JP6979741B2 - Flat yarn laminated sheet for molding and molded products - Google Patents

Description

The present invention relates to a flat yarn laminated sheet used for molding by a mold and a molded product using the same.

As a member used for automobiles, ships, aircraft, home appliances, buildings, etc., a fiber reinforced plastic (FRP) formed by compounding reinforcing fibers typified by glass fiber or carbon fiber is used. However, this FRP has the drawback of being extremely difficult to recycle and dispose of. Therefore, in recent years, research has been conducted to replace FRP by molding a sheet using a polyolefin flat yarn woven fabric. Molded products using this flat yarn woven fabric are expected to be easy to dispose of and to be lightweight.

Regarding such a flat yarn woven fabric and its molding, for example, in Patent Document 1, a plurality of cloth-like bodies woven from uniaxially stretched flat yarn in which a surface layer is laminated with an intermediate layer are used and heat-compressed. This describes an integrated cloth laminate, and Patent Document 2 describes a method for forming a thermoplastic composite material using a fabric made of a coextruded tape having an ABA structure.

Patent Documents 1 and 2 both utilize a flat yarn woven fabric obtained by coextrusion of a two-kind three-layer structure (ABA structure), and in particular, in order to form a plate using this, Although there is no problem, there is a problem in the sealing part and the curved surface part of the molded product when the molding process using the molding die, especially deep drawing, is performed. For example, when an attempt is made to perform deep drawing in a state where the flat yarn fabrics are stacked, a portion where the flat yarn fabrics are hardly adhered to each other is generated in the curved surface portion, the curved surface strength is not obtained, and the shape is different from the conventional shape. It looks like it. In addition, once the plate is formed by pressing while applying heat, if deep drawing is performed, wrinkles are likely to occur on the curved surface, and if wrinkles are formed, the design is impaired and the curved surface is curved. It was a situation where strength could not be obtained.

Japanese Unexamined Patent Publication No. 2014-019074 Special Table 2009-516603 Gazette

One of the causes of the above-mentioned defects in deep drawing is considered to be heat shrinkage caused by using flat yarn obtained by stretching polyolefin as a material. In order to apply high heat enough to melt the surface layer of the flat yarn, it is speculated that the flat yarn shrinks significantly toward the inside of the curved surface, causing poor adhesion and deformation between the layers. Will be done.

Regarding this heat shrinkage, it is considered that the heat shrinkage of the flat yarn can be suppressed to some extent by the heat setting effect once the heat shrinkage is formed into a plate shape by pressing while applying heat. However, once the plate is formed, the gaps inside the flat yarn fabric and between the flat yarn fabrics are compressed, and the gaps such as the texture are also filled with the resin that was the surface layer of the flat yarn. , The flat yarn is too restrained and difficult to follow the curved surface. In addition, when the plate is made, the resin on the surface layer of the flat yarn moves to the gaps such as the texture, so when trying to change the shape along the curved surface, the resin moves again according to the shape. It is considered difficult to do.

The present invention solves the problems caused by these causes, and flat yarn for molding processing using a flat yarn woven fabric that can secure designability and curved surface strength even for a molded product having a curved surface having an angle close to a right angle. It is an object of the present invention to provide a laminated sheet and a molded product using the same.

The present invention is a finding obtained from the study results of a flat yarn laminated sheet, that is, a flexible laminated sheet in which a flat yarn woven fabric made of polypropylene is adhered via a laminated layer made of a low melting point polypropylene resin. However, it was made based on the finding that it is suitable for molding with a molding die.

That is, the present invention is as follows.

(1) A flat yarn laminate sheet for use in molding using a mold, made of polypropylene, 2-10 Like flat yarn woven fabric each having a basis weight by weight is 50 to 250 g / ^{m 2} is lower than the flat yarn Laminated sheet bonded by extrusion laminating method via a laminating layer made of polypropylene resin having a melting point and MFR (measured at 230 ° C. and 2.16 kgf at 230 ° C. according to JIS K 7210) of 4 to 50 g / 10 min. A flat yarn laminated sheet comprising and characterized in that the laminated sheet has flexibility.
(2) The flat yarn laminate sheet according to (1) above, wherein the flat yarn forming the flat yarn woven fabric has a heat shrinkage rate of 5% or less when exposed to a hot air temperature of 130 ° C. for 10 minutes.
(3) The flat yarn laminate sheet according to (1) or (2) above, wherein the basis weight of the laminate layer is 70 to 300 g / m ^2.
(4) The flat yarn laminate sheet according to any one of (1) to (3) above, wherein the surface layer material is further laminated on the surface layer via an adhesive resin layer.
(5) A molded product formed by using the flat yarn laminated sheet according to any one of (1) to (4) above.

By using the flat yarn laminated sheet of the present invention, even in the case of molding having a curved surface having an angle close to a right angle, the molding process can be performed with almost no wrinkles.

It is sectional drawing which shows the example of the flat yarn laminated sheet structure of this invention. It is a schematic diagram which shows an example of a molding die.

Hereinafter, the flat yarn laminated sheet of the present invention and the molded product obtained by using the flat yarn laminated sheet will be described in detail.
FIG. 1 is a diagram showing a configuration example of the flat yarn laminated sheet of the present invention. The flat yarn laminated sheet 1 is made of a laminated sheet in which a plurality of flat yarn woven fabrics 2 made of polypropylene are bonded via a laminated layer 3 made of a low melting point polypropylene resin. The configuration example of FIG. 1 shows an example in which four flat yarn woven fabrics 2 are bonded and laminated via a three-layer laminated layer 3. In the configuration example of FIG. 1, the surface layer material 4 is further laminated on the laminated sheet via the adhesive resin layer 5.

The flat yarn of the present invention refers to a tape-shaped yarn stretched in the longitudinal direction. It is a yarn obtained mainly by shredding and stretching a film made by a known method such as a T-die method or an inflation method. In general, the stretching is imparted by stretching in the longitudinal direction while heating with a hot roll, a hot plate, and / or hot air, while applying a weight according to the speed ratio between the rolls. By applying heat and relaxing the stretched state, the annealing treatment to prevent stretching back is selectively performed.

The main raw material of the flat yarn of the present invention is polypropylene. Among polyolefins, polypropylene has a relatively high melting point, is easy to obtain hardness, is excellent in creep property, and is easy to obtain strength. This polypropylene is preferably homopolypropylene, and there are types such as isotactic polypropylene and syndiotactic polypropylene, but it is preferably isotactic polypropylene having high crystals and easy to obtain high strength. The melting point of the crystal varies depending on the stretching state and the like, but it is generally at 160 to 170 ° C.

It is known that a flat yarn can be produced by using a coextruded film to form a multi-layer yarn in which a low melting point resin is provided on the surface layer. May be. Since the multi-layer yarn is provided with a low melting point resin in the surface layer, it is difficult to sufficiently heat it in stretching and particularly annealing treatment, and there is a problem that heat shrinkage is likely to occur during molding. If heat shrinkage is emphasized, the melting point of the surface layer cannot be made much lower than that of the inner layer. Further, since the multilayer yarn is mainly made of a coextruded film, there is a restriction that the melting characteristics such as the melt flow rate (MFR) of the resin of the surface layer must be close to that of the resin of the inner layer.

The fineness of the flat yarn is appropriately selected, but is preferably selected between 500 and 3000 dtex, and more preferably between 800 and 2000 dtex. The yarn width of the flat yarn is appropriately selected, but is preferably in the range of 1 to 20 mm for both vertical and horizontal, and more preferably in the range of 2 to 10 mm.

The tensile strength of the flat yarn of the present invention is appropriately selected according to the purpose of the molded product after molding. Its strength is preferably 4 cN / dtex or more. Since it affects the strength of the molded product after molding, it is desired to have higher strength, but the higher the stretching, the higher the strength, but the more the elongation is impaired, and as a result, the molded product. Impact resistance and applicability to molding dies are impaired. Therefore, the tensile strength is preferably limited to 15 cN / dtex. In particular, in order to follow a curved surface close to a right angle, it is preferable to design with an emphasis on elongation, and the tensile elongation ratio of the flat yarn of the present invention is preferably in the range of 10 to 30%.

In the present invention, it is necessary to pay attention to the heat shrinkage of the flat yarn because high heat is applied during the molding process to melt the laminated layer as described later, and the laminated layer does not shrink significantly in a temperature range close to the melting temperature. Must be avoided. Therefore, the flat yarn preferably has a heat shrinkage rate of 5% or less, and more preferably 3% or less, when exposed to a hot air temperature of 130 ° C. for 10 minutes.

The flat yarn obtained as described above is woven into a flat yarn woven fabric. There are no particular restrictions on the weaving structure of the woven fabric, and any of plain weave, twill weave, satin weave, etc. may be used. Twill weave is preferable from the viewpoint of making it difficult.

The weaving density is not particularly limited, but it is preferably 5 to 20 pieces / 25.4 mm for both vertical and horizontal lines. If it is less than 5 pieces / 25.4 mm, it will look too bad as a woven fabric. It can be said that the higher the weaving density, the more beautiful the woven fabric looks, but the larger the weaving density, the stronger the restraint between the threads, and it becomes difficult to fit the flat yarn laminated sheet along the molding die. Therefore, the weaving density is preferably limited to 20 pieces / 25.4 mm in both vertical and horizontal directions, and more preferably to 12 pieces / 25.4 mm. Further, from the viewpoint that the flat yarn is woven in a state where it is not folded as much as possible, the restraint of the yarn is small and the tensile strength is easily exhibited, it is obtained by the following [Equation 1] and [Equation 2]. It is preferable that both C ₁ and C ₂ are larger than 0 mm. C ₁ indicates the gap between the vertical flat yarns, and C ₂ indicates the gap between the horizontal flat yarns. From the viewpoint that if each gap is too wide, unevenness may be left after molding, _{both C 1} and C ₂ are preferably 0.5 mm or less.
[Number 1] C ₁ = (25.4 / D ₂ ) -W ₂
[Number 2] C ₂ = (25.4 / D ₁ ) -W ₁
However, above, W ₁ = warp yarn width (mm), W ₂ = weft yarn width (mm), D _{1 = warp weave density (book / 25.4 mm), D 2} = weft weave density (book / 25.4 mm). ) Is shown.

The basis weight of the flat yarn woven fabric of the present invention is appropriately selected depending on the intended purpose, but is preferably selected between ^{50 and 250 g / m 2.} In the present invention, the flat yarn woven fabric is related to the strength of the molded product. If the basis weight is too small, it is necessary to stack a larger number of flat yarn woven fabrics in order to obtain higher strength. As a result, there may be a problem that the flat yarn laminated sheet becomes too thick and is too hard to fit in the molding die, or the molded product does not become thin. On the other hand, if the basis weight is too large, the individual flat yarn woven fabrics become too hard, which impairs the softness of the flat yarn laminated sheet and makes it difficult to fit the molding die. It is more preferable to select the basis weight in the range of 70 g / m ² or more and 180 g / m ^{2 or less.}

A plurality of flat yarn woven fabrics obtained as described above are prepared and adhered to each other via a laminated layer. The number of flat yarn woven fabrics is appropriately selected according to the strength and thickness of the target molded product. In the present invention, the range is preferably 2 to 10 sheets, and the range is preferably 3 to 8 sheets from the viewpoint that the number of sheets becomes too hard if the number of sheets is increased too much. When the number of woven fabrics is three or more, the laminate layer of the present invention is arranged between the woven fabrics.

In the present invention, the flat yarn woven fabrics are previously bonded to each other via a laminated layer to form a laminated sheet before the molding process is performed by the mold. The reason why the flat yarn woven fabrics are previously bonded to each other is to ensure that the woven fabric and the laminated layer are in contact with each other and to counter the heat shrinkage of the woven fabric that occurs during molding. Since the flat yarn is stretched, the woven fabric inevitably shrinks when heat is applied, but the laminate layer of the present invention is melted and then adhered to the woven fabric without going through a stretching step. Therefore, it is in a state where it is hardly stretched, so to speak, in an unstretched state. When heat is applied without bonding, the woven fabric shrinks and the laminated layer does not shrink, so that uneven bonding and wrinkles are likely to occur in the molded product obtained by molding. If it is adhered, the heat shrinkage of the woven fabric is suppressed by the laminated layer, and if the heat shrinkage is suppressed to some extent in the flat yarn, the laminated sheet can be in a state where the heat shrinkage is hardly generated in a wide temperature range. ..

In the present invention, the laminated sheet is made flexible in order to facilitate the molding process by the mold. For that purpose, it is necessary to make the yarns not completely fixed to each other when adhering the flat yarn woven fabrics to each other. As a method of adhering the flat yarn woven fabrics to each other in this state, it is preferable to use an extrusion laminating method. In the bonding by the extrusion laminating method, a T-die extruder is used to melt the resin forming the laminate layer at a high temperature, and then the molten resin is dropped between flat yarn woven fabrics to be cooled and solidified, and then flat yarn is used. Adhere the woven fabrics together. Adhesion by the extrusion laminating method does not require much pressure during bonding because the surface of the flat yarn woven fabric is slightly melted and bonded, so that the flat yarn woven fabric is not excessively compressed, and the laminated layer is further bonded. It is not necessary for the resin that forms the material to bite excessively between the flat yarn woven fabrics. Therefore, the obtained laminated sheet is finished in a state of having flexibility, which is a state of leaving moderate flexibility.

A low melting point polypropylene resin is used as a main raw material for the laminated layer of the present invention. This low melting point polypropylene resin is a resin containing a polypropylene structure and has a lower melting point than polypropylene used for flat yarn. The reason for using the low melting point polypropylene resin is that the same polypropylene resin is preferable in order to obtain good adhesiveness by melt bonding with the polypropylene constituting the flat yarn, and in the present invention, it is woven at the time of molding. In relation to melting the laminated layer without melting the cloth, it is necessary to use a resin having a lower melting point than polypropylene used for flat yarn.
Examples of such a low melting point polypropylene-based resin include a copolymer of propylene and other monomers such as ethylene and butene-1, and a polypropylene-based resin having controlled stereoregularity (for example, low stereoregular polypropylene). Can be mentioned. Above all, it is preferable to use an ethylene-propylene copolymer resin from the viewpoint that the adhesiveness is not hindered by the monomer and a suitable melting point can be easily selected. The melting point of the ethylene-propylene copolymer resin can be selected in the range of 125 to 150 ° C.

The resin of the laminated layer is preferably selected in consideration of MFR as a melting property because it is melted at the time of molding and permeates into the woven fabric. The polypropylene used for the flat yarn is generally less than 3 g / 10 min, but the MFR of the resin used for the laminate layer is naturally higher than this. A suitable MFR (according to JIS K 7210, measured at 230 ° C. and 2.16 kgf) is 4 to 50 g / 10 min, and if the MFR is less than 4 g / 10 min, it is difficult to infiltrate the resin into the woven fabric during molding. As a result, it is difficult to obtain the hardness of the molded product after molding, and it tends to cause wrinkles during molding. More preferably, the MFR is 10 g / 10 min or more. Further, if the MFR exceeds 50 g / 10 min, the resin has already penetrated too much when the flat yarn woven fabrics are bonded to each other, and as a result, the flexibility of the laminated sheet may be impaired. More preferably, it is kept at 35 g / 10 min or less, and by leaving the stickiness even at a high temperature, it is possible to counter the heat shrinkage of the flat yarn woven fabric even at a higher temperature range.

The basis weight of the laminated layer of the present invention is preferably in the range of ^{70 to 300 g / m 2.} In the present invention, the laminated layer has a role of entering between the woven fabrics at the time of molding to bring hardness to the flat yarn laminated sheet, and also has a role of suppressing heat shrinkage of the woven fabric at the time of molding as described above. It plays a role of providing cushioning by thickness to make it easier to follow the molding mold. If it is less than 70 g / m ² , the hardness of the molded product obtained after molding may be insufficient and the heat shrinkage may not be suppressed. On the other hand, if ^{it exceeds 300 g / m 2} , the strength of the laminated layer may be insufficient due to the small amount of woven fabric. The basis weight mentioned above refers to the basis weight per layer of the laminated layer.

The laminated sheet provided with the laminated layer on the flat yarn woven fabric as described above is separately provided on the surface layer of the laminated sheet in order to make the appearance look more beautiful after molding, to impart functionality, or to supplement the performance. A laminated layer made of a low melting point polypropylene resin may be provided, or a non-woven fabric, a woven fabric, a film or the like may be provided as a surface layer material. The laminated layer and the surface layer material may each be composed of two or more layers.

The above surface layer material may be made of polypropylene as a main raw material, but is not limited to polypropylene, and may be made of polyester, polycarbonate, polyamide or the like as a main raw material, such as aluminum foil and carbon fiber products (carbon). Inorganic substances such as fiber woven fabrics, carbon fiber films, etc.) may be used as the main raw material. Two or more kinds of these surface layer materials may be laminated and used. The surface layer material preferably has a melting point higher than that of the resin of the laminated layer (in the case of an amorphous resin, a softening point higher than that of the resin of the laminated layer), and since it is a surface layer, it is most exposed to high heat during molding. , Those having a higher melting point than flat yarn are more preferable.

Even when this surface layer material is used, it is preferable that the flat yarn laminated sheet is previously bonded to the laminated sheet before the molding process by the mold is performed. An adhesive resin or the like that has become an emulsion may be applied immediately before the molding process and pasted with the adhesive resin interposed therebetween, but like the laminate layer, it may be attached via the adhesive resin layer by the extrusion laminating method. It is preferable that they are laminated. The adhesive resin referred to here is preferably one in which the surface layer material and the laminated sheet are sufficiently adhered to each other, and it is not necessary to consider permeating the resin into the woven fabric as in the laminated layer. Therefore, the resin of the adhesive resin layer is selected in consideration of the adhesiveness with the laminated sheet according to the surface layer material used.
When the surface layer material is a raw material other than polyolefin, it is preferable to use a resin different from the raw material used for the laminate layer as the adhesive resin with an emphasis on polarity. When the surface layer material is adhered by the extrusion laminating method, a polar polyolefin obtained by copolymerizing a monomer having a polar group with an olefin or imparting polarity to the polyolefin is preferably used. Examples of polar polyolefins include "Admer", "Toughmer" M series (manufactured by Mitsui Kagaku Co., Ltd.), "Binel", "Fusabond" (manufactured by DuPont), "Olevac" (manufactured by Alchema), and "Plexer" (Ikui). In addition to commercially available polar group-modified polyolefins such as Star Co., Ltd.) and Modic AP (Mitsubishi Chemical Co., Ltd.), ethylene vinyl acetate copolymer (EVA), ethylene acrylic acid copolymer (EAA), and ethylene methacrylic acid co-weight. Examples thereof include a coalescence (EMAA), an ethylene methyl methacrylate copolymer (EMMA), and an ethylene ethyl acrylate copolymer (EEA).

In the present invention, a flat yarn laminated sheet can be obtained as described above. In addition, as the material constituting each composition of the flat yarn laminated sheet of the present invention, a colorant, a weathering stabilizer, a lubricant, an antioxidant, a filler, other synthetic resins and the like are appropriately used as long as the gist of the present invention is not deviated. It may be added according to the purpose.

The flat yarn laminated sheet of the present invention may be used for any known molding process using a mold such as hot press molding, vacuum forming, and pressure forming. Above all, vacuum forming makes it easy for the resin of the laminated layer to penetrate into the woven fabric, and a good molded product can be obtained.

The molded product obtained by using the flat yarn laminated sheet of the present invention is a molded product that is lightweight and has an excellent appearance without wrinkles. For example, bags such as suitcases and attache cases; cases such as camera cases and musical instrument cases. ; Various covers; Door trims, trim materials forming the trunk side, mat materials such as floor mats and trunk mats, automobile parts such as ceiling materials; building materials such as wall materials and ceiling materials; applications such as housings for home appliances Can be used for.

Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited to the following Examples.

In Examples and the like, the melting point was measured by differential scanning calorimetry (DSC) according to JIS K 7121, and the maximum peak (Tm) was taken as the melting point.

[Production example 1 of flat yarn]
A film was prepared by an inflation method using homopolypropylene having a melting point of 165 ° C., and after shredding, drawing and annealing treatments were carried out to obtain a flat yarn X having a yarn width of 3 mm and a fineness of 1500 dtex. The tensile strength of this flat yarn X measured by the JIS L 1013 method was 6 cN / dtex, and the tensile elongation was 20%. Further, a hot air type constant temperature bath kept at a temperature of 130 ° C. was prepared, flat yarn X cut to a length of 1 m was exposed to the constant temperature bath for 10 minutes, and the heat shrinkage rate was determined. The heat shrinkage rate of% was shown.

[Production example 2 of flat yarn]
Using a two-kind, three-layer coextruded film using homopolypropylene with a melting point of 165 ° C as the inner layer and ethylene-propylene random copolymer resin with a melting point of 146 ° C as the raw material for the surface layer, it is shredded and then stretched to obtain a thread width: A flat yarn Y having a fineness of 3 mm and a fineness of 1500 dtex was obtained. The tensile strength of this flat yarn Y measured by the JIS L 1013 method was 5 cN / dtex, and the tensile elongation was 18%. Further, a hot air type constant temperature bath kept at a temperature of 130 ° C. was prepared, and flat yarn Y cut to a length of 1 m was exposed to the constant temperature bath for 10 minutes, and the heat shrinkage rate was determined to be 9.5. The heat shrinkage rate of% was shown. The layer ratio of this flat yarn Y was 1: 8: 1.

[Production example 1 of flat yarn woven fabric]
The flat yarn X was used as the warp and weft yarns, and both the vertical and horizontal yarns were woven into a twill weave with a weaving density of 8 yarns / 25.4 mm to prepare a flat yarn woven fabric A.

[Production example 2 of flat yarn woven fabric]
A flat yarn woven fabric B was produced in the same manner as in Production Example 1 of the flat yarn woven fabric except that the flat yarn X was changed to the flat yarn Y.

[Example 1]
Ethylene-propylene random copolymer resin with a melting point of 135 ° C is melted using an extrusion laminating machine, and then sandwiched between two flat yarn woven fabrics A to bond and laminate the woven fabrics. Further, the laminated sheets were similarly bonded and laminated using the ethylene-polypropylene random copolymer resin to obtain a laminated sheet X provided with four flat yarn woven fabrics A. The ethylene-propylene random copolymer resin used for lamination had an MFR (230 ° C./2.16 kgf) of 14 g / 10 min, and a basis weight of each layer was 150 g / m ² . The laminated sheet X was soft enough to be wound around a paper tube.
Further, a commercially available polyester film A having a thickness of 50 μm is prepared as a surface layer material, and using a commercially available polar polyolefin, it is adhered and laminated on the surface of the laminated sheet X with a basis weight of ^{80 g / m 2 by an extrusion laminating machine.} A laminate A was obtained.

[Comparative Example 1]
A laminated sheet Y obtained by adhering and laminating the polyester film A of Example 1 and the flat yarn woven fabric A at ^{a basis weight of 80 g / m 2 by an extrusion laminating machine using the polar polyolefin used in Example 1.} I prepared it. Next, a film B having ^{a basis weight of about 150 g / m 2} was prepared using an ethylene-propylene random copolymer resin having a melting point of 135 ° C. as a raw material. The laminated body B was obtained by stacking the laminated sheet Y, the film B, the flat yarn woven fabric A, the film B, the flat yarn woven fabric A, the film B, and the flat yarn woven fabric A in this order. In the laminated body B, the laminated sheet Y and the film B, and the film B and the flat yarn woven fabric A were not adhered to each other.

[Comparative Example 2]
The laminated body B obtained in Comparative Example 1 was hot-pressed to obtain a laminated body C. The conditions for the hot press were a temperature of 150 ° C. and a pressure of 20 MPa for about 3 minutes, and then a temperature of about 35 ° C. and a pressure of 20 MPa for about 3 minutes. The laminate C had a hard plate shape with all layers adhered to each other.

[Example 2]
A laminated sheet Z was obtained in the same manner as in Example 1 except that the flat yarn woven fabric A was changed to the flat yarn woven fabric B. The laminated sheet Z was slightly harder than the laminated sheet X, but had a softness enough to be wound on a paper tube. Further, in the same manner as in Example 1, a commercially available polyester film A having a thickness of 50 μm as a surface layer material is used in an extrusion laminating machine using a commercially available polar polyolefin, with ^{a basis weight of 80 g / m 2} and a laminated sheet Z. The laminated body D was obtained by adhering and laminating on the surface of the above.

[Comparative Example 3]
A laminated body E was obtained by stacking three flat yarn woven fabrics B under the laminated sheet Y used in Comparative Example 1.

[Comparative Example 4]
The laminated body F was obtained by hot-pressing the laminated body E. The conditions for hot pressing were the same as in Comparative Example 2. The laminate F had a hard plate shape with all layers adhered to each other.

Upper mold (female mold) having a suction function in the shape shown in FIG. 2 after cutting the laminates A to F obtained in Examples 1 and 2 and Comparative Examples 1 to 4 into a size of 600 mm × 800 mm. A molded product was produced by vacuum suctioning while heating by a vacuum forming method using a molding die consisting of a lower mold (male mold). The degree of vacuum was between 0.5 atm and 0.9 atm, and the heating conditions were between 100 and 150 ° C., which were appropriately adjusted and processed according to the composition of the laminated body.

[Evaluation method for molded products]
The appearance of the molded product was evaluated on a three-point scale.
◯: There are no wrinkles in the molded product. The woven pattern is also beautiful.
Δ: Some wrinkles are seen in the molded product, but there is no problem as a molded product.
X: There are many wrinkles and uneven adhesion between layers in the molded product, and there is a problem as the molded product.

The evaluation results by the above method were ◯ in Example 1, Δ in Example 2, and × in Comparative Examples 1 to 4.

The molded product using the laminated body A of Example 1 was in a beautiful woven pattern. In the molded product using the laminated body B of Comparative Example 1, it was found that the layers were not adhered at the curved surface portion. In the molded product using the laminated body C of Comparative Example 2, the layers were well adhered to each other, but the woven pattern was distorted and wrinkled on the curved surface portion.
The molded product using the laminated body D of Example 2 was in a state where the woven pattern was distorted and some wrinkles were formed, but it was in a state where it could be used as a molded product. In the molded product using the laminated body E of Comparative Example 3, the portion not adhered between the layers was considerably conspicuous. The molded product using the laminated body F of Comparative Example 4 had large wrinkles on the curved surface portion.

1 Flat yarn laminated sheet 2 Flat yarn woven fabric 3 Laminate layer 4 Surface layer material 5 Adhesive resin layer

Claims (5)

2 to 10 flat yarn woven fabrics made of polypropylene, each having a grain weight of 50 to 250 g / m ^2, which are used for molding with a mold, have a lower melting point and MFR than the flat yarn. (Measured at 230 ° C. and 2.16 kgf according to JIS K 7210) consists of a laminated sheet bonded by an extrusion laminating method via a laminating layer made of a polypropylene resin having a weight of 4 to 50 g / 10 min. A flat yarn laminated sheet, characterized in that the laminated sheet has flexibility. The flat yarn laminated sheet according to claim 1, wherein the flat yarn forming the flat yarn woven fabric has a heat shrinkage rate of 5% or less when exposed to a hot air temperature of 130 ° C. for 10 minutes. The flat yarn laminated sheet according to claim 1 or 2, wherein the basis weight of the laminated layer is 70 to 300 g / m ^2. The flat yarn laminated sheet according to any one of claims 1 to 3, wherein a surface layer material is laminated on the surface layer via an adhesive resin layer. A molded product formed by using the flat yarn laminated sheet according to any one of claims 1 to 4.

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