JPH04265738A - Covering method of base body section with skin material - Google Patents

Abstract

PURPOSE:To conduct molding and sticking as a single process, and to improve the operating efficiency by thermoforming a skin material composed of thermoplastic fibers positioned between a base body section as one mold and the other mold and attaching the skin material to the base body section. CONSTITUTION:A base body section is used as one mold of a molding die, and a skin material consisting of thermoplastic fibers positioned between the base body section and the other mold is thermoformed, and attached to the base body section at the same time as molding. To be concrete, a foundation (a skin material) 2 made up of acrylic fibers heated at a fixed temperature is laid on the surface of a wrapping material (the base body section) 1 from a resin-foamed molded form. The foundation 2 is pushed in the direction of the base body section 1 and molded by a molding top force (a molding die) 3 having a shape adapted to the surface shape of the base body section 1. Consequently, the surface of the base body section 1 is covered with the foundation 2. A skin material prepared by a pile skin and the thermoplastic fibers having a ductility/strength ratio at the time of rupture at 100 deg.C of 50%/g/denier or more is proper as the skin material.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of coating a substrate. More specifically, the present invention relates to a method of coating a soft base material made of, for example, a resin foam molded product with a skin material along the mold at the same time as the molding.

0002

[Prior Art] Conventionally, packaging materials made of a resin foam molded body covered with a base fabric having piles on one side, etc.
Widely used for cases for musical instruments, accessories, etc.

[0003] As a method for covering such a base portion with a base cloth, a method is generally used in which the base cloth is cut and pasted onto the surface according to the shape of the base portion by manual work such as sewing. That is,
For example, in packaging, musical instrument cases, upholstered furniture, etc., skin materials are manually attached to the base using sewn or cut materials (incisions are made in the fabric). However, with this conventional method, it is difficult to fit the base part because it is pasted by hand (especially for small pieces), and there are also problems such as wrinkles and deterioration of quality. The reality is that it takes time to produce.

[0004] The present inventors have developed a sinker pile using rayon as the ground pile yarn at 170 to 180°C x 6
After heating for 0 seconds, compression molding was performed, but the outline of the molded product became unclear and there were tears in some places, so the product could not be used as a commercial product.

[0005]

[Problems to be Solved by the Invention] The present invention has been made in view of the problems of the conventional base part coating method, and has high working efficiency, improved productivity, and a method that does not lift up from the base part. It is an object of the present invention to provide a method for coating a substrate portion without any problems.

[0006]

[Means for Solving the Problems] During research, the present inventor discovered that a skin material made of thermoplastic fibers can be easily thermoformed and moreover accurately maintains the shape after molding, and based on that knowledge, The present invention was achieved by realizing a method of using the base portion as one mold during thermoforming, which no one had been able to propose until now.

That is, in the present invention, for example, 120 to 1
A skin material made of acrylic fiber or the like heated to 30° C. is laid down, and the skin material is pressed in the direction of the base portion using the other mold having a shape that matches the surface shape of the base portion. The present invention relates to a method for coating a base body, in which the surface of the base body is coated with the skin material.

[0008] The method of the present invention is a method of covering a base with a skin material (woven, knit, nonwoven, etc.) to make the base look more luxurious as a packaging material, and the method covers plastic (including foam), metal, etc. A base made of , wood, or a composite thereof is used as one mold during molding, and during molding, the skin material is molded along the mold of the base and attached and bonded at the same time, and the upper mold Alternatively, there is a covering molding method that does not require either one of the lower molds and instead uses the base portion as one of the molds.

[0009] The skin material is a skin material using thermoplastic fibers.

[0010] The skin material may be a raised product, a two-layer structure product, or a structure in which a plastic sheet or the like is bonded to a base fabric.

[0011] The above-mentioned raised product and two-layer structure product are as follows:
It is a woven or knitted fabric having a pile face material and a base fabric, and specific examples thereof include moquette, tricot, velvet, kohl pile, tuft pile, and raschel pile.

[0012] Furthermore, when a napped product or a two-layer product is used, a skin material using thermoplastic fibers may be used only in the portion that becomes the base fabric.

When the above-mentioned structural product is used as a skin material, the softening temperature difference between the front surface of the pile or two-layer structure product and the base fabric (
It is preferable that the temperature is 30° C. or higher (higher in the surface of pile or two-layer structure products), and more preferably, the surface of pile or two-layer structure products is made of fibers that do not soften. The softening temperature is 3000 denier, which is the temperature at which rapid contraction begins when a load of 5 mg/denyl is applied to a 30 mm long fiber and the temperature is increased at 3° C./min. However, the temperature is determined by the tangential method.

[0014] As such skin materials, thermoplastic fibers are used for the base fabric, and non-softening fibers such as rayon, cotton, wool, silk, acetate, etc., or highly heat-resistant fibers such as PET and aramid are used for the pile surface material. Here are the things I used.

The thermoplastic fiber preferably has an elongation/strength ratio at break of 50%/g/denyl or more, preferably 75%/g/denyl or more at 100°C.

[0016] Elongation/strength at break has a meaning as a measure representing the rate of elongation with a weak force.

FIG. 3 shows the elongation/strength ratio at break of several thermoplastic fibers.

In FIG. 3, +, ○, and △ represent synthetic fibers made of a polymer containing 30% acrylonitrile units and 70% polyvinyl chloride, respectively, and synthetic fibers containing 50% acrylonitrile units and 50% polyvinyl chloride. Measured values are shown for synthetic fibers made of polymers, polyacrylonitrile synthetic fibers.

[0019] From FIG. 3, those represented by + and ○ are 10
It can be seen that the value of the ratio is 75%/g/denyl or more at 0°C.

[0020] The molding method may be vacuum forming, air pressure pressing, or other methods. however,
Since the skin material is breathable, a composite body is used in which a thermoplastic plastic sheet that is impermeable to the skin material is attached to the skin material when used in vacuum or compressed air.

[0021] As the base portion, for example, foamed plastic, non-foamed plastic, pressed metal, woodwork, or composite products thereof (such as injection molded products) are used. In particular, the method of the present invention is characterized in that even soft materials such as foamed plastics can be easily and well coated with a skin material (for example, one using the above-mentioned thermoplastic fibers).

[0022] The adhesion method can be performed by applying adhesive to the base part or the back of the skin material or both sides with a spray or brush, or by placing an adhesive sheet on the back surface of the skin material, or by performing adhesion at the same time as molding. good.

[0023]

[Function] In the method of the present invention, the base portion is used as a mold, so to speak, and molding and adhesion are performed simultaneously, so that the work efficiency is dramatically improved.

For example, among thermoplastic fibers, a base fabric made of acrylic fibers has a low thermoforming temperature and a wide range of thermoforming, and also has the property of being moldable with a small force (hereinafter referred to as ease of molding). Because of this, it is possible to perform sufficient molding at lower temperatures and pressures than base fabrics made of other materials, and it has higher heat resistance and compressive strength than normal mold materials such as wood and metal. This makes it possible to perform molding on a base made of a resin foam molded product with a low carbon content.

[0025] In particular, the skin material made of acrylic fibers does not return to its original shape after molding and has the property of maintaining the molded shape (hereinafter referred to as shape retention), so that the base material It is molded into a shape that matches the surface shape throughout, and is bonded to the base to cover the base. Therefore, it is not always necessary to apply an adhesive between the base fabric and the base portion, and it is only used as an auxiliary agent if necessary.

[0026]

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a schematic cross-sectional view for explaining the method of the present invention, and FIG. 2 is a schematic cross-sectional view of a coated substrate obtained by the method of the present invention.

As shown in FIG. 1, according to the method of the present invention, a material made of acrylic fiber heated to 120 to 130° C. is placed on the surface of a packaging material (substrate portion) 1 made of a resin foam molded product. A base fabric (skin material) 2 is laid down, and the base fabric 2 is pressed in the direction of the base body 1 by a molding upper mold (mold) 3 having a shape that matches the surface shape of the base body part 1. By doing so, the surface of the base portion 1 becomes the base fabric 2.
covered with.

Specific examples of the resin foam used for the base portion 1 include polystyrene foam, polyurethane foam,
Examples include polyethylene foam and polypropylene foam. Among these, polystyrene foam and polyethylene foam have good adhesion to the base fabric 2 made of thermoplastic fibers (
It is preferable because it has good adhesion (adhesion) and small deformation when compressed.

Examples of thermoplastic fibers used for the base fabric 2 include polyvinyl chloride, polyvinylidene chloride, polypropylene, polyacrylonitrile, modacrylic, polyester, and polyamide, among which Kanekalon (trademark, Kanekabuchi Chemical Co., Ltd.) Modacrylic resins such as those manufactured by ) are preferred because they have particularly excellent moldability and shape retention.

For example, when modacrylic is used for the base fabric 2, a method for heating the base fabric 2 to 120 to 130°C is, for example, heating the base fabric 2 to 170 to 180°C in a heating furnace.
Examples include, but are not limited to, a method of heating for 0 seconds.

[0031] If the temperature of the base fabric 2 is inappropriately low, the ease of molding and shape retention will decrease, and as a result,
Since the base fabric 2 does not stretch sufficiently during embossing, there is a risk that the base portion 1 may be at least partially compressed and deformed, or that the base fabric 2 after being coated may float. Furthermore, if the above range is exceeded, the base fabric 2 is likely to be hardened by heat or even torn due to heat shrinkage.

The base fabric 2 has, on the side not facing the base portion 1,
For example, it may have a pile made of rayon, polyester, nylon, or the like.

The pressing force (including the mold's own weight) for pressing the base fabric 2 against the base portion 1 using the upper mold 3 is 0.5 to 1.2 in the case of a musical instrument case for a trumpet, for example.
About kg/cm2 is sufficient.

As mentioned above, the base fabric 2 made of acrylic resin has excellent shape retention properties, so it can be molded into a shape that follows a mold and bonded to the packaging material, and can be floated without relying on adhesives. Although every corner of the surface of the base body 1 is covered minutely without causing any damage, an adhesive may be applied between the surface of the base body 1 and the base fabric 2 if desired.

As specific examples of the adhesive, synthetic resin-based adhesives are usually used, but both natural and synthetic adhesives can be used. Alternatively, a hot melt film or the like may be used.

In this way, as shown in FIG.
The base portion 1 is covered with the base fabric 2 that follows the surface shape of the base portion 1 throughout, and the molding and pasting are performed in a single step.

[0037]

[Effects of the Invention] According to the present invention, the molding process and the adhesion process in the conventional base coating method become a single process, and detailed manual work is eliminated, so work efficiency is dramatically improved. .

Furthermore, the excellent formability and shape retention of thermoplastic fibers, particularly modacrylic fibers, prevent the occurrence of coating defects such as floating of the substrate.

[Brief explanation of the drawing]

FIG. 1 is a schematic cross-sectional view for explaining the method of the present invention.

FIG. 2 is a schematic cross-sectional view of a coated substrate obtained by the method of the invention.

FIG. 3 is a graph showing the relationship between elongation/strength ratio at break of thermoplastic fibers and temperature.

[Explanation of symbols]

1 Base part 2　Skin material 3 Molding mold

Claims (3)

[Claims] Claim 1: A method for manufacturing a product comprising a base part and a skin part, the base part being used as one mold of a mold, and a thermoplastic resin molded product disposed between the base part and the other mold. By thermoforming the skin material using fibers,
1. A method of coating a base material with a skin material, the method comprising adhering the skin material to the base material simultaneously with molding. Claim 2: The skin material has a pile skin and a base fabric,
The method of claim 1, wherein the base fabric comprises thermoplastic fibers. 3. The method according to claim 2, wherein the thermoplastic fiber has an elongation/strength ratio at break at 100° C. of 50%/g/denyl or more.