WO2011065476A1 - 静電粉体接着剤を用いた接着工法および該接着工法に用いる粉末状接着剤 - Google Patents
静電粉体接着剤を用いた接着工法および該接着工法に用いる粉末状接着剤 Download PDFInfo
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- WO2011065476A1 WO2011065476A1 PCT/JP2010/071116 JP2010071116W WO2011065476A1 WO 2011065476 A1 WO2011065476 A1 WO 2011065476A1 JP 2010071116 W JP2010071116 W JP 2010071116W WO 2011065476 A1 WO2011065476 A1 WO 2011065476A1
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- powder
- adhesive
- molding
- automobile interior
- adherend
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J5/00—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/16—Nitrogen-containing compounds
- C08K5/29—Compounds containing one or more carbon-to-nitrogen double bonds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
- C08L67/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J167/00—Adhesives based on polyesters obtained by reactions forming a carboxylic ester link in the main chain; Adhesives based on derivatives of such polymers
- C09J167/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/24—Acids; Salts thereof
- C08K3/26—Carbonates; Bicarbonates
- C08K2003/265—Calcium, strontium or barium carbonate
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/34—Silicon-containing compounds
- C08K3/346—Clay
Definitions
- the present invention relates to a method for bonding members, and more particularly to a bonding method used in molding automobile interior parts.
- the present invention also relates to a powdery adhesive used for the bonding method.
- Patent Documents 1 to 4 propose various adhesives and the like.
- Patent Document 1 proposes a chloroprene-based adhesive composition that is not a two-component type but a one-component type, but since this is a solvent-based adhesive, environmental problems are not improved.
- Patent Document 2 proposes a water-based adhesive rather than a solvent-based adhesive. However, since it is a two-component type, problems such as material loss remain and it takes time to dry because it is aqueous. There's a problem.
- Patent Document 3 proposes a hot-melt adhesive rather than a solvent-based adhesive, but this has a problem that the open time after application of the adhesive is short and material loss occurs during application.
- Patent Document 4 discloses a precoat skin material for automobile interior in which a hot melt adhesive is pre-applied to the back surface of an automobile interior skin material. There is a problem that material loss occurs in the case of doing so.
- Patent Document 5 powder coating curing agents
- Patent Document 6 An electrostatic powder coating method that can be used is disclosed (Patent Document 6), but the application to adhesion technology, particularly application to automobile interior parts, includes heat resistance (including heat resistance in a high temperature environment). The same shall apply hereinafter.)
- heat resistance including heat resistance in a high temperature environment
- thermosetting compositions described in Patent Documents 7 and 8 as the fine powder for coating the active amino group, in the examples, as the fine powder used for the coating amine, titanium oxide, hydrophobic silica, polyvinyl chloride. Only examples using are shown.
- the object of the present invention is to spray-apply a powdery adhesive to an adherend, and use the adherend to form an automotive interior part having excellent heat resistance and bonding strength. And providing a powdery adhesive used in the bonding method and the bonding method. Also, an adhesive construction method that enables spray coating on an adherend even after long-term storage of a powdered adhesive, and enables molding of automobile interior parts having excellent heat resistance and bonding strength, and the adhesive construction method The object is to provide a powdery adhesive used in the above.
- the inventors of the present invention have intensively studied to solve the above-mentioned problems.
- the powdered adhesive is spray-applied to the adherend using an electrostatic powder spray gun.
- the present inventors have found that parts can be molded and have completed the present invention.
- the present invention relates to an adhesion method used for molding automobile interior parts including a step of spray-applying a powdery adhesive to an adherend using an electrostatic powder spray gun.
- the present invention relates to an adhesive construction method used for molding automobile interior parts according to (1), wherein the powdery adhesive is a mixture of two or more powders containing compounds having reactivity with each other.
- One of the powders is a powder having a carboxyl group and containing a polyester resin compound having a number average molecular weight of 1000 to 35000. Concerning construction method.
- the present invention relates to an adhesion method used for molding an automobile interior part according to (4), wherein the functional group containing a nitrogen atom is a carbodiimide group.
- a fine powder made of calcium carbonate and / or clay is fixed to the surface of a powder containing a compound having a functional group containing a nitrogen atom, and used for molding an automobile interior part according to (4). It relates to the bonding method.
- the present invention relates to an adhesive construction method used for molding automobile interior parts according to any one of (1) to (6), including a step of heating and melting a powdery adhesive spray-coated on an adherend using an infrared heater. .
- the present invention relates to a powdery adhesive used for molding automobile interior parts formed by mixing two or more kinds of powders containing mutually reactive compounds.
- One of the powders is a powder adhesive used for molding an automobile interior part according to (8) or (9), wherein the powder contains a compound having a functional group containing a nitrogen atom.
- a fine powder made of calcium carbonate and / or clay is fixed to the surface of a powder containing a compound having a functional group containing a nitrogen atom, and used for molding an automobile interior part according to (10). It relates to a powdery adhesive.
- the bonding method of the present invention since a powdery adhesive is used, there is no problem in terms of environment and equipment due to solvent dispersion, and spray loss and material reduction are possible. Moreover, when the predetermined powdery adhesive of the present invention is used, it is possible to provide an automobile interior part having more excellent heat resistance and bonding strength. In addition, when using a specific powder with a specific fine powder fixed, it is possible to more effectively suppress aggregation and blocking of the powder adhesive, thus maintaining excellent heat resistance and bonding strength. However, it is possible to form automobile interior parts in the bonding method.
- the bonding method used for molding the automobile interior part of the present invention includes a step of spray-applying a powdery adhesive to an adherend using an electrostatic powder spray gun.
- a powdery adhesive since the powdery adhesive is used, the load on the working environment and the external environment that has occurred by using the conventional solvent-based adhesive is reduced, and as described below. Since the adhesive can be easily collected and reused, the spray loss can be greatly reduced.
- the principle of spray application using an electrostatic powder spray gun is that the same charge is applied to each particle of the powdered adhesive transferred to the spray gun or its spray head in a gas flow such as air and grounded coating. Each particle is adhered to the adherend by electrostatic force, and a coating layer of a powdery adhesive is temporarily formed on the adherend.
- the powdery adhesive can be efficiently attached to the adherend by the action of the electrostatic force between the powder and the adherend generated by using the electrostatic powder spray gun.
- electrostatic charges are uniformly generated on the surface of the adherend, it is particularly effective when the adherend has a complicated structure.
- the electrostatic powder spray gun used in the present invention is not particularly limited as long as the powdered adhesive to be used can be charged, and a corona charging type spray gun using corona charging, tribo (friction) charging.
- a tribo-charging spray gun using the above, a spray gun using these systems in combination, and the like can be appropriately selected and used, and commercially available ones can be used.
- a spray gun using corona charging is used (including combined use)
- a high DC voltage is applied between the grounded adherend and the tip of the electrostatic powder spray gun, and an electric field is generated.
- the powdery adhesive is more efficiently attached to the adherend.
- the powdery adhesive used in the present invention can be stably applied by the electrostatic powder spray gun described above, and has characteristics such as heat resistance and bonding strength required for automobile interior parts, and further described below. If the adherend is melted at a temperature at which the adherend is not thermally deformed in the heating and melting step, it can be used without limitation.
- a powder having a particle diameter of 5 to 400 ⁇ m is preferable. More preferably, it is 10 to 200 ⁇ m, and still more preferably 20 to 50 ⁇ m. If it is smaller than 5 ⁇ m or larger than 400 ⁇ m, the coating property is lowered.
- the particle diameter can be measured, for example, with a commercially available measuring instrument such as a particle size distribution analyzer LA700 (manufactured by Horiba Ltd.).
- the melting point of the powdery adhesive is preferably 80 ° C. to 140 ° C. from the viewpoint of having the heat resistance and bonding strength as the latter automobile interior product and melting the adherend at a temperature at which it is not thermally deformed.
- the melting point is lower than 80 ° C., the heat resistance of the obtained bonded body is inferior, and when it is higher than 140 ° C., the melting temperature must be set high, which is not preferable from the viewpoint of the heat resistance of the adherend and the energy used.
- the powder adhesive one obtained by mixing two or more kinds of powders containing mutually reactive compounds may be used.
- the molecular weight and the melting temperature are initially suppressed to a certain degree to prevent thermal deformation of the adherend as much as possible, while melting and reacting each powder to increase the molecular weight and heat resistance. It can be used as an automobile interior product.
- composition of the powder that can have the above-described characteristics include, for example, a resin compound such as an acrylic resin compound, an epoxy resin compound, or a polyester resin compound, or a powder containing a combination of these appropriately. And a powder containing a reactive compound can be used and a mixture of two or more powders can be used.
- a resin compound such as an acrylic resin compound, an epoxy resin compound, or a polyester resin compound
- a powder containing a combination of these appropriately a powder containing a reactive compound can be used and a mixture of two or more powders can be used.
- one of the powders is a powder containing a polyester resin compound having a carboxyl group and having a number average molecular weight of 1000 to 35000, preferably 2000 to 30000, more preferably 2000 to 25000. If it is, it has characteristics, such as heat resistance and joining strength, and it is preferable at the point which fuse
- the polyester resin compound is preferable as the resin compound constituting one of the powders because it has excellent adhesiveness and an appropriate melting temperature. Further, when the number average molecular weight is less than 1000, the heat resistance tends to be insufficient, and when it is more than 35000, the wettability of the adhesive is lowered and the adhesive strength tends to be lowered.
- the number average molecular weight can be measured by, for example, a commercially available measuring instrument such as a high performance liquid chromatograph (gel permeation chromatograph (GPC)) RID-10A, SPD-10A, CTO-10A (manufactured by Shimadzu Corporation).
- a commercially available measuring instrument such as a high performance liquid chromatograph (gel permeation chromatograph (GPC)) RID-10A, SPD-10A, CTO-10A (manufactured by Shimadzu Corporation).
- the polyester resin compound having a carboxyl group various compounds can be used as long as the resin compound has a carboxyl group within the range having the above characteristics.
- the carboxyl group content is preferably from 1 to 100 mgKOH / g, more preferably from 20 to 80 mgKOH / g, in terms of acid value.
- the acid value is less than 1 mgKOH / g, the crosslink density is low, and thus the heat resistance is not sufficient.
- the acid value is more than 100 mgKOH / g, the polarity is increased and the adhesion to a low-polar adherend such as polypropylene is lowered. There is a tendency.
- the acid value can be measured according to JIS K0070.
- the polyester resin compound which has the above carboxyl groups can be manufactured by a well-known method, and a commercially available thing can be used.
- the polyester resin compound used in the present invention is a polybasic acid such as malonic acid, succinic acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, terephthalic acid, isophthalic acid, and the like, Ethylene glycol, propylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, neopentyl glycol, diethylene glycol, triethylene glycol, polyethylene glycol, polypropylene glycol, Polybutylene glycol, polycaprolactone diol, 2,2-dimethylpropanediol, 2,2-bis (4-hydroxycyclohexyl) propane, 1,4-dihydroxymethylcyclohexane, trimethylolpropane, 1,2,3-trihydroxypropane Polyhydric alcohols such as tetramethylol methane
- a powder containing a compound having a functional group reactive with a carboxyl group can be used as one of the powders.
- the compound include a hydroxyl group, an aldehyde group, a carboxyl group, and a sulfo group.
- a compound having a functional group containing a nitrogen atom is preferred, and a compound containing a carbodiimide group is more preferred.
- a powder containing a predetermined polyester resin compound containing the carboxyl group as another kind of powder by mixing the compound with a powder containing a predetermined polyester resin compound containing the carboxyl group as another kind of powder, and reacting the various functional groups with the carboxyl group, Heat resistance can be improved by increasing the molecular weight while maintaining the basic skeleton characteristics of the resin compound.
- the compound containing a carbodiimide group reacts with the active hydrogen group (carboxyl group, amino group, hydroxyl group) of the compound contained in other powder, and can improve heat resistance and adhesive strength more.
- the resin compound containing a carboxyl group as described above can also be used in combination with a resin compound containing an active hydrogen group such as an amino group or a hydroxyl group.
- the compound having a carbodiimide group described above can be used without particular limitation as long as it has the functional group in the molecule, and a known one can be used, but two or more carbodiimide groups in the molecule can be used.
- the polycarbodiimide having is preferable in terms of reactivity. Specific examples of the polycarbodiimide include Carbodilite (registered trademark) manufactured by Nisshinbo Industries, Ltd.
- These fine powders are particularly suitable because of their high thermal stability and moisture stability.
- agglomerates are generated due to heat and moisture. It can be effectively prevented. Further, even if agglomeration occurs to some extent, it is easily broken, so that the agglomerates are clogged in the spray nozzle, and it becomes almost impossible to perform spray coating, so that there is almost no obstacle in the spray coating process.
- Calcium carbonate used in the present invention is not particularly limited in terms of particle structure and surface characteristics as long as it has thermal stability and moisture stability.
- the particle structure may be a spherical shape, a cubic shape, a spindle shape, or a mixture thereof.
- the surface characteristics may be either hydrophilic or hydrophobic. In the case of making the surface hydrophobic, it is preferable to use a surface modified and treated with a fatty acid or the like. A commercially available calcium carbonate can be used.
- the clay used in the present invention is not particularly limited in terms of the structure and surface characteristics of the particles as long as it has thermal stability and moisture stability.
- the particle structure may be indefinite.
- the surface characteristics may be either hydrophilic or hydrophobic, and when the surface is made hydrophobic, it is preferable to use a surface treated with silane.
- silane treatment include, but are not limited to, those using vinyl silane, mercaptosilane, and the like.
- such a clay can use a commercially available thing.
- the powder containing a compound having a functional group containing a nitrogen atom to which a fine powder made of calcium carbonate or clay is fixed on the surface is a nitrogen-based functional group. While pulverizing the contained powder to a predetermined center particle size range, at the same time, adding a fine powder to this, mixing and pulverizing the fine powder to a predetermined center particle size range, Manufactured by a shear friction mixing method in which fine powder is fixed to the surface.
- the amount of calcium carbonate or clay used is a powder containing a compound having a functional group containing a nitrogen atom (such as a carbodiimide group) (hereinafter sometimes abbreviated as nitrogen-based functional group-containing powder) and carbonic acid.
- the weight ratio of the fine powder made of calcium and / or clay is preferably 100/1 to 100, more preferably 100/50 to 90. When the ratio of the fine powder is less than 1, the effect of storage stability is not recognized, and when it exceeds 100, the storage stability is not further improved.
- the fine powder adheres to the surface of the nitrogen-based functional group-containing powder, or the mechanical force of the mixing stirrer
- the fine powder adheres due to the local melting and fixing phenomenon of the nitrogen-containing functional group-containing powder due to heat generated by friction, impact, compression shear, etc., or is physically applied to the surface of the nitrogen-containing functional group-containing powder. It is predicted that it will be embedded and fixed, or chemically activated and fixed (that is, the active nitrogen atom-containing group on the surface of the nitrogen-based functional group-containing powder is coated with a fine powder. Become).
- the center particle size of the fixed fine powder is preferably 1/10 or less of the nitrogen-based functional group-containing powder. When this value is exceeded, there is a tendency that it does not adhere to the surface of the nitrogen-based functional group-containing powder.
- the mixing ratio of the powder obtained by combining two or more kinds of powders containing compounds having reactivity with each other is not particularly limited as long as the effect of the present invention is obtained.
- the powder containing the predetermined polyester resin And a powder containing a compound having a functional group reactive with a carboxyl group, the functional group that reacts with the carboxyl group is contained in an amount of 0.5 to 2.0 mol with respect to 1 mol of the carboxyl group. It is preferable to configure. If it is less than 0.5 mol or more than 2.0 mol, the heat resistance of the adhesive tends to decrease.
- the powdered adhesive as described above is pulverized using a known pulverizer after preparing a predetermined resin or the like by a known method, or a compound having a functional group reactive with a carboxyl group, for example.
- This pulverized product is prepared by uniformly mixing and dispersing with a powder mixer such as a known container rotating mixer or container fixed mixer. At this time, the mixing and dispersing is preferably performed at 50 ° C. or lower. When the temperature at the time of manufacture exceeds 50 ° C., the powder particles constituting the powdered adhesive obtained may be consolidated in a powder mixer or a pulverizer.
- a plate-like molded body made of a synthetic resin such as an ABS plate, a Noryl plate, an ASG plate, a polycarbonate plate, or a polypropylene (PP) board, or a woody material such as kenaf or wood chip.
- the plate-shaped molded body, the steel plate, or a composite thereof can be used as a base material. Moreover, you may process to the surface of each said base material so that the said powdery adhesive may adhere easily if needed.
- an adherend 4 that is grounded 3 is arranged in a coating booth 1 via a conveyor 2, and powder is applied to the adherend 4 using an electrostatic powder spray gun 5.
- the adhesive 6 is applied by spraying.
- the electrostatic powder spray gun 5 is connected with a compressor 8 to the powder adhesive supply tank 7 in order to supply air for pumping the powder adhesive, and the tank 7 and the spray gun. 5 is connected through a pipe.
- a high voltage generator 9 for generating a high voltage at the tip of the spray gun 5 is provided. That is, in this example, the spray gun 5 is a corona discharge type.
- the powder-form adhesive spray-applied what was not adhered to the to-be-adhered body 4 WHEREIN:
- recovery apparatus provided in the coating booth 1 via the duct 10 11 and may be reused as a powdery adhesive.
- the powdery adhesive that has not adhered to the adherend can be collected and reused, so that the spray loss can be greatly reduced.
- the adhesive is spray-coated on the adherend to form a coating layer (adhesive layer) of the powdered adhesive, and then the adhesive is heated and melted.
- a heating means a method using hot air, a method using infrared rays, or the like can be used, and a general hot air dryer, an infrared heater, or the like can be used.
- the infrared rays pass through the entire coated adhesive layer that adheres to the adherend surface and extends from the outermost surface of the coated adhesive to the adherend surface.
- the entire adhesive can be heated and melted simultaneously.
- the heating by infrared rays is by radiant heat transfer, the heating rate is higher than that of convective heat transfer such as hot air drying, and a high heat flux can be put into the powder adhesive.
- the infrared heater used in the present invention includes a near infrared (short wavelength infrared) heater having a radiator temperature of about 1400 to 2100 ° C., a medium wavelength infrared heater having a radiator temperature of about 800 to 1200 ° C., and a radiator temperature of 400 to 700
- a far-infrared (long wavelength infrared) heater of about 0 ° C. can be used.
- a near infrared heater a quartz glass heater or the like
- a medium wavelength infrared heater a carbon heater or a quartz glass heater or the like
- Examples of the far infrared heater include a ceramic heater.
- the heating conditions by the infrared heater include the melting point of the powder adhesive, the melting point of the adherend or the glass transition temperature, and the infrared irradiation temperature, the infrared heater and the powder adhesive of the adherend.
- the distance from the coated surface, the irradiation time, etc. can be determined as appropriate.
- the adherend in which the applied powdery adhesive is heated and melted is used for molding automobile interior parts. Specifically, it is as follows, but is not limited thereto. That is, while maintaining the adherend, in which the powdered adhesive is heated and melted as described above, at a surface temperature of 130 ° C. or higher, preferably 150 to 180 ° C., the skin material is superposed on the adherend, and 0.05 MPa or higher. By performing thermocompression bonding for 10 seconds or more under the pressure of and performing molding and adhesion at the same time, a desired automobile interior part in which the skin material is adhered to the adherend is obtained. Examples of automobile interior parts include inside trims such as door rims, front pillars, rear pillars, deck side trims, and center pillars; instrument panels; molded ceilings; console boxes; trunk rooms and the like.
- polyester resin 1 is Iupika Coat GV-250 manufactured by Nippon Yupica Co., Ltd.
- polyester resin 2 is ER-8700 manufactured by Unitika Co., Ltd.
- polyester resin 3 is manufactured by Toyobo Co., Ltd.
- Byron registered trademark
- GA-6300 and carbodiimide is Carbodilite (registered trademark) HMV-80CA manufactured by Nisshinbo Co., Ltd.
- Each prepared powdery adhesive was coated with a kenaf / polypropylene resin composite board (thickness 2 mm, width 100 mm, length) using an electrostatic powder spray gun (Nihon Parkerizing Co., Ltd., GX7000C cup gun system). 75 mm) (hereinafter referred to as a composite board).
- the adhesive coated surface of the composite board was irradiated with infrared rays by an infrared heater, and the adhesive coated surface was heated for 2 minutes to adjust the surface temperature to 170 ° C.
- FIG. 2A schematically shows the produced automobile interior part (evaluation sample) 20 and shows a state in which the composite board 21 and the fabric 22 with urethane foam are pressure-bonded.
- the fabric 22 with urethane foam was made longer than the composite board 21.
- Each prepared powdery adhesive (immediately after preparation (before storage), after long-term storage (after storage)) is used with an electrostatic powder spray gun (manufactured by Sanno Co., Ltd., JP80T type).
- the kenaf / polypropylene resin composite board (thickness 2 mm, width 100 mm, length 75 mm) (hereinafter referred to as the composite board), which is the adherend, was applied by spraying.
- the amount of the powder adhesive applied to the composite board was 20 g.
- FIG. 2A schematically shows the produced automobile interior part (evaluation sample) 20 and shows a state in which the composite board 21 and the fabric 22 with urethane foam are pressure-bonded.
- the fabric 22 with urethane foam was made longer than the composite board 21.
- each powder adhesive is heated in a hot air circulation oven under the curing conditions shown in Table 3, and each cured product after cooling. was dissolved in tetrahydrofuran and diluted, and the molecular weight of each cured product was measured in terms of polystyrene using a GPC measuring apparatus (manufactured by Shimadzu Corporation, RID-10A). Table 3 shows the measurement results.
Abstract
Description
特許文献1には、2液型ではなく1液型のクロロプレン系接着剤組成物が提示されているが、このものは溶剤系接着剤であるため、環境上の問題は改善されない。また、特許文献2には、溶剤系ではなく水系の接着剤が提示されているが、2液型であるため、材料ロス等の問題が残るうえ、水系であることから乾燥に時間がかかるといった問題がある。特許文献3には、溶剤系ではなくホットメルト系の接着剤が提示されているが、このものは、接着剤の塗布後のオープンタイムが短く、塗布時の材料ロスが発生するという問題がある。特許文献4には、ホットメルト接着剤を自動車内装表皮材の裏面に予め塗布した自動車内装用プレコート表皮材が開示されているが、プレコート型で表皮材に予め塗布することから、不要部分をカットする場合などに材料ロスが発生するという問題がある。
また、粉末状接着剤を長期保存後でも、被着体へのスプレー塗布が可能であり、耐熱性、接合強度に優れる自動車内装部品を成形することを可能とする、接着工法、および当該接着工法に用いる粉末状接着剤を提供することにある。
(1)静電粉体スプレーガンを用いて粉末状接着剤を被着体にスプレー塗布する工程を含む自動車内装部品の成形に用いる接着工法に関する。
さらに、特定の微粉末が固着された特定の粉体を用いた場合、粉末状接着剤の凝集やブロッキングをより効果的に抑制することが可能となるため、優れた耐熱性、接合強度を保持しつつ、接着工法において自動車内装部品の成形を行うことが可能となる。
また、上記のようなカルボキシル基を有するポリエステル樹脂化合物は、公知の方法により製造することができる他、市販のものを用いることができる。
エチレングリコール、プロピレングリコール、1,3-プロパンジオール、1,4-ブタンジオール、1,5-ペンタンジオール、1,6-ヘキサンジオール、ネオペンチルグリコール、ジエチレングリコール、トリエチレングリコール、ポリエチレングリコール、ポリプロピレングリコール、ポリブチレングリコール、ポリカプロラクトンジオール、2,2-ジメチルプロパンジオール、2,2-ビス(4-ヒドロキシシクロヘキシル)プロパン、1,4-ジヒドロキシメチルシクロヘキサン、トリメチロールプロパン、1,2,3-トリヒドロキシプロパン、テトラメチロールメタン、などの多価アルコールと、
を縮合反応させて得られるポリエステルなどが挙げられる。
また、カルボジイミド基を含有する化合物は、他の粉体中に含まれる化合物の活性水素基(カルボキシル基、アミノ基、水酸基)と反応して、耐熱性や接着強度をより向上させることができることから、上記のようなカルボキシル基を含有する樹脂化合物に限らず、アミノ基や水酸基等の活性水素基を含む樹脂化合物と組合せて用いることもできる。
上述のカルボジイミド基を有する化合物としては、該官能基を分子内に有するものであれば、特に制限なく使用可能であり、公知のものを用いることができるが、分子内にカルボジイミド基を2個以上有するポリカルボジイミドが反応性の点で好ましい。具体的には、ポリカルボジイミドとしては日清紡績株式会社のカルボジライト(登録商標)などが挙げられる。
このような微粉末が固着されたものを用いた場合は、互いに反応性を有する化合物を含む粉体を2種以上混合した状態で長期間保存したときに、熱や湿気による凝集体の発生を効果的に防止できる。また、ある程度凝集が発生しても容易に破壊されるため、凝集体がスプレーノズルに詰まり、スプレー塗布することが殆どできなくなるなど、スプレー塗布工程において障害となることは殆どない。
尚、長期間保存とは、常温で少なくとも4カ月間保存すること(これと同等の条件を含む。例えば、いわゆる加速試験など。)を意味する。
図1に示すように、塗布ブース1内に、コンベヤ2を介して接地3された被着体4を配し、該被着体4に対して、静電粉体スプレーガン5を用いて粉末状接着剤6をスプレー塗布する。本例では、静電粉体スプレーガン5には、粉末状接着剤を圧送するための空気を供給するために、粉末状接着剤供給用タンク7にコンプレッサー8を接続するとともにタンク7とスプレーガン5とを管を介して接続している。また、スプレーガン5の先端に高電圧を発生させるための高電圧発生装置9を設けている。即ち、本例では、スプレーガン5はコロナ放電式である。
従って、赤外線を用いて接着剤を加熱溶融する場合は、被着体の表面に付着、被覆した接着剤層全体を短時間で同時に加熱溶融することができるため、被着体自体の加熱が大幅に低減され、被着体の熱変形等をより効果的に防止することができる。
自動車内装部品としては、例えば、ドアートリム、フロントピラー、リヤピラー、デッキサイドトリム、センターピラーなどのインサイドトリム類;インストルメントパネル;成形天井;コンソールボックス;トランクルーム等が挙げられる。
ポリエステル樹脂およびカルボジイミドの粉末を、表1に示す組成で混合し、粉末状接着剤を調製した。尚、表1中、ポリエステル樹脂1は、日本ユピカ株式会社製のユピカコートGV-250であり、ポリエステル樹脂2は、ユニチカ株式会社製のER-8700であり、ポリエステル樹脂3は、東洋紡績株式会社製のバイロン(登録商標)GA-6300であり、カルボジイミドは、日清紡株式会社製のカルボジライト(登録商標)HMV-80CAである。
調製した各粉末状接着剤を、静電粉体スプレーガン(日本パーカライジング株式会社製、GX7000Cカップガンシステム)用いて、被着体であるケナフ・ポリプロピレン樹脂複合ボード(厚み2mm、幅100mm、長さ75mm)(以下、複合ボードという。)に対してスプレー塗布した。次に、当該複合ボードの接着剤塗布面に対し、赤外線ヒーターにより赤外線を照射して、接着剤塗布面を2分間加熱し表面温度を170℃に調整した。その後、複合ボードの接着剤塗布面に、表皮材であるウレタンフォーム付ファブリックを重ね合わせ、0.2MPaにて10秒間圧着を行い、自動車内装部品(評価用サンプル)を得た。図2(a)は、作製した自動車内装部品(評価用サンプル)20を模式的に示したもので、複合ボード21とウレタンフォーム付ファブリック22が圧着された状態を示したものである。尚、評価試験を行う都合上、ウレタンフォーム付ファブリック22が複合ボード21より長くなるようにした。
カルボジイミド(日清紡(株)社製、10M-SP、中心粒径約10μm)100重量部に対して、炭酸カルシウム(白石カルシウム(株)製、白艶華CCR、脂肪酸にて疎水性表面処理、中心粒径約0.8μm)80重量部を混合し、奈良機械製作所製、ハイブリダイザーI型にて粉砕することにより、中心粒径約10μmの炭酸カルシウムコーティングカルボジイミド78部を得た。
カルボジイミド(日清紡(株)社製、10M-SP、中心粒径約10μm)100重量部に対して、クレー(白石カルシウム(株)製、ST-309、メルカプトシランにて疎水性表面処理、中心粒径約0.7μm)70重量部を混合し、製、ハイブリダイザーI型にて粉砕することにより、中心粒径約10μmのクレーコーティングカルボジイミド139部を得た。
カルボジイミド(日清紡(株)社製、10M-SP、中心粒径約10μm)100重量部に対して、酸化チタン(石原産業(株)製、TTO-55、Al(OH)3/ステアリン酸にて表面処理、中心粒径約0.03~0.05μm)10重量部を混合し、奈良機械製作所製、ハイブリダイザーI型にて粉砕することにより、中心粒径約10μmのクレーコーティングカルボジイミド94部を得た。
<粉末状接着剤の調製>
ポリエステル樹脂1(分子量2200、酸価74、日本ユピカ(株)製、GV-250)、ポリエステル樹脂2(分子量6800、酸価24、ユニチカ(株)社製、ER-8700)および製造例1~3で調製したいずれかの微粉末コーティングカルボジイミドまたは未処理のカルボジイミドの粉末を、表2に示す組成で混合し、粉末状接着剤を調製した。調製直後の粉末状接着剤を後述する、自動車内装部品の製造、ゲルパーミエーションクロマトグラフィー(GPC)測定および長期保存安定性の評価に供した。
上記のようにして調製した直後の各粉末接着剤を、40℃にて20日間保存した。保存後の各粉末状接着剤を後述する、自動車内装部品の製造およびGPC測定に供した。
調製した各粉末状接着剤(調製した直後(保存前)のもの、長期保存した後(保存後)のもの)を、静電粉体スプレーガン((株)山王製、JP80T型)を用いて、被着体であるケナフ・ポリプロピレン樹脂複合ボード(厚み2mm、幅100mm、長さ75mm)(以下、複合ボードという。)に対してスプレー塗布した。複合ボードへの粉体接着剤の塗布量は20gとした。
次に、当該複合ボードの接着剤塗布面に対し、赤外線ヒーターにより赤外線を照射して、接着剤塗布面を3分間加熱し表面温度を195℃に調整した。その後、複合ボードの接着剤塗布面に、表皮材であるウレタンフォーム付ファブリックを重ね合わせ、0.2MPaにて10秒間圧着を行い、自動車内装部品(評価用サンプル)を得た。図2(a)は、作製した自動車内装部品(評価用サンプル)20を模式的に示したもので、複合ボード21とウレタンフォーム付ファブリック22が圧着された状態を示したものである。尚、評価試験を行う都合上、ウレタンフォーム付ファブリック22が複合ボード21より長くなるようにした。
上記の調製した直後(保存前)および長期保存した後(保存後)の各粉末接着剤を、熱風循環式オーブン内にて、表3に示す硬化条件にて加熱し、冷却後の各硬化物をテトラヒドロフランに溶解、希釈したものを、GPC測定装置(島津製作所製、RID-10A)によるポリスチレン換算にて各硬化物の分子量を測定した。測定結果を表3に示す。
上記のようにして作製した自動車内装部品について、下記の条件で剥離試験を行った。測定結果を表1、4に示す。尚、参考例5および6の保存後の粉末状接着剤については、凝集体が発生し、評価サンプルを作製することが困難であったため、ブロッキング以外の評価は行わなかった。
<初期クリープ>
複合ボード21とウレタンフォーム付ファブリック22を圧着した直後に、60℃雰囲気下で、図3に模式的に示すように、ワイヤ24を介して分銅(200g)23を5分間吊り下げた時の剥がれ長さLを測定した。実施例3、4、参考例5、6については、剥離状態も観察した。
<常態剥離>
20℃、65%RHで24時間養生(放置)した後、室温条件下にて剥離強度[N/25mm]を測定した。図2(b)の模式図で示すようにして、複合ボード21からウレタンフォーム付ファブリック22を剥がした時の強度を測定するとともに、剥離状態を観察した。
<耐熱クリープ>
20℃、65%RHで24時間養生(放置)した後、80℃雰囲気下で、図3に模式的に示すように、ワイヤ24を介して分銅(100g)23を24時間吊り下げた時の剥がれ長さLを測定した。実施例3、4、参考例5、6については、剥離状態も観察した。
<ブロッキング>
長期保存後の各粉末状接着剤について、凝集体の発生の有無を目視により確認した。
評価基準:凝集なしを○、凝集ありを×とした。
2 コンベヤ
3 接地
4 被着体
5 静電粉体スプレーガン
6 粉末状接着剤
7 粉末状接着剤供給用タンク
8 コンプレッサー
9 高電圧発生装置
10 ダクト
11 回収装置
20 自動車内装部品(評価用サンプル)
21 ケナフ・ポリプロピレン樹脂複合ボード
22 ウレタンフォーム付ファブリック
23 分銅
24 ワイヤ
L 剥がれ長さ
Claims (12)
- 静電粉体スプレーガンを用いて粉末状接着剤を被着体にスプレー塗布する工程を含む自動車内装部品の成形に用いる接着工法。
- 前記粉末状接着剤が、互いに反応性を有する化合物を含む粉体を2種以上混合してなる請求項1記載の自動車内装部品の成形に用いる接着工法。
- 前記粉体のうちの1種が、カルボキシル基を有し、かつ数平均分子量が1000~35000のポリエステル樹脂化合物を含む粉体である請求項2記載の自動車内装部品の成形に用いる接着工法。
- 前記粉体のうちの1種が、窒素原子を含む官能基を有する化合物を含む粉体である請求項2又は3に記載の自動車内装部品の成形に用いる接着工法。
- 前記窒素原子を含む官能基が、カルボジイミド基である請求項4記載の自動車内装部品の成形に用いる接着工法。
- 前記の窒素原子を含む官能基を有する化合物を含む粉体の表面に、炭酸カルシウム及び/又はクレーよりなる微粉末が固着されている請求項4に記載の自動車内装部品の成形に用いる接着工法。
- 被着体にスプレー塗布した粉末状接着剤を、赤外線ヒーターを用いて加熱溶融する工程を含む請求項1~6のいずれかに記載の自動車内装部品の成形に用いる接着工法。
- 互いに反応性を有する化合物を含む粉体を2種以上混合してなる自動車内装部品の成形に用いる粉末状接着剤。
- 前記粉体のうちの1種が、カルボキシル基を有し、かつ数平均分子量が1000~35000のポリエステル樹脂化合物を含む粉体である請求項8記載の自動車内装部品の成形に用いる粉末状接着剤。
- 前記粉体のうちの1種が、窒素原子を含む官能基を有する化合物を含む粉体である請求項8又は9に記載の自動車内装部品の成形に用いる粉末状接着剤。
- 前記窒素原子を含む官能基が、カルボジイミド基である請求項10記載の自動車内装部品の成形に用いる粉末状接着剤。
- 前記の窒素原子を含む官能基を有する化合物を含む粉体の表面に、炭酸カルシウム及び/又はクレーよりなる微粉末が固着されている請求項10に記載の自動車内装部品の成形に用いる粉末状接着剤。
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US13/510,106 US8790755B2 (en) | 2009-11-27 | 2010-11-26 | Adhering method using electrostatic powder adhesive, and powder adhesive to be used in adhering method |
JP2011543318A JP5729309B2 (ja) | 2009-11-27 | 2010-11-26 | 静電粉体接着剤を用いた接着工法および該接着工法に用いる粉末状接着剤 |
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JP2005187515A (ja) * | 2003-12-24 | 2005-07-14 | Dainippon Ink & Chem Inc | 不織布接着用球形ポリエステル樹脂粒子分散体及び不織布接着用球形ポリエステル樹脂粒子 |
JP2008248042A (ja) * | 2007-03-29 | 2008-10-16 | Furukawa Electric Co Ltd:The | ホットメルト接着剤およびそれを用いたフラットケーブル |
Also Published As
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JPWO2011065476A1 (ja) | 2013-04-18 |
EP2505627A4 (en) | 2016-11-09 |
US20120231176A1 (en) | 2012-09-13 |
EP2505627B1 (en) | 2019-10-23 |
CN102639658B (zh) | 2014-01-29 |
CN102639658A (zh) | 2012-08-15 |
EP2505627A1 (en) | 2012-10-03 |
US8790755B2 (en) | 2014-07-29 |
JP5729309B2 (ja) | 2015-06-03 |
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