JPH0525779A - Artificial leathery formed laminate and method for forming the same - Google Patents

Abstract

PURPOSE:To obtain an artificial leathery formed laminate capable of bending from a laminated sheet having an artificial leathery uneven pattern in which an oriented film is laminated to base fabric without breaking or deteriorating the oriented film without eliminating the artificial leathery uneven pattern and discoloring and fading of a color tone and a method for forming the laminate. CONSTITUTION:An oriented plastic film (A), a cushioning layer (B) and base fabric (C) are laminated in the order of (A)/(B)/(C) and a tension applied to the oriented plastic film (A) in bending is absorbed by the aforementioned cushioning layer (B). Thereby, its toughness is kept and breaking is prevented from occurring. Furthermore, the oriented plastic film (A) is laminated through the base fabric (C) and the cushioning layer (B) to provide a laminated sheet. The resultant laminated sheet is then heated at a lower temperature than the melting point of the above-mentioned oriented plastic film (A) by >=50 deg.C to carry out bending. As a result, the tension applied to the oriented plastic film (A) in bending is absorbed and relaxed with the aforementioned cushioning layer (B) and the oriented plastic film (A) is simultaneously prevented from breaking or deteriorating. The above-mentioned artificial leathery uneven pattern is prevented from being eliminated and a color tone is prevented from discoloring and fading.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a pseudo skin-like molded laminate in which a stretched plastic film and a base cloth are integrally molded, and a molding method thereof.

[0002]

2. Description of the Related Art Conventionally, as an interior material composed of a pseudo-skin-like molded laminate of a passenger car or the like, it can be molded with synthetic leather in which a foamed sheet layer such as polyurethane or polyvinyl chloride is formed on a base cloth such as a woven fabric or a non-woven fabric. It is used that is vacuum-formed or pressure-formed by bonding with another resin substrate. Since these synthetic leathers are easily stretched and generally have an elongation of 300% or more, they can be easily integrally molded under the above-mentioned molding conditions of the moldable resin substrate. However, the surface of the synthetic leather of the molded product is inferior in abrasion resistance, and is easily scratched,
There is a drawback that it easily gets dirty. Furthermore, if you try to clean the surface by wiping it off with a solvent such as gasoline or thinner,
There is a problem that swelling, discoloration, breakage, etc. occur.

Such drawbacks and problems can be solved by laminating a stretched plastic film (hereinafter abbreviated as a stretched film) which is tough, solvent-resistant and excellent in dimensional stability on the surface of synthetic leather. However, since the stretched film has a small elongation and is generally 200% or less, it has a drawback that it is easily deformed by being greatly deformed such as bent or curved. This drawback can be solved by heating the stretched film to a temperature near its melting point and melt-molding it.
In this case, there is a problem that the toughness and dimensional stability originally possessed by the stretched film are lost, the pseudo skin-like unevenness pattern is lost, and the color tone is discolored. It was difficult.

[0004]

The object of the present invention is to solve the above-mentioned conventional drawbacks and problems, and to obtain a laminated sheet having a pseudo skin-like uneven pattern in which a stretched film is laminated on a base fabric,
It is an object of the present invention to provide a pseudo skin-like molded laminate that can be bent and molded without causing breakage or deterioration of a stretched film, disappearance of a pseudo skin-like uneven pattern, and discoloration of color tone, and a molding method thereof.

[0005]

In the pseudo-leather molding laminate of the present invention which achieves the above object, a stretched film A, a cushion layer B and a base cloth C are arranged in the order of A / B / C. It is characterized in that the laminated laminated sheets are formed by bending. In addition, the method for forming a pseudo skin-like formed laminate according to the present invention is a method in which a stretched film A and a base cloth C are laminated via a cushion layer B, and the laminated sheet is heated at a temperature lower than the melting point of the stretched film A by 50 ° C. or more. It is characterized in that it is heated to and bent to be molded.

Since the stretched film A is laminated on the base cloth C via the cushion layer B in the pseudo skin-like laminate according to the present invention, the tension applied to the stretched film A when the cushion layer B is flexibly formed is absorbed. However, it maintains toughness and prevents breakage. In addition, the cushion layer B absorbs tension to prevent the pseudo skin-like uneven pattern from disappearing.

In addition, the molding method of the present invention absorbs and relaxes the tension generated in the stretched film A by the cushion layer B during the flex-molding and has a temperature of 5 or more than the melting point of the stretched film A.
It is heated to a temperature of 0 ° C. or lower to prevent the stretched film A of the pseudo skin-like molded laminate from tearing or deteriorating, the pseudo skin-like uneven pattern not to disappear, and the discoloration of the color tone to be prevented.

The present invention will be described in detail below with reference to the drawings. 1 and 2 are cross-sectional views each showing an example of the pseudo skin-like molded laminate according to the present invention, in which 1 is a bend-molded pseudo skin-like molded laminate as an interior material for passenger cars. In FIG. 1, the pseudo skin-like laminated body 1 is formed by bending and laminating a laminated sheet 2 on the surface of a resin substrate D. Further, in FIG. 2, the pseudo skin-like molded laminate 1 is independently bent and formed as it is.

FIG. 3 is a sectional view of the laminated sheet 2. The laminated sheet 2 has a cushion layer B having a large number of voids 4 therein and a colored layer 3 for printing or pigments, dyes, etc. on a base cloth C.
It has a structure in which stretched films A are laminated via By subjecting the laminated sheet 2 of FIG. 3 to a rubbing process, as shown in FIG. 4, a large number of wrinkle-like pseudo skin-like concavo-convex patterns can be formed on the surface of the stretched film A.

As the stretched film A, polyester,
Stretched film made of polyamide, polypropylene, etc.,
A biaxially stretched film that can be formed with good balance is preferable. Among the biaxially stretched films, it is desirable to use a polyester film made of a polyester homopolymer or a copolymer, which has excellent heat resistance and can increase the molding processing temperature.

The cushion layer B has a cushioning property for absorbing the tension generated in the stretched plastic film A on the surface layer of the pseudo skin-like molded laminate 1, and preferably has a porous structure having many voids inside. It is preferable to use a stretched film. Such a porous stretched film is obtained by molding an unstretched film containing a large amount of filler, and stretching the unstretched film to form a large number of voids with the filler as a core. The voids 4 in such a porous stretched film (cushion layer B) have a concavo-convex pattern formed by crushing a part of the state shown in FIG. 3 by mechanical wrinkling such as rubbing or embossing. A permanent strain is created, and the permanent strain causes a pseudo skin-like uneven pattern to be formed on the stretched film A on the surface as shown in FIG.

As the resin used for such a porous stretched film, that is, the cushion layer B, resins such as polyester, polyamide and polypropylene having film forming property can be mentioned. Further, as the filler added to these resins, both inorganic particles and organic particles having different compatibility with the resin can be used. The inorganic particles include calcium carbonate, magnesium carbonate, alumina,
Aluminum silicate, kaolin, kaolinite, talc,
Examples thereof include clay, diatomaceous earth, dolomite, titanium oxide, magnesium oxide, and zeolite. These inorganic particles may be used alone or in combination of two or more. As the organic particles, when the resin is polyester, there are polyolefin resin particles such as polyethylene, polypropylene, polybutene, and polymethylpentene, which have good releasability from the polyester, and these may be used alone or in combination of two or more kinds. You can

The amount of these fillers added to the resin is 10
The range is preferably 40 to 40% by weight, more preferably 15 to 35.
Weight% is good. When the amount of the filler added is less than 10% by weight, the formation of voids is small and it is difficult to form an uneven pattern on the surface by mechanical wrinkling such as rubbing.
On the other hand, if the amount exceeds 40% by weight, the number of voids becomes so large that tears are likely to occur during stretching, or the porous stretched film becomes brittle.

As the base fabric C, it is preferable to use a fabric which can be sewn or laminated after the laminated body 2 such as a knitted woven fabric, a non-woven fabric, paper, a flexible base made of synthetic resin or the like is molded. . If the surface of the woven fabric is raised and the raised surface is impregnated with a flexible resin, the cushion layer B can also have the function. Further, the resin substrate D may be any one as long as it can maintain the form of the laminated sheet 2,
It is preferably made of a moldable material that is plastically deformed by heating. Examples of such a resin substrate D include a foamed sheet made of polyethylene, polypropylene, polyurethane or the like, or a thermoplastic resin sheet. The thermoplastic resin is a resin which is in a thermoplastic state at the time of molding, but may be a resin which is cured after molding. Further, the thermoplastic resin may be used as a single sheet, or may be used as a composite in which the thermoplastic resin is impregnated in paper, non-woven fabric, woven fabric or the like.

Further, the stretched film A and the cushion layer B
A printed color layer such as a pigment or a dye, a colored adhesive layer, and a vapor deposition layer can be interposed between and, as shown in FIG. The color tone includes a single color, coloring such as pattern printing, metallic tone and the like. Since such a colored layer is covered and protected by the stretched film A, there is no discoloration or discoloration, and the durability can be improved. Furthermore, the surface of the stretched film A can be subjected to a hardening treatment or printing.

As a method of flex-molding a pseudo skin-like molded laminate as shown in FIG. 1 using the above-mentioned laminated sheet 2, for example, after laminating the laminated sheet 2 and the resin substrate D, this is used. There are a method of inserting into the mold and integrally molding, and a method of superposing the laminated sheet 2 on the resin substrate D via an adhesive layer and inserting this into the mold to integrally mold. In this case, it is important to heat the molding temperature to a temperature lower than the melting point of the stretched film A constituting the laminated sheet by 50 ° C. or more.
By flex-forming at such a molding temperature, it is possible to flex-form the laminated sheet while preventing the stretched film A from breaking or deteriorating due to the synergistic effect with the tension absorbing action of the cushion layer B. In addition, it is possible to prevent the stretched film A from being broken or deteriorated, and also to prevent the formed pseudo skin-like uneven pattern from disappearing and the color tone of the laminated sheet from discoloring.

Examples of the adhesive include acrylic ester adhesive, thermosetting urethane adhesive, synthetic resin such as epoxy adhesive, and rubber adhesive. These adhesives can be coated or applied to the adhesive surface, or a powdery adhesive agent can be sprinkled on the overlapping surface and heated and melted for adhesion. Such a pseudo skin-like molded laminate of the present invention can be used not only as an interior material for cars, ships and buildings, but also as an exterior material for furniture, furniture, cases, bags and the like.

[0018]

【Example】

Example 1 A biaxially stretched polyester film having a surface gloss of 17 and a thickness of 25 μ (“Lumirror” X44 type manufactured by Toray Industries, Inc.) defined by JIS Z-8741 Method 3 (60-degree specular gloss) and a thickness of 60 μm. An axially stretched porous polypropylene film ("Trephan" YP56 type manufactured by Toray Industries, Inc.) is laminated via a colored printing adhesive layer made of a polyurethane adhesive containing a pigment, and the biaxially stretched porous polypropylene is further laminated. A polyester / rayon fabric base fabric was attached to the film side using a polyurethane adhesive to produce a laminated sheet.

This laminated sheet was applied with a clamping machine YS type manufactured by Yamasa Giken Co., Ltd. at a room temperature of 0.5.
A wrinkle rubbing process of m / min was applied to form a pseudo skin-like uneven pattern on the surface. On the base cloth surface of this laminated sheet, a polypropylene foam sheet having a thickness of 3 mm (“Pef” P manufactured by Toray Industries, Inc.)
The surface of PAM25030) was subjected to frame (flame) treatment to make it a molten state, and then laminated and adhered. The laminated sheet provided with the polypropylene foam sheet is set in a lid mold having R = 2.0 cm (length 30 cm × width 57 cm), and the surface of the biaxially stretched polyester film having the uneven pattern is heated to about 80 ° C. At the same time, the polypropylene foam sheet side was heated to about 100 ° C. and vacuum-pressure formed for about 45 seconds.
Then, it was cooled (for 2 minutes) and the pseudo skin-like molded laminate was taken out from the mold.

This pseudo skin-like molded laminate was excellent in durability without the pseudo skin uneven pattern disappearing or the color tone being discolored due to the die molding. Example 2 In Example 1, as a biaxially stretched porous polyester film, “Lumirror” E6 manufactured by Toray Industries, Inc. having a thickness of 50 μm.
"Pef" PPA manufactured by Toray Industries, Inc. using 0 type, polyester / rayon fabric (T / R7050) as a base fabric, and a polypropylene foam sheet having a thickness of 3 mm.
A laminated sheet was prepared in the same manner using M25030. This laminated sheet was set in a lid mold in the same manner as in Example 1, the biaxially stretched polyester film surface and the polypropylene foam sheet surface were heated to about 120 ° C., and vacuum pressure formed for about 45 seconds.

This pseudo skin-like molded laminate was excellent in durability without the pseudo skin-like uneven pattern disappearing or the color tone being discolored by the die molding. Further, when the pseudo-leather molded laminate formed in the lid mold was sewn and finished as a bag, a soft bag having a pseudo-leather appearance that was light and resistant to surface abrasion was obtained. Example 3 The same as in Example 1, except that the foamed sheet was not laminated and adhered to the laminated sheet which was subjected to wrinkling and rubbing on the surface to give the pseudo skin-like concavo-convex pattern and color tone in Example 2, and was set in the lid mold as in Example 1. Then, the surface of the biaxially stretched polyester film is heated to about 120 ° C., vacuum pressure molding is performed for about 45 seconds, and then cooled (2 minutes).
Then, the pseudo skin-like molded laminate was taken out from the mold.

The obtained pseudo skin-like molded laminate did not have the pseudo skin uneven pattern on the surface disappeared or the color tone did not discolor, and it had the same shape as the mold and was foldable with a flexible cable. It was Comparative Example 1 Biaxially stretched polyester film (“Lumirror” X44 type manufactured by Toray Industries, Inc.) having a surface gloss of 17 and a thickness of 25 μ as specified in JIS Z-8741 Method 3 (60-degree specular gloss) and polypropylene having a thickness of 3 mm. A foamed sheet ("Pef" PPAM25030 manufactured by Toray Industries, Inc.) was attached and laminated via a polyurethane adhesive.

This laminated sheet was treated with R in the same manner as in Example 2.
= 2.0 cm lid mold (vertical 30 cm x width 57 c
m) and heat the biaxially stretched polyester film surface and the polypropylene foam sheet surface to about 120 ° C.,
After vacuum pressure molding for 5 seconds, it was cooled (2 minutes), and the molded laminate was taken out from the mold. In the obtained molded laminate, the polypropylene foam sheet was molded, but the biaxially stretched polyester film was cut at the R portion, and a practical product could not be obtained. Example 4 A laminate obtained by subjecting the surface obtained in Example 2 to wrinkling and rubbing to give a pseudo skin-like uneven pattern and a color tone, and a foamed polypropylene sheet having a thickness of 3 mm (“Pef” PPAM manufactured by Toray Industries, Inc.
25030) was vacuum-pressure molded with a mold at a temperature of 120 ° C. via a thermoplastic polyurethane adhesive.

The obtained pseudo skin-like molded laminate was an integrally formed body in which the pseudo skin-like concavo-convex pattern on the surface did not disappear and the color tone did not deteriorate. Example 5 The biaxially stretched polyester film having a thickness of 25 μm obtained in Example 2 and a biaxially stretched porous polypropylene film having a thickness of 60 μm were adhered and laminated with a polyurethane-based adhesive to obtain the biaxially stretched porous polypropylene film. A laminated polypropylene sheet with a polyester / rayon woven fabric as a base cloth attached to the side without wrinkling and rubbing, and a 3 mm thick expanded polypropylene sheet ("Pef" PPA manufactured by Toray Industries, Inc.
M25030) was laminated and vacuum-pressure formed by a die.

The resulting pseudo-derivative molded laminate had no uneven pattern, but the color tone was not discolored at all.

[0026]

As described above, in the pseudo skin-like molded laminate according to the present invention, the tough and small stretched stretched film is laminated on the base fabric via the cushion layer, so that the cushion layer is formed during bending molding. It is possible to absorb the tension applied to the stretched film and prevent breakage. Also, by the tension absorbing action of the cushion layer, it prevents the disappearance of the wrinkled pseudo skin-like uneven pattern on the stretched film,
Discoloration of the color tone can be prevented.

Further, according to the molding method of the present invention, the tension of the stretched film is absorbed and relaxed by the cushion layer during the bending and the stretched film is deteriorated because the molding temperature is 50 ° C. or more lower than the melting point of the stretched film. Bending can be performed without causing any breakage.

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view showing an example of a pseudo skin-like molded laminate of the present invention.

FIG. 2 is a schematic cross-sectional view showing another example of the pseudo skin-like molded laminate of the present invention.

FIG. 3 is a cross-sectional view showing a part of a wrinkle-free laminated sheet used in the pseudo skin-like molded laminate.

FIG. 4 is a cross-sectional view showing a part of a wrinkled laminated sheet used in the pseudo skin-like molded laminate.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Pseudo skin forming laminated body 2 Laminated sheet A Stretched plastic film B Cushion layer C Base cloth D Resin substrate

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Seiji Murakami             1-1 1-1 Sonoyama, Otsu City, Shiga Prefecture Toray Co., Ltd.             Ceremony company Shiga business site

Claims (3)

[Claims] 1. A pseudo-leather molded laminate obtained by bending a laminated sheet in which a stretched plastic film A, a cushion layer B and a base cloth C are laminated in the order of A / B / C. 2. The pseudo-derivative molded laminate according to claim 1, wherein a resin substrate D is provided on the base cloth C side of the laminated sheet, and the laminate is laminated in the order of A / B / C / D and bend-molded. 3. A stretched plastic film A and a base cloth C are laminated via a cushion layer B to form a laminated sheet, and the laminated sheet is bent at a temperature lower than the melting point of the stretched plastic film A by 50 ° C. or more. A method for forming a pseudo skin-like molded laminate to be formed.