JPS58214589A - Production of resin molded article having fibrous raised surface - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for efficiently producing a resin molded product having a fibrous raised surface with an excellent texture and excellent bonding strength between the raised surface and a base material. be.

Raised molded products, which are created by providing a raised surface on the surface of a thermoplastic resin molded product to give it the texture of so-called animal hair or back skin, have both a shock absorption effect and a decorative effect, and are used for automobile interiors. ,
It is widely used for a variety of purposes, such as for the interior and exterior of furniture, bags, and housings, and for packaging precision instruments and glass materials.

Conventionally, the manufacturing method for such raised molded products is (1)
A method of laminating a nonwoven fabric on the surface of a notebook-shaped or three-dimensionally shaped base resin, and then subjecting it to raising treatment if necessary (
dry lamination method and wet lamination method), (
2) A method in which the melt-extruded sheet-like base resin and nonwoven fabric are bonded together by nip rollers, and then subjected to napping treatment if necessary (extrusion lamination method); 6) Base resin containing napping fibers. and (4) a method of electro-flocking fibers onto the surface of the base resin. However, in method (1) above, not only does the working environment deteriorate due to the use of adhesive, but the process is complicated and requires a great deal of labor.
In the above method Q), there is a problem in that the adhesive strength between the base material and the nonwoven fabric is poor, and delamination is likely to occur.

In addition, the above method C) is undesirable in that the entire base material contains multi-purpose fibers, and the above method (4) has the drawbacks of high equipment cost, long time required for hair transplantation, and easy hair loss of the fibers. be.

Therefore, the present inventors conducted studies with the aim of efficiently obtaining a resin molded product that has a fibrous raised surface with an excellent texture and excellent adhesive strength between the raised surface and the base material. The inventors have discovered that the above object can be effectively achieved by using composite fibers having a specific structure as the nonwoven fabric material in the above method Q), and have arrived at the present invention.

That is, in the present invention, the thermoplastic resin is a sea component, and the resin (
5) A fabric foil made of a sea-island type composite fiber in which the island component is a thermoplastic resin (b) with a melting point''! and a softening point 10°C or more higher than The solubility index for the resin (c) is ±
A resin molded product having a fibrous raised surface characterized by laminating it on the surface of a base material made of a thermoplastic resin (Q) within the range of 2, heat-sealing it, and then subjecting the laminated surface to a raising treatment. A manufacturing method is provided.

Examples of the thermoplastic resin (A) forming the sea component of the seabird-type composite fiber used in the present invention include polystyrene, styrene-acrylonitrile copolymer, polymethylmethacrylate, polyamide, copolyamide, polyester, copolyester , polyether N del block copolymer, polyester amide block copolymer, polyethylene, polypropylene, polyvinyl chloride 7+z, A
Examples include BS resin, high impact polystyrene, and mixtures thereof.

In addition, thermoplastic resin (
G) is a resin whose melting point or softening point is 10°C or more higher than that of the resin (6), and specific examples thereof include polyester such as polyethylene terephthalate, polyamide, polypropylene, polyethylene, polystyrene, polyphenylene sulfide, and polyethylene terephthalate. ethernulfon,
Examples include polyetheretherketone, polyamideimide, and mixtures thereof. Here, it is important that the melting point or softening point of the resin (c) is higher than that of the resin (g) by 10°C or more, especially by 20°C or more, and the difference is 1
If the temperature is below 0°C, the island phase of the composite fiber will partially melt when bonded to the base resin, which will cause the fiber morphology to be lost and it will be difficult to develop a fibrous raised surface, which is not preferable.

Preferred examples of sea/island combinations of seabird-type composite fibers include polyether ester block copolymer/polyethylene terephthalate, polystyrene/polyethylene terephthalate, styrene/acrylonitrile copolymer/polycapramide, polyethylene/polypropylene, and the like.

The form of these seabird type composite fibers needs to be a mutually arranged composite type in which a plurality of island components are distributed in the cross section. Excellent raised surface is not developed.

The mutually arranged composite fiber here refers to a fiber in which a large number of fine island components made of resin are highly dispersed in its cross section, and in which the island components are continuously arranged in parallel in the fiber axis direction. However, it is particularly preferable that the thickness of each island component is 1710 or less of the diameter of the composite fiber, and the number of island components is 5 or more, particularly 10 or more and 1.

Further, the cross-sectional shape of the composite fiber may be tape-shaped or ribbon-shaped in addition to the usual fibrous shape. The ratio of the island component in the composite fiber is 5 to 70% by weight, especially 1a to 70% by weight.
A preferable amount is 60% by weight, and if the amount is less than 5% by weight, the fibrous raised surface cannot generate sufficient dust.

These seabird-type composite fibers can be manufactured by ordinary composite spinning method or polymer blend spinning method and used unstretched, but in order to develop a sufficient fibrous nap surface, they must be stretched or - It is preferable to use a heat-treated one.

Fabric foils made of these sea-island composite fibers are:
Examples include mat-like materials made of continuous long fibers, and needle-punch nonwoven fabrics and stitch bonded nonwoven fabrics made of composite fibers cut into staple/I/or similar lengths, the thickness and density of which are selected as appropriate depending on the desired degree of napping. can do.

- In the strength wood invention, the thermoplastic resin G) that constitutes the base material must have a solubility index within the range of ±2, particularly ±1.5, with respect to the resin (A) that is the sea component of the composite fiber. . The solubility index referred to here is a multimeter that expresses the magnitude of the cohesive energy of molecules, and the solubility index of various resins can be found, for example, in Polymer Hunt' Book (published by Interscience Publishers), Chapter 658 pages (
(1966) and others. Resin (Koto (q)
If the difference in the solubility index of This is not preferable because it causes peeling between layers during the forming process.

The specific example of the thermoplastic resin (0) that is the base material of the present invention corresponds to the specific example of the above-mentioned resin (-), and among them, one that satisfies the above-mentioned solubility index condition is selected.

Among these, particularly desirable effects can be obtained when resins (Q and resin particles are the same or of the same genus) are combined.

The most common shape of the thermoplastic resin base material is a sheet, but it is also possible to apply the present invention to shapes having a three-dimensional shape.

In addition, thermoplastic resin (6
), (0 and the thermoplastic resin of the base material (Q) contains various additives to improve its properties, e.g.
Heat resistant agents, weather resistant agents, antioxidants, coloring agents such as pigments and dyes,
Flame retardants, fillers, antistatic agents, lubricants, crystal nucleating agents, ultraviolet absorbers, mold release agents, and the like can be added.

In order to obtain the raised resin molded article of the present invention, first, a fabric foil made of seabird type composite fiber is laminated on the desired surface of the base resin,
Heat-seal. The specific method is (a) A laminate of a cloth foil and a sheet-like base material is placed in a heating oven, and heated to a temperature above the melting point of the resin and (0) and below the melting point of the resin (g). After that, pressurize with a cooling press and heat seal.
←) A method in which the heated laminate is inserted into a mold with a predetermined shape and pressurized in the same manner as the method (a) above, and shaped at the same time as heat fusion, (c) A method in which the base resin is melted from an extruder. A method in which a cloth foil is brought into contact with the extruded molten sheet and laminated by applying pressure with nip rolls. 2) A cloth foil is attached to the desired surface of a three-dimensional object pre-molded with a base resin by high frequency welding, etc. Examples include methods of laminating and fusing.

In this lamination and heat-sealing process, it is preferable to preheat only the heat-sealable surface of the fabric foil made of sea-island composite fibers. The sheet-like or plate-like laminate obtained by the methods (a) and (c) above can be further subjected to a forming process before or after the napping treatment. Examples include a method of melting or softening the base material and pressing it with a mated die, a vacuum forming method, a pressure forming method, and a plug assist method.

The surface of the laminate obtained in this way is due to the small difference in the solubility index between the base resin (Q) and the sea component (gradient) of the composite fiber, so that the two resins are preferably compatible with each other during the melting history. , the bonding is so excellent that it is difficult to distinguish between the layers, and it appears as if the island components of the composite fibers, that is, the fine fibers, are directly dispersed on the surface of the base material.

Therefore, by subjecting the surface of this laminate to a normal napping treatment, you can easily obtain a napped surface with excellent textures such as velor-like, velour-like, and velvet-like textures, and the bonding strength of the raised surface to the base material is extremely high. There is. Raising can be easily accomplished by conventional puffing using sandpaper or water jets, and mechanical means using clothed rollers.

The thus obtained resin molded article having a fibrous raised surface of the present invention has extremely excellent texture and adhesive strength on the raised surface, and is highly expected to be applied to various fields.

The effects of the present invention will be further explained below with reference to Examples.

Example 1 Using polyethylene terephthalate with a melting point of 260°C as the island component and polyethylene with a softening point of 85°C and a solubility index of 8.5 as the sea component, the number of island components obtained by a normal composite spinning method was 16 / filament, island component ratio 60 weight, fineness 4
A nonwoven fabric was formed from denier mutually arranged composite fibers cut into fiber lengths of 50 mm.

On the other hand, ABS resin with a softening point of 90°C and a solubility index of 10.0 (
Prepare a 21-thick sheet from 'Toyowok'' 300) made by Bun V■, laminate the above nonwoven fabric on the surface, heat and soften it in an oven at 200°C, and then pressurize and heat-seal it with a cooling press. A laminated sheet was obtained.

When this laminated sheet was subjected to a plug-assist molding machine and molded into a box-shaped object, the drawing ratio H/l1=0.5-
Deep drawing was possible with No. 1, and no interlayer peeling occurred at all.

Next, the surface of the deep drawn product was raised by puffing it with sandpaper, resulting in a raised surface with a velor-like texture, and the adhesive strength of this raised surface was extremely excellent. Comparative Example 1 Melting Point A 1 to 2 inch thick sheet of polybutylene terephthalate with a solubility index of 10.7 was prepared at 215°C, and the same nonwoven fabric as in Example 1 was laminated thereon, and the surface of the laminated sheet of Example was lightly sanded with sandpaper. As a result of puffing, the nonwoven fabric peeled off, making it impossible to obtain a raised surface.

Comparative Example 2 A laminated sheet was prepared in the same manner as in Example 1, using instead of the nonwoven fabric in Example 1, a nonwoven fabric made from 4-denier fibers cut into 50aII+ fibers made by melt-spinning polyethylene terephthalate with a melting point of 260C. When the surface was puffed with sandpaper, the nonwoven fabric peeled off, making it impossible to form a raised surface.

Example 2 A nonwoven fabric was formed from mutually arranged conjugate fibers having the same seabird structure as in Example 1, number of island components 24/filament, island component ratio 60% by weight, fineness 6 denier, cut to a fiber length of 30. did.

Next, 60% of the glue with a softening point of 85°C and a solubility index of 86 and I impact vorinutylene (I Nutairon 475 manufactured by Asahi Dow ■) was added.
Melt and extrude a 3#L#I thick sheet using a 0 tunφ extruder and at the same time apply the above nonwoven fabric on the surface.
A laminate was obtained by applying pressure with a nip roller. When the surface of this laminate was sanded with sandpaper, a raised surface with a buckskin-like texture was obtained, and the adhesive strength of the raised surface was extremely excellent (7c).

Comparative Example 3 Melting point 215'C1 solubility index 16.0 as base resin
In the laminate obtained by extrusion laminating and pressing at the same time as in Example 2 using nylon 6, the base material and the nonwoven fabric peeled off at the same time as cooling.

Example 5 Polyethylene terephthalate with a melting point of 260°C as an island component and a melting point of 147'C1 with a solubility index a of 9.6 as a sea component
Using the polyether ester block copolymer of No. 4 (polybutylene terephthalate/isophthalate/polytetramethylene glycol: 70:30/100 weight ratio),
A non-woven fabric was formed from mutually arranged composite fibers obtained by a conventional composite spinning method, having an island component number of 70 filaments, an island component ratio of 50 by weight, and a fineness of 6 denier, which were cut into fiber lengths of 50I+III+.

On the other hand, melting point 164℃, solubility index 10.2 Polyny 7-
A 7-layer sterblock copolymer (polyethylene terephthalate L/-)/isophthasort/polytetramethylene glycol: 70150/25 weight ratio) was melt-extruded into a sheet with a thickness of 2 vans, and the above nonwoven fabric was prepared in the same manner as in Example 2. were simultaneously laminated to obtain a laminated sheet.

When this laminated sheet was subjected to a deep drawing machine and formed into a box-shaped object, deep drawing was possible up to a print ratio H/D = 0.7, and no peeling between the layers occurred.

Next, the surface of the deep-drawn product was raised by puffing it with sandpaper, and as a result, a raised surface with a texture similar to that of Nupaku was obtained, and the adhesive strength of this raised surface was extremely excellent.

Comparative Example 4 Nylon 6 with a melting point of 215°C and a solubility index of 13IO was
A laminated sheet was obtained in the same manner as in Example 2 by melt-extruding it into a thick sheet and laminating the same nonwoven fabric as in the actual side 6 on this.

When the surface of this laminated layer 2-) was lightly puffed with sandpaper, the nonwoven fabric peeled off, making it impossible to obtain a raised surface.

Claims (1)

[Claims] The thermoplastic resin (A) is a sea component, the thermoplastic resin (c) has a melting point or softening point higher than that of the resin (A) by 10C or more is an island component, and has a structure in which a plurality of island components are distributed in its cross section. Fabric foils made of sea-island composite fibers,
It is characterized by laminating it on the surface of a base material made of a thermoplastic resin (C1) having a solubility index within the range of ±2 with respect to the resin (A), heat-sealing it, and then subjecting the laminated surface to a napping treatment. A method for producing a resin molded product having a fibrous raised surface.