JPS62111720A - Manufacture of suede tone sheet-like material - Google Patents

Abstract

PURPOSE:To form a suede tone plastic sheet-like material whose napping is superior in a color tone, precise and fine, by molding and manufacturing the titled material under specific heating and pressurizing terms by making use of either one kind out of acrylic series resin and polyamide resin or polyester series resin. CONSTITUTION:A material to which a filling of nylon piles whose thickness is 2 deniers and fiber length is 1mm has been applied is used as a master form material, to which templating uncured silicone rubber is applied and a cured silicone pattern obtained by curing the material is fitted, for example, to rayon woven fabric whose density is high as an endless belt 8 and a compound sheet 1 obtained by laminating the same with an acrylic resin sheet and soft polyvinyl chloride sheet under heating is used for the titled material. As for treating terms, fusion is performed by setting up a heating device 3, heating roll 4 and pressurizing rolls 5, 6 through heating so that heating at the temperature of 130-250 deg.C is performed for 5-600sec under pressure of 1-80kg/cm<2>. The compound sheet is pierced through so that the surface of the same confronting with the endless belt 8 becomes an acrylic resin sheet, which is wound round a wind-up part 16 by peeling off from the endless belt 8 after cooling the same by cooling rolls 13, 14.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention is applicable to vehicles, interior materials such as walls, shoes, bags, and other items that have an excellent suede feel and design with fine fluff on the surface. This article relates to a method of manufacturing a suede-like plasti-socundum material useful as a material for miscellaneous goods.

[Conventional technology]

Conventionally, as a method for manufacturing suede-like plastic sheets, a variety of methods have been widely used in which electrostatic flocking is applied to plastic sheets. Another known method is to press a thermoplastic resin sheet in a heated molten state onto a roll having pores, press it into the pores of the roll, and then peel it off while stretching the surface layer through the pores. There is.

However, the former method has drawbacks such as coloring of the flocked short fibers and adhesion of the short fibers to the plastic sheet, and also has insufficient light radiation and heat discoloration resistance due to dyes. Furthermore, as a means to solve this problem,
A method of coloring short fibers with pigments, which have excellent heat resistance, is considered, but it is impossible to dye with pigments, and short fibers manufactured by kneading pigments in advance require a complicated manufacturing process, so it is possible to dye the desired variety. It has the disadvantage that it is difficult to freely obtain and use a wide variety of colors. On the other hand, emulsion-type adhesives have come to be commonly used to join short fibers from the viewpoint of environmental hygiene and fire prevention during work, but products using these adhesives have poor moisture resistance. It has various disadvantages such as poor heat resistance and water resistance, and depending on the conditions of use, the joined short fibers may fall off, impairing the appearance of the product, and complicating the manufacturing process. On the other hand, Japanese Patent Publication No. 43-2234 discloses a method for manufacturing a suede-like plastic sheet using the latter roll, but with this method, it is extremely difficult to manufacture a roll with fine holes. During production, the sheet is stretched in a heated molten state and then peeled off from the roll, resulting in irregular shapes of the individual fluffs, and insufficient fineness and density of the fluffs, resulting in a product with an excellent suede feel. Moreover, it has various disadvantages, such as the fact that the valleys between the fluffs become glossy, which may cause problems in terms of appearance depending on the application.

In order to eliminate such drawbacks, the applicant should first file a patent application in 1984-2.
No. 1079 was proposed. This invention involves coating a cured silicone rubber mold with micropores with a plastic material that is fluid at room temperature, filling the micropores of the pattern with the plastic material, and peeling it off from the hardened hind leg mold to create a suede-like sheet. This is a method for manufacturing a shaped product.

However, in this method: (a) Since the plastic material is a solution or plastisol type that has fluidity at room temperature, the types of plastic materials are naturally limited, and various thermoplastic resins cannot be used.

(b) When the plastic material is applied and filled into the silicone mold, air bubbles are likely to be mixed into the fluid plastic material, which may lead to the formation of uneven fuzz. be.

(c) Contains problems such as it takes time to solidify the fluid plastic material, which reduces production efficiency, and requires consideration of environmental hygiene and fire safety due to the use of organic solvents, etc. There is.

[Problems to be solved by the present invention]

As mentioned above, the present invention has no drawbacks in the fluff colorability, light resistance, heat discoloration resistance, heat and humidity resistance, water resistance, bondability, etc. caused by the short fibers used, and also has environmental sanitation during production. It can be easily and continuously manufactured without causing problems such as surface area and fire occurrence, and without having the problems of the earlier invention, and has an excellent color tone design, and is extremely dense and fine. To provide a method for producing a suede-like plastic sheet material having an excellent suede feel and fluff.

[Means for solving problems]

In the present invention, a plastic sheet is placed on a cured silicone rubber mold with many dense micropores, which is made from a material consisting of many dense napped fibers, and heated and pressurized to produce a suede-like sheet. In the method of manufacturing,
The resin layer facing the mold of the suede-like sheet is 25
A material that becomes molten or semi-molten at a temperature of 0°C or lower, and is made of any one of acrylic resin, polyamide resin, or polyester resin, and the heating conditions during molding are in the temperature range of 130 to 250°C. This is a method for producing a suede-like sheet material, which is produced by applying pressure for 5 to 600 seconds under a pressure of 1 to 80 Ky 7 cm2.

[Effect]

The manufacturing method of the present invention will be sequentially explained below.

In the present invention, a cured silicone rubber mold (hereinafter referred to as a cured silicone mold) is used to produce a suede-like sheet material, and the pattern mold is a material whose surface is composed of a large number of dense napped fibers, that is, short fiber electrostatic flocking.

Appropriately select and use a material that has a large number of densely raised short fibers on the surface of a knitted fabric such as a pile-cut piled blanket or short fiber-raised fabric, use this as a prototype, and heat it at room temperature or low temperature on the material. Apply uncured silicone rubber that hardens with
After heating and curing in step C), the original mold material is removed to create a cured silicone mold having many dense micropores. Next, the plastic sheet is heated using the cured silicone mold created above to melt or semi-melt the resin layer, and pressurizes it to fit into the fine pores of the layer. After cooling, the mold is peeled off to form a suede-like sheet. Manufacture things.

The pressure conditions required for the press fitting are 1 to 80 to 7/crn.
2 good mashiku is 2 to 30, 2/CrIT2 no pressure corner, 13
Heat and pressurize at a temperature of 0 to 250°C, preferably 140 to 2000C, for 5 to 600 seconds, preferably 10 to 300 seconds, to melt or semi-melt the plastic sheet and completely press it into the micropores of the mold. do. In this case, if the above-mentioned pressure is IKy/an2 or less, the heating temperature is 1309C or less, and the heating and pressurizing time is 5 seconds or less, the plastic sheet-like material will not be completely press-fitted into the micropores of the mold, which will not meet the purpose of the present invention. I can't get the product I want.

In addition, the pressure is 8QKy/z or more and the heating temperature is 25
If the temperature is higher than 0°C, the cured silicone mold will be destroyed and the object of the present invention cannot be achieved, and even if the heating and pressing time is 600 seconds or more, the effect of the press-fitting will not change, and longer time is unnecessary. .

As the plastic sheet material used in the present invention, a thermoplastic resin sheet can be used alone, but other materials (paper, flame-retardant paper, etc.) may be used as appropriate.

It can also be used by bonding to a woven fabric (knitted fabric, non-woven fabric, glass cloth, plastic sheet, or a laminate of two or more of these) using an adhesive or after heat treatment.

In addition, after preparing a single sheet with a suede-like surface in advance by the method described above, use other base materials (paper, flame-retardant paper).

It is also possible to make a product by laminating a woven fabric (knitted fabric, non-woven fabric, glass cloth, plastic sheet, etc.) and an adhesive, or by applying heat treatment.

Further, by subjecting the surface of the suede-like sheet to secondary processing such as an embossed pattern, a printed pattern, and in some cases a valley print pattern, a more three-dimensional and versatile design can be imparted. In this case, the embossed pattern may be formed either before or after the printed pattern is formed. As the above-mentioned resin used in the present invention, 2
A thermoplastic resin that melts or semi-melts at a temperature of 50° C. or lower is used, and the resin layer facing the cured silicone mold is made of any one of acrylic resins, polyamide resins, and polyester resins. is formed.

The reason why the resin layer is limited to the above three types of resins is because polyvinyl chloride resin or polyurethane resin has conventionally been generally used as the material for the surface layer of suede-like plastic sheets. In the case of a suede-like sheet material having a large number of dense fine fluffs, which is the object of the present invention, if a polyvinyl chloride resin is used in the layer, the fluff strength will be insufficient and the abrasion resistance will be poor, and furthermore, the plasticity in the sheet will be reduced. As the agent migrates, the fluff becomes hard and the texture is impaired, and furthermore, the strength of the fluff becomes insufficient. These drawbacks cause the inconvenience that the applications of the obtained products are limited.

(2) When a polyurethane resin is used in the layer, the fluff strength is considerably improved and the problem of plasticizer migration does not occur. It has a tendency to be difficult to recover its hardness (presumably due to slow crystallization), therefore, the resin and sheet are press-fitted into the cured silicone mold in a molten or semi-molten state, and after cooling, the mold is removed. When the resin sheet is peeled off, problems arise such as the fluff portion being stretched or cut due to resistance when the fluff portion is pulled out through the fine holes of the mold. Furthermore, even if it is peeled off, fluff is likely to fall, and when the sheet-like material is rolled up in the manufacturing process of the product, the winding pressure will cause the appearance to deteriorate. mosquito\
In order to overcome the drawbacks of this method, it is necessary to ripen for 24 hours or more without applying external pressure.

This is because, in order to eliminate the above-mentioned problems, it is necessary to use a resin that does not have the above-mentioned drawbacks, that is, one of acrylic resins, polyamide resins, and polyester resins.

In carrying out the present invention, a cured silicone mold is formed into an endless belt shape, and a plastic sheet is heated and pressed against the cured silicone mold through a pressure roll, and then peeled off with a peeling roll. Although it can be manufactured continuously, it can also be manufactured continuously by attaching it directly to the surface of a heating roll and heating and pressurizing a plastic sheet-like material thereon.

As described above, the present invention eliminates the need to coat the plastic with an organic solvent when producing a cured silicone-type suede-like plastic sheet, and therefore, the solidification time can be greatly shortened, and the process can be simplified.

In addition, since no organic solvents are used, there is no need to take precautions against environmental pollution or fire caused by organic solvents.
Moreover, costs can be kept low.

〔Example〕

The drawings show an example of a manufacturing apparatus used to carry out the present invention.Next, the specific configuration of the present invention will be explained with reference to the illustrated figures and embodiments.

The plastic sheet-like material 1 is unwound from the unwinding section 2,
The heating device 3 heats the surface of the plastic sheet 1 to 130°C.
After being heated in a temperature range of ~250°C to a melted or semi-molten state, it is inserted between the nip between the heating roll 4 and the pressure roll 5.

On the other hand, pressure rolls 5 and 6 are attached to the heating roll 4, and an endless pressure belt 7 runs from the outer circumference of the pressure roll 5 to the outer circumference of the heating roll 4 and further to the outer circumference of the pressure roll 6. is attached to the surface of the pressure belt 7 of the pressure rolls 5 and 6, and a hardened silicone type endless heald 8 having many dense micropores formed on the surface is attached to the surface of the pressure belt 7 of the pressure rolls 5 and 6. And a hardened silicone-type endless belt 8 is rotating as shown by the arrow in the figure.

The molten or semi-molten plastic sheet material 1 is in contact with the outer circumferential surface of the heating roll 4 and the pressure roll 5.
Therefore, on the outer peripheral surface of the heating roll 4, the plastic sheet-like material 1. The cured silicone encircling belt 8 and the pressure belt 7 are sequentially laminated on the outermost side and are moved under heating and pressure.

The plastic sheet-like material 1 on the outer peripheral surface of the heating roll 4 is maintained in a molten or semi-molten state by the heat of the heating roll 4.
/ crn and for a pressurizing time of 5 to 600 seconds, it is press-fitted into a large number of dense micropores formed on the opposing surfaces of the endless belt 8 made of cured silicone.

In this case, the pressure is adjusted by the pressure rolls 5, 6, the pressure roll 9 attached to the pressure roll 5, and the pressure belt 7.
The pressure can be adjusted as appropriate by adjusting the tension roll 10 of and the tension roll 11 of the cured recone endless belt 8, and the pressing time can be adjusted by appropriately adjusting the rotational speed of the heating roll 4.

As described above, the surface layer of the plastic sheet material is press-fitted into the many dense micropores of the cured silicone endless belt 8 on the outer peripheral surface of the heating roll 4, and the plastic sheet material 1 and the cured silicone endless belt 8 are integrated. The resulting laminate 12 is separated from a pressure belt 7 by a pressure roll 6, and the pressure belt 7 is circulated through a tension/control roll 10 for use.

On the other hand, a laminate 12 in which the cured silicone type endless belt 8 and the plastic sheet-like material 1 are integrated,
After being sequentially cooled by cooling drums 13 and 14, the plastic sheet material 1 is peeled off from the cured silicone endless belt 8 by a peeling roll 15 and wound up by a winding section 16.

It was. The cured silicone endless belt 8 is circulated through a tension roll 11 for use.

The plastic sheet-like material 1 wound up by the winding section 16 as described above is obtained as a suede-like sheet-like material having many dense fluff-like surfaces and a beautiful and unique texture.

Although the illustrated example uses a cured silicone endless belt 8, the present invention is not limited to this, and may be wound directly around the outer peripheral surface of the heating drum 4.

Example 1 Made of densely woven rayon fabric with a thickness of 2 denier.

The prototype material is a flocked nylon pile with a fiber length of 1 m. After applying uncured silicone rubber for mold making, it is left to harden at room temperature, the core layer is separated from the prototype material, and a large number of dense particles are formed. A cured silicone mold with fine pores was obtained.

The cured silicone mold is attached as an endless belt 8 as shown in the illustrated example, and the plastic sheet material 1 is an acrylic resin sheet with a thickness of 50 microns (manufactured by Kanefuchi Kagaku Co., Ltd., trade name: Sunduren 5DOO2A), and a soft sheet with a thickness of 250 microns. A composite sheet made by laminating polyvinyl chloride sheets under heat is used.

In this case, the heating device 3, the heating roll 4, the pressure rolls 5 and 6, and the hardened silicone type endless belt 8 of the apparatus shown in the figure are used so that the surface of the composite sheet reaches about 180'C.
are respectively heated and set to melt the surface of the composite sheet.

The composite sheet is inserted so that the surface facing the hardening/recone endless belt 8 is the acrylic resin sheet, cooled by cooling rolls 13 and 14, and then peeled off from the hardening/recone endless belt 8 and wound up. It is wound up in section 16.

The obtained product was a suede-like sheet having a beautiful appearance with a dense surface and a large number of fuzz, and a unique moist texture.

Example 2 A plastic sheet-like article was created by bonding a sheet made of polyester-based nidistomer with a thickness of 0.2 (Hytrel 4057 manufactured by DuPont, East) to a nonwoven fabric having a basis weight of 150 P/m and a thickness of about 2 WrIR. . Using the same hardened silicone belt as in Example 1, the surface of the sheet was heated to about 160° C. to melt it, and the inside of the fine pores of the pattern was melted under a pressure of about 3 Ky 7 cm. A suede-like sheet material was obtained in the same manner.

The obtained product was a suede-like sheet-like product having a beautiful, smooth and unique texture as in Example 1.

Example 3 A plate-shaped cured silicone mold prepared in the same manner as in Example 1 was used, and a sheet of polyaminyl nidistomer (Glylax A manufactured by Dainippon Ink) with a thickness of about 1IIIll was placed on the mold.
-150) were piled up, set in a heat press machine with a hot plate temperature of about 170° C., and pressed for about 200 seconds at a pressure of about 10 Ky/cm 2 . Next, this was cooled to room temperature and then peeled off along the pattern pattern to obtain a suede-like sheet material. The product was also an excellent suede-like sheet with a beautiful appearance and a unique smooth texture.

Example 4 After applying a cloud print pattern to the surface of the product obtained in Example 1 using a gravure printing machine in a color tone different from the surface color of the product, the surface was further printed using an embossing machine. Regardless of the shape of the striped embossed pattern, a suede-like sheet material with an excellent suede feel and high added value with a wide variety of designs was obtained.

[Brief explanation of drawings]

The drawing is an explanatory diagram of an example of an apparatus for implementing the present invention. 1 Nibras≠Tsuku sheet-like material, 2: Unwinding section, 3: Heating device, 4: Heating roll, 5, 6: Pressure roll, 7: Pressure belt, 8: Cured silicone type endless bell), 9:
Pressing roll, io. 11: Tension roll, 12: Laminated product in which a cured silicone type belt and a plastic sheet-like material are integrated, 1
3, 14: cooling roll, 15: peeling roll, 16: winding section.

Claims (1)

[Claims] A plastic sheet-like material is placed on a cured silicone rubber mold having a large number of dense micropores made using a material whose surface is made of a large number of dense napped fibers, and heated and pressurized. In the method for manufacturing a suede-like sheet-like article, (a) the resin layer facing the mold of the plastic sheet-like article is formed of a material that becomes molten or semi-molten at a temperature of 250°C or less; (b) the resin layer of the plastic sheet-like article is made of any one of acrylic resin, polyamide resin, or polyester resin; (c) the heating condition is in a temperature range of 130 to 250°C; A method for producing a suede-like sheet material, characterized in that the pressurizing conditions are pressurizing for 5 to 600 seconds under a pressure of 1 to 80 kg/cm^2.