JPH09228257A - Pvc-based leathercloth for monolithic molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a PVC leathercloth composed of PVC-based resin which is, as a skin material for various kinds of plastic moldings, suitable for monolithic molding with a main body of the molding. SOLUTION: This PVC-based leathercloth is obtained by laying PVC-based resin coating layers (a skin layer 2 and a foamed plastic layer 3) on a base fabric 4, nonwoven fabric that is composed of a fiber containing polypropylene fiber and has a basis weight of 20g/m<2> or more. It is preferable that the coating layers 2 and 3 on the base fabric 4 are obtained by coating the fabric with PVC-based resin paste, and that the nonwoven fabric 4 composed of fabric which contains the polypropylene fabric consists of a mixture of polypropylene and polyester fibers at a wt. ratio of mixing within the range of (10:90) to (90:10).

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vinyl leather made of vinyl chloride resin, and more particularly to a leather suitable for being integrally molded with a main body as a skin material for various molded products.

[0002]

BACKGROUND ART Leather generally called "vinyl leather" or "vinyl chloride leather" conventionally has a skin layer made of vinyl chloride resin, and a foam layer (generally, a skin layer) is formed on the lower surface side of the skin layer. (Uses the same vinyl chloride resin as the layer)
The mainstream is a structure having a substrate layer (generally a woven fabric or a knitted fabric) in this order.

Vinyl or vinyl chloride leather (hereinafter referred to as vinyl chloride leather) having the above-mentioned structure is used for interior materials such as doors, seats and inner walls for vehicles (passenger cars, trucks, etc.), furniture such as chairs and cabinets, bags, etc. It is widely used as a skin material for various personal items.

Among these skin materials, those used as skin materials for molded articles such as vehicle doors and seats have the following usage modes (a) and (b), for example. Has been taken. In addition, the usage examples of (a) and (b) are as follows.
A case where the above-mentioned molded product is a vehicle door will be described.

(A) As shown in FIG. 4, the wood chip board 11 which is the main body of the door is first shaped into a door shape 11 '. Next, an adhesive 12 is applied to the surface of the wood chip board door body 11 'located inside the vehicle, and then the above-mentioned vinyl chloride leather 13 serving as a skin material is placed. And
These three members are integrally heat-press-molded to obtain the door 14 provided with the skin material forming a part of the interior material.

(B) As shown in FIG. 5, as the material of the door main body, a flat plate 21 made of polypropylene resin having a hot melt agent layer 22 on one side is used. First, the hot melt agent layer 22 is heated to be softened, and the vinyl chloride leather 23 serving as a skin material is placed thereon. Next, these are integrally heat press-molded to obtain the door 24 including the skin material forming a part of the interior material.

However, in the above-mentioned use mode (a), a step of preliminarily shaping the wood chip board 11 into the door shape 11 'is required, and the step of applying the adhesive 12 and by extension the adhesive A process for drying 12 is also required, and the number of processes is large, resulting in poor productivity. On the other hand, in the use mode of the above (b), the step of shaping the polypropylene resin flat plate 21 into the door shape is unnecessary, but the hot melt agent layer 2
The step of providing 2 and the step of heating and softening the hot-melt agent layer 22 are required, and the number of steps is also large, and the productivity is not necessarily high.

[0008]

The object of the present invention is to eliminate the various drawbacks of the above-mentioned use modes (a) and (b) and to obtain a highly productive integrally molded product, which is a so-called integrally molded salt for a skin material. The purpose is to provide bilazers at low cost.

[0009]

SUMMARY OF THE INVENTION The present inventors have made the following findings as a result of repeated studies to achieve the above object.

In any of the above modes (a) and (b), the vinyl chloride leather 13 and 23 are integrally heat-press-molded together with the wood chip plate 11 'and the polypropylene resin plate 21. Needs some elasticity. This stretchability is left to the base material of PVC leather. Therefore, as described above, the base material of the integrally molded vinyl chloride leather has a high cost but an elongation of 160 to 170.
It was said that it was limited to knitted fabrics and woven fabrics, which had excellent elasticity of about 100%. However, the inventors of the present invention dare to use a non-woven fabric, which has been conventionally unsuitable as a base material for a vinyl chloride leather for integral molding, because the cost is low, but the elongation is about 70 to 80% and the elasticity is poor. When used as a base material of the above, and using the leather as a skin material according to the usage modes of (a) and (b) above, surprisingly, there is no problem and the surface material is in a good state and has a high quality. We have found that an integrally molded product can be obtained.

Therefore, the present inventors have made the above (a),
As a result of further study in order to eliminate the use of the adhesive 12 and the hot melt agent 22 which are indispensable to the use mode of (b), it is necessary to use a specific type of fiber as the fiber constituting the nonwoven fabric. I got the knowledge of.

The vinyl chloride resin leather for integral molding of the present invention is based on the above findings, and is made of a fiber containing polypropylene fiber, and a nonwoven fabric having a basis weight of 20 g / m ² or more is used as a substrate. It is characterized in that it has a coating layer of vinyl chloride resin on it. At this time, the coating layer on the substrate is preferably obtained by a coating method such as a vinyl chloride resin paste casting method or a vinyl chloride resin calendar method, and a non-woven fabric made of fibers containing polypropylene fibers. Is a mixture of polypropylene fiber and polyester fiber, and the mixing ratio of polypropylene fiber and polyester fiber is 10/90 by weight.
It is preferably 90/10.

The nonwoven fabric in the present invention is composed of fibers containing polypropylene fibers, and may be polypropylene fibers alone or a mixture with other fibers.
Other fibers include synthetic fibers such as polyester fibers, polyamide fibers, vinyl fibers, acrylic fibers, acetate fibers, and polyolefin fibers other than polypropylene, as well as natural fibers such as cotton, hemp, hair, silk, pulp, rayon, etc. Semi-synthetic fibers, mixed fibers or mixed fibers of these,
Various fibers can be used. Above all, a mixture with a polyester fiber is preferable because of its good compatibility with polypropylene fiber and the like.

The above-mentioned polypropylene fibers are, for example, the material for the main body of the above-mentioned vehicle doors and seats, and other various molded products (hereinafter sometimes simply referred to as "molded products"), and the vinyl chloride leather of the present invention. Melts when and are integrally molded,
It acts as a so-called adhesive agent for integrally fixing the material of the main body and the vinyl chloride leather of the present invention. Of course, among the other fibers that make up the mixture with polypropylene fibers,
Some of them have the property of being melted during the above integral molding to promote the action of the above polypropylene fibers as an adhesive.

The content of the polypropylene fiber having the above-mentioned function is not particularly limited, but it is necessary that the content of the main body material and the vinyl chloride resin of the present invention be such that they can be fixed with practical strength. is there. Further, this amount may be appropriately selected in consideration of the content of this fiber when another fiber having the property of promoting the action of the polypropylene fiber as an adhesive is used as described above.

Particularly in the case of a mixture of polypropylene fiber and polyester fiber, the mixing ratio of polypropylene fiber and polyester fiber is preferably 10/90 to 90/10 by weight for the following reason. . Polyester fiber has a high melting point, and does not have the property of promoting the action of polypropylene fiber as an adhesive as described above,
Adhesion between the molded body and the leather of the present invention is exclusively made of polypropylene fiber. For this reason, if the content of polypropylene fiber is too small, it becomes impossible to obtain an integrally molded product with practical adhesive strength. On the contrary, if the content is too large, the amount of polyester fiber becomes relatively small, The technical significance (sufficient heat resistance in the leather manufacturing process) as a mixture with is not expressed.

The mixture of polypropylene fiber and polyester fiber may be obtained by spinning or fiberizing them separately and mixing them uniformly at the above mixing ratio. It may be made of a blended fiber having a mixing ratio, or may be made of a core (polyester) sheath (polypropylene) type fiber having the above mixing ratio.

It is important that the basis weight of the non-woven fabric containing the polypropylene fiber is 20 g / m ² or more. When the basis weight is less than 20 g / m ² , not only is it difficult to maintain the shape (sheet-like shape) of the vinyl chloride leather of the present invention, but the amount of polypropylene fibers that perform the above-mentioned action is also relatively small. It is also extremely difficult to fix the molded product body and the vinyl chloride leather of the present invention with practical strength.
The upper limit of the basis weight is not particularly limited, but if it is too large, the above-mentioned integral molding operation becomes difficult, and the appearance of the molded product as a skin material may be impaired, and the material cost also rises. Therefore, it is generally preferable that the amount is about 200 g / m ² .

The vinyl chloride resin coating layer on the substrate made of the non-woven fabric as described above is, as schematically shown in FIG.
The vinyl chloride leather 1 of the present invention comprises a skin layer 2 forming a surface layer and a foam layer 3 on the lower surface side. In addition, in FIG. 1, 4 is a base material which consists of said nonwoven fabric.

The coating layer is made of a vinyl chloride resin as a raw material, or a vinyl chloride resin paste (a vinyl chloride resin paste mixed with a plasticizer). Cast (ca
The coating layer may be provided by the st) method or other various methods, but in the present invention, the coating layer by the casting method is preferable.

The casting method will be briefly described below. First, on an appropriate material having release properties such as release paper,
A vinyl chloride resin paste to be the skin layer (reference numeral 2 in FIG. 1) is coated, and the paste is heated to gel. Next, the gelling layer is coated with a foamable vinyl chloride resin paste (a vinyl chloride resin paste containing a foaming agent) to be a foam layer (reference numeral 3 in FIG. 1), and the paste is heated again. Gels and foams. Thereafter, the vinyl chloride resin coating layer thus formed is coated with an adhesive, and the above-mentioned non-woven fabric substrate (reference numeral 4 in FIG. 1) is formed.
Is placed. When this state is finally heated for secondary foaming, drying of the adhesive, etc., and the release paper is peeled off, the vinyl chloride resin of the present invention coated with a vinyl chloride resin paste (reference numeral 1 in FIG. 1 is used. ) Is obtained. In addition, at the time of this final heating, a punching process may be performed from the base material side, and gas generated by secondary foaming, drying of the adhesive, or the like may be exhausted from the punching hole.

The vinyl chloride leather obtained by the above-mentioned casting method has the following effects as compared with the vinyl chloride leather obtained by the calendar method or other methods. (A) A good balance of vertical and horizontal elongation. (B) There is little restoration property (the property of returning to the state of the flat leather before molding) after the above integral molding. (C) When a release paper having a pattern such as a striated pattern is used as a material having a release property, the release paper or the like is formed on the vinyl chloride resin layer (skin layer) formed on the release paper or the like. Since the striated pattern is transferred, it is possible to easily attach a pattern to the surface of PVC leather. (D) Since the casting method uses a vinyl chloride resin paste as a raw material, the squeezing temperature is 190 to 200 ° C., which is higher than the squeezing temperature of 150 to 160 ° C. in the calendering method. For this reason, there is a possibility that the pattern by the calendar method may be erased at the temperature at the time of integral molding (for example, when the material of the main body of the molded product is polypropylene resin which is widely used, about 160 to 180 ° C.). On the other hand, there is no fear that the pattern produced by the casting method will be erased. (E) When forming the vinyl chloride resin coating layer, the foam layer below the skin layer can be formed at the same time, and the step of providing the foam layer separately can be omitted.

As the vinyl chloride resin used in the above vinyl chloride resin paste, vinyl chloride alone or vinyl chloride and other monomers such as vinyl acetate, ethylene, propylene, maleic acid ester, methacrylic acid ester, Polymers and copolymers obtained by emulsion polymerization, microsuspension polymerization, etc., with acrylic acid esters, higher vinyl ethers, etc., and vinyl chloride-based polymers and copolymers commonly used in ordinary vinyl chloride leather are available. Each of these alone,
Alternatively, a plurality of them can be used together.

Examples of the plasticizer used to make these vinyl chloride resins into a paste include di-2-
Ethylhexyl phthalate (DOP), Diisononyl phthalate (DINP), Butyl benzyl phthalate (B
BP), diisodecyl phthalate (DIDP), diundecyl phthalate (DUP), and other general phthalate ester plasticizers; dioctyl adipate (DO)
A), general fatty acid ester plasticizers represented by dioctyl sebacate (DOS), dioctyl azelate (DOZ) and the like; trioctyl trimellitate (TOT)
M) and other trimellitic acid ester plasticizers;
Triaryl phosphate ester-based plasticizers such as tricresyl phosphate (TCP) and trixylyl phosphate (TXP); epoxy-based plasticizers such as epoxidized soybean oil and polyesters such as polypropylene adipate Polymer plasticizers such as system plasticizers; general plasticizers such as chlorinated paraffins; and the like, and these may be used alone or in combination of two or more.

The proportion of these plasticizers to be used is not particularly limited, but it is suitable for preparing the vinyl chloride leather of the present invention by the above-mentioned casting method, and the vinyl chloride leather of the present invention prepared by this method is used. In order to make it suitable for use as a skin material for a molded product, it is generally preferable to use about 30 to 100 parts by weight with respect to 100 parts by weight of a vinyl chloride resin.

The above vinyl chloride resin paste contains various types of stabilizers, fillers, pigments, antistatic agents, ultraviolet absorbers, light stabilizers, antiaging agents, and other types of vinyl chloride resin commonly used in ordinary vinyl chloride leather. You may mix an additive.

In addition to these additives, a vinyl chloride resin paste for obtaining a foam layer may be used when a vinyl chloride resin such as azodicarbonamide, dinitrosopentatetramine and oxybisbenzenehydrazide is foamed. Common foaming agents used are compounded.

Generally, the same kind of vinyl chloride resin is used for the skin layer 2 and the foamed layer 3 which constitute the vinyl chloride resin coating layer, but different kinds of vinyl chloride resins are used if they are well compatible. You may use the vinyl chloride resin of.

In order to use the vinyl chloride leather of the present invention obtained as described above as a skin material for a molded product, for example, a mode as shown in FIG. 2 is adopted. In FIG. 2, 5
Is a material of the main body of the molded product, and here, it is assumed that a polypropylene resin plate is used. First, the polypropylene resin plate 5 is heated to 160 to 180 ° C.,
Soften. Next, the vinyl chloride leather 1 of the present invention is placed on the softened polypropylene resin plate 5 with the substrate (reference numeral 4 in FIG. 1) surface made of a non-woven fabric facing the resin plate 5, and the upper mold 61 is placed.
And a lower die 62 for press molding. In this way, a molded product 7 having the vinyl chloride leather 1 of the present invention as the skin material and the polypropylene resin 5 as the main body can be obtained.

Further, the vinyl chloride leather of the present invention can be used in a mode as shown in FIG. Also here,
As the material of the main body, polypropylene resin will be described. First, a molten mass 5'of polypropylene resin is injected onto the lower mold 62, and the vinyl chloride laser 1 of the present invention is placed thereon. Then, the upper die 61 is press-molded to obtain a molded product 7 having the vinyl chloride leather 1 of the present invention as a skin material and a polypropylene resin as a main body portion 5.

As described above, by using the vinyl chloride leather of the present invention, the preforming step (see FIG. 4) of the material 11 for the main body of the molded article, which is necessary when the conventional skin material is used, and The use of the main body material 21 with the adhesive 12 or the hot melt agent 22 (see FIG. 5) becomes unnecessary, and the manufacturing cost of the molded product and the material cost can be significantly reduced. In particular, even when adopting the molding mode of the main body portion as shown in FIG. 3, the vinyl chloride leather of the present invention may be simply placed on the amorphous polypropylene resin injected onto the lower mold, It is an important skin material for further reduction of manufacturing cost.

When the vinyl chloride leather of the present invention is used as a skin material, the material which can be used for the main body of the molded product is not limited to the above-mentioned polypropylene resin, but polyethylene resin, the above-mentioned wood chip board, or other ordinary materials. It may be the material used for the body of the molded article.

[0033]

【Example】

Examples 1 to 3 and Comparative Example 1 A non-woven fabric made of a mixed fiber of polyester fiber and polypropylene fiber having four kinds of compositions shown in Table 1 is used as a base material,
Using the vinyl chloride resin pastes of Formula 1 and Formula 2 shown in Table 2, the vinyl chloride leather of the present invention and the comparative vinyl chloride leather were prepared by the casting method in the following manner.

[0034]

[Table 1]

[0035]

[Table 2]

First, a polyvinyl chloride paste having a composition of 1 shown in Table 2 was coated on a release paper having a striated pattern to a thickness of 0.50 mm and heated in a gear oven at 150 ° C. for 3 minutes, The paste was gelled. Next, a polyvinyl chloride paste of the formulation 2 shown in Table 2 was coated on the gelled surface to a thickness of 0.50 mm, and heated in a gear oven at 200 ° C. for 3 minutes to gel the paste. And foamed. Then, the gelled / foamed surface is coated with a two-component curing type urethane sol adhesive in a thickness of 0.1 mm,
While the adhesive does not dry (wet), the base material made of the non-woven fabric shown in Table 1 is placed on the adhesive layer (wet laminating) and heated in a gear oven at 80 ° C. for 3 minutes. The adhesive was dried. After that, the release paper was peeled off and left at room temperature for 1 day or more for curing.

The above operation was carried out on each of the four types of non-woven fabric substrates shown in Table 1 to obtain three types of the PVC leather of the present invention and one comparison PVC leather. The cross-sectional structures of these four types of vinyl chloride leather were the same as those shown in FIG. 1, and the surface pattern of the skin layer 2 was formed with a print pattern transferred from the release paper.

Each of the three kinds of vinyl chloride leather of the present invention thus obtained and one kind of comparative vinyl chloride leather was used as a skin material of a molded product according to the embodiment shown in FIG. That is, the vinyl chloride leather 1 of the present invention was placed on the polypropylene resin plate 5 which was heated to 170 ° C. to be softened, with the base material surface made of the non-woven fabric facing the resin plate 5, and the upper mold 61
And by the lower mold 62, 20 at a pressure of 40 kgf / cm ² .
Press molding was performed for 2 seconds to obtain a molded product. After cooling to room temperature, a sample with a width of 3 mm was cut out from the molded product, and a skin material 1 made of the vinyl chloride leather of the present invention or a comparative vinyl chloride leather
And the peel strength between the molded product body 5 made of polypropylene resin was measured. The results are shown in Table 3.

[0039]

[Table 3]

As is clear from Table 3, when the vinyl chloride leather of the present invention is used as the skin material, it is impossible to peel the skin material from the main body portion, which means that the skin made of the vinyl leather of the present invention is used. The material clearly indicates that the material is molded as an integral part of the main body by press molding.
On the other hand, when using the comparative PVC leather as the skin material,
It peels off extremely easily, and it is understood that an adhesive or the like is required as in the conventional case in order to use it as a skin material for a molded product.

[0041]

As described in detail above, the use of the vinyl chloride leather of the present invention as the skin material of various molded products can bring about the following effects. (1) The skin material and the main body of the molded product can be integrally molded by simply pressing together with the material of the main body of the molded product. (2) Therefore, it is not necessary to preform the main body material of the molded product and to install the hot-melt agent layer on the main body material, which is required when using the conventional skin material, and the manufacturing process of the molded product Can be simplified and the material cost can be reduced.

[Brief description of drawings]

FIG. 1 is a diagram schematically showing a cross section of a vinyl chloride laser of the present invention.

FIG. 2 is a diagram showing an example of an embodiment in which the vinyl chloride leather of the present invention is used as a skin material of a molded product.

FIG. 3 is a view showing another example of the case where the vinyl chloride leather of the present invention is used as a skin material of a molded product.

FIG. 4 is a diagram showing an example of a case where conventional vinyl chloride leather is used as a skin material of a molded product.

FIG. 5 is a diagram showing another example of the case where a conventional vinyl chloride leather is used as a skin material of a molded product.

[Explanation of symbols]

 1 PVC Leather of the Present Invention 2 Skin Layer 3 Foaming Layer 4 Base Material Made of Nonwoven Fabric Containing Polypropylene Fibers 5, 5 ', 11, 11'21 Body Material of Molded Product 61 Upper Mold 62 Lower Mold 7, 14, 24 Molding Product 12 Adhesive 13,23 Conventional PVC leather 22 Hot melt agent

Claims (3)

[Claims] 1. A non-woven fabric made of fibers including polypropylene fibers and having a basis weight of 20 g / m ² or more as a base material,
A vinyl chloride resin leather for integral molding, comprising a vinyl chloride resin coating layer on the base material. 2. The vinyl chloride resin leather for integral molding according to claim 1, wherein the coating layer on the substrate is obtained by coating with a vinyl chloride resin paste. 3. The non-woven fabric made of fibers containing polypropylene fibers is made of a mixture of polypropylene fibers and polyester fibers, and the mixing ratio of polypropylene fibers and polyester fibers is 10/90 to 90/10 by weight. Item 1. A vinyl chloride resin leather for integral molding according to item 1 or 2.