JPS61111170A - Manufacture of suede sheet material for forming - Google Patents

Abstract

PURPOSE:To manufacture the titled suede sheet material looking fine externally by forming an adhesive layer of a paint of vinyl chloride resin paste on a vinyl chloride resin layer contg. a plasticizer, and flocking electrostatically a stable fiber of soft vinyl chloride resin on the adhesive layer. CONSTITUTION:A soft composition contg. polyvinyl chloride resin and a plasticizer is used as the base material, and heated and softened to form a sheet material. A paint paste using a vinyl chloride resin composition in then coated on the surface of said sheet material as an adhesive to form an adhesive layer. A staple fiber consisting of soft vinyl chloride resin is successively flocked electrostatically on the adhesive layer by using a electrostatic flocking device. A suede sheet material for forming with an excellent suede feel is manufactured in this way.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention has shapeability that is suitable for molding processing, that is, vacuum forming, pressure forming, and press forming. The present invention relates to a method for producing a suede-like/t-like material that has fine flocking on its surface and has an excellent suede feel and flexibility and is useful as a material for vehicle interior materials, furniture, daily necessities, etc.

[Conventional technology]

In recent years, the use of molded products with a suede-like appearance has been increasing due to their solid design, but especially for interior materials such as vehicles, it is important to have anti-glare properties against direct sunlight, safety, tactility, etc. Therefore, there is a demand for the use of materials with a flexible texture. For this reason, many suede-like molding sheets have been manufactured using plastinokuntu as a base material. From the viewpoint of productivity and production cost, soft vinyl chloride resin notebooks are optimal, and various methods of manufacturing suede-like molded notebook materials using this as a base material are known. That is, as a method for producing a suede-like molded notebook using a conventional soft vinyl chloride resin, a sheet of soft vinyl chloride resin is pressed in a heated molten state onto a roll having fine holes.

A method of press-fitting into the pores of a roll, then stretching and peeling it from the pores, and other methods.

A vinyl acetate or acrylic resin paint is applied as an adhesive onto a soft vinyl chloride resin, and electrostatic flocking is performed on the adhesive layer using various short fibers such as nylon/polyester, rayon, and cotton. There are known processing methods.

However, in the former method, it is not only extremely difficult to produce a roll having micropores, but also it is difficult to produce the suede-like/tray-like product.

As the notebook is stretched in a heated and molten state and peeled off by the roll, the shape of the individual fluffs becomes irregular, and there is a limit to how closely the pores of the roll can be spaced, resulting in a lack of density and the assembled fluff. It is difficult to obtain a material with an excellent suede feel, and when it is molded, the spacing between the fluffs is further expanded, causing gloss in the troughs and causing problems in appearance. On the other hand, the latter method of making various short fibers into a suede-like or sheet-like material by electrostatic flocking uses a soft vinyl chloride resin sheet as a base material and coats the surface with vinyl acetate resin, urethane resin, or acrylic resin. An adhesive layer consisting of 1 is coated and then various short fibers are electrostatically flocked onto this layer. Although it has a honey bean and excellent suede look, when vacuum forming is performed using the sheet, the adhesive layer made of vinyl acetate resin has poor heat resistance and softens when it reaches the heating temperature during the forming process. As it melts, the function of the adhesive layer is lost, and a suede-like molded product cannot be obtained.Also, since the acrylic resin adhesive layer is hard and does not stretch, it cannot withstand the heating and stretching force during molding, and the adhesive layer film breaks. However, this method also has the disadvantage that a suede-like molded product with a perfect appearance cannot be obtained.

[Problems to be solved by the present invention]

The present invention is directed to a product 7 due to the complexity of roll creation in the roll shaping method as described above and the lack of pore density of the roll.
- There is no lack of suede-like appearance of the sheet and its molded product, and on the other hand, heating in the vacuum forming process due to the adhesive layer on the soft vinyl chloride resin sheet in the electrostatic flocking method.

There is no deterioration in heat resistance due to stretching and no breakage of the film of the layer,
In addition, it has a dense and fine fuzz that does not cause problems such as lack of adhesion to the short fibers to be applied, and has an excellent suede feel that maintains its excellent appearance even after the above-mentioned molding. A method for manufacturing a suede-like notebook is provided.

[Failure to solve the problem]

The present invention is a molding process in which an adhesive layer of vinyl chloride paste resin paint is formed as an adhesive on a soft vinyl chloride resin layer containing a plasticizer, and short fibers of soft vinyl chloride resin are electrostatically flocked on the surface of the adhesive layer. This is a method for manufacturing a suede-like sheet material.

[Effect]

The method of the present invention will be explained below.

In the present invention, a soft composition containing a polyvinyl chloride resin and a plasticizer is used as a base material, and this is softened by heating.
A colored or uncolored 7-tab material is formed, and then a paste paint using a vinyl chloride resin composition is applied to the surface of the material to form an adhesive layer, and an electrostatic flocking device is continuously applied on the layer. By electrostatic flocking processing of short fibers made of soft vinyl chloride resin using a method, a suede-like suede-like material for molding is obtained. Various methods can be used to form the soft vinyl chloride resin layer that serves as the base material of the present invention, such as calendering, coating, and extrusion, but calendering is preferable from the standpoint of mass productivity and production cost. . In addition, the above-mentioned sheet can be used as a single sheet, but it can also be laminated with a material that can be appropriately formed (for example, a non-woven fabric, a plastic sheet made of nylon cloth, or a laminate of two or more of these). It can also be used as

Further, as the above-mentioned coating method, a knife coater, a bar coater, a roll coater 1, a flat coating method using a flat printing machine, etc. can be applied. In this method, the above-mentioned soft vinyl chloride resin composition is used as a paste coating, coated on a mold release material, heated to gel, and after cooling, the release paper is peeled off to obtain a single base material.

The moldable material is bonded directly or with an adhesive before peeling off the release paper, and then the release paper is peeled off to obtain a composite base material. No matter which method is used, the thickness of the sheet layer is 0.3 mm or more.
The amount should be in the range of 1.0 fl, preferably 0.3 to 0.8 fl. If the thickness is less than 0.31 m, the notebook will be too thin and will break due to stretching when the sheet-like product is shaped.
If it is 6 or more, it is too thick and does not fit the molding shape.

The /-to layer of the base material is not limited to a non-porous material, but may be a porous material produced by a method such as chemical foaming, reactive gas, or mechanical stirring. It's okay. The porous layer may be used alone or may be laminated on the moldable material. In this case, the thickness of the porous layer is 0.511111-3. Off is preferable. If it is less than 0.5, it will be too thin and will break due to stretching, and if it is more than 3.0, it will be too thick and will not be suitable for molding.

Next, a paste paint made of a soft vinyl chloride resin containing a plasticizer as an adhesive is laminated on the surface of the first layer of the base material 7. Method -f: is performed using a knife coater, bar coater, roll coater, or gravure printing machine. A general coating method such as a solid coating method is used. The coating thickness of the adhesive layer is preferably 0.01 to 0.10 fi. 0
．． 01 order and below are used during the electrostatic flocking process in the subsequent process.

It is too thin and lacks the bonding strength of short fibers, 0.1OIII+
If it is +1 or more, it is too thick and the short fibers become embedded, resulting in the loss of the suede feel of the product. After the adhesive layer is formed, soft vinyl chloride resin short fibers are electrodeposited on the surface of the adhesive layer using an electrostatic flocking device to perform flocking. As a method for performing the electrostatic flocking process, any known device and method that are generally widely used may be used. After the completion of the processing, the temperature is subsequently increased from 120°C to 170°C, preferably from 140°C to
Heat treated at a temperature of 160°C.

The adhesive layer is gelled to bond and fix the flocked short fibers. In this case, if the treatment temperature is below 140°C, the adhesive layer will not completely gel and the short fibers will not be fully bonded and fixed, and if the processing temperature is above 170°C, the adhesive layer will soften, melt and become fluid. The short fiber bonding function is lost.

Subsequently, a cooling treatment is performed to cool and solidify the adhesive layer, and the flocked short fibers are completely set to obtain a suede-like notebook-like article for molding, which is the object of the present invention.

The notebook-like article obtained as described above not only easily blends in because the base material 9 adhesive and the short fibers to be electrostatically flocked are both based on vinyl chloride resin, but also because the adhesive layer is made of vinyl chloride paste resin. Because the gelation temperature is low, the short fibers flocked to it can be sufficiently held without the risk of softening and deforming, and it also forms a net without heat resistance deterioration and film breakage due to heating and stretching during the molding process. can get things.

Next, the soft vinyl chloride resin used in the base resin layer of the present invention is vinyl chloride, or vinyl acetate containing vinyl chloride alone or polyvinyl chloride as a main component.

Copolymers of acrylic acid, ethylene-vinyl acetate, etc.; acrylic, butadiene, styrene copolymers; mutual mixtures of urethane, synthetic rubber, etc. and vinyl chloride, etc. When vinyl chloride resin is used alone, the degree of polymerization is the average Degree of polymerization is 800
-3000 can be used, but 1000-1700 is preferable. If the degree of polymerization is less than 800, the base material will break due to the stretching force during the vacuum forming process,
If it is 3,000 or more, the tensile strength of the notebook is too high and does not suit the shape during molding.

The above-mentioned resins are mixed with plasticizers, stabilizers, pigments, foaming agents, fillers, etc. as necessary. In this case, the plasticizer that can be used is mainly a known phthalate ester plasticizer that is commonly used for polyvinyl chloride.

Acid/acid ester plasticizers, chlorinated paraffin, etc. can also be mixed and used as appropriate. The amount of the plasticizer mixed in is 10% of the resin used.
30 to 100 parts by weight relative to 0 parts by weight, but 50 to 100 parts by weight
80 parts by weight is preferred.

If it is less than 30 parts by weight, it will be too heated and softened during the molding process and the base material/layer will be cut, and if it is more than 80 parts by weight, the degree of heat softening will be low and the mixture other than the plasticizer will not be suitable for molding. may be used in an appropriate amount within a range that does not impede the moldability.

Next, as the resin for the soft vinyl chloride resin paste paint applied to the surface of the base material/-t, a vinyl chloride resin for paste is used, and in addition to this, the same kind of plasticizer as used for the base material notebook, Stabilizers are mixed in to create a paste paint. In this case, it is necessary to use a vinyl chloride resin for the paste that has a low gelation temperature.

The reason for this is that it is essential that the short fibers are not softened or deformed when they are heated and gelled in order to bond and fix the electrostatically flocked soft vinyl chloride short fibers in the subsequent process. . The average degree of polymerization used for this resin is 80.
0 to 2500 is used, but 1000 to 170
It is preferable to use 0.

If the degree of polymerization is less than 800, the gelation temperature will be too low.
When the short fibers are heated and softened and melted during the molding process, the desired suede-like appearance cannot be obtained because the short fibers cannot be retained, and if it is more than 2,500, the short fibers are deformed when the short fibers are set, and the tensile strength during molding is too strong. Not suitable for molding. The amount of plasticizer to be mixed is preferably 50 to 80 parts by weight, taking into account the problems mentioned above during short fiber centrifugation and molding.

・The short fibers of the soft vinyl chloride resin for electrostatic flocking used in the present invention are polyvinyl chloride resin alone or copolymers of vinyl acetate, acrylic acid, ethylene acetic acid, etc. whose main component is vinyl chloride resin; Acrylic, butadier/,
Styrene copolymer: A mutual mixture of ureta/7 synthetic rubber or the like and a vinyl chloride resin, and when the vinyl chloride resin is used alone, the average degree of polymerization is preferably 1,000 to 3,000. If the polymerization degree is less than 1000, the short fibers will be softened and deformed during the heat treatment of the adhesive layer after the flocking process and the molding process, and if it is more than 3000, it will be difficult to manufacture the short fibers used in the present invention, which is not preferable. .

Commonly used plasticizers, stabilizers, and agents similar to those used in the base material of the present invention for these resins,
Depending on the case, fillers may be used in combination. In this case, the amount of plasticizer mixed is preferably 30 to 100 parts by weight per 100 parts by weight of the resin.

If the amount is less than 30 parts by weight, the flocked short fibers made of the blended composition will be softened and deformed during the heat treatment of the adhesive layer and the molding process, and if it is more than 100 parts by weight, the flocked fibers will have a fluffy texture as a product of the present invention. is too hard, so the purpose of the present invention cannot be achieved.

In addition, the fiber length and thickness of the short fibers used in the present invention are in the range of 0.2 to 5 mm and 140 to 20 denier, respectively, in view of the suede feel of the suede-like molded product to be finally obtained. It is preferable to select and use them appropriately.

The thus obtained product of the present invention has an excellent suede feel and design, and also has excellent moldability.It can be used as an automobile interior material, especially as an interior material for automobiles, especially as an interior material for automobiles, for example, as an interior material for automobiles.
It is useful as a molding material for doors, pillar materials, furniture, daily necessities, etc.

Example 1 Approximately 150% of the soft vinyl chloride resin composition for substrates having the following formulation
The mixture was kneaded using a milling machine at 100°C, and then molded into a beige base material with a thickness of about 100 mm and 500 cm using Kanrenodarol. Next, using a knife coater, a soft vinyl chloride resin paste paint of the following composition was applied and laminated as an adhesive to a thickness of 0.0181R11 to form a beige adhesive layer, and then After using an electrostatic flocking device to electrostatically flock beige short fibers with a fiber length of 3 mm and a thickness of 5 denier made of soft vinyl chloride resin of the following composition: 1
, continuous, hot air heating furnace? 15 using
The adhesive layer was heated at 0° C. for 2 minutes to gel, and then cooled to completely fix the flocked short fibers to obtain a product.

The obtained product is a suede-like note-like material with a large number of dense flocks on the surface, and when this is molded using a vacuum forming machine, a molded product with an excellent suede feel and suitable as a suede-like interior material for a vehicle is obtained. was gotten.

(1) Soft polyvinyl chloride resin composition for base material 100 parts by weight of vinyl chloride resin (suspension resin p=t3oo) Plasticizer (DOP)
50g stabilizer 2
〃Pigment (beige color) 8 〃Filler
10〃(2) Soft vinyl chloride resin paste paint compounded vinyl chloride resin for adhesives
100 parts by weight (paste resin P=12QO) Plasticizer (DOP) 80 u stabilizer
2.5 Vinyl chloride resin
ioo parts by weight (suspension resin P=2100
) Plasticizer (DOP) 80 J/Stabilizer 2 Pigment (beige color)
8 Example 2 A paste coating consisting of a soft vinyl chloride composition with the following formulation was prepared for the base material 7-T, applied onto release paper using a knife coater, heated to gel in a heating oven, and coated with a paste coating of about 0.05 mm. After forming an 8fi thick eye poly-colored base notebook layer, a bar coater is used to apply a soft vinyl chloride resin paste paint of the following formulation to the surface as an adhesive, and then a soft vinyl chloride resin paste of the following formulation is continuously applied. 0.0 using paste paint as adhesive
The layers were coated and laminated to a thickness of 2M, and the fiber length was 2 with an eye poly color made of a soft vinyl chloride resin composition with the following composition.
rtrm, thickness 8 denier, the product is a moldable notebook with an excellent suede-like appearance similar to that of Example 1, and has a shape suitable for vacuum forming, and the molded product is suitable for use in vehicles. It was a suede-like molded product suitable for use as interior material.

(1) Soft vinyl chloride resin paste for base material Paint blended vinyl chloride resin 100 parts by weight (resin for paste P=1650) Plasticizer (DOP) 60rl stabilizer
2 Pigment (eye poly color)
18 〃Filler 15 〃(
2) Soft vinyl chloride resin paste for adhesives Paint blended vinyl chloride resin 100 parts by weight (resin for paste P=900) Plasticizer (DOP) 65 Stabilizer
2 Pigment (eye poly color)
5 (3) Soft vinyl chloride resin Vinyl chloride resin containing short fibers for flocking 100 parts by weight (suspension resin P=1700) Plasticizer (DOP)
70 parts by weight stabilizer
2 Pigment (eye poly color) 10 Example 3 Fabric weight made of polyester fiber 80? A soft vinyl chloride notebook having the base material composition of Example 1 was applied to a 7mz eye poly-colored non-woven fabric using a calendar.
The materials were laminated to a + thickness, and thereafter a suede-like/-t-like product for molding was obtained using the same materials and processing method as in Example 1. The obtained product has an excellent suede-like appearance similar to that of Example 1, and is a material suitable for vacuum forming processing, and the molded product obtained from this is an excellent suede-like interior member with fine fluff. Met.

I Patent applicant Kyowa Leather Co., Ltd.

Claims (1)

[Claims] An adhesive layer of vinyl chloride paste resin paint is formed as an adhesive on the vinyl chloride resin layer containing a plasticizer, and electrostatic flocking of short fibers made of soft vinyl chloride resin is applied to the adhesive layer. A method for producing a suede-like sheet material for molding processing, characterized by: