JPH02151438A - Hot pressing integrated molded product of thermoplastic molded product and nonwoven fabric and preparation thereof - Google Patents

Abstract

PURPOSE:To obtain the hand-touch feeling of cloth having a high-grade feeling and a three- dimensional feeling and to enhance durability by superposing a nonwoven fabric made of a synthetic fiber on a thermoplastic molded product to perform hot-press molding and again heating the integrated one to higher temp. to apply vacuum or pressure forming. CONSTITUTION:A thermoplastic sheet and a nonwoven fabric made of a synthetic fiber are superposed one upon another and hot-pressed to be laminated and integrated. At this time, the upper nonwoven fabric layer is usually crushed or thermally deformed by surface pressure of about 15-40kg/cm<2> and heating to eliminate the nappy surface state possessed by the nonwoven fabric and the nonwoven fabric layer showing an emboss or stripe pattern is formed to the surface of the thermoplastic sheet, for example, a smooth layer is formed thereto when surface of a press or roll is in a mirror surface state and a matte layer is formed thereto when the surface of the press or roll is in a matte state. Next, when the integrated one is reheated to temp. higher than that of the previous hot-press process under a pressure free or low pressure condition (-5kg/cm<2>), the entanglement of a part of the fibers after reheating is released by heating and fibers are levitated and a hot-press integrated molded product having a good nappy feeling and a high-grade feeling is obtained.

Description

[Detailed description of the invention] (Industrial application field) The present invention relates to accessories such as rings, earrings, and jewelry.

Storage containers for storing and displaying personal items such as watches, glasses, fountain pens, lighters, tableware, cosmetics, toiletries, etc.
Furthermore, it has the feel of a fabric with a luxurious and three-dimensional feel, and is excellent in durability, making it useful as an interior material for transportation machinery such as automobiles, ships, and aircraft, and various buildings. Table 1 on the nonwoven fabric side relates to a heat-pressure integrated molded product of a nonwoven fabric and a thermoin plastic molded product in which the fIJ structure is integrated into the thermoplastic molded product, and a method for manufacturing the same.

(Prior Art and its Problems) Conventionally, plastics, paper, metals, etc. are known as materials for containers or interior materials for the above-mentioned uses.

Plastics and metals are molded into the desired shape, and then a lining material such as fluffy fabric or non-woven fabric is laminated onto the surface of the product. However, it is difficult to perform this bonding uniformly and beautifully to match the complex internal shape.

It was extremely difficult.

On the other hand, in JP-A-60-48324, a thin wall is provided around a desired area of a mold for vacuum forming, and a fabric of a molding material and a thermoplastic resin plate or a thermoplastic laminated resin plate are placed on the thin wall. A method for obtaining an interior material for an automobile door by attaching a fabric to the outer surface of a resin plate by placing, heating, and vacuum forming is shown. However, with this method, the heating is not uniform, so some fabrics may shrink, the fabric may burn in some places due to overheating, and the fabric may not stick evenly, causing wrinkles. was there.

Furthermore, for materials made from paper, a method has been proposed that utilizes the fluffiness of the paper itself to be processed into the desired shape, but this method is inferior in durability as it breaks and is susceptible to heat and moisture. (Problems to be Solved by the Invention) The present invention provides a container or interior material that has a complex and three-dimensional inner shape for the above-mentioned uses, and which is uniform and beautiful and has a luxurious and three-dimensional appearance. An object of the present invention is to provide a heat-pressing integrated molded product having a wrinkled or mottled pattern on one surface, which is made of nonwoven fabric fibers and has a texture similar to that of a cloth and is also excellent in durability, and a method for producing the same.

(Means for Solving the Problems) The thermopressure integrated molded product according to the present invention is a laminate of a thermoplastic molded product and a synthetic fiber nonwoven fabric, and the surface structure of the nonwoven fabric side is that of the thermoplastic molded product. The manufacturing method is to superimpose a thermoplastic molded product and a synthetic fiber nonwoven fabric, heat-press mold it, heat it again to a higher temperature, and then vacuum or pressure mold it. It is characterized by the fact that

For convenience of explanation, we will mainly explain thermoplastic sheets as a representative example of molded products, but this is not limited to sheets, but also includes films and plates.

It should be noted that any molded body that can be thermally softened at least on its surface, such as a block body, a tubular body, or a rod-shaped body, can be applied.

The above-mentioned thermo-pressure integrated molded product according to the present invention is first typically produced by laminating a thermoplastic sheet and a nonwoven fabric made of synthetic fibers and laminating them together by thermal lamination using a hot press, a hot roll, or the like. At this time, O~40kg/
aJ, usually by surface pressure of about 15 to 40 kg/d and heating, the upper nonwoven fabric layer is crushed or thermally deformed, and the fluffy surface of the nonwoven fabric disappears, and the surface of the thermoplastic plastic sheet has a A nonwoven fabric layer exhibiting a wrinkle pattern or a mottled pattern, for example, if the press surface or roll surface is mirror-like, a smooth layer will be formed, and if the surface is matte, a matte layer will be formed. The thickness of the nonwoven fabric in this state is approximately 0.
．． 05 to 1 m, usually about 0.1 to 0.2 mm. Next, remove this material from pressure-free to low pressure (~5 kg)
/d) Below, when the nonwoven fabric layer is reheated to a higher temperature than the previous heat-pressing process, the heat loosens some of the nonwoven fabric fibers and lifts the fibers, resulting in a thickness of about 0.2~2.
m, usually about 0.5 to 1.0 m, to complete a heat-pressure integrated molded product with a high-quality feel and a good fluffy feel.

In the present invention, the term "nonwoven fabric return" refers to the process of reviving the inherent fuzziness of the nonwoven fabric layer, which has once disappeared through heat lamination such as pressing, by heat.

The nonwoven fabric used in the present invention may be manufactured by dry method, wet method, or any other method, but wet method is particularly preferable because it produces a wrinkled and mottled pattern as described below. Among them, nonwoven fabrics are formed by mixing various types of fibers, each of which has a length of about 10 mm, and many types of these are intertwined to form a fabric with a predetermined fiber mixture ratio. is suitable.

Furthermore, the various fibers in this nonwoven fabric are mixed in a liquid layer. The fibers mixed in the liquid layer come out of the liquid layer and are placed on a mesh belt, where they are dehydrated and dried to become a product. This wet process method for manufacturing a nonwoven fabric is not only low in cost due to its high productivity, but also extremely convenient for obtaining the heat-pressure integrated molded product of the present invention. In other words, when mixed fibers are placed on a mesh belt and dehydrated, coarse and dense areas inevitably occur, and as a result, the nonwoven fabric inevitably has coarse and dense areas. They will coexist. Therefore, when hot-pressing is performed, a wrinkled or mottled pattern appears on the surface layer due to coarse and dense areas. If the coarse and dense areas are relatively large, it will be a mottled pattern, and if the coarse and dense areas are concentrated, it will be a wrinkled pattern.

On the other hand, this nonwoven fabric is made of a mixture of various fibers, and it is particularly preferable that these fibers are composed of fibers that melt at the heat press temperature and fibers that remain unmelted. The wrinkled and mottled pattern also appears due to the difference in melting point of these fibers. In hot-press molding, the nonwoven fabric and thermoplastic sheet are usually placed between a pair of mirror plates, so the upper and lower surfaces of the sheet after hot-press molding are IP-smooth. If a matte-treated board is used instead of this mirror-finished sheet, a sheet can be created that has a mirror surface on one side and a matte surface on the other, or a matte surface on both sides.

There are various types of nonwoven fabrics used in the present invention, such as those containing a mixture of several types of synthetic fibers and those containing only a single fiber, but preferably 40% vinyl chloride fibers, 60% acrylic fibers, and vinyl chloride fibers. 80% fiber and 20% polypropylene fiber, 50% vinyl chloride fiber, 20% polypropylene fiber and 30% acrylic fiber, 60% vinyl chloride fiber and 40% polyester fiber, 50% vinyl chloride fiber, 30% polyester fiber and acrylic fiber 20%, vinyl chloride fiber 40%, polypropylene fiber 30%, polyester fiber 30%, vinyl chloride fiber 1. Various combinations such as O0% are preferable.

Under this configuration, when the nonwoven fabric and the thermoplastic sheet are first heated and pressed at a resin temperature of 100 to 120'Ca degrees using a hot press, the vinyl chloride fibers in the nonwoven fabric have a higher degree of polymerization than other fibers. Most vinyl chloride fibers melt into thermoplastic sheets because of the low temperature, whereas other fibers have a
Since it does not melt at a certain level, fibers other than vinyl chloride fibers remain on the surface of the thermoplastic sheet. Furthermore, since these fibers are randomly mixed with vinyl chloride fibers, when the vinyl chloride fibers dissolve and disappear, a nonwoven fabric layer with a wrinkled and mottled pattern is formed.

Next, this laminated sheet is heated to a temperature higher than the temperature at the time of hot-pressing described above by 10° C. or higher, preferably 20° C. or higher, and subjected to vacuum or pressure forming. As a result, the nonwoven fabric returns and the remaining undissolved fibers in the nonwoven fabric are lifted up, and the fluffy feel of the nonwoven fabric is regained.

That is, - if there are two or more types of synthetic fibers constituting the nonwoven fabric in the shell, at least one of them should have a melting temperature lower than or equal to the melting temperature of the thermoplastic sheet, and the other types of synthetic fibers should be The melting temperature of the plastic sheet is preferably 10° C. or higher, preferably 20° C. or higher than that of the plastic sheet.

Hereinafter, a method for manufacturing a thermo-pressure integrated molded product having a wrinkled or mottled pattern according to the present invention will be explained based on FIG. 1.

First, a pair of upper and lower surface plates 1.2 are heated to a predetermined temperature.
A thermoplastic sheet 3 is placed on the lower surface plate 2 of the
and the nonwoven fabric 4 are placed (Figure a).

Next, the upper and lower surface plates are placed on top of each other and the rain sound is pressed for a certain period of time. Then, the nonwoven fabric 4 becomes the thermoplastic plastic sheet 3
The surface is unwrinkled and has a mottled pattern (5). The thickness of the nonwoven fabric is approximately 0.5 to 3+1 before compression.
11 to about 0.05-1■ after suppression, usually about 0.1
It is crimped to ~0.2m (Figure b).

Next, the mold, often vacuum (and/or compressed air)
Place the laminated and integrated sheet 5 on a molding frame (usually a mold) 6. In the case of vacuum pressure forming, the nonwoven fabric side should be on the pressure side and the plastic sheet side should be on the vacuum side. Of course, the opposite is also possible. At this time, the sheet 5 is heated to the required temperature above the above-mentioned heat pressure temperature using an appropriate heating device @ 7 such as a heater (Fig. 0), and at the same time vacuum (or air pressure) forming is performed to form the desired shape. A molded heat-pressing integrated molded article (product) 8 with a wrinkled and mottled pattern is obtained (Fig. d). At this time, the nonwoven fabric is returned by reheating and the nonwoven fabric portion is lifted. Regarding the surface condition of the nonwoven fabric, setting the thickness to 1 to 1.51, which is about 1/2 to 1/3 of the initial thickness, results in good fluffiness.

As described above, the present invention makes it possible to obtain a product lined with a uniform and beautiful nonwoven fabric even if the thermoforming frame has a very complicated three-dimensional shape.

In addition, the nonwoven fabric and thermoplastic sheet are not separate but integrated, which is very effective in terms of process automation.The nonwoven fabric used here has a basis weight of about 65 to 120 g/d, and the color is Typical colors include white, beige, gray, pink, red, and blue.

Typical examples of thermoplastic plastic sheets include hard vinyl chloride resin, soft vinyl chloride resin, polypropylene, polyethylene, ABS resin, acrylic resin, blends and alloys of these resins, and laminates, with a thickness of 0. It is about 1 to 1 m. Further, this sheet may be a colored sheet, a transparent sheet, or a combination thereof, and can be appropriately selected and used depending on the purpose of the final product.

In addition, if you want to make the wrinkled and mottled pattern stand out, use 1.
For example, the color of the nonwoven fabric is red and the sheet is white and opaque.
On the other hand, if you do not want it to stand out, you can take measures such as making the sheet and the nonwoven fabric the same color.

The relationship between the basis weight of the nonwoven fabric and the return of the nonwoven fabric is expressed by the following equation, and the data confirmed through experiments are shown in the following table.

(Press: pressure 20 kg/cd, temperature 100°C, vacuum forming: forming temperature 120°C, time 20 seconds) Next, the apparatus used for forming the sheet of the present invention was prepared based on Figs. 2 and 3. explain.

FIG. 2 shows a press device used to laminate a nonwoven fabric and a thermoplastic sheet using a hot press.

This device consists of an upper cylinder 11, a piston rod 12
The hot plate 13 is raised and lowered as the
This hot plate 13 includes a heating/cooling means 14 consisting of a fluid, a heater, etc. for heating and cooling the hot plate 13, and an upper press plate 15.
and is provided.

Similarly, a heating plate 16 and heating/cooling means 17 are also provided at the bottom. A lower press plate 18 is provided, on which the nonwoven fabric 19 and the thermoplastic sheet 20 to be processed are placed.

Note that the lower press plate 18. The nonwoven fabric 19 and the thermoplastic sheet 20 are automatically conveyed to a heating and cooling means 17 immediately before being pressed (not shown).

As the cylinder 11 descends, the piston rod 12 also descends, and the upper press plate 15 also descends accordingly, so that the nonwoven fabric 19 and the thermoplastic sheet 20 are heated and pressed. Pressing is continued for a certain period of time until the resin temperature reaches a predetermined temperature, and after reaching the predetermined temperature, the heating and cooling means 14 and 17 are switched to cooling, and sufficient cooling is performed. After cooling is complete.

As the cylinder 11 rises, the upper press plate 15 also rises, and the press operation is completed. As a result, a portion of the nonwoven fabric 19 is embedded in the thermoplastic sheet 20, and a nonwoven fabric surface having a wrinkled and mottled pattern is formed.

Note that if the surfaces of the upper and lower press plates 15 and 18 are both mirror-finished, the thermoplastic sheet 2
0 is a smooth surface, but if the surface of the press plate 15.18 is made into a finely uneven surface, the thermoplastic plastic sheet 2
The surface of 0 is a so-called matte surface with an uneven surface.

Other heat-pressing methods mentioned above include a thermal lamination method in which the materials are laminated between a pair of heated rolls, and a nonwoven fabric and a thermoplastic sheet are continuously and simultaneously fed between a pair of metal belts to perform heating and cooling. There are methods etc.

FIG. 3 shows an example of a vacuum forming apparatus for obtaining a thermo-pressure integrated molded product from the laminated sheet 31 having the above-mentioned wrinkled and mottled pattern according to the present invention. here 32
33 is a heating heater, 33 is a mold for vacuum forming, 34 is a suction hole, 35 is a vacuum pump, 36 is an electric motor, and 37 is a vertically moving frame.

A laminated sheet 31 with a wrinkled and mottled pattern is placed on a vertically moving frame 37. The vertically movable frame 37 rises during heating and approaches the heating heater 32, so the laminated sheet 31 on the vertically movable frame 37 is heated until it reaches an appropriate resin temperature, and then the vertically movable frame 37 is lowered to be used for vacuum forming. It is transferred onto a mold 33. At the same time, the vacuum pump 35 is operated to perform vacuum forming and form the material into a predetermined shape. After sufficient cooling, the molded thermopressure integrated molded product is taken out of the system.

In addition, in the above description, the nonwoven fabric was laminated on only one side of the thermoplastic plastic sheet, but the nonwoven fabric may be laminated on both sides of the plastic sheet. In this case, the nonwoven fabric may be of different colors or types, or of the same color or type, and is appropriately selected depending on the purpose and use.

(Function of the Invention) The thermopressure integrated molded product according to the present invention is produced by first overlapping a thermoplastic plastic sheet and a nonwoven fabric made of synthetic fibers, and then laminating and integrating them by thermal lamination using a hot press, a hot roll, or the like. This causes the top non-woven layer to be crushed and
The fluffy surface condition of the nonwoven fabric disappears, and a nonwoven fabric layer with a wrinkled and mottled pattern is formed on the surface of the thermoplastic plastic sheet. Next, when this product is reheated to a higher temperature than the previous heat-pressing process, the nonwoven fabric layer of the product after reheating becomes a so-called ``nonwoven fabric return'' where some of the nonwoven fabric fibers become untangled due to the heat and the fibers rise. '', a product with a high-quality feel and good fluffiness is completed.

(Example) Next, specific embodiments of the present invention will be described with reference to Examples, but the present invention is not limited to the description of these Examples.

A transparent hard vinyl chloride sheet with a thickness of 0.4 mm and a basis weight of 80, made of 40% vinyl chloride fiber and 60% acrylic fiber.
g/rrr red nonwoven fabric was heated to a resin temperature of about 120 g/rrr using the press device shown in Fig. 2 at a pressure of 20 kg/cd.
Heat pressing was performed at ℃ for 2 minutes while holding between a pair of upper and lower mirror plates. After heating, the product was cooled until the resin temperature reached about 30° C. and taken out from the press. On the hard vinyl chloride sheet, the vinyl chloride fibers in the nonwoven fabric were dissolved and only the acrylic fibers remained, resulting in the formation of a smooth area with a wrinkled and mottled pattern. The thickness of the hard vinyl chloride sheet was about 0.4 + ns, which was unchanged from before pressing, but the thickness of the nonwoven fabric was about 21 mm before pressing and had a fluffy feel like a blanket, but after pressing it became about 0. It was compressed to about .2 am, and had a smooth mirror surface with an unwrinkled and mottled pattern due to the mirror plate used. The laminated state was so good that it could not be peeled off by hand.

Next, this laminated sheet was placed on the vertically movable frame of the vacuum forming apparatus shown in Fig. 3, the frame was raised and heated for 20 seconds until the resin temperature reached approximately 130°C, and then lowered. It was transferred onto a vacuum forming mold and vacuum formed into a heat-pressure integrated molded product. After sufficient cooling, the M product was taken out from the mold.

In addition, in order to compare the formability, vacuum forming was also performed only on a hard vinyl chloride sheet with a thickness of 0.41. Vacuum forming molds are circular, dish-shaped, and the edges are almost at right angles, but both molded products have edges that are almost at right angles, and there is a problem with the forming of edges that tends to occur during molding. No sweetness was observed.

In addition, regarding nonwoven fabric return, nonwoven fabric return occurred until the thickness of the nonwoven fabric was approximately 1 m. The fluffiness was also good. Furthermore, there was no abnormality in lamination, and the nonwoven fabric could not be peeled off by hand.6 (Effects of the Invention) According to the present invention. Heat-press integrated molded products with a wrinkled and mottled pattern are produced by laminating the nonwoven fabric that serves as the lining material on one or both sides of a thermoplastic sheet using heat press, etc., and then vacuum forming the product into the desired shape. Because of this, it can be made into complex shapes, and by returning the nonwoven fabric, it is possible to create a very uniform and beautiful surface.

In addition, although conventional nonwoven fabrics have fibers that come off from the nonwoven fabric and are unsuitable for use in record cases and compact disc cases, the heat-pressure integrated molded product of the present invention has no fibers that come off. Therefore, it is extremely useful as a storage container for articles that do not like these fiber wastes.

[Brief explanation of the drawing]

Figures 1 (a) to (d) are process explanatory diagrams showing the manufacturing process of a hot-press integrated molded product having a wrinkled and mottled pattern according to the present invention, and Figure 2 is a hot-pressure lamination of a nonwoven fabric and a thermoplastic sheet. A front view of a press apparatus for obtaining a wrinkled and mottled sheet, and FIG. 3 shows a vacuum forming apparatus for obtaining the heat-pressure integrated molded product of the present invention from the laminated sheet obtained with this press apparatus. FIG. (Explanation of main symbols) 3.20...Thermoplastic plastic sheet, 1
9...Nonwoven fabric, 5....Thermo-pressure integrated molded product. 31... Laminated sheet. Figure 1

Claims (1)

[Scope of Claims] 1. A thermo-pressure integrated molded product, which is a laminate of a thermoplastic molded product and a synthetic fiber nonwoven fabric, in which the surface texture of the nonwoven fabric side is integrated with the thermoplastic molded product. 2. The surface of the non-woven fabric side, which is characterized by laminating a thermoplastic plastic molded product and a synthetic fiber non-woven fabric, thermo-press molding them, then heating them again to a higher temperature and performing vacuum or pressure molding. A method for producing a thermopressure-integrated molded article of a thermoplastic molded article whose structure is integrated into the thermoplastic molded article and a nonwoven fabric.