JPS62162060A - Sheet like molding material - 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] [Field of Industrial Application] The present invention is applicable to structural materials for cases that need to maintain an appropriate external shape, such as semi-hard camera cases and Boston bags, and interior materials for automobile interiors. Can be used as
The present invention relates to a sheet-shaped molding material that has excellent moldability and particularly excellent shape retention after molding.

[Conventional technology]

For cases that need to maintain their external shape to some extent, such as semi-hard camera cases and Boston bags, and as interior materials for automobile interiors, core materials such as pole paper, wood boards, metal plates, etc.
It is known that a plastic plate is used and covered with a vinyl chloride sheet, a polyurethane sheet, a non-woven fabric sheet, a natural leather sheet, etc. as a surface material.

[Problem that the invention seeks to solve]

Manufacturing cases and interior materials for automobile interiors using the above-mentioned materials requires a step of bonding the facing material and the core material, which is time-consuming. Wrinkles and sagging occur easily when bonding the facing materials together, and skill is required to achieve a beautiful finish.

Furthermore, when the above-mentioned materials are used as interior materials for automobile interiors, wall materials for automobile trunks, etc., there are the following disadvantages. If a car is parked in the sun for a long time, the interior of the car can become very hot. In midsummer, the temperature usually reaches over 80 degrees Celsius. As a result, the interior material may become deformed or deteriorated, which often causes problems. Therefore, appropriate standards have been established for use as interior materials in automobile interiors.

Among the conventional materials mentioned above, materials using nonwoven fabrics are preferred as interior materials for automobile interiors because they are lightweight, but almost none are available that fully satisfy standards such as shape retention under heat resistance. The current situation is that there is no such thing.

The present invention solves the above-mentioned problems, and allows for beautiful and inexpensive mass production of cases and interior interior materials for automobile interiors by integral molding. The present invention provides a molding material that has maintainability.

[Means for solving problems]

A sheet-shaped molding material to which the present invention is applied in order to solve the above problems will be explained with reference to FIG. 1 corresponding to an example.

The sheet-like molding material 1 of the present invention shown in the figure is a needle-punched nonwoven fabric 3 having a cotton basis weight of 200 to 800 g/mm2.
A part of the constituent fibers contains 10 to 70% by weight of thermoplastic fibers having a lower melting point than the surrounding fibers, and the moldable resin 5 is attached to at least one surface of the needle-punched nonwoven fabric 3.

[Effect]

Since the sheet-shaped molding material 1 of the present invention is a needle-punched nonwoven fabric 3 having a structure containing low-melting thermoplastic fibers and having a moldable resin 5 attached thereto, it can be integrally molded by heating and pressurizing. The needle punched nonwoven fabric 3 has a relatively large cotton basis weight, contains an appropriate amount of low melting point thermoplastic fibers, and has the moldable resin 5 attached to it, so that it melts during heating during molding and is impregnated throughout the nonwoven fabric. It solidifies when cooled to room temperature. As a result, it is finished with a moderately flexible feel despite having good heat-resistant shape retention after molding.

〔Example〕

Examples of sheet-like molding materials to which the present invention is applied will be described in detail below.

FIG. 1 shows an example of the sheet-shaped molding material of the present invention.

The needle-punched nonwoven fabric 3 constituting the sheet-like molding material 1 shown in the figure is made of ordinary melting point fibers (e.g. polyester fibers, acrylic fibers, benzoate fibers) and low melting point thermoplastic fibers (e.g. low melting point polyester fibers, polyethylene fibers, polypropylene fibers). It is obtained by needle punching a web mixed with fibers or mixed fibers thereof. Examples of the moldable resin 5 to be adhered to and impregnated into the needle-punched nonwoven fabric 3 include heat-crosslinkable acrylic ester-styrene copolymer, acrylic ester-methyl methacrylate copolymer, styrene-butadiene, copolymer and styrene. There are mixtures with emulsions, vinyl acetate-ethylene-vinyl chloride copolymers and styrene emulsions, and thermosetting resins such as epoxy resins, melamine resins, and phenolic resins are mixed with each of the above resins. It is also possible to do so.

FIG. 2 shows another embodiment of a sheet-like molding material to which the present invention is also applied.

The needle-punched nonwoven fabric 3 constituting the sheet-like molding material 1 shown in the figure is covered with a covering material sheet 2 laminated on one side. The structural example of the 21-dorno-kunchi nonwoven fabric 3 and the structural example of the moldable resin 5 are the same as the above-mentioned structural example in the case of the sheet-shaped molding material shown in FIG. As the facing material sheet 2, for example, a polyvinyl chloride sheet, a polyurethane sheet, natural leather, various woven fabrics, and nonwoven fabrics can be used.

FIG. 3 also shows another embodiment of a sheet-like molding material to which the present invention is applied.

The needle-punched nonwoven fabric 3 constituting the sheet-like molding material 1 shown in the figure is covered with a backing sheet 4 laminated on one side. The configuration example of the needle-punched nonwoven fabric 3 and the configuration example of the moldable resin 5 are the same as the configuration example described above in the case of the sheet-shaped molding material shown in FIG. The backing sheet 4 is preferably a nonwoven fabric, and is obtained by needle-punching a web of polyester fiber, acrylic fiber, benzoate fiber, or the like.

FIG. 4 also shows another embodiment of a sheet-like molding material to which the present invention is applied.

The needle-punched nonwoven fabric 3 constituting the sheet-like molding material 1 shown in the figure is covered with a facing material sheet 2 laminated on one side and a backing material sheet 4 laminated on the other side. The configuration example of the needle-punched nonwoven fabric 3 and the configuration example of the moldable resin 5 are the same as the configuration example described above in the case of the sheet-shaped molding material shown in FIG. Further, the configuration example of the facing material sheet 2 and the configuration example of the backing material sheet 4 are the same as the aforementioned configuration example in the case of the sheet-shaped molding material shown in FIGS. 2 and 3, respectively.

Although not shown, the sheet-shaped molding material of the present invention includes:
An example in which the moldable resin 5 is attached to both sides of the needle-punched nonwoven fabric 3, an example in which the surface to which the moldable resin 5 is attached is covered with the facing material sheet 2, contrary to the example in FIG. 2, and an example in FIG. 3. Conversely, it can also be carried out by covering the surface to which the moldable resin 5 is not attached with the backing sheet 2.

The sheet-shaped molding material 1 shown on each side is heated under appropriate conditions, then placed in a female mold 7 as shown in FIG. 5, and press-molded by applying pressure P to the male mold 6. As a result, the sheet-like molding material 1 is reduced in thickness, and a molded article of the sheet-like molding material 1 as shown in FIG. 6 is formed.

Hereinafter, actual manufacturing examples of the sheet-like molding material of the present invention will be explained in Examples 1 to 1O. Examples 1 to 5 are examples in which the configuration is shown in FIG. 1, and Examples 6 to 10 are examples in which the configuration is shown in FIG. 4. Comparative Examples 1 to 4 are examples of sheet-like molding materials to which the present invention is not applicable. Note that the example in which the configuration is shown in FIG. 3 and FIG. 4 is substantially the same as Examples 1 to 10, so the description thereof will be omitted.

Example 1 Needle punched nonwoven fabric 3 has a melting point of 110°C
, 4 denier x 51mm low melting point polyester fiber! 11
0 parts by weight and normal polyester fiber 113 denier
It consists of 51.90 parts by weight, has a cotton basis weight of 600 g/2.2, and has a thickness of 5.5 mm. The needle punch nonwoven fabric 3
A heat-crosslinkable acrylic acid ester resin 5 with a resin solid content of 100 g/cm2 is adhered to one side of the sheet and dried to obtain a sheet-like molding material 1 shown in FIG. This sheet-like molding material 1 is molded into a molded product (see FIGS. 5 and 6).

During molding, the thickness was reduced to approximately 172 mm, resulting in a molded product with a wall thickness of approximately 2.7 m.

Example 2 Needle-punched nonwoven fabric 3 was made of low-melting point polyester fiber and #125 polyethylene fiber and 75 parts by weight of normal polyester fiber, and had a cotton basis weight of 50 parts by weight.
The weight is 0g/■2 and the thickness is 5■. Otherwise, when a molded product is made under the same conditions as Example 1, the wall thickness of the molded product is about 2.5 mm.
It becomes mm.

Example 3 Needle punched nonwoven fabric 3 is made of low melting point polyester fiber and polyethylene fiber! Consisting of 40 parts by weight of 1i and 60 parts by weight of regular polyester fiber, cotton weight 4
00 g/m2 with a thickness of 4 layers. If a molded article is otherwise produced under the same conditions as in Example 1, the wall thickness of the molded article will be approximately 2 mm.

Example 4 Needle-punched nonwoven fabric 3 was made of 55 parts by weight of low-melting polyester fibers and polyethylene fibers and 45 parts by weight of ordinary polyester fibers, and had a cotton basis of 300 parts by weight.
g/m2 and the thickness is 3 mm. Otherwise, when a molded product is made under the same conditions as Example 1, the wall thickness of the molded product is approximately 1.51cm.
become.

Example 5 A needle-punched nonwoven fabric 3 was made of 70 parts by weight of low melting point polyester fibers and polypropylene fibers and 30 parts by weight of ordinary polyester fiber #I, and had a cotton basis weight of 200 g/layer 2 and a thickness of 21. Others are Example 1
If a molded product is made under the same conditions as , the wall thickness of the molded product will be approximately [■.

Example 6 Needle punched nonwoven fabric 3 has a melting point of 110°C
, 40 4 denier x 511 low melting point polyester fibers
Weight part and regular polyester fiber 3 denier x 51mm
It has a cotton weight of 400 g/m2 and a thickness of 4 mm. A heat-crosslinkable acrylic ester resin 5 having a resin solid content of 100 g/m 2 is attached to one side of the needle-punched nonwoven fabric 3 and dried. On the surface to which the resin 5 is attached, a needle-punched nonwoven fabric (thickness: 2 am) made of ordinary polyester fibers of 3 denier x 51 mm and having a striped area of 200 g/m 2 is laminated as a backing sheet 4 using a synthetic rubber adhesive.

A heat-resistant polyvinyl chloride film having a thickness of 2507 Lm is laminated as a facing material sheet 2 to the other side of the needle-punched nonwoven fabric 3 using a synthetic rubber adhesive. The resulting three-layer sheet-like molding material l (see Figure 4) weighs 1025 g/m
It is 2. When this sheet-shaped molding material l is molded (fifth
(See Figure 6), the thickness is reduced by approximately 1/2 during molding, and the thickness of the molded product becomes approximately 3 mm.

Example 7 Needle-punched nonwoven fabric 3 was made of 30 parts by weight of low melting point polyester m fibers and polyethylene fibers 11t and 70 parts by weight of normal polyester fibers, and had a striped area of 35 parts by weight.
The thickness is 3.5 mm at 0 g/n+2. Backing sheet 4
Striped weight: 190g made of regular polyester fiber.
/m2 of needle-punched nonwoven fabric (thickness: 2 mm). Otherwise, when a molded product is manufactured under the same conditions as in Example 6, the wall thickness of the molded product will be approximately 2.8 ma+.

Example 8 Needle-punched nonwoven fabric 3 consists of 20 parts by weight of low-melting polyester fibers and polyethylene m fibers and 80 parts by weight of ordinary polyester fibers, and has a striped weight of 300 g.
/m2 and the thickness is 3 mm. As the backing sheet 4, a needle-punched nonwoven fabric (thickness 2I!1I11) made of ordinary polyester fiber and having a striped area weight of 180 g/m2 is used. If a molded article is otherwise produced under the same conditions as in Example 6, the wall thickness of the molded article will be approximately 2.4 mm.

Example 9 Needle-punched nonwoven fabric 3 consists of 10 parts by weight of low melting point polyester fibers and polyethylene fibers and 80 parts by weight of ordinary polyester fibers, and has a striped weight of 250 g.
/m2 and the thickness is 2.5 mm. The backing sheet 4 is made of regular polyester fiber with a striped weight of 180 g/m2.
(1)--Use dollar punch nonwoven fabric (thickness 2 mad). Otherwise, when a molded product is manufactured under the same conditions as in Example 6, the wall thickness of the molded product is approximately 2.3 mm.

Example 10 Needle punched nonwoven fabric 3 is made of low melting point polyester fiber and polypropylene fiber RAL.

It consists of parts by weight and 90 parts by weight of ordinary polyester fibers, and has a stripe weight of 200 g/m2 and a thickness of 2 mm.

As the backing sheet 4, a needle-punched nonwoven fabric (thickness 2
am). If a molded article is otherwise produced under the same conditions as in Example 6, the wall thickness of the molded article will be approximately 2 mm.

Comparative Example 1 The needle-punched nonwoven fabric 3 was made of 60 parts by weight of low-melting point polyester fibers and 40 parts by weight of normal polyester fibers, and had a stripe weight of 650 g/m2 and a thickness of 6 cm.
It is. This sheet-like molding material 1 has the structure shown in FIG. Otherwise, when a molded product is manufactured under the same conditions as in Example 1, the wall thickness of the molded product will be approximately 3 mm+.

Comparative Example 2 The needle-punched nonwoven fabric 3 was made of 10 parts by weight of low melting point polyester m fibers and 90 parts by weight of normal polyester fibers, and had a stripe weight of 150 g/m2 and a thickness of 1.5
It is mm. When a molded article is otherwise produced under the same conditions as in Example 1, the wall thickness of the molded article is approximately 0.8 mm.

Comparative Example 3 The needle-punched nonwoven fabric 3 was composed of 75 parts by weight of low-melting point polyester fibers and 25 parts by weight of ordinary polyester fibers, and had a stripe weight of 300 g/m2 and a thickness of 3 mm. If a molded article is otherwise produced under the same conditions as in Example 1, the wall thickness of the molded article will be approximately 14 m+s.

Comparative Example 4 The needle-punched nonwoven fabric 3 was composed of 5 parts by weight of low-melting point polyester fibers and 85 parts by weight of ordinary polyester fibers, and had a stripe weight of 300 g/m2 and a thickness of 3 m+o. When a molded article is manufactured under the same conditions as in Example 1, the wall thickness of the molded article is approximately 1.5 mm.

The performance of each of the above embodiments will be compared using the following table.

The quality of shape maintenance in the table is determined based on the criterion that the molded product does not deform when exposed to 83° C. for 200 hours. Even if the shape retention is good, it is unsuitable if the molded product itself is too hard (Comparative Examples 1 and 3). As can be seen from this table, all of the molded products made of the sheet-like molding material of the present invention have superior shape retention compared to the molded products made of the sheet-like molding material to which the present invention is not applied, but they have a moderate shape retention property. It's flexible.

(The following is a blank space) 1 5 As explained above, if the sheet-form molding material to which the present invention is applied is used, when manufacturing cases, there is no need for the process of bonding the facing material and inner lining, and it is possible to mold the case in one piece. I can do it. This simplifies manufacturing and allows mass production at low cost. Additionally, there is no wrinkles, sagging, or twitching that can occur when bonding facing materials together, resulting in a beautiful finish. The resulting molded product is lightweight, maintains a soft texture in both the outer layer and the inner layer, maintains its shape well, and does not lose its shape even under extremely harsh temperature conditions, so it has the advantage of being able to adequately protect items stored within it. It is also particularly excellent as an interior material for automobile interiors.

[Brief explanation of drawings]

Figures 1 to 4 are cross-sectional views of examples of sheet-like molding materials to which the present invention is applied, Figure 5 is cross-sectional views during molding with sheet-like molding materials, and Figure 6 is molding of sheet-like molding materials. FIG. 1.Sheet-shaped molding material 2...Face material sheet 3.Needle-punched nonwoven fabric sheet 4.
,, Backing sheet 5... Moldable resin 8-7. ,,,Mold Figure 1 Figure 2 Figure 3

Claims (1)

[Claims] 1. A needle-punched nonwoven fabric with a cotton basis weight of 200 to 600 g/mm^2, in which some of the constituent fibers contain 10 to 70% by weight of thermoplastic fibers having a lower melting point than surrounding fibers. 1. A sheet-like molding material comprising: a needle-punched nonwoven fabric having a moldable resin attached to at least one surface thereof. 2. The sheet-shaped molding material according to claim 1, wherein one side of the needle-punched nonwoven fabric is covered with a covering sheet. 3. The sheet-shaped molding material according to claim 1, wherein one side of the needle-punched nonwoven fabric is covered with a backing sheet. 4. The sheet-shaped molding material according to claim 1, wherein both sides of the needle-punched nonwoven fabric are covered with a facing material sheet and a backing material sheet.