flocked product produced by the above method is usually a pile thickness (dT value) /2+0.9 or less, preferably a pile thickness (dT value) /2+0.87 or less, and the dynamic friction coefficient is Usually, the pile thickness (dT value) /2+0.7 or less, preferably the pile thickness (dT value) /2+0.65 or less.
The above-mentioned static friction coefficient and dynamic friction coefficient mean values determined by plastic friction tests according to JIS K7125: 1999.

In the following examples , reference examples and comparative examples, the present invention will be described specifically and in detail. The following examples are for illustrative purposes only and are not intended to limit the technical scope of the present invention.
Reference example 1
The pile was obtained by treating nylon fiber having a thickness of 0.88 dT and a length of 0.6 mm with an electrodeposition treatment agent and a smoothing agent (Softifloc Ajinomoto Omnichem Co., Ltd.) containing synthetic tannin and colloidal silica. Using.
As a base material, a PP sheet (4 points) of 15 cm × 20 cm was used. After applying an adhesive (AA-99) on the base material, a pile was applied to the adhesive layer of the base material with an electrostatic spray gun (Nordson The spraying amount was 30 g / min to 60 g / min. At this time, four flocked articles each having a basis weight of 35 g / m ² , 40 g / m ² and 45 g / m ² were prepared.
The voltage at that time is 50 KV (50,000 volts), and the paint surface of the substrate is grounded. Also, the conveying air pressure of the electrostatic spraying gun is set to 4 kg / cm ² , the spraying air pressure is set to 1 kg / cm ² , and the pile is transported to the charging chamber in the electrostatic spraying gun by the conveying air pressure, and the pile is removed. After being charged, it was sprayed on the surface of the coating material of the substrate by the air pressure of the electrostatic spray gun. Then, it was left to dry at room temperature for 2 days.
The obtained flocked product was used for measuring the frictional force.
An electron micrograph of the obtained flocked product is shown in FIG.

Comparative Example 1
A flocked article was produced in the same manner as in Reference Example 1 except that colloidal silica was not added to the electrodeposition treatment agent. As in Reference Example 1, four flocked articles each having a basis weight of 35 g / m ² , 40 g / m ² and 45 g / m ² were prepared.
In addition, the electron micrograph of the obtained flocked product was shown in FIG.

Reference example 2
A flocked product was produced in the same manner as in Reference Example 1 except that nylon fiber having a thickness of 0.88 dT and a length of 0.4 mm was used as the pile. As in Reference Example 1, four flocked articles each having a basis weight of 35 g / m ² , 40 g / m ² and 45 g / m ² were prepared.

Comparative Example 2
A flocked article was produced in the same manner as in Reference Example 2 except that colloidal silica was not added to the electrodeposition treatment agent. In the same manner as in Reference Example 2, four flocked articles each having a basis weight of 35 g / m ² , 40 g / m ² and 45 g / m ² were prepared.

Example 1
A flocked product was produced in the same manner as in Reference Example 1 except that nylon fiber having a thickness of 0.55 dT and a length of 0.4 mm was used as the pile. In addition, the flocked products with a basis weight of 25 g / m ² , 30 g / m ^2, and 35 g / m ² were prepared for each four points.

Comparative Example 3
A flocked article was produced in the same manner as in Example 1 except that colloidal silica was not added to the electrodeposition treatment agent. In the same manner as in Example 1 , four flocked articles each having a basis weight of 25 g / m ² , 30 g / m ² and 35 g / m ² were prepared.

Comparative Example 4
A flocked article was produced in the same manner as in Reference Example 1 except that nylon fiber having a thickness of 1.7 dT and a length of 0.6 mm was used as the pile, and no colloidal silica was added to the electrodeposition treatment agent. In addition, the flocked products with a basis weight of 35 g / m ² , 45 g / m ^2, and 55 g / m ² were prepared for each four points.

Test example
Reference Examples 1 and 2, to determine the friction force using the Example 1 and Comparative Example 1 to flocked articles manufactured by 4 (each 4 for each basis weight) (static friction and dynamic friction), static friction The coefficient and the dynamic friction coefficient were calculated.
The measurement was performed by the following test method according to JIS K 7125: 1999.
Using a constant speed extension type tensile tester, load: 432 g, speed: 16 cm / min, friction measurement facing: Kanakin No. 3 was used, and an average value of 4 points was obtained.
The measurement results are shown in Table 1.
The abrasion test was rubbed 1000 times and 2000 times with a load of 500 g, and the surface abrasion state was evaluated.
The evaluation criteria were as follows.
4th grade: Pile omission and almost no pile breakage 3rd grade: Pile omission and pile breakage are somewhat noticeable but 2nd grade: Pile omission and pile breakage are remarkable
Results As shown in Comparative Example 4, when a thick pile (1.7 dT) was used, a third grade evaluation was obtained only by treating the pile with synthetic tannin and a smoothing agent.
However, as in Comparative Examples 1 and 2 (0.88 dT) and Comparative Example 3 (0.55 dT), if the pile is thinned, only a second grade evaluation can be obtained by simply treating the pile with synthetic tannin and a smoothing agent. There wasn't.
When treated with an electrodeposition treating agent and a smoothing agent containing synthetic tannin and colloidal silica as in Example 1, a third grade evaluation was obtained even when a thin pile was used.
At this time, the dynamic friction coefficient in the flocked product of Example 1 is equal to or less than the pile thickness (dT value) /2+0.7, and the static friction coefficient is equal to the pile thickness (dT value) /2+0.9. It was as follows.

It is an electron micrograph which shows the state of the pile surface of the flocked product obtained in Example 1. FIG. It is an electron micrograph which shows the state of the pile surface of the flocked product obtained in Comparative Example 1.

Claims (1)

The adhesive layer of the base material was treated with an electrodeposition treatment containing synthetic tannin and colloidal silica and an alkyl sulfate as a smoothing agent. The thickness was 0.1 to 0.55 dT, and the length was 0.1 to 0.00. This is a method for producing a flocked product for automobile interiors by filing a 6 mm nylon fiber pile at a spraying amount of 30 g / min to 60 g / min by fiber coating by electrostatic spraying using an electrostatic spray gun. The dynamic friction coefficient of the flocked product is a pile thickness (dT value) /2+0.7 or less and / or the static friction coefficient is a pile thickness (dT value) /2+0.9 or less.