JPS6290380A - Production of fiber sheet molded article having raised part - 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 [Industrial Field of Application] The present invention relates to a method for manufacturing a fiber sheet molded product having a raised portion. For more information, please see Automotive Interior Materials,
The present invention relates to a molding method for preventing damage to the napped part of a molded product made of a fiber sheet-like material having a napped part, which is suitable for uses such as building materials, furniture, exterior materials for home appliances, toys, and the like.

[Prior art]

Conventionally, a fabric having raised portions, that is, a fiber sheet-like material, is made into a composite fiber sheet-like material either alone or by bonding it to a moldable plastic sheet, and this fiber sheet-like material is formed all at once by thermoforming or vacuum forming. It has been proposed to mold it into a desired shape.

However, the problem with adopting this efficient molding method is that
During molding, the fiber sheet material is heated and pressurized by the molding die, which damages the front napped portions of the napped fabric, reducing the surface quality of the molded product. In particular, for products with long piles in the raised part, the change is large, and the difference in the contact pressure of the mold causes changes in the length of the raised pile, which deteriorates the appearance (and reduces the product value).Surface This changes not only the quality but also the tactile feel.Such defects are thought to be due to the fact that the raised portions are easily deformed by small deformation stress during molding.

On the other hand, a method of adding a commercial value by imparting a three-dimensional uneven pattern to a fiber sheet-like material such as a fabric having raised portions has also been carried out. Generally speaking, this technique applies textile printing technology to reveal a two-dimensional pattern, but although the pattern obtained by this method is beautiful in terms of design,
It had the disadvantage of not being three-dimensional and lacking in change.

Furthermore, various efforts have been made to obtain raised fabrics with a three-dimensional effect. For example, there is a method in which a fabric obtained by knitting and weaving two or more types of yarns having different shrinkage characteristics is subjected to a shrinkage treatment using high heat or the like to form irregularities. However, this method has the disadvantage that it requires a high degree of skill because it is necessary to weave the &g woven fabric so that it maintains its balance even after the shrinkage treatment.

Another method is to perform molding at a high temperature close to the softening or melting point of the fiber. Furthermore, a method of partially dissolving and shrinking fibers by treating them with organic solvents, strong acids, strong alkaline agents, etc. is also well known. That is,
Examples of the former type of patterning by high-temperature heating include embossing and Schreiner processing, in which uneven patterns are formed on the fabric using the contact pressure of an engraved roll.

This involves inserting the fabric between heated rolls under heavy pressure.
There are defects such as hardening of the texture and flattening of the fabric, and metallic luster caused by hot rolls, and sometimes thermal discoloration. In addition, creating an engraved roll requires a huge amount of cost and a long engraving period for each pattern, and in terms of design, it is limited to the roll circumference and has considerable restrictions on pattern configuration, making it extremely costly for small-lot production. disadvantageous in terms of

On the other hand, as a method for obtaining surface effects on fabrics using the latter agent, alkali weight loss processing using sodium hydroxide has been widely adopted for polyester fibers as a typical method in recent years. However, this method has the problem that the fiber loses weight and deteriorates, exposing the base and significantly lowering the quality.

In addition, such fabrics have the disadvantage that they have a stiff texture, have a marked deterioration in tear strength, and cannot provide the soft texture characteristic of raised fabrics.

[Purpose of the invention]

In view of these conventional problems, it is an object of the present invention to prevent damage to the raised portions, to prevent changes in appearance and texture, and to provide a fiber sheet having raised portions that is easy to produce and has great commercial value. An object of the present invention is to provide a method for manufacturing a molded article. Furthermore, the present invention also provides a method for obtaining a fiber sheet-like molded product having a fine and clear three-dimensional pattern.

[Structure of the invention]

In order to achieve the above-mentioned object, the present invention, when molding a fiber sheet having a raised portion, involves interposing an adhesive substance on at least a part of the raised surface of the fiber sheet, and This method is characterized in that the adhesive substance is removed from the raised portions of the obtained fiber sheet molded article.

The fiber sheet-like material having raised portions used in the present invention is based on woven fabric, knitted fabric, nonwoven fabric, etc., and has raised raised portions formed thereon by means such as pile knitting, flocking, and raising. The raised portion is formed from one or more synthetic fibers such as acrylic, nylon, polyester, polyolefin, and vinylon. Further, the base fabric portion may be made of synthetic fiber, natural fiber, or semi-synthetic fiber, and may also be a nonwoven fabric impregnated with polyurethane or the like. More specifically, for example, mokeft, synthetic velvet, suede, and other articles.

Further, the raised fabric structure may be a warp knitted fabric having a single layer structure made of the above-mentioned fibers, or a so-called two layer structure using, for example, polyester for the front and elastic fibers such as polyurethane elastic yarn for the banks. The structure of the fabric is preferably a warp-knitted fabric that provides balanced elongation during molding.

From the viewpoint of knitting properties of the warp knitted fabric, it is preferable that the yarn used be a long fiber filament yarn, but of course a yarn using short fibers, such as a spun yarn, may also be used.

It is preferable that the warp knitted fabric is knitted with a coarse gauge so that the back yarn can be easily stretched during forming.

In the present invention, the above-mentioned fiber sheet-like material may be subjected to molding processing alone as it is, but it may also be used as a composite sheet bonded with a moldable resin sheet such as plastic. In this case, the resin sheet is used by being attached to the side of the fibrous sheet that does not have raised portions.

Such a fiber sheet-like material or composite is formed into a molded product by known means such as thermoforming or vacuum forming, and the heating means at this time may be either wet heat or dry heat. As a resin sheet when laminating,
Any material that can be molded, such as a polypropylene foam sheet, a polyethylene foam sheet, or a vinyl chloride sheet, can be used. Specifically, for example, the sheet is sandwiched between certain molds and heated for 0.5 to 60 k at 60 to 220°C.
It is possible to perform compression molding processing at g/cd.

Further, in the present invention, when a fiber sheet-like article having a napped portion is molded using a predetermined mold or the like, an adhesive substance is interposed on at least a portion of the napped surface. Introducing an adhesive substance means pasting, coating, impregnating, or scattering an adhesive substance on the raised surface of the fiber sheet in advance, and removing the adhesive substance by appropriate means after forming. do. The intervening adhesion may be performed on the entire surface, or may be applied partially or in a pattern.

The method of adhesion is to form a layer of adhesive material in advance on the surface of the mold that comes into contact with the raised portion of the fiber sheet, and then remove the adhesive material when taking the molded product out of the mold after molding. A preferred method is to remove it from the raised surface.

The adhesive substance used in the present invention must be capable of joining and separating, unlike general adhesives.

Any of liquid, solid, powder, or semi-solid forms can be used. Further, it is desirable that such an adhesive substance has viscoelastic properties at room temperature.

The main component of adhesive is rubber elastic body (natural rubber, synthetic rubber).
, vinyl acetate polymer, vinyl chloride copolymer, acrylic ester polymer, acrylonitrile vinyl acetate copolymer, polyvinyl ether, polyvinyl butyral, styrene butadiene rubber, acrylonitrile butadiene rubber, polyacrylate, etc. It is preferable to mix a rosin derivative, a coumaron resin, a terpene resin, etc. as a tackifier, and also to add a filler, anti-aging agent, etc.

In the present invention, these adhesives can be applied or impregnated onto the raised part, applied by spraying or other methods, applied in the form of a film, or adhered to a piece of other base material like an adhesive tape. It may also be attached as a material to which an agent has been applied.

In the case of adhesive tape, depending on the type of base material, kraft paper adhesive tape, cloth adhesive tape, cellophane tape, polyvinyl chloride tape, acetate tape, polyester tape,
It can be used as something called filament reinforced tape.

The amount of adhesive substance adhered is preferably about 5 to 40 g/g. In addition, the peeling strength between the adhesive substance and the raised fabric is 50 to 4.
Approximately 50g/18mm width is preferable. In addition, as for the strength and elongation characteristics of the above-mentioned adhesive substance, the breaking strength is 1.5 kg/1
Particularly preferred is one having a width of about 8 mm or more and a breaking elongation of about 4 to 50%. Further, it is preferable that the tackifying sheet has a heat resistance of at least 110° C. and a thickness of approximately 0.05 to 201Il111. Molding can also be carried out by stacking the above-mentioned adhesive substance and a fiber sheet having raised portions and pressurizing them for a certain period of time, but this requires a long time to obtain the desired shape at room temperature. , maintaining either the adhesive substance or the fiber sheet-like material having raised portions, or both, at a high temperature before and during shaping;
It is advantageous to set the surface temperature of the fiber sheet material to a temperature that makes it easy to shape it. The temperature range in this case is 60-220℃
, preferably 75-190°C, particularly preferably 90-1
The temperature is preferably 70°C. In addition, the pressure conditions are 0.5 to 60
kg/cd, preferably in the range of 4 to 50 kg/J, particularly preferably in the range of 6 to 45 kg/csi. If the temperature and pressure are lower than the lower limit of the above range, it will be difficult to obtain a molded article as the object of the present invention, and in particular, it will be difficult to obtain the depth of the uneven pattern. Furthermore, if the temperature and pressure exceed the upper limits of the above ranges, the texture of the sheet becomes stiff, which is not preferable.

As described above, various methods such as a spray method, a dipping method, a flow coating method, and a brush coating method can be adopted as a method for applying the adhesive substance to the inner surface of the mold. After application, heat curing may be performed to form a film if necessary. Further, in order to improve the adhesion between the film and the inner surface of the mold, the inner surface of the mold may be treated with a primary resin in advance.

The form in which such an adhesive substance is applied to the inner surface of the mold can be arbitrarily selected such as the entire surface, dots, stripes, or lattice form. At this time, the peeling strength of the adhesive substance from the raised fabric is preferably about 50 to 450 g/18 mm width.

To specifically explain the present invention with reference to the drawings, FIG.
It is composed of a concave mold 2 and a convex mold 3 corresponding to the concave mold 2. A sheet-like adhesive substance 5 is placed on the mold surface 4 of the convex mold 3.
is attached, and a fiber sheet-like material 6 having a raised portion 7 is interposed between the convex mold 3 and the concave mold 2 for molding. After forming the fiber sheet-like material 6, the sheet-like adhesive substance 5 is removed from the raised portion 7.

On the other hand, FIG. 2 shows another method. In this method, a mist-like adhesive substance 9 is sprayed onto the part of the mold surface 4 of the convex mold 3 of the mold 1 shown in FIG. It is applied at step 8. The method for removing the interposed adhesive substance 5.9 is not particularly limited, but it can be easily carried out by any suitable method such as peeling, pulling, elution, stamping, etc.

〔Example〕

Example 1 75 denier, 3 as a fiber sheet-like material with raised portions
6 filament polyester processed yarn on the front, 2
After knitting a warp knitted fabric with a knitting density of 50 knots/inch using 0 denier polyurethane fiber as the backing, this knitted fabric is dyed at 130℃, dried, raised, and finished at a dry heat temperature of 168℃. processed. A 5-fi thick polyethylene foam was laminated on the back side of the dyed raised knitted fabric and used as a fiber sheet.

On the other hand, on the mold surface 4 of the convex mold 3 of the mold 1 shown in FIG. It was interposed so as to be in contact with the raised portion of the fiber sheet-like material. Next, the fiber sheet-like material is pressed between the convex mold 3 and the concave mold 2,
After heating at 135° C. for 1 minute, it was integrally molded into a car seat (chair) having a curved surface shape with a maximum drawing ratio of 0.32 (diameter of 101 yen and concave depth of 3.2 cm). Next, the molded fiber sheet was taken out from the mold, and the adhesive tape stuck to the surface of the raised portion was peeled off at a speed of about 1N1 minute.

The molded product was easily molded toward the curved surface of the car seat, and there was almost no difference in the appearance or feel of the raised portion between the area with the maximum drawing ratio and the area with the small drawing ratio, and a beautiful car seat was obtained.

On the other hand, in the case where the above-mentioned adhesive tape was not interposed on the mold surface 4 of the convex mold 3 and the molding was performed under the same conditions, the raised portions fell over the entire surface and appeared whitish. In addition, it felt rough and hard to the touch, and there were scattered areas where some of the raised parts were discolored and faded, so it could not be used as a commercial product.

Example 2 The same laminated fiber sheet as in Example 1 was prepared as a fiber sheet having raised portions.

On the other hand, as shown in FIG. 2, a sticky substance mainly composed of styrene-butadiene rubber and rosin derivative was sprayed onto the mold surface 4 of the convex mold 3 of the mold 1 using a spray nozzle, and the dry solid weight was approximately 25 g. /cA was given.

Next, after heating the above fiber sheet at 140°C for 1 minute, a car seat (chair) having a curved surface shape with a maximum drawing ratio of 0.29 (concave depth 2.9cm for a circle with a diameter of 10cm) was heated.
It was integrally molded into.

The molding is done easily along the curved surface of the car seat.
A beautiful car seat was obtained, with almost no difference in the appearance or feel of the raised portion between the area with the maximum aperture ratio and the area with a small aperture ratio.

On the other hand, when the above-mentioned adhesive substance was not applied to the mold surface 4 of the convex mold 3 and all other parts were molded in the same way, the raised part almost fell down and became whitish, and the feel was only rough and hard. It was impossible to obtain this product, and there was no way it could be made into a commercial product.

Example 3 The same laminated fiber sheet as in Example 1 was prepared as a fiber sheet having raised portions.

On the other hand, on the mold surface 4 of the convex mold 3 of the mold l as shown in FIG.
It was applied in a floral pattern so that it was rd.

Next, the raised fiber sheet was pressed in a mold and heated to 140°C.
After heating for 1 minute at
It was integrally molded into a car seat (chair) having a curved surface shape with a concave depth of 2.9 aa) relative to a circle.

As a result, the length of the pile in the floral pattern area remains the same,
The remaining pile formed a concave surface, and the flower pattern of the convex portion stood out in a raised state, resulting in a fiber sheet molded product having a beautiful three-dimensional nap.

In addition, the raised hairs in the convex areas had a glossy feel and stood out, making them appear dark in color, while the raised hairs in the recessed areas lacked luster and appeared pale in color, with a bright contrast. This fabric had a three-dimensional jacquard pattern and was comparable to the so-called Kinkasan textile.

〔Effect of the invention〕

As described above, in the process of molding a fiber sheet having a raised portion, the present invention involves adhering and intervening an adhesive substance between the molding die and the surface of the raised portion of the fiber sheet having a raised portion. During molding, the force applied to the raised part under heat and pressure by the mold is absorbed and relaxed, and the tackiness is reduced when the fiber sheet is removed from the mold or after it is removed from the mold. When the material is peeled off, the raised portions are raised by the adhesive substance to which the material is attached, making it possible to obtain a fiber sheet-like product having a uniform appearance and excellent raised portions. In addition, not only can a uniform raised state be obtained as described above, but the original feel and softness are not impaired. In other words, by peeling off the adhesive substance interposed in the raised portion after molding, the raised hair that has temporarily sagged during molding can be efficiently raised, and a uniform raised state can be achieved. It can be done.

This makes it possible to prevent heat discoloration and fading of the fiber sheet material due to molding, and when it is desired to reveal a pattern, it is possible to freely reveal any three-dimensional pattern consisting of at least convex parts and concave parts. can. In addition, it has a fine and clear uneven pattern, has a soft texture, is rich in elasticity, and has a voluminous feel.
You can walk around molded products that have a raised pile that feels good to the touch.

In addition, in the molded product obtained as a three-dimensional uneven pattern pattern according to the present invention, the hues of the raised hairs in the concave and white parts appear different, with the raised parts appearing dark and the concave parts appearing light, making it appear as if the raised parts are different. It looks like it's made of fibers, but it also has a pattern that gives it a more three-dimensional feel.

The products obtained in this way are used as automobile interior materials, building materials, furniture,
Ideal for applications such as exterior packaging for home appliances and toys.

[Brief explanation of drawings]

FIG. 1 is an explanatory diagram showing a state when implementing the method of the present invention, and FIG. 2 is an explanatory diagram illustrating another embodiment of the present invention. ■...Molding mold, 2...Concave, 3...Convex, 4...
... Mold surface, 5.9... Adhesive substance, 6... Fiber sheet-like material, 7... Raised portion, 8... Spray.

Claims (1)

[Scope of Claims] 1. When molding a fiber sheet having a napped portion, a fiber obtained by molding with an adhesive substance interposed in at least a part of the napped surface of the fiber sheet A method for producing a fiber sheet molded article having a raised portion, the method comprising removing the adhesive substance from the raised portion of the sheet molded article. 2. A method for manufacturing a fiber sheet molded article having a raised portion according to claim 1, wherein an adhesive substance is interposed and adhered to the entire raised surface. 3. A method for manufacturing a fiber sheet molded article having a raised portion according to claim 1, wherein an adhesive substance is interposed and adhered to the raised surface in a pattern. 4. A method for manufacturing a fiber sheet molded product having a napped part according to claim 1, 2 or 3, wherein the fiber sheet having a napped part is laminated with a moldable resin sheet. 5. Claims 1 and 2, wherein the adhesive substance is one selected from adhesives, adhesive sheets, and adhesive tapes.
A method for producing a fiber sheet molded article having a raised portion according to item 1 or 3. 6. A method for manufacturing a fiber sheet molded product having a raised portion as set forth in claim 1, 2, or 3, wherein an adhesive substance is previously present on the surface portion of the mold with which the raised portion comes into contact. .