JP6845551B2 - Molded product and its manufacturing method - Google Patents
Molded product and its manufacturing method Download PDFInfo
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- JP6845551B2 JP6845551B2 JP2016168472A JP2016168472A JP6845551B2 JP 6845551 B2 JP6845551 B2 JP 6845551B2 JP 2016168472 A JP2016168472 A JP 2016168472A JP 2016168472 A JP2016168472 A JP 2016168472A JP 6845551 B2 JP6845551 B2 JP 6845551B2
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- 238000004519 manufacturing process Methods 0.000 title claims description 14
- 239000002759 woven fabric Substances 0.000 claims description 129
- 239000004744 fabric Substances 0.000 claims description 73
- 239000004745 nonwoven fabric Substances 0.000 claims description 68
- 229920005992 thermoplastic resin Polymers 0.000 claims description 61
- 238000010438 heat treatment Methods 0.000 claims description 20
- 235000019646 color tone Nutrition 0.000 claims description 15
- 238000005520 cutting process Methods 0.000 claims description 15
- 238000001816 cooling Methods 0.000 claims description 14
- 239000003086 colorant Substances 0.000 claims description 11
- 238000000034 method Methods 0.000 claims description 11
- 238000010030 laminating Methods 0.000 claims description 6
- 229920003043 Cellulose fiber Polymers 0.000 claims description 5
- 239000000835 fiber Substances 0.000 description 20
- 238000002844 melting Methods 0.000 description 18
- 230000008018 melting Effects 0.000 description 18
- 239000000463 material Substances 0.000 description 11
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 10
- 230000009477 glass transition Effects 0.000 description 7
- 229920001684 low density polyethylene Polymers 0.000 description 7
- 239000004702 low-density polyethylene Substances 0.000 description 7
- 229920002994 synthetic fiber Polymers 0.000 description 7
- 239000012209 synthetic fiber Substances 0.000 description 7
- -1 Polyethylene Polymers 0.000 description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 6
- 239000004698 Polyethylene Substances 0.000 description 5
- 229910052742 iron Inorganic materials 0.000 description 5
- 238000005498 polishing Methods 0.000 description 5
- 229920000573 polyethylene Polymers 0.000 description 5
- 238000003825 pressing Methods 0.000 description 5
- 229920000728 polyester Polymers 0.000 description 4
- 229920000742 Cotton Polymers 0.000 description 3
- 239000004677 Nylon Substances 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 238000004043 dyeing Methods 0.000 description 3
- 229920001778 nylon Polymers 0.000 description 3
- 229920000098 polyolefin Polymers 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000000227 grinding Methods 0.000 description 2
- 239000000123 paper Substances 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 210000002268 wool Anatomy 0.000 description 2
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 239000004925 Acrylic resin Substances 0.000 description 1
- 244000025254 Cannabis sativa Species 0.000 description 1
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 description 1
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 description 1
- 229920010126 Linear Low Density Polyethylene (LLDPE) Polymers 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 229920000297 Rayon Polymers 0.000 description 1
- 229920002978 Vinylon Polymers 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 235000009120 camo Nutrition 0.000 description 1
- 235000005607 chanvre indien Nutrition 0.000 description 1
- 238000004040 coloring Methods 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000011487 hemp Substances 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 239000010985 leather Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000000088 plastic resin Substances 0.000 description 1
- 238000007517 polishing process Methods 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000002964 rayon Substances 0.000 description 1
- 238000009958 sewing Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Manufacturing Of Multi-Layer Textile Fabrics (AREA)
Description
本発明は、織布、編地又は不織布が積層されて熱可塑性樹脂で接着されてなる、意匠性に優れた成形品及びその製造方法に関する。 The present invention relates to a molded product having excellent design and a method for producing the same, which is obtained by laminating a woven fabric, a knitted fabric or a non-woven fabric and adhering them with a thermoplastic resin.
インテリア製品、文具、装飾用小物などの素材としては、織布、編地、不織布、木材、紙、皮革、ガラス、金属、プラスチックなど、様々なものが用途に応じて使い分けられているが、近年では、デザインの多様化に伴い、これまでにない意匠性や質感を有する新たな素材が求められている。 As materials for interior products, stationery, decorative accessories , etc., various materials such as woven fabric, knitted fabric , non-woven fabric, wood, paper, leather, glass, metal, and plastic are used according to the purpose, but in recent years. With the diversification of designs, new materials with unprecedented design and texture are required.
従来から用いられている上記素材の中でも織布、編地及び不織布は、多様な色彩表現が可能であるとともに、優しい質感を有することから、カーテン、絨毯、壁紙、ソファー生地などのインテリア製品をはじめ、文具や装飾用小物などにも広く用いられている。織布、編地及び不織布は柔軟であることから、柔軟性が要求される用途に採用されることがほとんどである。 Among the above-mentioned materials that have been used conventionally, woven fabrics, knitted fabrics, and non-woven fabrics are capable of expressing various colors and have a gentle texture, so they include interior products such as curtains, rugs, wallpaper, and sofa fabrics. , Widely used for stationery and decorative accessories. Since woven fabrics, knitted fabrics and non-woven fabrics are flexible, they are mostly used in applications that require flexibility.
一方、薄手の織布、編地又は不織布を複数枚重ねて厚地の積層体にすることは広く行われている。その際、接着剤を用いて積層することも知られている。特許文献１には、接着剤を染み込ませた織物を重ね合わせて板状の成形物を形成し、その後圧縮乾燥させて得られる織物成形品が記載されていて、建材などの代わりに利用できるとされている。しかしながら、接着剤の乾燥に時間がかかるし、その意匠性については何ら記載されていない。 On the other hand, it is widely practiced to stack a plurality of thin woven fabrics, knitted fabrics or non-woven fabrics to form a thick laminated body. At that time, it is also known to laminate using an adhesive. Patent Document 1 describes a woven fabric molded product obtained by superimposing woven fabrics impregnated with an adhesive to form a plate-shaped molded product and then compressing and drying it, and it can be used instead of a building material or the like. Has been done. However, it takes time to dry the adhesive, and there is no description about its design.
近年、デザインの多様化に対応するために、これまでにない意匠性や質感を有する新たな素材を提供することが求められている。 In recent years, in order to respond to the diversification of designs, it has been required to provide new materials having unprecedented design and texture.
上記課題は、色調の異なる５枚以上の織布が積層されて熱可塑性樹脂で接着されてなる成形品であって、該成形品の切断面に縞模様が形成されていることを特徴とする成形品を提供することによって解決される。 The above object is a molded product obtained by laminating five or more woven fabrics having different color tones and adhering them with a thermoplastic resin, and is characterized in that a striped pattern is formed on the cut surface of the molded product. It is solved by providing an article.
このとき、前記切断面が曲面であることが好ましい。前記成形品中の前記織布が湾曲していることも好ましい。また、少なくとも一方の表面が織布で覆われていることも好ましい。 At this time , it is preferable that the cut surface is a curved surface. It is also preferable that the woven fabric in the molded product is curved. It is also preferable that at least one surface is covered with a woven fabric.
また、上記課題は、織布と熱可塑性樹脂フィルムを交互に重ねてから、加熱及び加圧することによって溶融した熱可塑性樹脂を織布中に含浸させ、次いで加圧しながら冷却することによって熱可塑性樹脂を固化させ、得られた固化物を切断して切断面を露出させることを特徴とする、前記成形品の製造方法を提供することによっても解決される。 Further, the above-mentioned problem is to impregnate the woven fabric with the melted thermoplastic resin by alternately stacking the woven fabric and the thermoplastic resin film, then heating and pressurizing the woven fabric, and then cooling the woven fabric while pressurizing the thermoplastic resin. It is also solved by providing a method for producing the molded product, which comprises solidifying the molded product and cutting the obtained solidified product to expose the cut surface.
このとき、曲面を有する型で加圧しながら冷却することによって固化させて、成形品中の織布を湾曲させることが好ましい。織布と熱可塑性樹脂フィルムを交互に重ねてから加熱及び加圧することによって溶融した熱可塑性樹脂を織布中に含浸させる操作を繰り返して、全体厚みを増大させた後に、加圧しながら冷却することによって熱可塑性樹脂を固化させることも好ましい。また、セルロース繊維を含む織布を用い、マイクロ波によって加熱することも好ましい。
また、上記課題は、色調の異なる５枚以上の織布、編地又は不織布が積層されて熱可塑性樹脂で接着されてなる成形品であって、該成形品の切断面が傾斜していて、該切断面に縞模様が形成されていることを特徴とする成形品を提供することによっても解決される。
さらに、上記課題は、色調の異なる５枚以上の織布、編地又は不織布が積層されて熱可塑性樹脂で接着されてなる成形品であって、該成形品の切断面に縞模様が形成されている成形品の製造方法であって；織布、編地又は不織布と熱可塑性樹脂フィルムを交互に重ねてから、加熱及び加圧することによって溶融した熱可塑性樹脂を織布、編地又は不織布中に含浸させ、次いで加圧しながら冷却することによって熱可塑性樹脂を固化させ、得られた固化物を切断して切断面を露出させた後に、該切断面を研磨することを特徴とする、成形品の製造方法を提供することによっても解決される。
At this time , it is preferable to bend the woven fabric in the molded product by solidifying it by cooling it while applying pressure in a mold having a curved surface. The operation of impregnating the woven fabric with the molten thermoplastic resin by alternately stacking the woven fabric and the thermoplastic resin film and then heating and pressurizing the woven fabric is repeated to increase the overall thickness, and then the woven fabric is cooled while being pressurized. It is also preferable to solidify the thermoplastic resin by. It is also preferable to use a woven fabric containing cellulose fibers and heat it by microwaves.
Further, the above-mentioned problem is a molded product obtained by laminating five or more woven fabrics, knitted fabrics or non-woven fabrics having different colors and adhering them with a thermoplastic resin, and the cut surface of the molded product is inclined. It is also solved by providing a molded product characterized in that a striped pattern is formed on the cut surface.
Further, the above-mentioned problem is a molded product in which five or more woven fabrics, knitted fabrics or non-woven fabrics having different colors are laminated and bonded with a thermoplastic resin, and a striped pattern is formed on the cut surface of the molded product. A method for producing a molded product; the thermoplastic resin melted by alternately stacking a woven fabric, a knitted fabric or a non-woven fabric and a thermoplastic resin film, and then heating and pressurizing the thermoplastic resin in the woven fabric, the knitted fabric or the non-woven fabric The thermoplastic resin is solidified by impregnating the resin with pressure and then cooling while pressurizing, and the obtained solidified product is cut to expose the cut surface, and then the cut surface is polished. It is also solved by providing the manufacturing method of.
本発明の成形品は、これまでにない意匠性や質感を有するので、インテリア製品、文具、装飾用小物などの分野に新たな素材を提供することができる。また、本発明の製造方法によれば、様々なデザイン上の要請に応えて、意匠性に優れた成形品を製造することができる。 Since the molded product of the present invention has an unprecedented design and texture, it is possible to provide a new material in the fields of interior products, stationery, decorative accessories and the like. Further, according to the manufacturing method of the present invention, it is possible to manufacture a molded product having excellent design in response to various design demands.
本発明の成形品は、色調の異なる５枚以上の織布、編地又は不織布が積層されて熱可塑性樹脂で接着されてなる成形品である。 The molded product of the present invention is a molded product obtained by laminating five or more woven fabrics, knitted fabrics or non-woven fabrics having different colors and adhering them with a thermoplastic resin.
本発明では、織布、編地、不織布のいずれを用いることもできる。なかでも、剛性に優れた高強度の成形品を得るためには織布を用いることが好ましい。織布、編地又は不織布の目付は特に限定されず、用途に応じて適宜選択されるが、通常５０〜１０００ｇ／ｍ２である。織布、編地又は不織布を構成する繊維素材も特に限定されず、ポリエステル、ナイロン、アクリル、ビニロンなどの合成繊維、レーヨン、アセテートなどの半合成繊維、綿、麻、羊毛、絹などの天然繊維などを用いることができる。複数種類の繊維を含む織布、編地又は不織布を用いてもよい。また、異なる繊維を含む織布、編地又は不織布を複数種用いて、それらを重ねて積層体を得てもよい。 In the present invention, a woven fabric, knitted fabric, can be formed using either a non-woven fabric. Above all, it is preferable to use a woven fabric in order to obtain a high-strength molded product having excellent rigidity. The basis weight of the woven fabric, knitted fabric or non-woven fabric is not particularly limited and is appropriately selected depending on the intended use, but is usually 50 to 1000 g / m 2 . The fiber material constituting the woven fabric, knitted fabric or non-woven fabric is not particularly limited, and synthetic fibers such as polyester, nylon, acrylic and vinylon, semi-synthetic fibers such as rayon and acetate, and natural fibers such as cotton, linen, wool and silk. Etc. can be used. Woven fabrics, knitted fabrics or non-woven fabrics containing a plurality of types of fibers may be used. Further, a plurality of types of woven fabrics, knitted fabrics or non-woven fabrics containing different fibers may be used and laminated to obtain a laminate.
合成繊維を用いる場合には、その融点又は軟化点が、接着に用いられる熱可塑性樹脂の融点又はガラス転移点よりも高いことが必要である。具体的には、合成繊維の融点又は軟化点は２００℃以上であることが好ましく、２３０℃以上であることがより好ましい。ここで、合成繊維が明確な融点を持っている場合には融点が、そうでない場合には軟化点が上記条件を満足していればよい。合成繊維の中でも、高融点かつ高強度であることから、ポリエステルが好ましく使用される。 When synthetic fibers are used, their melting points or softening points need to be higher than the melting points or glass transition points of the thermoplastic resins used for adhesion. Specifically, the melting point or softening point of the synthetic fiber is preferably 200 ° C. or higher, and more preferably 230 ° C. or higher. Here, if the synthetic fiber has a definite melting point, the melting point may be satisfied, and if not, the softening point may satisfy the above conditions. Among synthetic fibers, polyester is preferably used because of its high melting point and high strength.
天然繊維や半合成繊維の場合には、通常、２３０℃未満では軟化しないので、本発明に好ましく用いられる。多くの場合、これらの繊維はさらに高温に加熱することによって分解する。なかでも、綿、麻などのセルロース繊維は、繊維が水分を含んでいて耐熱性が良好であることから、マイクロ波で加熱する場合に好適に用いられる。 In the case of natural fibers and semi-synthetic fibers, they usually do not soften below 230 ° C., and are therefore preferably used in the present invention. In many cases, these fibers are decomposed by heating to a higher temperature. Among them, cellulose fibers such as cotton and hemp are preferably used when heating with microwaves because the fibers contain water and have good heat resistance.
本発明で用いられる織布、編地又は不織布としては、新品の良品を用いても構わないが、規格外品やリサイクル品を用いることが、コスト面から好ましい。規格外品としては、染色後の織布、編地又は不織布の色彩が製品規格から外れたもの、製織時に欠陥を生じたもの、製品取り扱い時に破損や汚損したものなどが挙げられる。また、リサイクル品としては、縫製加工に供されなかった在庫品の織布、編地又は不織布、裁断時の余り布、縫製加工後の在庫品、消費者の使用後のリサイクル品などが挙げられる。本発明の成形品においては、表面の１枚の織布、編地又は不織布を除けば、切断面以外では織布、編地又は不織布が外観に現れないので、様々な規格外品やリサイクル品を問題なく用いることができる。規格外品やリサイクル品を用いることで廃棄品を減らすことができるので、環境に優しい成形品であるといえる。 As the woven fabric, knitted fabric or non-woven fabric used in the present invention, a new non-defective product may be used, but it is preferable to use a non-standard product or a recycled product from the viewpoint of cost. Examples of non-standard products include those in which the color of the dyed woven fabric, knitted fabric or non-woven fabric deviates from the product standard, those in which defects occur during weaving, and those in which the product is damaged or soiled during handling. In addition, examples of recycled products include woven fabrics, knitted fabrics or non-woven fabrics , surplus fabrics at the time of cutting, in-stock products after sewing, and recycled products after use by consumers. .. In the molded product of the present invention, except for one woven fabric, knitted fabric or non-woven fabric on the surface, the woven fabric, knitted fabric or non-woven fabric does not appear on the appearance other than the cut surface. Can be used without problems. By using non-standard products and recycled products, waste products can be reduced, so it can be said that it is an environmentally friendly molded product.
本発明の成形品においては、色調の異なる５枚以上の織布、編地又は不織布が積層されていなければならない。織布、編地又は不織布を５枚以上積層して熱可塑性樹脂で接着することによって、剛性に優れた成形品を得ることができるとともに、切断面の意匠性に優れた成形品を得ることができる。積層される織布、編地又は不織布の枚数は、好適には１０枚以上であり、より好適には２０枚以上である。積層される織布、編地又は不織布の枚数の上限は特に限定されないが、生産性などを考慮すれば、通常１０００枚以下である。ここで、「色調の異なる」とは、全部の織布、編地又は不織布が同じ色調ではない、ということである。色調の異なる織布、編地又は不織布をランダムに配置してもよいし、規則正しく配置してもよい。目指すデザインの縞模様が切断面に形成されるように色調の異なる織布、編地又は不織布を積み重ねればよい。豊かな色彩表現のためには、３色以上の織布、編地又は不織布を使用することが好ましく、４色以上の織布、編地又は不織布を使用することがより好ましい。 In the molded product of the present invention, five or more woven fabrics, knitted fabrics or non-woven fabrics having different color tones must be laminated. By laminating five or more woven fabrics, knitted fabrics or non-woven fabrics and adhering them with a thermoplastic resin, it is possible to obtain a molded product having excellent rigidity and a molded product having excellent design of the cut surface. it can. The number of woven fabrics, knitted fabrics or non-woven fabrics to be laminated is preferably 10 or more, and more preferably 20 or more. The upper limit of the number of woven fabrics, knitted fabrics or non-woven fabrics to be laminated is not particularly limited, but is usually 1000 or less in consideration of productivity and the like. Here, " different color tones " means that not all woven fabrics, knitted fabrics or non-woven fabrics have the same color tone. Woven fabrics, knitted fabrics or non-woven fabrics having different colors may be arranged randomly or regularly. Woven fabrics, knitted fabrics, or non-woven fabrics of different colors may be stacked so that a striped pattern of the desired design is formed on the cut surface. For rich color expression, it is preferable to use a woven fabric, knitted fabric or non-woven fabric of three or more colors, and it is more preferable to use a woven fabric, knitted fabric or non-woven fabric of four or more colors.
本発明の成形品の製造方法は特に限定されないが、織布、編地又は不織布と熱可塑性樹脂フィルムを交互に重ねてから、加熱及び加圧することによって溶融した熱可塑性樹脂を織布、編地又は不織布中に含浸させ、次いで加圧しながら冷却することによって熱可塑性樹脂を固化させる方法が好ましい。こうすることによって織布、編地又は不織布中の繊維集合体に熱可塑性樹脂が含浸され、織布、編地又は不織布同士が強固に接着される。 The method for producing the molded product of the present invention is not particularly limited, but the woven fabric, knitted fabric or non-woven fabric and the thermoplastic resin film are alternately laminated, and then the molten thermoplastic resin is woven or knitted by heating and pressurizing. Alternatively, a method of solidifying the thermoplastic resin by impregnating the non-woven fabric and then cooling while pressurizing is preferable. Woven by so doing, the thermoplastic resin is impregnated into the fiber aggregate of the knitted fabric or nonwoven fabric, woven fabric, is knitted or non-woven with each other are firmly bonded.
織布、編地又は不織布と重ねられる熱可塑性樹脂フィルムは、織布、編地又は不織布に含まれる繊維の融点あるいは軟化点よりも低い融点又はガラス転移点を有する。ここで、熱可塑性樹脂フィルムが明確な融点を持っている場合には融点が、そうでない場合にはガラス転移点が上記条件を満足していればよい。加熱及び加圧する際に繊維の強度を低下させないためには、熱可塑性樹脂フィルムの融点又はガラス転移点が、織布、編地又は不織布に含まれる繊維の融点又は軟化点よりも、４０℃以上低いことが好ましく、８０℃以上低いことがより好ましい。フィルムに含まれる熱可塑性樹脂の融点又はガラス転移点は、６０〜１８０℃であることが好ましく、８０〜１６０℃であることがより好ましい。熱可塑性樹脂の融点又はガラス転移点が上記範囲に含まれることによって、繊維強度の低下を抑制しながら織布、編地又は不織布を接着することができるとともに、成形品の耐熱性を確保することができる。 The thermoplastic resin film layered on the woven fabric, knitted fabric or non-woven fabric has a melting point or glass transition point lower than the melting point or softening point of the fibers contained in the woven fabric, knitted fabric or non-woven fabric. Here, if the thermoplastic resin film has a definite melting point, the melting point may be satisfied, and if not, the glass transition point may satisfy the above conditions. In order not to reduce the strength of the fiber during heating and pressurization, the melting point or glass transition point of the thermoplastic resin film is 40 ° C. or higher than the melting point or softening point of the fiber contained in the woven fabric, knitted fabric or non-woven fabric. It is preferably low, and more preferably 80 ° C. or higher. The melting point or glass transition point of the thermoplastic resin contained in the film is preferably 60 to 180 ° C, more preferably 80 to 160 ° C. By including the melting point or glass transition point of the thermoplastic resin in the above range, it is possible to bond the woven fabric, knitted fabric or non-woven fabric while suppressing the decrease in fiber strength, and to secure the heat resistance of the molded product. Can be done.
熱可塑性樹脂フィルムに用いられる熱可塑性樹脂としては、ポリオレフィン、ポリエステル、ナイロン、ポリカーボネート、アクリル樹脂、ポリ塩化ビニル、ポリスチレン、ＡＢＳ樹脂、ＡＳ樹脂などを用いることができる。なかでも、融点が比較的低くて安価なポリオレフィンが好適に用いられる。ポリオレフィンは、一般的に他の樹脂への接着性は良好ではないが、本発明では加熱及び加圧することによって溶融した熱可塑性樹脂を織布、編地又は不織布中の繊維集合体に含浸させているので、織布、編地又は不織布同士を十分に強固に接着することができる。ポリオレフィンとしては、低密度ポリエチレン、高密度ポリエチレンなどのポリエチレンや、ポリプロピレンを用いることができる。エチレン−プロピレン共重合体を用いることもできる。なかでも、融点が低くて安価であることから、低密度ポリエチレンが好適に用いられる。ここで、低密度ポリエチレンには、高圧法の低密度ポリエチレンだけでなく直鎖状低密度ポリエチレン（ＬＬＤＰＥ）も含まれる。 As the thermoplastic resin used for the thermoplastic resin film, polyolefin, polyester, nylon, polycarbonate, acrylic resin, polyvinyl chloride, polystyrene, ABS resin, AS resin and the like can be used. Of these, polyolefins having a relatively low melting point and low cost are preferably used. Polyethylene generally does not have good adhesiveness to other resins, but in the present invention, a thermoplastic resin melted by heating and pressurizing is impregnated into a fiber aggregate in a woven fabric, knitted fabric or non-woven fabric. Therefore, the woven fabric, the knitted fabric, or the non-woven fabric can be sufficiently firmly adhered to each other. As the polyolefin, polyethylene such as low-density polyethylene and high-density polyethylene, and polypropylene can be used. Ethylene-propylene copolymer can also be used. Among them, low-density polyethylene is preferably used because it has a low melting point and is inexpensive. Here, the low-density polyethylene includes not only low-density polyethylene produced by the high-pressure method but also linear low-density polyethylene (LLDPE).
織布、編地又は不織布の間に配置される熱可塑性樹脂フィルムの厚さは特に限定されず、通常１０〜５００μｍであり、好適には２０〜３００μｍである。フィルムの厚さは、重ねられる織布、編地又は不織布の目付や厚さなどに応じて調整される。織布、編地又は不織布と織布、編地又は不織布との間に挟まれるフィルムは１枚だけであってもよく、複数枚であってもよい。複数枚のフィルムからなる場合には、合計の厚さが上記厚さの範囲に含まれていればよい。 The thickness of the thermoplastic resin film arranged between the woven fabric, the knitted fabric or the non-woven fabric is not particularly limited, and is usually 10 to 500 μm, preferably 20 to 300 μm. The thickness of the film is adjusted according to the basis weight and thickness of the woven fabric, knitted fabric or non-woven fabric to be stacked. The number of films sandwiched between the woven fabric, knitted fabric or non-woven fabric and the woven fabric, knitted fabric or non-woven fabric may be only one, or may be multiple. In the case of a plurality of films, the total thickness may be included in the above-mentioned thickness range.
織布、編地又は不織布と熱可塑性樹脂フィルムを交互に重ねてから、加熱及び加圧することによって溶融した熱可塑性樹脂を織布、編地又は不織布中に含浸させる。加圧方法は特に限定されないが、プレス装置などを用いて加圧することができる。プレス装置などにおいて加熱しながら加圧してもよいし、あらかじめ加熱した積層体を、プレス装置などで加圧してもかまわない。この時の加熱温度は、熱可塑性樹脂フィルムの融点又はガラス転移点よりも高く、織布、編地又は不織布に含まれる繊維の融点又は軟化点よりも低い温度とする。次いで、加圧しながら冷却することによって熱可塑性樹脂を固化させる。溶融した熱可塑性樹脂を加圧下で固化させることによって、溶融した熱可塑性樹脂が織布、編地又は不織布中の繊維の隙間に十分に含浸された状態で固化して織布、編地又は不織布同士が強固に接着される。積層体に加える圧力は、成形品の用途に応じて適宜調整すればよく、切削加工で剥がれない程度に接着させるだけであれば、０．５Ｎ／ｃｍ２以上の圧力であればよい。本発明者は、１Ｎ／ｃｍ２の圧力でも接着可能であることを確認している。より強固に接着させるためには、プレス圧力が５Ｎ／ｃｍ２以上であることが好ましく、１０Ｎ／ｃｍ２以上であることがより好ましい。プレス圧力の上限値は特に限定されないが装置やエネルギーのコストなどを考慮すれば、１００００Ｎ／ｃｍ２以下とすることが現実的である。 The woven fabric, knitted fabric or non-woven fabric and the thermoplastic resin film are alternately layered, and then the woven fabric, knitted fabric or non-woven fabric is impregnated with the melted thermoplastic resin by heating and pressurizing. The pressurizing method is not particularly limited, but pressurization can be performed using a press device or the like. Pressurization may be performed while heating in a press device or the like, or a preheated laminate may be pressurized in a press device or the like. The heating temperature at this time is higher than the melting point or glass transition point of the thermoplastic resin film and lower than the melting point or softening point of the fibers contained in the woven fabric, knitted fabric or non-woven fabric. Then, the thermoplastic resin is solidified by cooling while pressurizing. By solidifying the molten thermoplastic resin under pressure, woven solidified in a state in which molten thermoplastic resin is woven, it is sufficiently impregnated in gaps of fibers of the knitted fabric or nonwoven fabric, knitted or non-woven fabric They are firmly bonded to each other. The pressure applied to the laminate may be appropriately adjusted according to the intended use of the molded product, and may be 0.5 N / cm 2 or more as long as it is only adhered to the extent that it does not peel off by cutting. The present inventor has confirmed that adhesion is possible even at a pressure of 1 N / cm 2. To more firmly adhered is preferably pressing pressure is 5N / cm 2 or more, more preferably 10 N / cm 2 or more. The upper limit of the press pressure is not particularly limited, but it is realistic to set it to 10,000 N / cm 2 or less in consideration of the cost of equipment and energy.
熱プレス装置を用いる場合、加熱と同時に加圧することによって、溶融した熱可塑性樹脂を織布、編地又は不織布中に含浸させることができる。熱プレス装置を用いて加熱する場合には、熱盤からの伝熱によって積層体を加熱しなければならないが、織布、編地又は不織布は内部に空気を含んでいるために伝熱係数が小さい。したがって、成形品の厚みが大きい場合には、中心部の熱可塑性樹脂フィルムを溶融させるのに長時間を要することになる。このような場合には、少ない枚数の織布、編地又は不織布と熱可塑性樹脂フィルムを交互に重ねてから、加熱及び加圧することによって溶融した熱可塑性樹脂を織布、編地又は不織布中に含浸させるという一連の操作を複数回繰り返して、織布、編地又は不織布の枚数及び全体厚みを徐々に増大させた後に、加圧しながら冷却することによって熱可塑性樹脂を固化させることが好ましい。 When a hot press device is used, the molten thermoplastic resin can be impregnated into the woven fabric, knitted fabric or non-woven fabric by applying pressure at the same time as heating. When heating using a heat press device, the laminate must be heated by heat transfer from the hot plate, but the woven fabric, knitted fabric or non-woven fabric contains air inside, so the heat transfer coefficient is high. small. Therefore, when the thickness of the molded product is large, it takes a long time to melt the thermoplastic resin film in the central portion. In such a case, a small number of woven fabrics, knitted fabrics or non-woven fabrics and a thermoplastic resin film are alternately laminated, and then the thermoplastic resin melted by heating and pressurizing is put into the woven fabric, knitted fabric or non-woven fabric. It is preferable to repeat a series of operations of impregnation a plurality of times to gradually increase the number of woven fabrics, knitted fabrics or non-woven fabrics and the total thickness, and then to solidify the thermoplastic resin by cooling while pressurizing.
また、マイクロ波を用いて積層体を加熱することもできる。これによって、成形品の厚さが大きい場合でも中心部まで効率的に加熱することが可能である。ただしこの場合には、積層体が水分を含んでいる必要があり、セルロース繊維、羊毛、絹、ナイロンなど、水分率の高い繊維を用いる必要がある。なかでも、セルロース繊維は、繊維が水分を含んでいて耐熱性が良好であることから、マイクロ波で加熱する場合に好適である。マイクロ波で加熱した後は、加圧しながら冷却することによって熱可塑性樹脂を固化させる。 It is also possible to heat the laminate using microwaves. As a result, even when the thickness of the molded product is large, it is possible to efficiently heat up to the central portion. However, in this case, the laminate needs to contain water, and it is necessary to use fibers having a high water content such as cellulose fiber, wool, silk, and nylon. Among them, cellulose fibers are suitable for heating with microwaves because the fibers contain water and have good heat resistance. After heating with microwaves, the thermoplastic resin is solidified by cooling while pressurizing.
このようにして熱可塑性樹脂を固化して得られる成形品の厚さは特に限定されず、用途に応じて適当に設定される。縞模様の観察しやすさを考慮すれば、成形品の厚さが２ｍｍ以上であることが好ましく、５ｍｍ以上であることがより好ましい。一方、生産性などを考慮すれば、成形品の厚さは通常３００ｍｍ以下である。 The thickness of the molded product obtained by solidifying the thermoplastic resin in this way is not particularly limited, and is appropriately set according to the intended use. Considering the ease of observing the striped pattern, the thickness of the molded product is preferably 2 mm or more, and more preferably 5 mm or more. On the other hand, in consideration of productivity and the like, the thickness of the molded product is usually 300 mm or less.
本発明の成形品は、色調の異なる５枚以上の織布、編地又は不織布が積層されて熱可塑性樹脂で接着されている。本発明の成形品は、織布、編地又は不織布同士が強固に接着されているので、剥離することなく切削加工することが可能である。そして、切削加工によって露出した切断面には、意匠性に優れた縞模様が形成される。このとき、切断面に露出する織布、編地又は不織布の色調の相違に由来する変化に富んだ独特の縞模様が形成されることが本発明の成形品の大きな特徴である。 In the molded product of the present invention, five or more woven fabrics, knitted fabrics or non-woven fabrics having different color tones are laminated and bonded with a thermoplastic resin. Since the woven fabric, knitted fabric, or non-woven fabric is firmly adhered to each other in the molded product of the present invention, it can be cut without peeling. Then, a striped pattern having excellent design is formed on the cut surface exposed by the cutting process. At this time, it is a major feature of the molded product of the present invention that a unique striped pattern rich in variation is formed due to the difference in color tone of the woven fabric, knitted fabric or non-woven fabric exposed on the cut surface.
本発明の成形品において、切断面を形成する方法は特に限定されず、のこぎり、ノミ、カンナ、彫刻刀などの刃物で切断してもよいし、旋盤、フライス盤、ボール盤、電動ドリル、電動グラインダーなどの切削機械や研削機械によって切断してもよい。なお、ここでの切断は、表面をはぎ取ることによって切断面を露出させる研削も含む。また、ウォータージェットやレーザー加工機によって切断することもできる。 In the molded product of the present invention, the method for forming the cut surface is not particularly limited, and cutting may be performed with a cutting tool such as a saw, a chisel, a plane, or a chisel, a lathe, a milling machine, a drilling machine, an electric drill, an electric grinder, or the like. It may be cut by a cutting machine or a grinding machine. The cutting here also includes grinding that exposes the cut surface by peeling off the surface. It can also be cut by a water jet or a laser machine.
切断面は、表面に対して垂直であってもよいし、傾斜していてもよい。切断面が傾斜している場合には、切断面が広くなるとともに縞模様の間隔も広くなるので、縞模様を観察しやすくなり、意匠的に有利な場合が多い。また切断面は、平面であってもよいし曲面であってもよい。切断面が平面である場合には、切断作業が容易である。切断面が曲面である場合には、切断面に現れる縞模様が見る角度によって曲がるので、変化に富んだ意匠とすることができる。 The cut surface may be perpendicular to the surface or may be inclined. When the cut surface is inclined, the cut surface becomes wider and the interval between the striped patterns becomes wider, so that the striped pattern becomes easier to observe, which is often advantageous in terms of design. Further, the cut surface may be a flat surface or a curved surface. When the cut surface is flat, the cutting operation is easy. When the cut surface is a curved surface, the striped pattern appearing on the cut surface bends depending on the viewing angle, so that the design can be varied.
また、成形品中の織布、編地又は不織布が湾曲していることも好ましい。この場合には、切断面が平面であっても曲線状の縞模様が形成されて、木目のような模様とすることができる。成形品中の織布、編地又は不織布を湾曲させる方法は特に限定されないが、曲面を有する型で加圧しながら冷却することによって、熱可塑性樹脂を固化させる方法が好適である。湾曲させる形状は特に限定されないが、積層体が球面や円筒形状の一部を形成するように大きく曲げてもよいし、波型に屈曲させてもよい。 It is also preferable that the woven fabric, knitted fabric or non-woven fabric in the molded product is curved. In this case, even if the cut surface is flat, a curved striped pattern is formed, and a wood grain-like pattern can be obtained. The method of curving the woven fabric, knitted fabric, or non-woven fabric in the molded product is not particularly limited, but a method of solidifying the thermoplastic resin by cooling while pressurizing with a mold having a curved surface is preferable. The shape to be curved is not particularly limited, but the laminated body may be greatly bent so as to form a part of a spherical surface or a cylindrical shape, or may be bent into a wavy shape.
本発明の成形品において、少なくとも一方の表面が織布、編地又は不織布で覆われていることが好ましい。これにより、織布、編地又は不織布で覆われた表面と縞模様が形成された切断面の両方を有する、特徴的な意匠の成形品を提供することができる。このとき、両表面が織布、編地又は不織布で覆われていてもよいし、一方の表面だけが織布、編地又は不織布で覆われて他の表面では切断面が露出していてもよい。また、一方の表面だけが織布、編地又は不織布で覆われて他の表面は熱可塑性樹脂で覆われていてもよい。さらにまた、両表面において切断面が露出していてもよい。これらの構成は、目的とするデザインに応じて適宜選択することができる。 In the molded article of the present invention, it is preferable that at least one surface is covered with a woven fabric, a knitted fabric or a non-woven fabric. Thereby, it is possible to provide a molded article having a characteristic design having both a surface covered with a woven fabric, a knitted fabric or a non-woven fabric and a cut surface in which a striped pattern is formed. In this case, both surfaces woven fabric, may be covered with knitted or nonwoven, only one surface is woven, covered with knitted or nonwoven be exposed cutting surface in the other surface Good. Further, only one surface may be covered with a woven fabric, a knitted fabric or a non-woven fabric , and the other surface may be covered with a thermoplastic resin. Furthermore, the cut surfaces may be exposed on both surfaces. These configurations can be appropriately selected according to the desired design.
本発明の成形品において、切断面を露出させた後に、該切断面を研磨することも好ましい。本発明の成形品は、織布、編地又は不織布中の繊維集合体に熱可塑性樹脂が含浸して、織布、編地又は不織布同士が強固に接着されているので、研磨することによって熱可塑性樹脂と繊維が同時に研磨され、平滑な表面を得ることができる。これにより、切断面の縞模様を明瞭に観察できるようになるし、織布、編地又は不織布の積層体とは思えない平滑な切断面を得ることもできる。研磨方法は特に限定されず、サンドペーパー、電動グラインダーなどを用いることができる。 In the molded product of the present invention, it is also preferable to polish the cut surface after exposing the cut surface. Molded article of the present invention, woven fabric, and a thermoplastic resin is impregnated in the fiber aggregate of the knitted fabric or nonwoven fabric, since the fabric, is knitted or non-woven with each other are firmly bonded, heat by polishing The plastic resin and the fiber are polished at the same time to obtain a smooth surface. As a result, the striped pattern on the cut surface can be clearly observed, and a smooth cut surface that does not seem to be a laminate of woven fabric, knitted fabric or non-woven fabric can be obtained. The polishing method is not particularly limited, and sandpaper, an electric grinder, or the like can be used.
本発明の成形品を、更に着色してもよい。これにより、原材料の織布、編地又は不織布の色調を生かしながら、さらにその色調を調整することができる。着色する方法は特に限定されないが、繊維染色用の染料を用いることが好ましい。その場合、染液に含浸して全体を染色したり、染液を塗布して全部又は一部を染色したりすることができる。また、塗装を施すこともできるが、この場合には、断面の縞模様が観察できるような透明な塗装が好ましい。 The molded article of the present invention may be further colored. This makes it possible to further adjust the color tone of the woven fabric, knitted fabric, or non-woven fabric of the raw material while making the best use of the color tone. The method of coloring is not particularly limited, but it is preferable to use a dye for fiber dyeing. In that case, the dyeing solution can be impregnated to dye the whole, or the dyeing solution can be applied to dye all or part of it. Further, coating can be applied, but in this case, transparent coating is preferable so that a striped pattern on the cross section can be observed.
こうして得られた本発明の成形品の用途は特に限定されない。切断面の縞模様の意匠や織布、編地又は不織布としての質感などを生かして、インテリア製品をはじめ、文具や装飾用小物など様々な用途に用いることができる。インテリア用品としては、額縁、壁面装飾材、ドアノブ、机の天板などが挙げられる。文具としては、ペントレー、ペン立て、ホッチキスカバー、メジャーカバー、ペーパーウェイトなどが挙げられる。装飾用小物としては、携帯ストラップ、キーホルダー、スマートフォンカバー、アクセサリーなどが挙げられる。用途に応じて、他の部材と接着することもできるし、穴開けしたり、ねじ止めしたりすることもできる。 The use of the molded product of the present invention thus obtained is not particularly limited. Utilizing the striped design of the cut surface and the texture of woven fabric, knitted fabric or non-woven fabric, it can be used for various purposes such as interior products, stationery and decorative accessories. Examples of interior goods include picture frames, wall decoration materials, doorknobs, and desk tops. Stationery includes a pen tray, a pen stand, a stapler cover, a tape measure cover, a paper weight, and the like. Decorative accessories include cell phone straps, key chains, smartphone covers, and accessories. Depending on the application, it can be bonded to other members, drilled, or screwed.
実施例１
織布として、ポリエステル６５質量％及び綿３５質量％を含み、目付が２５５ｇ／ｍ２である綾織の織布を用いた。熱可塑性樹脂フィルムとして、厚さ７０μｍの低密度ポリエチレンフィルムを用いた。前記織布と前記フィルムをそれぞれ３０ｃｍ×３０ｃｍの大きさに切断し、織布が最下面と最上面に配置されるように、織布２０枚とフィルム１９枚を交互に重ねた。ここで用いた織布には、色調の異なるものが含まれており、所望する断面デザインに応じて適宜配列して重ねた。得られた積層体を鉄板に挟み、プレス機で１０分間熱プレスした。プレス温度は１６０℃であり、プレス圧力は０．１Ｎ／ｃｍ２であった。
Example 1
As the woven fabric , a twill woven fabric containing 65% by mass of polyester and 35% by mass of cotton and having a grain size of 255 g / m 2 was used. As the thermoplastic resin film, a low-density polyethylene film having a thickness of 70 μm was used. The woven fabric and the film were cut to a size of 30 cm × 30 cm, respectively, and 20 woven fabrics and 19 films were alternately stacked so that the woven fabrics were arranged on the lowermost surface and the uppermost surface. The woven fabrics used here include those having different color tones, and were appropriately arranged and stacked according to the desired cross-sectional design. The obtained laminate was sandwiched between iron plates and heat-pressed with a press machine for 10 minutes. The press temperature was 160 ° C. and the press pressure was 0.1 N / cm 2 .
織布が最下面に配置されるようにして織布１０枚とフィルム１０枚を交互に重ね、その上に織布を２０枚含む熱プレス成形直後の上記積層体を載置し、さらにその上に、織布が最上面に配置されるようにして織布１０枚とフィルム１０枚を交互に重ねたものを載置し、これらをまとめて鉄板に挟み、上記と同じ条件で熱プレスした。これにより、織布を４０枚含む高温の積層体を得た。このときも、所望する断面デザインに応じて、色調の異なる織布を適宜選択して重ねた。 10 woven fabrics and 10 films are alternately stacked so that the woven fabrics are arranged on the lowermost surface, and the above-mentioned laminate immediately after hot press molding containing 20 woven fabrics is placed on the laminated fabrics. On the other hand, 10 woven fabrics and 10 films were alternately stacked so that the woven fabrics were arranged on the uppermost surface, and these were put together on an iron plate and hot-pressed under the same conditions as above. As a result, a high-temperature laminate containing 40 woven fabrics was obtained. Also at this time, woven fabrics having different color tones were appropriately selected and layered according to the desired cross-sectional design.
この操作をさらに３回繰り返して、織布を１００枚含み、最下面と最上面が織布である高温の積層体を得た。ここで用いた織布には、色調の異なるものが１２色含まれていた。この積層体をプレス圧力が５０Ｎ／ｃｍ２の冷却プレスに挟み、ポリエチレンを固化させてから荷重を除いて、両表面に織布が露出した厚さ３０ｍｍの固化物を得た。得られた固化物は硬く、十分な剛性を有していた。また、各層は強固に接着されており、後の切削加工や研磨加工でも剥離することはなく、手で力を加えた位では剥離することはなかった。ここで、厚さ７０μｍの低密度ポリエチレン（密度０．９２／ｃｍ３）フィルムの目付は６５ｇ／ｍ２であるから、成形品全体の重量に対して２０質量％の低密度ポリエチレンを含んでいる。こうして得られた積層体の外観を図１に示す。 This operation was repeated three more times to obtain a high-temperature laminate containing 100 woven fabrics and having the lowermost surface and the uppermost surface woven fabrics. The woven fabric used here contained 12 colors having different color tones. This laminate was sandwiched between cooling presses having a press pressure of 50 N / cm 2 , and the polyethylene was solidified and then the load was removed to obtain a solidified product having a thickness of 30 mm in which the woven fabric was exposed on both surfaces. The obtained solidified product was hard and had sufficient rigidity. In addition, each layer was firmly adhered and did not peel off even in the subsequent cutting or polishing process, and did not peel off when a force was applied by hand. Here, since the texture of the low-density polyethylene (density 0.92 / cm 3 ) film having a thickness of 70 μm is 65 g / m 2, it contains 20% by mass of low-density polyethylene with respect to the total weight of the molded product. .. The appearance of the laminated body thus obtained is shown in FIG.
得られた固化物を電動丸鋸で垂直に切断したところ、切断面にカラフルな縞模様が現れたが、毛羽が目立っていた（図２）。この切断面を４００番のサンドペーパーで研磨したところ、光沢感のある切断面にすることができ、より明確な縞模様を観察することができた（図３）。研磨後の切断面の拡大写真を図４に示す。織布中の繊維集合体に熱可塑性樹脂が含浸されていることがわかるとともに、毛羽立つことなく平滑な切断面になっていることがわかる。固化物を斜めに切断したところ、切断面の面積が広がるとともに縞模様のピッチが大きくなった。また、丸ノミを用いて削って刃の跡が残るような曲面状の切断面にしたところ、カラフルな縞模様が湾曲して独特の意匠を示した（図５）。得られた成形品の両表面には織布が露出していて、いわゆるファブリックとしての質感を有していながら、切断面には独特の縞模様が形成されており、個性的な風合いを有する成形品が得られた。 When the obtained solidified material was vertically cut with an electric circular saw, colorful striped patterns appeared on the cut surface, but fluff was conspicuous (Fig. 2). When this cut surface was polished with No. 400 sandpaper, a glossy cut surface could be obtained, and a clearer striped pattern could be observed (Fig. 3). An enlarged photograph of the cut surface after polishing is shown in FIG. It can be seen that the fiber aggregate in the woven fabric is impregnated with the thermoplastic resin, and that the cut surface is smooth without fluffing. When the solidified material was cut diagonally, the area of the cut surface increased and the pitch of the striped pattern increased. In addition, when a curved cut surface was cut using a round chisel to leave a trace of a blade, a colorful striped pattern was curved to show a unique design (Fig. 5). The woven fabric is exposed on both surfaces of the obtained molded product, and while it has a texture as a so-called fabric, a unique striped pattern is formed on the cut surface, and the molded product has a unique texture. Goods were obtained.
実施例２
実施例１と同じ織布とフィルムを、それぞれ３０ｃｍ×３０ｃｍの大きさに切断し、織布が最下面と最上面に配置されるように、織布２０枚とフィルム１９枚を交互に重ねた。ここで用いた織布には、色調の異なるものが５色含まれており、所望する断面デザインに応じて適宜配列して重ねた。得られた積層体を鉄板に挟み、プレス機で加圧することなく軽く挟んで１６０℃で１０分間加熱した。
Example 2
The same woven fabric and film as in Example 1 were cut to a size of 30 cm × 30 cm, respectively, and 20 woven fabrics and 19 films were alternately stacked so that the woven fabrics were arranged on the lowermost surface and the uppermost surface. .. The woven fabrics used here contained five colors having different color tones, and were appropriately arranged and layered according to the desired cross-sectional design. The obtained laminate was sandwiched between iron plates, lightly sandwiched without pressurization with a press machine, and heated at 160 ° C. for 10 minutes.
織布が最下面に配置されるようにして織布１０枚とフィルム１０枚を交互に重ね、その上に織布を２０枚含む加熱直後の上記積層体を載置し、さらにその上に、織布が最上面に配置されるようにして織布１０枚とフィルム１０枚を交互に重ねたものを載置し、これらをまとめて鉄板に挟み、上記と同じ条件で加圧することなく加熱した。これにより、織布を４０枚含む高温の積層体を得た。このときも、所望する断面デザインに応じて、色調の異なる織布を適宜選択して重ねた。 10 woven fabrics and 10 films are alternately stacked so that the woven fabrics are arranged on the lowermost surface, and the above-mentioned laminated body immediately after heating containing 20 woven fabrics is placed on the woven fabrics, and further on top of the laminated fabric. 10 woven fabrics and 10 films were alternately stacked so that the woven fabrics were arranged on the uppermost surface, and these were sandwiched together between iron plates and heated under the same conditions as above without pressurization. .. As a result, a high-temperature laminate containing 40 woven fabrics was obtained. Also at this time, woven fabrics having different color tones were appropriately selected and layered according to the desired cross-sectional design.
この操作をさらに３回繰り返して、織布を１００枚含み、最下面と最上面が織布である高温の積層体を得た。これを、相互に嵌合する一組の波型の木製の型の間に挟んでからプレス圧力が５０Ｎ／ｃｍ２の冷却プレスに挟み、２０分かけて冷却した。ポリエチレンを固化させてから荷重を除いて、両表面が波打った厚さが３０ｍｍの固化物を得た（図６）。得られた固化物を電動丸鋸で切断し、４００番のサンドペーパーで研磨したところ、切断面が平面であるにもかかわらず、切断する向きによっては湾曲した縞模様が現れた（図７）。また、得られた固化物を所定の寸法に切り出すとともにノミで形状を整え、得られた成形品の切断面を１８０番〜１６００番のサンドペーパーで順次研磨して表面を平滑にした。その後、成形品を組み立てて写真フレームの形とした。引き続き、黒のスレン染料３０ｍｌを１リットルの水で薄めた溶液中に、溶液が十分に浸透するまでフレームを浸してから自然乾燥させた。これにより、重厚な色調の写真フレームとすることができた（図８）。 This operation was repeated three more times to obtain a high-temperature laminate containing 100 woven fabrics and having the lowermost surface and the uppermost surface woven fabrics. This was sandwiched between a set of corrugated wooden molds that fit each other, then sandwiched between cooling presses with a press pressure of 50 N / cm 2 , and cooled over 20 minutes. After solidifying the polyethylene, the load was removed to obtain a solidified product having a wavy surface and a thickness of 30 mm (FIG. 6). When the obtained solidified material was cut with an electric circular saw and polished with No. 400 sandpaper, a curved striped pattern appeared depending on the cutting direction even though the cut surface was flat (Fig. 7). .. Further, the obtained solidified product was cut out to a predetermined size and the shape was adjusted with a chisel, and the cut surface of the obtained molded product was sequentially polished with sandpaper Nos. 180 to 1600 to smooth the surface. After that, the molded product was assembled into the shape of a photo frame. Subsequently, the frame was immersed in a solution of 30 ml of black slene dye diluted with 1 liter of water until the solution was sufficiently permeated, and then air-dried. As a result, it was possible to obtain a photo frame with a heavy color tone (Fig. 8).
実施例３
実施例１と同じ織布とフィルムを、それぞれ２０ｃｍ×２０ｃｍの寸法に切断し、織布が最下面と最上面に配置されるようにして、織布１００枚とフィルム９９枚を交互に重ねた。これを電子レンジに投入して５００Ｗで７分間加熱してから、鉄板で挟み、実施例１と同様にしてプレス機で１０分間熱プレスした。プレス温度は１６０℃であり、プレス圧力は０．１Ｎ／ｃｍ２であった。その後、実施例１と同様に冷却プレスで冷却することによってポリエチレンを固化させてから荷重を除いて、両表面に織布が露出した厚さ３０ｍｍの固化物を得た。当該固化物を切断したところ、実施例１と同様に切断面に縞模様が観察された。
Example 3
The same woven fabric and film as in Example 1 were cut to a size of 20 cm × 20 cm, respectively, and 100 woven fabrics and 99 films were alternately stacked so that the woven fabrics were arranged on the lowermost surface and the uppermost surface. .. This was put into a microwave oven and heated at 500 W for 7 minutes, sandwiched between iron plates, and hot-pressed with a press for 10 minutes in the same manner as in Example 1. The press temperature was 160 ° C. and the press pressure was 0.1 N / cm 2 . Then, the polyethylene was solidified by cooling with a cooling press in the same manner as in Example 1, and then the load was removed to obtain a solidified product having a thickness of 30 mm in which the woven fabric was exposed on both surfaces. When the solidified product was cut, a striped pattern was observed on the cut surface as in Example 1.
Claims (10)
織布、編地又は不織布と熱可塑性樹脂フィルムを交互に重ねてから、加熱及び加圧することによって溶融した熱可塑性樹脂を織布、編地又は不織布中に含浸させ、次いで加圧しながら冷却することによって熱可塑性樹脂を固化させ、得られた固化物を切断して切断面を露出させた後に、該切断面を研磨することを特徴とする、成形品の製造方法。
Manufacture of a molded product in which five or more woven fabrics, knitted fabrics or non-woven fabrics having different colors are laminated and bonded with a thermoplastic resin, and a striped pattern is formed on the cut surface of the molded product. It's a method;
The woven fabric, knitted fabric or non-woven fabric and the thermoplastic resin film are alternately layered, and then the woven fabric, knitted fabric or non-woven fabric is impregnated with the thermoplastic resin melted by heating and pressurizing, and then cooled while pressurizing. thermoplastic resin is solidified, after exposing the cut surface by cutting the solidified product obtained is characterized that you polish the sections sectional, manufacturing method of a molded article by.
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