JPH06262695A - Manufacture of lamination molding - Google Patents

Abstract

PURPOSE:To fuse woven fabric or non-woven fabric as being a skin material to a fiber composite not requiring a hot melt film to be disposed therebetween and having no fear of damaging the appearance. CONSTITUTION:A fiber composite having a great deal of glass fiber locally joined with polyethylene and also having a large number of gaps in the overall part is heated higher than the melting temperature of polyethylene in order to melt polyethylene, and on the fiber composite in a state in which polyethylene remains molten, woven fabric consisting of polyester fiber and polyethylene fiber having higher melting temperature than that of polyethylene is laminated, with result that a lamination molding is obtained by molding a lamination into a predetermined shape by press.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a laminated molded article used as an automobile interior material such as an automobile ceiling core material or a door core material and an interior material for construction.

[0002]

2. Description of the Related Art Generally, the above interior materials are required to be lightweight and have excellent properties such as rigidity, heat resistance, and adhesiveness with a skin material. Conventionally, as a material of this type, a fiber composite is known in which a large number of inorganic fibers are partially bonded to each other with a thermoplastic resin and have a large number of voids throughout (Japanese Patent Application Laid-Open No. 1-156562). (See the official gazette).

[0003]

When the above fiber composite is used for the interior material, it is heated to melt the thermoplastic resin, and then the surface of woven cloth, non-woven cloth, leather-like resin sheet, etc. is covered. The materials are laminated and formed into a predetermined shape. When laminating a leather-like resin sheet, the surface resin on the side in contact with the fiber composite is melted by the heat retained by the fiber composite,
It can be fused. However, in the case of an ordinary woven fabric or non-woven fabric, it is mainly composed of polyester fibers, and has a high melting temperature and is difficult to be fused. Therefore, it is necessary to interpose a hot melt film for fusion. Further, when a woven fabric or a non-woven fabric of low melting point fibers is used, there is a problem that the fibers shrink due to heat at the time of fusion, or they melt and impair the appearance.

An object of the present invention is to provide a method for producing a laminated molded article which allows a woven or non-woven fabric as a skin material to be fused to a fiber composite without interposing a hot melt film and without fear of impairing the appearance. To provide.

[0005]

According to a first aspect of the present invention, there is provided a method for producing a laminated molded article, wherein a large number of inorganic fibers are partially bonded with a thermoplastic resin (A) and have a large number of voids throughout. The fiber composite in which the thermoplastic resin (A) is kept in a molten state is heated to a temperature higher than the melting temperature of the thermoplastic resin (A) to melt the thermoplastic resin (A). Lamination and lamination of a woven fabric made of a thermoplastic resin (B) fiber higher than the thermoplastic resin (A) and a thermoplastic resin (C) fiber having a melting temperature equal to or lower than that of the thermoplastic resin (A). It is characterized in that an article is formed into a predetermined shape by pressing. In the method for producing a laminated molded article according to the invention of claim 2, a fiber composite in which a large number of inorganic fibers are partially joined by a thermoplastic resin (A) and which has a large number of voids throughout the thermoplastic resin ( A)
The thermoplastic resin (A) is melted by heating the thermoplastic resin (A) to a temperature higher than the melting temperature of the thermoplastic resin (A) to obtain a fiber composite having a higher melting temperature than the thermoplastic resin (A). A fiber made of B) and a thermoplastic resin (C) having a melting temperature equal to or lower than that of the thermoplastic resin (A) are defibrated and needle-punched from one direction to obtain a nonwoven fabric,
It is characterized in that the side opposite to the side subjected to the needle punching treatment is laminated and the laminate is formed into a predetermined shape by pressing.

According to the third aspect of the present invention, in the method for producing a laminated molded article, a large number of inorganic fibers are partially bonded with the thermoplastic resin (A) and the fiber composite having a large number of voids is heated. The thermoplastic resin (A) is heated to a temperature not lower than the melting temperature of the thermoplastic resin (A) to melt the thermoplastic resin (A),
A fiber composite having a melting temperature higher than that of the thermoplastic resin (A) and a thermoplastic resin having a melting temperature equal to or lower than that of the thermoplastic resin (A). (C) fibers are separately defibrated and laminated and needle-punched nonwoven fabrics are laminated on the thermoplastic resin (C) fiber side, and the laminate is formed into a predetermined shape by pressing. It is a feature.

Specific examples of the inorganic fiber include glass fiber,
Rock wool, carbon fiber, etc. may be mentioned, and the length thereof is preferably 5 to 200 mm from the viewpoint of moldability of the mat-like material described later, and the thinner the thickness, the lower the mechanical strength, and the thicker the mat during molding. 5 to 30μ because it easily breaks
m is preferable, and more preferably 7 to 20 μm. Examples of the thermoplastic resin (A) include polyeletin, polypropylene, vinyl chloride, polystyrene and the like. When the fiber composite is obtained from the mat-like material described later, it is necessary to laminate it on both sides thereof as films. The thickness of this film can be appropriately determined by the ratio with the inorganic fibers constituting the mat-like material.

The method for producing the mat-like material for obtaining the fiber composite is arbitrary, and examples thereof include a method in which inorganic fibers are supplied to a card machine, defibrated, mixed, and needle punched. The needle punch density at this time is preferably 50 to 100 per cm ² . The fibers are entangled by the needle punching process.

Thermoplastic resin films are laminated on both surfaces of the mat-like material, and the laminate is heated and compressed to impregnate the mat-like material with the molten thermoplastic resin, and then decompressed so that the impregnated resin is in a molten state. Inside, the laminate is pulled in the thickness direction and inflated to obtain a fiber composite. When manufacturing the mat-like material, thermoplastic organic fibers such as polyethylene, polypropylene, polyamide, and polyacrylonitrile may be added to join the fibers to each other and to increase the bulk of the mat-like material. In addition, at the same time, cotton,
You may add vegetable fiber, such as flax.

The fiber composite is heated by a far infrared heater, hot air or the like.

Examples of the thermoplastic resin (B) include saturated polyester and polyamide, and examples of the thermoplastic resin (C) include polypropylene, polyethylene, vinyl chloride-vinyl acetate copolymer and ethylene-vinyl acetate copolymer. Examples thereof include polymers.

The woven cloth is a cloth-like cloth used for ordinary clothes, and may be woven by mixing and spinning two kinds of fibers, or two kinds of fibers which are spun with each fiber. It may be woven with thread.

The proportion of the two kinds of fibers in the woven fabric of the invention of claim 1 and the nonwoven fabric of the invention of claim 2 is preferably 30 to 70% by weight of the fibers made of the thermoplastic resin (C). If it is less than 30% by weight, the adhesiveness will be lowered, and if it exceeds 70% by weight, shrinkage will occur on the surface of the epidermis and spoil the appearance.
Similarly, the weight of each woven and non-woven fabric is 100 to 400 g /
m ² is preferred. If it is less than 100 g / m ² , it does not have bulkiness and the fused state of the low melting point fibers becomes noticeable even from the surface. If the amount is too large, there is no problem, but 400 g / m ² or less is suitable in terms of light weight and the fusion state is inconspicuous.

The non-woven fabric according to the second aspect of the present invention is made into a non-woven fabric by defibrating and mixing with a card machine and needle punching from one direction. The length of each fiber is produced by the card machine. From the standpoint of easiness, the fiber diameter is preferably 20 to 100 mm, and the fiber diameter is not particularly limited, but is preferably 6 denier or less from the viewpoint of appearance and easiness of mixed fibers.

When manufacturing the non-woven fabric according to the third aspect of the invention, two card machines are prepared, and these are arranged in parallel toward one side of the belt conveyor. Then, for example, the thermoplastic resin (C) fibers are supplied to the card machine on one end side of the conveyor, and the thermoplastic resin (B) fibers are supplied to the remaining card machines, and these are defibrated by the card machine. After mixing the fibers, the discharged paper-like materials are laminated while being folded, and then needle punched to obtain a nonwoven fabric. By performing the needle punching process, some of both fibers are mixed with each other, but there is no particular problem.

The layer of fibers made of the thermoplastic resin (B) is preferably 100 to 300 g / m ² . If the amount is less than 100 g / m ² , there is no bulkiness, and the fused state of the thermoplastic resin (C) fibers becomes noticeable even from the surface. If the amount is too large, there is no problem, but 300 g / m ² or less is suitable in terms of light weight and fusion state. 20-100 g / m < ² > is suitable for the layer which consists of a thermoplastic resin (C) fiber. If it is less than 20 g / m ² , the fusion property is deteriorated.
There is no problem if it is too much, but it is wasteful, and this range is preferable from the viewpoint of fusion property.

[0017]

According to the method for producing a laminated molded article according to the present invention, a plurality of inorganic fibers are partially bonded with a thermoplastic resin (A) and a fiber composite having a large number of voids is heated. The thermoplastic resin (A) is melted by heating it to a temperature higher than the melting temperature of the thermoplastic resin (A), and the thermoplastic resin (A) is kept in a molten state. A woven fabric made of fibers made of a high thermoplastic resin (B) and fibers made of a thermoplastic resin (C) having a melting temperature equal to or lower than that of the thermoplastic resin (A) is laminated, and the laminate is pressed into a predetermined shape. Because it is molded into
When the woven cloth is laminated on the fiber composite, the heat of the thermoplastic resin (A) held in the molten state of the fiber composite causes the thermoplastic resin (C) made of the thermoplastic resin (C) on the side of the fiber composite contact surface of the woven cloth to be retained. The fibers melt and the woven fabric fuses to the fiber composite. As a result, the obtained laminated molded article has a surface layer made of a woven cloth on the surface.

In the method for producing a laminated molded article according to the second aspect of the present invention, a plurality of inorganic fibers are partially bonded with the thermoplastic resin (A), and a fiber composite having a large number of voids is heat-treated. The thermoplastic resin (A) is heated to a temperature not lower than the melting temperature of the thermoplastic resin (A) to melt the thermoplastic resin (A),
A fiber composite having a melting temperature higher than that of the thermoplastic resin (A) and a thermoplastic resin having a melting temperature equal to or lower than that of the thermoplastic resin (A). Nonwoven fabrics made of (C) fibers are laminated,
Since the laminate is formed into a predetermined shape by pressing, when the nonwoven fabric is laminated on the fiber composite, due to the heat retained by the thermoplastic resin (A) kept in the molten state of the fiber composite,
The fibers made of the thermoplastic resin (C) on the side of the fiber composite contact surface of the nonwoven fabric are melted, and the nonwoven fabric is fused to the fiber composite. As a result, the obtained laminated molded product has a surface skin layer made of a non-woven fabric on the surface.

Further, a nonwoven fabric obtained by defibrating fibers made of a thermoplastic resin (B) and fibers made of a thermoplastic resin (C) and subjecting to needle punching from one direction is opposite to the side subjected to needle punching ( When the needle is driven into the nonwoven fabric, the tip end side of the needle is the "opposite side" and the barb side is the "needle punched" side.) The treated side has a large number of fine small holes to give a beautiful surface and is suitable as a surface skin. On the back side, many fibers are projected by needle punching and the thermoplastic resin (C)
Not only the low-melting point fibers made of resin are heat-sealed, but also the high-melting point fibers made of thermoplastic resin (B) are pressed by the molten resin on the surface of the fiber composite, resulting in a physical adhesion effect due to the unevenness, resulting in better adhesion. become.

In the method for producing a laminated molded article according to the invention of claim 3, a plurality of inorganic fibers are partially bonded with the thermoplastic resin (A), and a fiber composite having a large number of voids throughout is heat-treated. The thermoplastic resin (A) is heated to a temperature not lower than the melting temperature of the thermoplastic resin (A) to melt the thermoplastic resin (A),
A fiber composite having a melting temperature higher than that of the thermoplastic resin (A) and a thermoplastic resin having a melting temperature equal to or lower than that of the thermoplastic resin (A). (C) fibers are separately defibrated and laminated and needle-punched nonwoven fabric is laminated on the thermoplastic resin (C) fiber side, and the laminate is formed into a predetermined shape by pressing. Therefore, when a nonwoven fabric is laminated on the fiber composite, the heat of the thermoplastic resin (A) held in the molten state of the fiber composite causes the thermoplastic resin (C) on the fiber composite contact surface side of the nonwoven fabric to be made. The fibers are melted, and the nonwoven fabric is fused to the fiber composite. As a result, the obtained laminated molded product has a surface skin layer made of a non-woven fabric on the surface.

[0021]

Embodiments of the invention of claim 1 will be described below.

Example 1 In this example, polyethylene was used as the thermoplastic resins (A) and (C), and polyester (polyethylene terephthalate) was used as the thermoplastic resin (B).

In the fiber composite of this embodiment, a large number of glass fibers are partially joined with polyethylene and have a large number of voids throughout.

The fiber composite is manufactured as follows. That is, length 50 mm, diameter 1
0 μm glass fiber and 50 mm long, 30 μm diameter polyethylene fiber were supplied to a card machine at a weight ratio of 2: 1, and after disentanglement, needle punching was performed at 80 points per 1 cm ² to obtain a thickness of 7 mm and a width of 1 m. Length 1m, average weight 4
A mat-like product with a weight of 50 g / m ² was obtained.

A high density polyethylene film having a thickness of 120 μm and a weight of 115 g / m ² was laminated on both sides of the mat-like material, and the obtained laminate was sandwiched between polytetrafluoroethylene films having a thickness of 250 μm at 200 ° C. After heating for 3 minutes, press at 200 ° C to press 5 kg / c
While compressing at a pressure of m ² and maintaining the temperature at 200 ° C., the polytetrafluoroethylene films on both sides are vacuum-sucked in the thickness direction at a speed of 1 mm / sec, and the laminate is inflated to a thickness of 4 mm and then cooled. Then, the polytetrafluoroethylene film was peeled off from the laminate to obtain a fiber composite.

A polyethylene terephthalate fiber having a diameter of 2 denier and a polyethylene terephthalate fiber having a diameter of 6 denier were knitted at a weight ratio of 6: 4 to form a woven fabric having a weight of 300 g / m ² . The fiber composite was heated to 200 ° C. to melt the polyethylene, the woven cloth was laminated on the fiber composite in which the polyethylene was kept in a molten state, and cold press-molded into a flat plate shape (thickness: about 5.5 mm).

Comparative Example 1 This comparative example is the same as Example 1 except that a woven fabric made of only polyester fibers was used.

Comparative Example 2 This comparative example is the same as Example 1 except that a woven fabric consisting of polyethylene fibers only was used.

An embodiment of the invention of claim 2 will be described below.

Example 2 In this example, a polyester fiber having a diameter of 2 denier and a length of 50 mm and a polyethylene fiber having a diameter of 6 denier and a length of 50 mm were defibrated and mixed by a card machine at a weight ratio of 6: 4. Needle punch processing from the direction (50 places / cm
² ) to obtain a non-woven fabric (thickness: about 2 mm). This example was the same as Example 1 except that this nonwoven fabric was laminated on the fiber composite on the side opposite to the side where the needle punching treatment was performed.

Comparative Example 3 This comparative example is the same as Example 2 except that a non-woven fabric made of only polyester fibers was used.

Comparative Example 4 This comparative example is the same as Example 2 except that a non-woven fabric made of polyethylene fibers alone was used.

An embodiment of the invention of claim 3 will be described below.

Example 3 In this example, a non-woven fabric is manufactured as follows.

That is, as shown in FIG. 1, two card machines (1) and (2) are prepared, and these are arranged in parallel toward one side of the belt conveyor (3). Then, the first card machine (1) was supplied with polyethylene fibers (3) having a diameter of 6 denier and a length of 50 mm, and the second card machine (1) was originally supplied.
The polyester fiber with a diameter of 2 denier and a length of 50 mm was supplied to (2), and after defibration with both card machines (1) and (2),
Papers discharged from the first card machine (1) are stacked on the belt conveyor (3) while being folded at a rate of 50 g / m ² , and then paper discharged from the second card machine (2). After further layering the shaped materials at a rate of 250 g / m ² from above, needle-punched them with a needle punch (4) at a density of 40 points / cm ² on both sides of the nonwoven fabric (5) (thickness about 2 mm ) Got. This example is the same as Example 1 except that this non-woven fabric is laminated on the fiber composite on the polyethylene fiber side.

Comparative Example 5 This comparative example is the same as Example 3 except that a nonwoven fabric made of only polyester fibers was used.

Comparative Example 6 This comparative example is the same as Example 3 except that a non-woven fabric made of polyethylene fibers alone was used.

The laminates obtained in the above Examples and Comparative Examples were cut into strips having a width of 30 mm, the skin material was peeled off from one end of the laminate, and 180 pieces of the fiber composite material and the skin material were removed by a tensile tester. Table 1 shows the results of the peeling test and the appearance. The average peel strength was taken as the adhesive strength.

[0039]

[Table 1]

[0040]

According to the method for producing a laminated molded article of the invention of claims 1 to 3, the fiber composite is provided with a woven or non-woven fabric as a skin material without interposing a hot melt film and the appearance is impaired. It can be easily fused without fear of being broken.

[Brief description of drawings]

FIG. 1 is a plan view of a nonwoven fabric manufacturing apparatus according to an embodiment of the present invention.

[Explanation of symbols]

 (1) (2): Card machine (3): Conveyor (4): Needle punch (5): Non-woven fabric

Claims (3)

[Claims] 1. A fiber composite in which a large number of inorganic fibers are partially bonded with a thermoplastic resin (A) and have a large number of voids throughout is heated to a temperature above the melting temperature of the thermoplastic resin (A). Of a thermoplastic resin (B) whose melting temperature is higher than that of the thermoplastic resin (A) and the melted thermoplastic resin (A) and the thermoplastic resin (A) are kept in a molten state. A laminated molded article, characterized in that a woven fabric made of fibers made of a thermoplastic resin (C) having a temperature equal to or lower than that of the thermoplastic resin (A) is laminated and the laminate is molded into a predetermined shape by pressing. Production method. 2. A fiber composite in which a large number of inorganic fibers are partially bonded with a thermoplastic resin (A) and have a large number of voids throughout is heated to a temperature not lower than the melting temperature of the thermoplastic resin (A). Of a thermoplastic resin (B) whose melting temperature is higher than that of the thermoplastic resin (A) and the melted thermoplastic resin (A) and the thermoplastic resin (A) are kept in a molten state. A non-woven fabric obtained by defibrating fibers made of a thermoplastic resin (C) whose temperature is equal to or lower than that of the thermoplastic resin (A) and needle-punched from one direction is laminated on the side opposite to the needle-punched side. Then, the laminated product is formed into a predetermined shape by pressing, and a method for producing a laminated product. 3. A fiber composite in which a large number of inorganic fibers are partially bonded with a thermoplastic resin (A) and have a large number of voids throughout is heated to a temperature not lower than the melting temperature of the thermoplastic resin (A). To melt the thermoplastic resin (A) and keep the thermoplastic resin (A) in a molten state, and to melt the thermoplastic resin (B) fiber having a higher melting temperature than the thermoplastic resin (A). A thermoplastic resin (C) -made nonwoven fabric obtained by separately defibrating and needle-punching a thermoplastic resin (C) fiber having a temperature equal to or lower than that of the thermoplastic resin (A) A method for manufacturing a laminated molded article, comprising laminating on a side, and molding the laminated body into a predetermined shape by pressing.