JPWO2020075669A1 - Laminated body and its manufacturing method - Google Patents

Abstract

To provide a method for efficiently producing a laminate composed of a molded body and a coating material thereof, and a laminate produced by the manufacturing method, while achieving both mold releasability and adhesiveness of the molded body.
A laminate in which a molded body, an adhesive, and a coating are laminated, and the molded body is a support made of resin, fine particles partially embedded in the surface of the support, and the surface of the fine particles and the surface of the support, respectively. The laminate, and a method for producing the same, which comprises a mold release agent adhering to at least a part of the above-mentioned laminate.

Description

The present invention relates to a laminate composed of a molded body and a covering thereof, and a method for producing the same.

When producing a molded product, for example, a molded product of a porous plastic foam, a mold release agent containing wax or silicone as a non-volatile component or a mixture thereof is used. Various types of such release agents have been developed and marketed (for example, Patent Document 1).

In the molded body after molding, components derived from the mold release agent are adhered to the surface of the molded body, so that it is difficult to bond the molded body to other substances. Therefore, the molded body after molding is subjected to shot blasting treatment, sandblasting treatment, flame treatment, corona treatment, plasma treatment, etc., or cleaning with a solvent such as alcohol, ketone, ester, or hydrocarbon (for example, Patent Document 2).

Shot blasting and sand blasting can provide strong adhesiveness, but the work environment deteriorates and the processing time becomes long. Flame treatment has the risk of thermal deformation, melting, ignition and fire. Corona processing takes time to create a vacuum, and the cost of equipment is high. Cleaning with a solvent such as alcohol, ketone, ester, or hydrocarbon is convenient, but depending on the type of mold release agent, it is not possible to give the molded body sufficient adhesiveness. In addition, there are restrictions on the usage environment due to the use of dangerous materials.

Conventionally, in a resin molded body in which a coating material is laminated, the molded body resin material is molded using a mold release agent, and the mold release agent adhering to the surface of the molded body is removed from the mold after the mold is released. After that, the molded body was laminated and coated with a coating material. That is, it has been difficult to achieve both releasability and adhesiveness of the molded product by eliminating the post-treatment step.

Japanese Unexamined Patent Publication No. 6-39845 Japanese Unexamined Patent Publication No. 2003-221458

The present invention has been made in view of the above circumstances, and is a method for efficiently producing a laminate composed of a molded body and a coating thereof while achieving both releasability and adhesiveness of the molded body, and a method for producing the same. It is an object of the present invention to provide a laminate manufactured by.

The above object is achieved by a method for producing a laminate, which comprises going through the following production steps (1) to (6).
(1) Mold release agent application step of applying a water-based mold release agent to the mold surface,
(2) Support raw material injection step of injecting the support raw material of the molded body into the mold,
(3) A curing foaming step of curing and optionally foaming the support raw material,
(4) A molding body taking-out step of taking out the molded body obtained in the curing foaming step from the mold,
(5) Following the step (4), an adhesive coating step of applying an adhesive to the molded body, and (6) a covering laminating step of laminating a coating material on the molded body to which the adhesive is applied. ..

In the present invention, the maintenance of the releasability of the molded body in the manufacturing process and the maintenance of the releasability such as the good adhesive force of the coating material to the molded body without treating the surface of the molded body after molding are contradictory. It is possible to achieve both the effects and the improvement.
INDUSTRIAL APPLICABILITY The present invention provides a novel method for producing a laminated body and a laminated body, which have not existed in the past.

Schematic cross-sectional view of the laminated body of this invention. The perspective view of the molded body A molded in the Example. The perspective view of the molded body B molded in the Example.

An important aspect of the present invention is to provide a method for producing a laminate, which comprises going through the following production steps (1) to (6).
(1) Mold release agent application step of applying a water-based mold release agent to the mold surface,
(2) Support raw material injection step of injecting the support raw material into the mold,
(3) A curing foaming step of curing and optionally foaming the support raw material,
(4) A molding body taking-out step of taking out the molded body obtained in the curing foaming step from the mold,
(5) Following the step (4), an adhesive coating step of applying an adhesive to the molded body, and (6) a covering laminating step of laminating a coating material on the molded body to which the adhesive is applied. ..

In the method for producing a laminate of the present invention, after the molded body is taken out from the mold, the post-treatment that has been conventionally performed, that is, the molded body is shot blasted, sandblasted, flame treated, corona treated, plasma treated or alcohol. Adhesive is directly applied to the molded body taken out from the mold without performing treatment such as cleaning with a solvent such as ketone, ester, hydrocarbon, etc., and the coating is applied to the molded body to which this adhesive is applied. There is a big feature in laminating. The above-mentioned "(5) step of applying an adhesive to the molded body following the step of (4)" means a step in such an order.
According to the method for producing a laminate of the present invention, the laminate can be efficiently produced, and the obtained laminate is excellent in adhesiveness between the molded body and the coating material. It is possible to achieve both releasability and adhesiveness, which could never be achieved by conventional technology.

Release Agent Application Step The water-based release agent used in the release agent application step contains fine particles, and contains at least a release agent component, fine particles, and water.
Water constitutes at least the remaining part of the water-based mold release agent other than the mold release agent component and the fine particles.
As the release agent component, waxes used in conventionally known water-based release agents, for example, paraffin wax, polyethylene wax, Fishertropch wax, microcrystallin wax, olefin polymer, higher fatty acid ester, oxide wax Etc., a fluorine component such as a perfluoro group-containing hydrocarbon compound and / or a silicone component such as silicone oil, silicone resin, straight silicone, modified silicone and the like may be used. Fluorine component and silicone component are used to improve releasability. It may be used only with a wax component, but it may also be used with a fluorine component and / or a silicone component. The fluorine component and / or the silicone component is usually used in an amount of 0 to 300% by weight, preferably about 2 to 100% by weight, based on the wax component.

The fine particles contained in the aqueous mold release agent are not particularly limited, and conventionally used particles such as silica particles, acrylic particles, urethane particles, silicone rubber powder, plastic powder, and PTFE powder can be used. The type of the fine particles is not particularly limited, but fine particles having a particle size in the range of 100 nm to 20 μm, preferably 1 μm to 20 μm, more preferably 1 μm to 18 μm, and even more preferably 2 μm to 15 μm are used. To do so. If it is 100 nm or less, it becomes difficult to achieve adhesiveness between the molded body and the coating material to be laminated in a later step. If it is 20 μm or more, there is a concern about the dispersion stability of the dispersion solution which is an aqueous release agent. The particle size referred to in the present invention means the average particle size.

The fine particles are 97: 3 to 20:80 (wax: fine particles), preferably 96: 4 to 25:75, and more preferably 95: 5 to 30 in terms of the weight ratio of the release agent to the wax component. : Use in the range of 70. The releasability at the time of molding is not impaired, and good adhesiveness between the molded body and the coating of the obtained laminate is achieved. The larger the amount of the fine particle component used, the higher the adhesive force between the molded body and the coating material tends to be.

The content of the release agent component in the water-based release agent is not particularly limited, and may be used in an amount within a conventionally known range. For example, the content of the release agent component in the water-based release agent is about 0.1 to 70% by weight, preferably 0.1 to 10% by weight, more preferably 0.1 to 5% by weight, and even more preferably. It may be used in an amount of 0.5 to 3% by weight.

In addition to the above components, preservatives, antibacterial agents, rust inhibitors, emulsifiers, surfactants and the like may be contained in an amount within a range that does not impair the effects of the present invention. The amount is usually about 0.1 to 300% by weight with respect to the wax component of the release agent.

As the mold used in the release agent application step, a conventional or newly created desired mold may be used, and the application method and application amount of the water-based release agent are not particularly limited. Instead, a conventionally known coating method, for example, spray coating, brush coating, immersion, etc., ^{may be applied, and a coating amount, for example, 50 to 150 g / m 2} , preferably 70 to 120 g / m ² , may be applied.

Support raw material injection step In the support raw material injection step, the support raw material is injected into the mold.
As the support raw material, one obtained by curing a urethane resin raw material in a mold to obtain a resin molded body is preferable. Various urethane resin raw materials are known and are commercially available. Those known ones may be used.
In addition to the above-mentioned support raw materials, thermosetting resin materials that can be injected into a mold, for example, thermosetting resin materials such as epoxy resin, phenol resin, styrene resin raw material, and fiber reinforced prepreg, can also be used.

The method of injecting the support raw material into the mold is not particularly limited, and a conventionally known injection method, for example, an injection machine, hand mixing, or the like may be used.

Curing and Foaming Step In the curing and foaming step, the support raw material injected into the mold is cured and foamed if desired. The curing method, curing conditions, foaming method, foaming conditions, etc. are not particularly limited, and conventionally known methods and conditions may be applied.
For example, when a foamable material is used as the support raw material, it may be foamed and cured according to the characteristics required for the final product. For example, when a urethane foam resin raw material is used, it is ^{foamed to about 0.01 to 1.0 g / cm 3} , and is used as a support for a leather-wrapped handle laminated product.

Molded Body Extraction Step Next, in the molded body extraction step, the molded body obtained in the curing foaming step is taken out from the mold. The removal from the mold is not particularly limited, and a conventionally known removal method may be adopted. Since the fine particles are added within a range that does not impair the releasability, the releasability of the molded body in the molding removing step is good with the conventional releasability ensured.

Adhesive application step In the adhesive application step, an adhesive is applied to the taken-out molded body after the molded body taking-out step. The adhesive is directly applied to the molded body taken out from the mold without post-treating the taken-out molded body.
The adhesive to be applied may be appropriately selected and used in consideration of the support raw material and the material of the coating material that is laminated on the molded body and adhered to the adhesive in the subsequent coating material laminating step, and is particularly limited. It's not a thing. For example, when the molded body is polyurethane foam and the coating is synthetic leather or leather, cloth, or PET film, for example, a chloroprene rubber-based adhesive or a vinyl acetate-based adhesive can be used.

The adhesive application method and conditions in the adhesive application step are not particularly limited, and conventionally known methods and conditions may be adopted.
Coating Laminating Step In the covering laminating step, at least a part or all of the surface of the molded body to which the adhesive obtained in the adhesive coating step is applied is covered with a covering, for example, leather, synthetic leather, cloth, or glass. , Metal, resin, carbon fiber, various films, etc., preferably a film such as leather, synthetic leather, cloth, PET film, etc. is laminated. As the method and conditions for laminating, conventionally known methods and conditions may be adopted.
As described above, the adhesive to be used is selected by considering the coating material, the molded body material, and the laminating method.
Laminate

Another important aspect of the present invention is to provide a laminate obtained through the above manufacturing process.
That is, it is a laminate in which a molded body, an adhesive, and a coating are laminated, and the molded body is a support made of resin, fine particles partially embedded in the surface of the support, the surface of the fine particles, and the surface of the support. The laminate is provided, which comprises a mold release agent attached to at least a part of each of the above.
A schematic cross-sectional view of the structure of the laminate provided by the present invention is shown in FIG.

The laminated body 1 of the present invention has a structure in which a molded body 5 composed of a support 2, fine particles 3 and a mold release agent 4, an adhesive 6 and a coating material 7 are laminated. The molded body 5 is a molded body taken out from the mold in the molded body taking-out process.

The support 2 is formed by curing the support raw material and, if desired, foaming it.

The fine particles 3 are fine particles contained in the water-based mold release agent applied to the surface of the mold, and are supported by the fine particles applied to the surface of the mold through the raw material injection step, the curing foaming step, and the molding body taking-out step. It exists with a part of it embedded in the body surface.

The mold release agent 4 is a mold release agent contained in the water-based mold release agent applied to the surface of the mold, and is subjected to a raw material injection step, a curing foaming step, and a molded body taking-out step, and is used on the surface of fine particles and the surface of the support. It is a mold release agent such as wax that is transferred and adhered to at least a part of each.

The adhesive is an adhesive applied in the adhesive application process.

The covering is a covering laminated in the covering laminating step.

In the laminate of the present invention, a mold release agent is present on at least a part of each of the fine particle surface and the support surface after molding due to the anchor effect of the fine particles 3 partially embedded in the support surface. Nevertheless, it is considered that the coating material 7 is attached to the support 2 with sufficient strength via the adhesive 6.

Specific examples of the laminated body of the present invention include seat cushions, armrests, footrests, handles and the like. When manufacturing these laminates, existing equipment can be used and the laminate can be manufactured efficiently.

Hereinafter, the present invention will be specifically described with reference to Examples, but the present invention should not be construed as being limited to those Examples, and can be conceived and implemented by those skilled in the art who are familiar with the concept of the present invention. Any technical idea that would be considered to be, and its specific aspects, should be understood as being included in the present invention.

Preparation of mold release agent sample The following waxes A, B, C, fluorine, and silicone were used as the mold release agent.
Wax A: In-house manufactured wax mixture; Main component paraffin wax Wax B: In-house manufactured wax mixture; Main component microcrystalline wax Wax C: In-house manufactured wax mixture; Main component microcrystalline wax Fluorine: In-house manufactured fluorine product Silicone: Modified silicone oil

The following fine particles A, B, and C were used as the fine particle components.
The fine particles A are silicone rubber powder I (average particle size: 4 μm);
Fine particles B are silicone rubber powder II (average particle size: 2 μm);
The fine particles C are urethane beads (average particle size: 15 μm).
The fine particles D are silica particles (average particle size: 15 nm);
The fine particles E are plastic beads (average particle size: 40 μm).

An aqueous mold release agent was prepared by dispersing the parts by weight of the above mold release agent and fine particle components shown in Tables 1 to 5 in water using a surfactant. In the release agent sample, water was added so that the wax component was 2% by weight, and the wax component and the fine particle component were adjusted to be in the range of 100: 0 to 10:90.

A ^{predetermined amount (100 g / m 2} ) of a mold release agent sample was applied to the inner wall surface of an aluminum test mold heated to 50 ° C. using a spray gun (manufactured by Anest Iwata Co., Ltd .: W-101). A predetermined amount of a stirring mixture of raw materials for the molded body (mixture of isocyanate and polyol at 50 kg / m ³ ) is injected into the mold, the mold top lid is closed, and the molded product A (mixed) is cured for 90 seconds. FIG. 2) and molded body B (FIG. 3) were obtained.

Liquid stability evaluation The manufactured release agent sample was allowed to stand at room temperature for 1 day, and then the liquid state of the release agent sample was visually observed.
The liquid stability was ranked as "○" if the compounding components were uniformly dispersed, and as "x" if it was non-uniform.

Releaseability evaluation After the resin was cured, the load applied to the opening of the upper lid of the mold was measured with a push-pull scale.
The results are shown in Tables 1 to 3.
The releasability was ranked as "○" (good) for less than 60N and "x" (poor) for 60N or more.

Adhesive evaluation Adhesive: Chloroprene rubber adhesive, vinyl acetate adhesive Coating: Leather, cloth (gold width No. 3), PET film The above adhesive and coating are used in the combination shown in Table 1, and the coating is used. About 1 g of an adhesive is applied to each of the adhesive surface and the adhesive surface 8 (FIG. 2) or the adhesive surface 9 (FIG. 3) of the molded body A or the molded body B, dried for about 100 seconds, and then the coating material and the molded body are applied. It was pasted (laminated).
The adhesive was uniformly applied to the coating material and the adhesive surface of the molded body A or the molded body B in an area of 2.5 cm × 7 cm.
After allowing to stand at room temperature for about 12 hours, a ring-shaped metal fitting was attached to the end of the covering, and the load required for peeling the covering from the molded body was measured using a push-pull scale.
The results are shown in Tables 1-5.
Adhesiveness was ranked as "○" (good) when the adhesive strength was 10 N or more and "x" (bad) when the adhesive strength was less than 10 N.

As shown in Examples 1 to 13, the releasability of the molded body in the manufacturing process and the good adhesive force of the coating material to the molded body without treating the surface of the molded body after molding are maintained. Achievement of both.
In Comparative Examples 1, 3, 4, 5, and 8, since fine particles are not used, the adhesive strength of the coating material to the molded body is inferior. In Comparative Example 8, the releasability is also inferior.
In Comparative Example 2, since the amount of the fine particle component is too large with respect to the wax component, the adhesive force of the coating material to the molded body is excellent, but the releasability of the molded body in the manufacturing process is inferior.
In Comparative Example 6, since the particle size of the particles used is too small, the releasability and adhesiveness are inferior.
In Comparative Example 7, the particle size of the particles used is too large, so that the water-based release agent, which is a dispersion solution, lacks stability.

1: Laminated body 2: Support 3; Fine particles 4: Mold release agent 5: Molded body 6: Adhesive 7: Coating 8: Adhesive surface 9: Adhesive surface

Claims (11)

A laminate in which a molded body, an adhesive, and a coating are laminated, and the molded body is a support made of resin, fine particles partially embedded in the surface of the support, and the surface of the fine particles and the surface of the support, respectively. The laminate, which comprises a mold release agent attached to at least a part of the above. The laminate according to claim 1, wherein the fine particles have a particle size of 100 nm to 20 μm. The laminate according to claim 1 or 2, wherein the coating is leather, synthetic leather, cloth, glass, metal, resin, carbon fiber, or film. A method for manufacturing a laminate, which comprises going through the following manufacturing steps (1) to (6):
(1) Release agent application step of applying a water-based release agent containing fine particles to the surface of a mold,
(2) Support raw material injection step of injecting the support raw material of the molded body into the mold,
(3) A curing foaming step of curing and optionally foaming the support raw material,
(4) A molding body taking-out step of taking out the molded body obtained in the curing foaming step from the mold,
(5) Following the step (4), an adhesive coating step of applying an adhesive to the molded body, and (6) a covering laminating step of laminating a coating material on the molded body to which the adhesive is applied. .. The method for producing a laminate according to claim 4, wherein the water-based release agent contains a release agent component, fine particles, and water. The method for producing a laminate according to claim 5, wherein the release agent contains wax. The method for producing a laminate according to claim 6, wherein the wax and the fine particles are contained in a weight ratio of 97: 3 to 20:80 (wax: fine particles). The method for producing a laminate according to any one of claims 5 to 7, wherein the fine particles have a particle size of 100 nm to 20 μm. The method for producing a laminate according to any one of claims 4 to 8, wherein the covering is leather, synthetic leather, cloth, glass, metal, resin, carbon fiber, or film. A laminate obtained by the production method according to any one of claims 4 to 9. The laminate according to any one of claims 1 to 3, which is characterized by undergoing the following manufacturing steps (1) to (6):
(1) Mold release agent application step of applying a water-based mold release agent to the mold surface,
(2) Support raw material injection step of injecting the support raw material of the molded body into the mold,
(3) A curing foaming step of curing and optionally foaming the support raw material,
(4) A molding body taking-out step of taking out the molded body obtained in the curing foaming step from the mold,
(5) Following the step (4), an adhesive coating step of applying an adhesive to the molded body, and (6) a covering laminating step of laminating a coating material on the molded body to which the adhesive is applied. ..

Images