WO2015029453A1 - テキスタイル調インモールド用シート、その製造方法、プレフォーム成形体、テキスタイル調樹脂成形体及びその製造方法 - Google Patents
テキスタイル調インモールド用シート、その製造方法、プレフォーム成形体、テキスタイル調樹脂成形体及びその製造方法 Download PDFInfo
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- WO2015029453A1 WO2015029453A1 PCT/JP2014/004455 JP2014004455W WO2015029453A1 WO 2015029453 A1 WO2015029453 A1 WO 2015029453A1 JP 2014004455 W JP2014004455 W JP 2014004455W WO 2015029453 A1 WO2015029453 A1 WO 2015029453A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0001—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor characterised by the choice of material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14688—Coating articles provided with a decoration
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14811—Multilayered articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1657—Making multilayered or multicoloured articles using means for adhering or bonding the layers or parts to each other
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
- B29C2045/14237—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14688—Coating articles provided with a decoration
- B29C2045/14696—Coating articles provided with a decoration transparent decorated inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14688—Coating articles provided with a decoration
- B29C2045/14713—Coating articles provided with a decoration decorations in contact with injected material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14688—Coating articles provided with a decoration
- B29C2045/14729—Coating articles provided with a decoration decorations not in contact with injected material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14836—Preventing damage of inserts during injection, e.g. collapse of hollow inserts, breakage
- B29C2045/14844—Layers protecting the insert from injected material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C2045/1692—Making multilayered or multicoloured articles one layer comprising fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2793/00—Shaping techniques involving a cutting or machining operation
- B29C2793/0081—Shaping techniques involving a cutting or machining operation before shaping
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/20—Inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2629/00—Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof, for preformed parts, e.g. for inserts
- B29K2629/14—Polyvinylacetals
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2713/00—Use of textile products or fabrics for preformed parts, e.g. for inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/10—Fibres of continuous length
- B32B2305/18—Fabrics, textiles
Definitions
- the present invention relates to a textile-like resin molded article having a textile-like appearance, an in-mold sheet for producing the same, a preform molded article thereof, and a production method thereof.
- a decorative molded body having a textile-like appearance is known as an exterior member for mobile phones, mobile devices, home appliances, interior parts such as vehicles and aircraft, building materials, and furniture.
- the textile style is an appearance formed of a fiber material such as woven fabric, knitted fabric, fabric, non-woven fabric, and artificial leather.
- Patent Document 1 discloses an injection molded body having a decorative portion on the surface of a body to be decorated.
- the decorative portion is formed by fusing a decorative material to the surface of the object to be decorated by in-mold molding, and the decorative material is a base film made of synthetic resin and fibers bonded thereto
- An injection molded body having a textile material including
- Patent Document 2 after a textile material is stretched on the mold cavity surface, the molten resin is injected into the cavity under pressure, so that the molten resin is infiltrated into the decorating material, and both are thrown.
- a technique for laminating and crimping to a state at the time of the molding, using a cloth-like decorative material having pores capable of allowing the molten resin material to permeate like a throwing shape, the decorative material is in a throwing state. It is disclosed that the bonding strength between the decorating material and the resin molding can be increased by bonding to the resin molding and laminating and pressure bonding.
- Patent Document 3 discloses that a transparent acrylic film layer, a textile layer bonded to the transparent acrylic film layer via an adhesive, and the textile layer are infiltrated into a gap between fibers of the textile layer.
- the decorative molded body which is a textile / resin laminated structure housing provided with the made base resin layer is disclosed.
- Patent Document 4 discloses a method of in-mold molding a textile layer thermocompression bonded body with an A-PET sheet thermocompression bonded on one side with the textile layer as a front.
- an exterior member made of a textile-like resin molded body in which a lace-knitted textile material or a lattice-shaped textile material is manually attached to the outer surface of the resin molded body is also known.
- JP 2010-36366 A JP-A-2005-47161 WO2012 / 105664 pamphlet WO2012 / 105665 pamphlet
- One aspect of the present invention is a textile-like in-mold sheet integrated with a resin molded body that is molded by injecting molten resin by in-mold molding, and is a side that is integrated with the resin molded body.
- 1 surface and the 2nd surface used as the back surface with respect to the 1st surface, and has at least a fiber sheet layer, a 1st adhesive bond layer, and a textile material layer in order from the 1st surface toward the 2nd surface. It is a sheet for textile in-mold.
- Another aspect of the present invention is a textile-like in-mold sheet integrated with a resin molded body that is molded by injecting molten resin by in-mold molding, and is integrated with the resin molded body.
- a surface that has a first surface and a second surface that is the back surface of the first surface, and is temporarily bonded to the textile material layer and the textile material layer in order from the first surface to the second surface so as to be peelable.
- a textile in-mold sheet having at least a temporary protective layer.
- a textile-like resin molded body in which a textile material having excellent texture and appearance is arranged on the surface layer can be obtained.
- FIG. 1 is a schematic perspective view of a textile-like resin molded body (housing) according to the first to sixth embodiments.
- FIG. 2 is a schematic cross-sectional view of the textile-like resin molded body 10 of the first embodiment taken along the II-II ′ cross section of FIG. 1.
- FIG. 3 is a schematic cross-sectional view taken along the line III-III ′ of FIG. 1 of the textile-like resin molded body 10 of the first embodiment.
- FIG. 4 is an explanatory view illustrating a protective film with an adhesive layer.
- FIG. 5 is an explanatory view illustrating a protective film with an adhesive layer.
- FIG. 6 is an explanatory diagram for explaining the manufacturing method of the first embodiment.
- FIG. 1 is a schematic perspective view of a textile-like resin molded body (housing) according to the first to sixth embodiments.
- FIG. 2 is a schematic cross-sectional view of the textile-like resin molded body 10 of the first embodiment taken along the II-II
- FIG. 7 is a schematic cross-sectional view taken along the line II-II ′ of FIG. 1 of the textile-like resin molded body 20 of the second embodiment.
- FIG. 8 is a schematic cross-sectional view taken along the line III-III ′ of FIG. 1 of the first embodiment.
- FIG. 9 is an explanatory diagram for explaining the manufacturing method of the second embodiment.
- FIG. 10 is a schematic cross-sectional view taken along the line II-II ′ of FIG. 1 of the textile-like resin molded body 30 of the third embodiment.
- FIG. 11 is a schematic cross-sectional view of the textile-like resin molded body 30 of the third embodiment taken along the line III-III ′ of FIG.
- FIG. 12 is an explanatory diagram for explaining the manufacturing method of the third embodiment.
- FIG. 10 is a schematic cross-sectional view taken along the line II-II ′ of FIG. 1 of the textile-like resin molded body 30 of the third embodiment.
- FIG. 11 is a schematic cross-sectional
- FIG. 13 is a schematic view of a resin-impregnated nonwoven fabric according to the third embodiment.
- FIG. 14A is a schematic perspective view of a textile-like resin molded body 130 according to a modification of the third embodiment.
- FIG. 14B is a partial schematic cross-sectional view taken along the line A-A ′ of the textile-like resin molded body 130 of FIG. 14A.
- FIG. 14C is a partial schematic cross-sectional view of the textile-like resin molded body 130 of FIG. 14A along the B-B ′ cross section.
- FIG. 15 is a schematic cross-sectional view taken along the line II-II ′ of FIG. 1 of the textile-like resin molded body 40 of the fourth embodiment.
- FIG. 16 is a schematic cross-sectional view taken along the line III-III ′ of FIG. 1 of the textile-like resin molded body 40 of the fourth embodiment.
- FIG. 17 is an explanatory diagram for explaining the manufacturing method of the fourth embodiment.
- FIG. 18A is a schematic perspective view of a textile-like resin molded body 140 according to a modification of the fourth embodiment.
- FIG. 18B is a partial schematic cross-sectional view of the textile-like resin molded body 140 of FIG. 18A taken along the line A-A ′.
- FIG. 18C is a partial schematic cross-sectional view taken along the B-B ′ cross section of the textile-like resin molded body 140 of FIG. 18A.
- FIG. 19 is a schematic cross-sectional view taken along the line II-II ′ of FIG.
- FIG. 20 is a schematic cross-sectional view taken along the line III-III ′ of FIG. 1 of the textile-like resin molded body 50 of the fifth embodiment.
- FIG. 21 is an explanatory diagram for explaining the manufacturing method of the fifth embodiment.
- FIG. 22 is a schematic cross-sectional view taken along the line II-II ′ of FIG. 1 of the textile-like resin molded body 60 of the sixth embodiment.
- FIG. 23 is a schematic cross-sectional view taken along the line III-III ′ of FIG. 1 of the textile-like resin molded body 60 of the sixth embodiment.
- FIG. 24 is an explanatory diagram for explaining the manufacturing method according to the sixth embodiment.
- FIG. 20 is a schematic cross-sectional view taken along the line III-III ′ of FIG. 1 of the textile-like resin molded body 50 of the fifth embodiment.
- FIG. 21 is an explanatory diagram for explaining the manufacturing method of the fifth embodiment.
- FIG. 22 is a schematic cross-sectional view taken along the line II-II
- FIG. 25 is a schematic cross-sectional view of an in-mold molding sheet 61 according to the sixth embodiment.
- FIG. 26 is a schematic cross-sectional view illustrating each step of preform molding according to the seventh embodiment.
- FIG. 27 is a schematic cross-sectional view illustrating each process of in-mold molding according to the seventh embodiment.
- FIG. 28 is an explanatory diagram for explaining a change in the area of the decorative surface in the in-mold molding according to the seventh embodiment.
- FIG. 29 is an explanatory diagram for explaining a state in which the surface temporary protective layer is peeled from the textile-like resin molded body of the seventh embodiment.
- FIG. 1 is a schematic perspective view of a textile-like resin molded body (housing) 10 according to the first embodiment.
- a textile-like resin molded body 10 has one protrusion P and one opening H at the bottom of the inverted tray structure.
- 2 is a schematic cross-sectional view taken along the line II-II ′ of FIG. 1
- FIG. 3 is a schematic cross-sectional view taken along the line III-III ′ of FIG.
- the textile-like resin molded body 10 has a surface integrated with the resin molded body 5 as a first surface and a surface that becomes the outer surface of the back surface with respect to the first surface as a second surface.
- a surface protective layer 2 an adhesive layer (second adhesive layer) 3, a textile material layer 1, and a resin molded body 5 are sequentially stacked from the second surface side to the first surface side.
- the in-mold sheet 11 is a laminate in which the surface protective layer 2 and the textile material layer 1 are bonded together with an adhesive layer 3.
- the surface protective layer 2 is a surface resin layer.
- the textile-like resin molded body 10 is obtained by in-mold molding an in-mold sheet 11 or a preform molded body 12 in which a three-dimensional shape is previously formed on the in-mold sheet 11.
- Textile material is a continuous or discontinuous sheet-like material containing a fiber material.
- woven fabrics such as plain weave fabric, oblique weave fabric, satin weave fabric, knitted fabric such as lace knitting and knitted fabric, felt, non-woven fabric, synthetic leather, artificial leather and the like. It may be a fiber material dyed with a dye or printed with a pattern or pattern.
- the textile material imparts design properties and reinforces the textile-like resin molded body.
- the fiber is not particularly limited, such as various synthetic fibers, natural fibers, and carbon fibers.
- the thickness of the textile material is not particularly limited and is selected depending on the intended use, but is generally preferably about 100 to 5000 ⁇ m.
- Textile materials are susceptible to wrinkles and pattern distortion due to thermal or mechanical influence from the mold during in-mold molding. Since the textile material protected by the surface protective layer is supported by the surface protective layer, misalignment, wrinkles, and pattern distortion during molding are less likely to occur. Further, after the in-mold molding, the surface of the textile material is given scratch resistance. In addition, since the surface protective layer is formed before in-mold molding, a complicated process of applying surface coating after in-mold molding is not required.
- the surface protective layer is formed by adhering a resin film to the surface of the textile material.
- a resin film for forming the surface protective layer (hereinafter, also simply referred to as a protective film), it does not deteriorate the design properties of the textile material, is thermally deformed along the shape of the mold at the time of preform molding, and A resin film having a lower thermal softening temperature than the resin injected during in-mold molding is preferably used.
- a transparent (meth) acrylic resin film is particularly preferable because it has an excellent balance between adhesion and scratch resistance.
- (Meth) acrylic means methacrylic or acrylic.
- a top coating having chemical resistance and scratch resistance may be formed on the protective film.
- the transparent (meth) acrylic resin preferably contains an elastomer component or an elastomer unit such as acrylic rubber, nitrile rubber, and isoprene rubber from the viewpoint of excellent flexibility.
- Transparent (meth) acrylic resins containing elastomeric units include those copolymerized with elastomeric units (for example, Kuraray's trade name Clarity Co., Ltd.) and those obtained by dispersing elastomeric components in acrylic resin. (For example, Sumitomo Chemical Co., Ltd. trade name Technoloy) etc. can be obtained as a commercial product.
- Kuraray's trade name Clarity is an acrylic thermoplastic elastomer containing a block copolymer of methyl methacrylate (MMA) units and butyl acrylate (BA) units which are elastomer units.
- the thickness of the protective film is preferably 10 to 400 ⁇ m, more preferably 15 to 300 ⁇ m, and particularly preferably about 50 to 200 ⁇ m.
- the thickness of the protective film is preferably 10 to 400 ⁇ m, more preferably 15 to 300 ⁇ m, and particularly preferably about 50 to 200 ⁇ m.
- Protective film is bonded to the surface of the textile material.
- an adhesive hereinafter also referred to as a second adhesive
- an adhesive that is easily heat stretched during preform molding or in-mold molding is used.
- the adhesive that is easily stretched by heat include an adhesive having a softening temperature in the range of 50 to 250 ° C., and further 70 to 220 ° C.
- the second adhesive include, for example, polyvinyl acetal adhesive (PCV) such as polyvinyl butyral (PVB) adhesive; polyvinyl alcohol adhesive; ethylene / vinyl acetate copolymer adhesive, ethylene / acrylic copolymer Ethylene-based adhesives such as polymer-based adhesives; propylene-based adhesives such as propylene / 1-butene copolymer adhesives, propylene / isobutene copolymer adhesives, styrene / propylene / isobutene copolymer adhesives; styrene / Isoprene copolymer adhesives, styrene / isoprene / isobutene copolymer adhesives, isoprene adhesives such as styrene / isoprene / butene copolymer adhesives; vinyl chloride adhesives and the like.
- PCV polyvinyl acetal adhesive
- polyvinyl acetal adhesives such as polyvinyl butyral (PVB) adhesives are particularly preferable because they can be easily stretched by heat and can maintain a low melt viscosity that does not leave voids.
- the polyvinyl acetal adhesive includes a polyvinyl acetal resin obtained by converting polyvinyl alcohol (PVA) into an aldehyde acetal such as formaldehyde or butyraldehyde.
- PVA preferably has a saponification degree of 80.0 to 99.9 mol%.
- the average degree of polymerization is preferably 500 to 3000, more preferably 1000 to 2000.
- the second adhesive may be mixed with a plasticizer for the purpose of imparting flexibility.
- a plasticizer include monobasic organic acid esters such as triethylene glycol di-2-ethylhexylate, triethylene glycol di-2-ethylbutyrate, triethylene glycol di-n-octylate, dibutyl sebacin
- polybasic organic acid esters such as acid esters and dioctyl azelaic acid esters
- polyglycerin derivatives such as polyoxypropylene polyglyceryl ether and polyethylene glycol polyglyceryl ether.
- the method for bonding the textile material and the protective film is not particularly limited, and various known methods can be applied.
- a method of laminating and pressing with the textile material, or forming the second adhesive into a film with a predetermined thickness For example, a method of pressing between a textile material and a protective film is used.
- the following method can be given as a specific method of the latter.
- the second adhesive solution or the second adhesive is applied to the release surface of the release paper 25 by knife coating, gravure printing, or the like. Then, an adhesive layer 3 having a predetermined thickness is formed. Then, as shown in FIG.
- the adhesive layer 3 formed on the release paper 25 is bonded to the protective film 2.
- the protective film with an adhesive layer which is a laminated body of the protective film 2 and the adhesive bond layer 3 formed by uniform thickness is obtained by peeling the release paper 25 from the obtained laminated body.
- the adhesive layer 3 of the protective film with the adhesive layer thus obtained is bonded to the surface of the textile material 1. In this way, the in-mold sheet 11 is obtained.
- the adhesive layer 3 having a uniform thickness is formed on the protective film 2 without leaving a void. When voids remain in the adhesive layer 3, the adhesive strength is reduced or the light transmittance is reduced.
- An example of a method for forming the adhesive layer 3 on the release paper is shown below.
- Polyvinyl acetal is dissolved in an alcohol or ketone solvent at a concentration of 25% or less to prepare an adhesive solution.
- an adhesive solution is applied on the release paper.
- the adhesive solution is applied to form an adhesive layer having a predetermined thickness (for example, 100 ⁇ m) by repeating a process of forming a coating film having a thickness of 5 to 50 ⁇ m and then drying at 60 to 100 ° C. . If the coating thickness of the adhesive solution per one time is too thick, voids are likely to remain.
- concentration of the polyvinyl acetal with respect to a solvent is too high, the viscosity of an adhesive solution will become high and coating property will fall.
- the thickness of the adhesive layer 3 is preferably about 25 to 200 ⁇ m, more preferably about 40 to 150 ⁇ m.
- the total thickness of the surface protective layer 2 and the adhesive layer 3 is preferably about 40 to 450 ⁇ m, more preferably about 60 to 350 ⁇ m.
- the thickness of the in-mold sheet 11 obtained in this manner depends on the thickness and design of the textile material layer and the intended use, but specifically, for example, when using a thin textile material. 300 to 1500 ⁇ m, more preferably about 500 to 1200 ⁇ m.
- the in-mold sheet 11 is preformed. As shown in step (I), the in-mold sheet 11 is placed so that the surface protective layer 2 faces the female mold 17 a of the preform mold (press mold) 17. The in-mold sheet 11 may be cut into a predetermined shape in advance. Next, as shown in step (II), the female mold 17a and the male mold 17b are clamped with a press machine, whereby the in-mold sheet 11 placed on the female mold 17a is fixed to the female mold. Push into the recess in 17a. As a result, a preform molded body 12 in which the in-mold sheet 11 is shaped is obtained.
- preform molding by press molding is exemplified, but instead of press molding, other preform molding methods such as vacuum molding, pressure molding, and vacuum / pressure molding, which have been conventionally known, are used. Also good.
- step (IV) injection molding is performed by an injection molding machine 13 provided with an in-mold die 18 including a movable die 18a and a fixed die 18b.
- the preform 12 is accommodated so that the surface protective layer 2 faces the concave portion of the cavity of the moving mold 18a, and the moving mold 18a and the fixed mold 18b are clamped.
- the cylinder 13a of the injection molding machine 13 is advanced, and the nozzle part 13b distribute
- the pellet-shaped resin 15 stored in the hopper 13d is measured while being melted in the cylinder 13a. Then, after weighing, the molten resin 15 is injected into the cavity of the in-mold die 18. The molten resin 15 enters the gaps between the fibers of the textile material layer 1 by injection. When the molten resin 15 enters the textile material layer 1 having air permeability, the bond strength between the textile material layer 1 and the resin molded body 5 is increased due to the anchor effect.
- the resin used for injection molding includes ABS resin, polycarbonate (PC) resin, PC and ABS alloy resin, polyolefin resin such as polypropylene, polymethacrylic (PMMA) resin, polyethylene terephthalate (PET) and poly Various thermoplastic resins such as polyester resins such as butylene terephthalate (PBT) and various polyamide resins are used without any particular limitation.
- a resin used for a casing of a mobile phone, a mobile device, a home appliance, etc. a resin excellent in impact resistance such as an ABS resin or a PC resin is used for applications where weight reduction is required (for example, vehicle interior parts)
- polyolefin resins such as polypropylene are preferably used.
- the injection molding conditions are such that the resin can flow to the flow end depending on the melting point and melt viscosity of the resin, the shape of the molded body, and the resin thickness (resin temperature, mold temperature, injection pressure, injection speed, post injection) Holding pressure and cooling time) are appropriately selected.
- the moving mold 18 a and the fixed mold 18 b are separated from each other.
- the textile-like resin molded body 10 in which the preform molded body 12 and the resin molded body 5 are integrated is taken out.
- the textile material 1 and the resin molded body 5 contract, and the textile material 1 and the resin molded body 5 are more firmly integrated. In this way, a textile-like resin molded body 10 is obtained.
- the thickness of the resin molded body is not particularly limited.
- it is preferably about 0.5 to 10.0 mm, more preferably about 0.8 to 5.0 mm. In this embodiment, 1.2 mm is adopted.
- FIG. 1 is a schematic perspective view of a textile-like resin molded body (housing) 20 according to the second embodiment.
- 7 is a schematic cross-sectional view taken along the line II-II ′ of FIG. 1
- FIG. 8 is a schematic cross-sectional view taken along the line III-III ′ of FIG.
- symbol shown in 1st Embodiment shows the same element as what was demonstrated in 1st Embodiment.
- the textile-like resin molded body 20 includes a surface temporary protective layer 4 and an adhesive layer (temporary adhesive layer) 6 that are laminated in order from the second surface side to the first surface side.
- the in-mold sheet 21 is a laminated body in which the surface temporary protective layer 4 and the textile material layer 1 are bonded by the adhesive layer 6.
- the surface temporary protective layer 4 is a surface resin layer.
- the textile-like resin molded body 20 is obtained by in-mold molding an in-mold sheet 21 or a preform molded body 22 in which a three-dimensional shape is previously formed on the in-mold sheet 21.
- the surface temporary protective layer 4 and the adhesive layer 6 are temporary surface protective layers that are peeled off from the surface of the textile material layer 1 after in-mold molding.
- Textile materials are susceptible to wrinkles and pattern distortion due to thermal or mechanical influence from the mold during in-mold molding. Since the textile material protected by the temporary surface protective layer is supported by the temporary surface protective layer, misalignment, wrinkles, and pattern distortion during molding are less likely to occur. Moreover, the textile raw material layer 1 holding the texture with a three-dimensional feeling can be exposed by peeling the surface temporary protective layer and the temporary adhesive layer after in-mold molding.
- the surface temporary protective layer is formed by adhering a resin film to the surface of the textile material.
- a resin film for forming the surface temporary protective layer (hereinafter, also simply referred to as temporary protective film), it can be peeled after in-mold molding, thermally deformed along the shape of the mold at the time of preform molding, and A resin film having a lower thermal softening temperature than the resin injected during in-mold molding is preferably used.
- the temporary protective film examples include polyester resin films such as polyethylene terephthalate (PET), polycarbonate films, and polyolefin films.
- PET polyethylene terephthalate
- An amorphous PET film or a biaxially stretched PET film having a high degree of crystallinity is particularly preferred because of its excellent balance between heat stretchability and heat resistance.
- the thickness of the temporary protective film is preferably 50 to 350 ⁇ m, more preferably 50 to 300 ⁇ m, and particularly preferably about 50 to 200 ⁇ m. If the temporary protective film is too thick, the preform moldability tends to decrease, and if the temporary protective film is too thin, the effect tends to be insufficient. The thickness of the temporary protective film is appropriately adjusted according to the type of film.
- an adhesive sheet having peelability is adhered to the temporary protective film using a hard-release adhesive or pressure-sensitive adhesive, or the temporary protective film
- a method of directly drying and laminating an adhesive sheet having peelability applying a liquid adhesive capable of forming an adhesive layer having peelability on a temporary protective film, and drying.
- the peelable adhesive resin for forming the peelable adhesive layer any adhesive resin that can be stretched by heat and has excellent peelability can be used without particular limitation.
- the peelable adhesive resin include polyvinyl acetal resins such as polyvinyl alcohol (PVA) resins and polyvinyl butyral (PVB) resins.
- PVA resin is preferable from the viewpoint of improving the adhesive strength because it is softened by hot pressing while maintaining the peelability at the time of preform molding.
- a plasticizer may be added to the peelable adhesive resin for the purpose of imparting flexibility.
- the plasticizer include polyhydric alcohols such as glycerin, diglycerin, propylene glycol and trimethylolpropane, sugar alcohols such as sorbitol and xylitol, and polyether compounds such as polyethylene glycol and polypropylene glycol. It is done.
- the pressure sensitive adhesive include acrylic resin pressure sensitive adhesive, silicone pressure sensitive adhesive, and rubber pressure sensitive adhesive. The method using a PVA-based film is preferable because a temporary adhesive layer having an accurate and uniform thickness can be easily formed.
- the PVA film As a PVA-type film, as a commercial item, the PVA film (Kuraray poval film) made from Kuraray Co., Ltd., the PVA film (Sorbron) made from Aicero Co., Ltd., etc. can be obtained, for example.
- the thickness of the temporary adhesive layer that bonds the textile material and the temporary protective film is not particularly limited, but is preferably about 20 to 200 ⁇ m, more preferably about 25 to 150 ⁇ m.
- the in-mold sheet 21 is preformed.
- the in-mold sheet 21 is placed so that the surface temporary protective layer 4 faces the female mold 17 a of the preform mold (press mold) 17.
- the in-mold sheet 21 may be cut into a predetermined shape in advance.
- the female mold 17a and the male mold 17b are clamped with a press machine, thereby pushing the in-mold sheet 21 into the recess of the female mold 17a.
- a preform molded body 22 in which the in-mold sheet 21 is shaped is obtained.
- the preform molded body 22 may be deburred or unnecessary parts may be cut and removed with a laser cutter or a cutting unit (cutting die) as necessary.
- step (IV) injection molding is performed by an injection molding machine 13 provided with an in-mold die 18 including a movable die 18a and a fixed die 18b.
- the preform molded body 22 is accommodated so that the surface temporary protection layer 4 faces the concave portion of the cavity of the moving side mold 18a, and the moving side mold 18a and the fixed side mold 18b are clamped.
- the cylinder 13a of the injection molding machine 13 is advanced, and the nozzle part 13b distribute
- the pellet-shaped resin 15 stored in the hopper 13d is measured while being melted in the cylinder 13a. Then, after weighing, the molten resin 15 is injected into the cavity of the in-mold die 18. The resin 15 melted by injection enters the gaps between the fibers of the textile material layer 1. When the molten resin enters the textile material layer 1 having air permeability, the bond strength between the textile material layer 1 and the resin molded body 5 is increased due to the anchor effect.
- the moving mold 18 a and the fixed mold 18 b are separated from each other.
- the textile-like resin molded body 20 in which the preform molded body 22 and the resin molded body 5 are integrated is taken out.
- the textile material 1 and the resin molded body 5 contract, and the textile material 1 and the resin molded body 5 are more firmly integrated. In this way, a textile-like resin molded body 20 is obtained.
- step (VI) by selectively peeling the surface temporary protective layer 4 and the second adhesive layer 6 from the textile-like resin molded body 20 after the second adhesive layer 6 is solidified, A textile-like resin molded body 20a having the textile material layer 1 on the surface is obtained.
- the peeling of the surface temporary protective layer 4 and the second adhesive layer 6 is not particularly limited, such as peeling by hand or peeling using a dedicated peeling equipment.
- FIG. 1 is a schematic perspective view of a textile-like resin molded body (housing) 30 according to a third embodiment.
- 10 is a schematic cross-sectional view taken along the line II-II ′ of FIG. 1
- FIG. 11 is a schematic cross-sectional view taken along the line III-III ′ of FIG.
- Elements having the same reference numerals as those shown in the first and second embodiments are the same elements as those described in the first and second embodiments.
- the textile-like resin molded body 30 includes a textile material layer 1 and an adhesive layer (first adhesive layer) 8 that are laminated in order from the second surface side to the first surface side. And a fiber sheet layer 7 and a resin molded body 5.
- the in-mold sheet 31 is a laminate in which the textile material layer 1 and the fiber sheet layer 7 are bonded together with an adhesive layer 8.
- the textile-like resin molded body 30 is obtained by in-mold molding an in-mold sheet 31 or a preform molded body 32 in which a three-dimensional shape is pre-shaped on the in-mold sheet 31.
- preform molding is performed.
- the in-mold sheet 31 is placed so that the textile material layer 1 faces the female mold 17 a of the preform mold (press mold) 17.
- the in-mold sheet 31 may be cut into a predetermined shape in advance.
- the female mold 17a and the male mold 17b are clamped with a press to push the in-mold sheet 31 into the recess of the female mold 17a.
- a preform formed body 32 obtained by shaping the in-mold sheet 31 is obtained.
- the preform molded body 32 may be deburred or unnecessary portions may be cut and removed with a laser cutter or a cutting unit (cutting die) as necessary.
- step (IV) injection molding is performed by an injection molding machine 13 provided with an in-mold die 18 including a movable die 18a and a fixed die 18b.
- the preform molded body 32 is accommodated so that the textile material layer 1 faces the concave portion of the cavity of the moving mold 18a, and the moving mold 18a and the fixed mold 18b are clamped.
- the cylinder 13a of the injection molding machine 13 is advanced, and the nozzle part 13b distribute
- the pellet-shaped resin 15 stored in the hopper 13d is measured while being melted in the cylinder 13a.
- the molten resin 15 is injected into the cavity of the in-mold die 18.
- the resin 15 melted by injection enters between the fibers of the fiber sheet layer 7.
- the fiber sheet layer 7 becomes a barrier layer for preventing the resin 15 melted in the textile material layer 1 from penetrating in in-mold molding.
- the thermal influence by the molten resin with respect to the textile material layer 1 is reduced.
- the molten resin permeates into the fiber sheet layer 7 in the in-mold molding, it is possible to maintain high adhesion due to the anchor effect with respect to the formed resin molded body 5.
- the textile material layer 1 and the fiber sheet layer 7 are bonded, they exhibit high adhesion due to the anchor effect of the adhesive.
- the moving mold 18 a and the fixed mold 18 b are separated from each other.
- the textile-like resin molded body 30 in which the preform molded body 32 and the resin molded body 5 are integrated is taken out.
- the fiber sheet layer 7 and the resin molded body 5 contract, and the fiber sheet layer 7 and the resin molded body 5 are more firmly integrated. In this way, a textile-like resin molded body 30 is obtained.
- the fiber sheet layer examples include fiber substrates selected from woven fabrics, knitted fabrics, nonwoven fabrics, and the like. Among these, non-woven fabrics are particularly preferable because the thickness can be easily controlled.
- the non-woven fabric used for the fiber sheet layer a non-woven fabric that is excellent in formability as well as blocking the penetration of the molten resin into the textile material layer in the in-mold forming step is preferably used.
- the nonwoven fabric include wet nonwoven fabrics such as papermaking nonwoven fabric, dry nonwoven fabrics, meltblown nonwoven fabrics, and spunbond nonwoven fabrics.
- a spunbonded nonwoven fabric, particularly a dense nonwoven fabric of ultrafine fibers is preferably used from the viewpoint that it can have a high barrier property even if it is thin.
- a papermaking nonwoven fabric is preferably used from the viewpoint of inexpensiveness.
- Specific examples of the papermaking nonwoven fabric include PY-100-60 manufactured by Awa Paper Co., Ltd.
- the thickness of the nonwoven fabric is preferably about 50 to 1000 ⁇ m.
- the fibers forming the papermaking nonwoven fabric preferably have a fiber diameter of 1 to 50 ⁇ m, a fiber length of 1 to 50 mm, and more preferably 2 to 15 mm.
- the fiber material forming the fiber sheet layer include, for example, polyethylene terephthalate (PET), modified polyethylene terephthalate, polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polytriethylene terephthalate, polyhexamethylene.
- Aromatic polyester resins such as terephthalate, polypropylene terephthalate and polyethylene naphthalate; aliphatics such as polylactic acid, polyethylene succinate, polybutylene succinate, polybutylene succinate adipate, polyhydroxybutyrate-polyhydroxyvalerate copolymer Polyester resin; Polyamide 6, Polyamide 66, Polyamide 610, Polyamide 10, Polyamide 11, Polyamide 12, Polyamide 6-12, etc.
- PET having a glass transition temperature (Tg) of 100 to 120 ° C., more preferably 105 to 115 ° C. is preferable because it softens at a relatively low temperature and easily stretches when softened.
- Tg glass transition temperature
- the PET having a Tg of 100 to 120 ° C. includes a modified PET containing a copolymer component that disturbs the linear structure as a constituent unit of an aromatic PET, in particular, isophthalic acid, phthalic acid, 5-sodium sulfone. Modified PET containing an asymmetric aromatic carboxylic acid such as isophthalic acid or an aliphatic dicarboxylic acid such as adipic acid as a copolymerization component in a predetermined ratio is preferable.
- modified PET containing 2 to 12 mol% of isophthalic acid units as a monomer component is preferable.
- the Tg is measured by, for example, using a dynamic viscoelasticity measuring apparatus (for example, FT Leospectra DDVIV manufactured by Rheology Co., Ltd.) to fix a test piece having a width of 5 mm and a length of 30 mm between chucks with a spacing of 20 mm. It can be obtained by measuring the dynamic viscoelastic behavior under the conditions of 30 to 250 ° C., heating rate of 3 ° C./min, strain of 5 ⁇ m / 20 mm, and measurement frequency of 10 Hz.
- a dynamic viscoelasticity measuring apparatus for example, FT Leospectra DDVIV manufactured by Rheology Co., Ltd.
- the dense non-woven fabric of ultrafine fibers is 2.0 dtex or less, further 0.9 dtex or less, particularly 0.5 dtex or less, especially 0.1 dtex or less, 0.01 dtex or more, further 0.05 dtex or more, especially Preferably includes a fiber entanglement of ultrafine fibers having a fineness of 0.07 dtex or more. If the fineness of the ultrafine fibers is too high, when preforming a sheet for in-mold, the stretchability at the time of softening by heating is lowered, making it difficult to accurately transfer the mold shape, and the formability is lowered. Tend to.
- Apparent density of the dense nonwoven microfibers 0.45 g / cm 3 or more, still more 0.45 ⁇ 0.70g / cm 3, particularly preferably a 0.50 ⁇ 0.65g / cm 3. If the dense non-woven fabric of ultrafine fibers has such a high apparent density, it is difficult for the molten resin to penetrate into the textile material layer in in-mold molding, and wrinkles are formed on the surface of the in-mold molded body or the pattern is In addition to being able to reduce distortion, it is excellent in the balance between shape stability and formability of the preform.
- the apparent density of the dense nonwoven fabric of ultrafine fibers was measured by, for example, the basis weight value measured by the method described in JIS L 1096 8.4.2 (1999) at a load of 240 gf / cm 2 according to JIS L1096. It can be determined by dividing by the thickness value.
- the ultrafine fibers are a bundle of multiple ultrafine fibers that are formed through ultrafine fiber-forming fibers such as sea-island composite fibers. It is preferable to exist as Specifically, for example, it is preferable that 5 to 1000, further 5 to 200, particularly preferably 10 to 50, and most preferably 10 to 30 ultrafine fibers are present as a fiber bundle. Thus, when the ultrafine fibers are present in the form of fiber bundles, the apparent density of the dense nonwoven fabric of the ultrafine fibers can be increased.
- the fiber length of the ultrafine fiber is not particularly limited, but a long fiber is particularly preferable from the viewpoint of easily increasing the apparent density.
- the long fiber means that it is not a short fiber cut by a predetermined length.
- the length of the long fibers is preferably 100 mm or more, and more preferably 200 mm or more from the viewpoint that the fiber density of the ultrafine fibers can be sufficiently increased.
- an upper limit is not specifically limited, For example, the fiber length of several m, several hundreds m, several km or more spun continuously may be sufficient. Further, these fibers may be mixed with several kinds of fibers instead of single.
- the dense nonwoven fabric of ultrafine fibers contains a polymer elastic body impregnated in the internal voids.
- a polymer elastic body improves the shape stability of the preform molded body.
- Specific examples of such a polymer elastic body include polyurethane, acrylonitrile elastomer, olefin elastomer, polyester elastomer, polyamide elastomer, acrylic elastomer, and the like.
- polyurethane, particularly crosslinked non-foamed polyurethane is preferred.
- the cross-linked non-foamed polyurethane suppresses deformation due to elastic recovery after release from the mold when preforming. As a result, when forming a deep-drawn preform, it is preferable because a sharp and sharp corner can be formed.
- uncrosslinked foamed polyurethane is used, it tends to deform due to elastic recovery after being released from the mold.
- the crosslinked non-foamed polyurethane is preferably formed using an aqueous emulsion of a crosslinkable polyurethane.
- a crosslinkable polyurethane e.g., water-based emulsion of polycarbonate-based polyurethane, polyester-based polyurethane, polyether-based polyurethane, and polycarbonate / ether-based polyurethane that form a crosslinked structure after drying.
- the crosslinked non-foamed polyurethane is a cross-linked non-foamed polyurethane having a mass reduction rate of 5% by mass or less, preferably 3% by mass or less with respect to DMF immersion. It is preferable from the point that the deformation due to the elastic recovery is suppressed.
- crosslinking non-foaming polyurethane is after immersing in DMF 100 times the mass of polyurethane for 24 hours at normal temperature, DMF is filtered, the obtained filtrate is dried, and the mass Measure.
- Mass reduction rate (%) (1 ⁇ weight after DMF immersion / weight before DMF immersion) ⁇ 100.
- the content of the polymer elastic body in the dense nonwoven fabric is 5 to 40% by mass, more preferably 8 to 35% by mass, and particularly 12 to 30% by mass with respect to the total amount with the ultrafine fibers. This is preferable from the viewpoint of excellent formability of foam molding.
- the thickness of the dense non-woven fabric of ultrafine fibers is not particularly limited as long as the denseness that prevents the molten resin from passing through the textile material layer in in-mold molding can be secured. It is preferable from the point that the in-mold molded product does not become too thick.
- the fiber sheet layer and the textile material layer are bonded.
- the adhesive for bonding the fiber sheet layer and the textile material layer include polyvinyl acetal adhesives such as polyvinyl butyral (PVB) adhesives, polyurethane adhesives, and acrylic adhesives. And epoxy adhesives.
- the thickness of the adhesive layer that bonds the fiber sheet layer and the textile material layer is not particularly limited, but is preferably about 30 to 150 ⁇ m, for example.
- a resin-impregnated nonwoven fabric 28 in which a resin such as an adhesive is impregnated in advance between the fibers of the nonwoven fabric may be used. Air between the fibers of the nonwoven fabric can be eliminated by impregnating the gap between the fibers of the nonwoven fabric with a resin such as an adhesive in advance. Thereby, the adhesiveness between the resin-impregnated nonwoven fabric 28 and the resin molded body 5 is improved. Further, by using the resin-impregnated nonwoven fabric 28, the bonding strength with the resin molded body is increased by mixing with the resin melted at the time of in-mold molding.
- the method for impregnating the nonwoven fabric with a resin such as an adhesive is not particularly limited. Specifically, for example, a liquid adhesive or a solution of an adhesive is dipped on a nonwoven fabric and squeezed, or a method of applying with a gravure roll. Further, in order to improve the impregnation property, a cut may be made in the nonwoven fabric. Further, as another impregnation method, an adhesive film or an adhesive powder may be stacked on the nonwoven fabric and press-fitted with a roller to impregnate.
- the textile-like resin molded body 130 is a housing in which a textile material 101 made of a lattice-patterned knitted fabric is arranged on the surface.
- 14A is a schematic perspective view
- FIG. 14B is a schematic diagram showing a part of the AA ′ cross section of FIG. 14A
- FIG. 14C is a schematic diagram showing a part of the BB ′ cross section of FIG. 14A.
- the textile-like resin molded body 130 in the textile-like resin molded body 130, the fiber sheet layer 7, the adhesive layer 8, and the textile material layer 101 are laminated on the surface of the resin molded body 5 in this order.
- the textile material 101 is stuck along the protruding portion P.
- FIG. 14C since the textile material layer 101 has a lattice pattern, only the fiber sheet layer 7 is laminated in a portion where the textile material layer 101 does not exist.
- the textile-like resin molded body 130 since the fiber sheet layer 7 is laminated on the side of the textile material 101 facing the resin molded body 5, the rigid resin molded body 1 does not enter the textile material 101. . Therefore, the textile material layer 101 does not lose a supple texture and a three-dimensional feeling.
- FIG. 1 is a schematic perspective view of a textile-like resin molded body (housing) 40 according to the fourth embodiment.
- 15 is a schematic cross-sectional view taken along the line II-II ′ of FIG. 1
- FIG. 16 is a schematic cross-sectional view taken along the line III-III ′ of FIG.
- Elements having the same reference numerals as those shown in the first to third embodiments are the same elements as those described in the first to third embodiments.
- the textile-like resin molding 40 is laminated
- a textile material layer 1 an adhesive layer (first adhesive layer) 8, a fiber sheet layer 7, and a resin molded body 5.
- the in-mold sheet 41 is a laminate in which the surface protective layer 2 and the textile material layer 1 are bonded by the adhesive layer 3, and the textile material layer 1 and the fiber sheet layer 7 are bonded by the adhesive layer 8.
- the textile-like resin molded body 40 is obtained by in-mold molding an in-mold sheet 41 or a preform molded body 42 in which a three-dimensional shape is previously formed on the in-mold sheet 41.
- the in-mold sheet 41 is preformed. As shown in step (I), the in-mold sheet 41 is placed so that the surface protective layer 2 faces the female mold 17 a of the preform mold (press mold) 17. The in-mold sheet 41 may be cut into a predetermined shape in advance. Next, as shown in step (II), the female mold 17a and the male mold 17b are clamped with a press to push the in-mold sheet 41 into the recess of the female mold 17a. As a result, a preform formed body 42 obtained by shaping the in-mold sheet 41 is obtained.
- the preform molded body 42 may be deburred or unnecessary portions may be cut and removed by a laser cutter or a cutting unit (cutting die) as necessary.
- step (IV) injection molding is performed by an injection molding machine 13 including an in-mold die 18 including a moving side die 18a and a fixed side die 18b.
- the preform molded body 42 is accommodated so that the surface protective layer 2 faces the concave portion of the cavity of the moving mold 18a, and the moving mold 18a and the fixed mold 18b are clamped.
- the cylinder 13a of the injection molding machine 13 is advanced, and the nozzle part 13b distribute
- the pellet-shaped resin 15 stored in the hopper 13d is measured while being melted in the cylinder 13a.
- the molten resin 15 is injected into the cavity of the in-mold die 18.
- the resin 15 melted by injection enters between the fibers of the fiber sheet layer 7.
- the fiber sheet layer 7 becomes a barrier layer for preventing the resin 15 melted in the in-mold molding from penetrating into the textile material layer 1.
- the thermal influence by the molten resin with respect to the textile material layer 1 is reduced.
- the molten resin permeates into the fiber sheet layer 7 in the in-mold molding, it is possible to maintain high adhesion due to the anchor effect with respect to the formed resin molded body 5.
- the textile material layer 1 and the fiber sheet layer 7 are bonded, they exhibit high adhesion due to the anchor effect of the adhesive.
- the moving mold 18 a and the fixed mold 18 b are separated from each other.
- the textile-like resin molded body 40 in which the preform molded body 42 and the resin molded body 5 are integrated is taken out.
- the fiber sheet layer 7 and the resin molded body 5 contract, and the fiber sheet layer 7 and the resin molded body 5 are more firmly integrated. In this way, a textile-like resin molded body 40 is obtained.
- the textile-like resin molded body 140 is a housing in which a textile material 101 made of a lattice-knitted fabric is arranged on the surface.
- 18A is a schematic perspective view
- FIG. 18B is a schematic diagram showing a part of the AA ′ cross section of FIG. 18A
- FIG. 18C is a schematic diagram showing a part of the BB ′ cross section of FIG. 18A.
- the fiber sheet layer 7, the first adhesive layer 8, the textile material layer 101, the second adhesive layer 3, and the surface protective layer are formed on the surface of the resin molded body 5. 2 are stacked in this order.
- the textile material 101 is stuck along the protruding portion P.
- FIG. 18C since the textile material layer 101 has a lattice pattern, only the fiber sheet layer 7, the second adhesive layer 3, and the surface protective layer 2 are laminated on the portion where the textile material layer 101 does not exist. ing.
- the textile-like resin molded body 140 since the fiber sheet layer 7 is laminated on the side of the textile material 101 facing the resin molded body 5, the rigid resin molded body 1 does not enter the textile material 101. . Therefore, the textile material layer 101 does not lose a supple texture and a three-dimensional feeling.
- FIG. 1 is a schematic perspective view of a textile-like resin molded body (housing) 50 according to a fifth embodiment.
- 19 is a schematic cross-sectional view taken along the line II-II ′ of FIG. 1
- FIG. 20 is a schematic cross-sectional view taken along the line III-III ′ of FIG.
- Elements having the same reference numerals as those shown in the first to fourth embodiments are the same as those described in the first to fourth embodiments.
- the textile-like resin molding 50 is laminated
- the in-mold sheet 51 is a laminated body in which the surface temporary protective layer 4 and the textile material layer 1 are bonded by the adhesive layer 6, and the textile material layer 1 and the fiber sheet layer 7 are bonded by the adhesive layer 8. .
- the textile-like resin molded body 50 is obtained by in-mold molding an in-mold sheet 51 or a preform molded body 52 in which a three-dimensional shape is previously formed on the in-mold sheet 51.
- the temporary surface protective layer 4 and the temporary adhesive layer 6 are temporary surface protective layers that are peeled off from the surface of the textile material layer 1 after in-mold molding.
- preform molding is performed.
- the in-mold sheet 51 is placed so that the surface temporary protective layer 4 faces the female mold 17 a of the preform mold (press mold) 17.
- the in-mold sheet 51 may be cut into a predetermined shape in advance.
- the female mold 17a and the male mold 17b are clamped with a press to push the in-mold sheet 51 into the recess of the female mold 17a.
- a preform molded body 52 formed with the in-mold sheet 51 is obtained.
- the preform molded body 52 may be deburred or unnecessary portions may be cut and removed by a laser cutter or a cutting unit (cutting die) as necessary.
- step (IV) injection molding is performed by an injection molding machine 13 including an in-mold die 18 including a moving side die 18a and a fixed side die 18b.
- the preform molded body 52 is accommodated so that the temporary surface protection layer 4 faces the concave portion of the cavity of the moving side mold 18a, and the moving side mold 18a and the fixed side mold 18b are clamped.
- the cylinder 13a of the injection molding machine 13 is advanced, and the nozzle part 13b distribute
- the pellet-shaped resin 15 stored in the hopper 13d is measured while being melted in the cylinder 13a.
- the molten resin 15 is injected into the cavity of the in-mold die 18.
- the resin 15 melted by injection enters the gap between the fibers of the fiber sheet layer 7.
- the fiber sheet layer 7 becomes a barrier layer for preventing the resin 15 melted in the in-mold molding from penetrating into the textile material layer 1.
- the thermal influence by the molten resin with respect to the textile material layer 1 is reduced.
- the molten resin permeates into the fiber sheet layer 7 in the in-mold molding, it is possible to maintain high adhesion due to the anchor effect with respect to the formed resin molded body 5.
- the textile material layer 1 and the fiber sheet layer 7 are bonded, they exhibit high adhesion due to the anchor effect of the adhesive.
- step (V) the textile-like resin molded body 50 in which the preform molded body 52 and the resin molded body 5 are integrated is taken out.
- the fiber sheet layer 7 and the resin molded body 5 contract, and the fiber sheet layer 7 and the resin molded body 5 are more firmly integrated.
- a textile-like resin molded body 50 is obtained.
- the bonding strength between the fiber sheet layer 7 and the resin molded body 5 is increased due to the anchor effect by infiltrating the molten resin into the fiber sheet layer 7 having air permeability. Yes.
- FIG. 1 is a schematic perspective view of a textile-like resin molded body (housing) 60 using the artificial leather of the sixth embodiment as a textile material.
- 22 is a schematic cross-sectional view taken along the line II-II ′ of FIG. 1
- FIG. 23 is a schematic cross-sectional view taken along the line III-III ′ of FIG.
- Elements having the same reference numerals as those shown in the first to fifth embodiments are the same elements as those described in the first to fifth embodiments.
- the textile-like resin molded body 60 includes a surface temporary protective layer 4 and an adhesive layer (temporary adhesive layer) 6 laminated in order from the second surface side to the first surface side. And an artificial leather layer 9 and a resin molded body 5.
- the in-mold sheet 61 is a laminate in which the surface temporary protective layer 4 and the artificial leather layer 9 are bonded together with an adhesive layer 6.
- the artificial leather layer 9 also serves as a fiber sheet layer and a textile layer.
- the textile-like resin molded body 60 is obtained by in-mold molding an in-mold sheet 61 or a preform molded body 62 in which a three-dimensional shape is previously formed on the in-mold sheet 61.
- the surface temporary protective layer 4 and the adhesive layer 6 are temporary surface protective layers that are peeled off from the surface of the textile material layer 1 after in-mold molding.
- preform molding is performed.
- step (I) the in-mold sheet 61 is placed so that the surface temporary protective layer 4 faces the female mold 17a of the preform mold (press mold) 17.
- the in-mold sheet 61 may be cut into a predetermined shape in advance.
- step (II) the female mold 17a and the male mold 17b are clamped with a press to push the in-mold sheet 61 into the recess of the female mold 17a.
- a preform molded body 62 formed with the in-mold sheet 61 is obtained.
- the preform molded body 62 may be deburred or unnecessary portions may be cut and removed by a laser cutter or a cutting unit (cutting die) as necessary.
- step (IV) injection molding is performed by an injection molding machine 13 including an in-mold die 18 including a moving side die 18a and a fixed side die 18b.
- the preform molded body 62 is accommodated so that the temporary surface protection layer 4 faces the concave portion of the cavity of the moving side mold 18a, and the moving side mold 18a and the fixed side mold 18b are clamped.
- the cylinder 13a of the injection molding machine 13 is advanced, and the nozzle part 13b distribute
- the pellet-shaped resin 15 stored in the hopper 13d is measured while being melted in the cylinder 13a.
- the molten resin 15 is injected into the cavity of the in-mold die 18.
- the resin 15 melted by injection enters between the fibers of the nonwoven fabric that is the base material of the artificial leather layer 9.
- the nonwoven fabric that is the base material of the artificial leather layer 9 provides a barrier against the molten resin reaching the decorative surface on the surface of the artificial leather layer 9.
- the decorative surface is supported by the surface temporary protective layer 6 and the influence of heat received from the mold surface is reduced, thereby forming wrinkles.
- the elastic texture of the decorative surface of the artificial leather layer 9 can be maintained. Moreover, since the molten resin permeates into the nonwoven fabric as the base material of the artificial leather layer 9 in the in-mold molding, it is possible to maintain high adhesion due to the anchor effect with respect to the formed resin molded body 5.
- the moving mold 18 a and the fixed mold 18 b are separated from each other.
- the textile-like resin molded body 60 in which the preform molded body 62 and the resin molded body 5 are integrated is taken out.
- the nonwoven fabric and the resin molded body 5 which are base materials of the artificial leather layer 9 contract, and the artificial leather layer 9 and the resin molded body 5 are more firmly integrated. In this way, a textile-like resin molded body 60 is obtained.
- the molten resin is infiltrated into the nonwoven fabric that is the base material of the artificial leather layer 9, so that the bond strength between the artificial leather layer 9 and the resin molded body 5 is high due to the anchor effect. It has become.
- the in-mold molding sheet 61 is preferably a dense non-woven fabric 9a containing ultrafine fibers having a fineness of 0.9 dtex or less as described above and a raised texture or silver attached formed on the surface of the dense non-woven fabric 9a.
- An artificial leather layer 9 having a decorative surface 9b like a tone is provided, and an adhesive layer 6 and a temporary surface protection layer 4 are laminated on the surface of the artificial leather layer 9.
- the raised tone is a suede-like or nubuck-like decorative surface formed by raising the ultrafine fibers forming the dense nonwoven fabric by buffing the surface of the dense nonwoven fabric.
- the silver-tone tone is a so-called silver-tone decorative surface in which a silver-tone decorative surface containing a polymer elastic body such as polyurethane is formed on the surface of a dense nonwoven fabric.
- the apparent density of the dense nonwoven fabric is 0.45 g / cm 3 or more, more preferably 0.45 to 0.70 g / cm 3 , and particularly preferably 0.50 to 0.65 g / cm 3 .
- the dense nonwoven fabric has such a high apparent density, it is difficult for the molten resin to reach the decorative surface in the in-mold molding, and it is easy to obtain a textile-like resin molded body having voids in the nonwoven fabric.
- the effect of heat on the decorative surface is suppressed, and the formation of wrinkles on the surface of the textile-like resin molded body obtained by in-mold molding is reduced, and the cushioning property due to the voids in the nonwoven fabric is maintained. can do.
- the surface of the fiber base material containing such a dense nonwoven fabric is buffed to obtain a raised artificial leather having a suede-like or nubuck-like decorated surface.
- a silver-tone artificial leather having a silver-tone decorative surface is obtained by forming a silver-tone resin layer containing a polymer elastic body such as polyurethane on the surface of a fiber substrate containing such a nonwoven fabric. It is done.
- the buffing treatment is a treatment in which the surface of the dense nonwoven fabric of ultrafine fibers is raised using sandpaper or the like.
- a resin layer containing a polymer elastic body such as polyurethane is formed on the surface of a dense nonwoven fabric of ultrafine fibers by a method such as a dry surface forming method or a direct coating method.
- a method such as a dry surface forming method or a direct coating method.
- a resin film containing a polymer elastic body is formed on a support substrate such as a release paper, and then an adhesive is applied to the surface of the resin film and bonded to the surface of a dense nonwoven fabric.
- the direct coating method is a method in which a liquid resin or a resin liquid containing a polymer elastic body is directly applied to the surface of a dense nonwoven fabric and then cured to form a silver-tone decorative surface.
- the polymer elastic body for forming the silver-added resin layer polyurethane, acrylic elastic bodies, silicone-based elastic bodies, etc. that have been conventionally used for forming silver-added resin layers can be used.
- the thickness of the resin layer with silver tone is not particularly limited, but is preferably about 60 to 200 ⁇ m, for example, because the balance between mechanical properties and texture can be maintained.
- the decorative surface of the artificial leather layer is protected by a temporary surface protection layer via a temporary adhesive layer.
- a temporary surface protective layer By protecting the decorative surface of the artificial leather layer with such a temporary surface protective layer, the thermal influence on the decorative surface from the mold surface is reduced by the temporary surface protective layer during in-mold molding. Thereby, generation
- the surface temporary protective layer supports the artificial leather layer, the preform molded body is prevented from being displaced from the original fixed position by the molten resin flowing into the cavity at the time of injection molding.
- the process of preforming the in-mold sheet 61 using the mold 117 (117a, 117b) will be described.
- the preform molding first, as shown in (a), the in-mold sheet 61 is softened by heating, and the surface temporary protective layer 4 is formed between the male mold 117a and the female mold 117b. It arrange
- the preform body 162a of the preform body may be used as a preform body as it is, but it is preferable to finish the preform body 162 by trimming and removing unnecessary portions.
- a cut surface is not formed on the end face of the resulting textile-like resin molded body, as in the case of trimming after injection molding, and is formed by injection molding.
- a resin having high wear resistance is preferable from the viewpoint of forming the end face.
- the cut surface of the preform molded product usually appears on the end surface.
- the in-mold mold 118 includes a movable-side mold 118a having a recess C and a fixed-side mold 118b. Further, a stripper plate 118d is disposed between the movable side mold 118a and the fixed side mold 118b.
- the preform molded body 162 provided with the artificial leather layer 9 having the decorative surface protected by the surface temporary protective layer 4 and the temporary adhesive layer 6 is placed so that the surface temporary protective layer 4 faces the recess C. Deploy.
- the method for disposing the preform molded body 162 inside the recess C is not particularly limited.
- the preform molded body 162 is preferably fixed inside the recess C for positioning.
- the preform molded body 162 may be misaligned with the flow of the molten resin during injection molding.
- Specific examples of the method for fixing the preform molded body 162 inside the recess C include, for example, a method for fixing the preform molded body 162 to the surface of the recess C with an adhesive, and holes and recesses included in the shape of the preform molded body 162.
- a method may be mentioned in which the core is fixed to the movable mold that matches the shape.
- a resin-like resin molded body 160 in which the preform molded body 162 is integrated is molded by injecting the resin 15 melted by the injection molding into the mold 118.
- the movable mold 118a and the fixed mold 118b are clamped, and the cylinder 13a of the injection molding machine 13 is advanced until the nozzle portion 13b contacts the resin injection port 118c of the fixed mold 118b.
- the molten resin 15 is injected into the mold 118 and injection molded.
- the injected resin 15 flows through the resin flow path R in the mold 118 and flows into the concave portion C of the cavity to be filled.
- the preform body 162 is preferably stretched so that the surface area thereof is increased by 5% or more by the heat and pressure of the molten resin 15 flowing into the mold.
- the resin 15 moderately penetrates into the nonwoven fabric that is the base material of the artificial leather layer 9, the preform molded body 162 is formed so that the bond strength between the artificial leather layer 9 and the resin molded body 5 is increased by the anchor effect. Integrated.
- the resin 15 is cooled to form the resin molded body 5, and the textile-like resin molded body 160 in which the preform molded body 162 stretched on the surface is integrated. Molded. Then, as shown in (d), when the mold 118 is opened, the movable mold 118a and the fixed mold 118b are separated from each other, and the runner 132 and the textile-like resin molded body 160 are taken out. In this way, a textile-like resin molded body 160 in which the artificial leather layer 9 protected by the temporary surface protective layer 4 and the resin molded body 5 are integrated is obtained.
- the preform molded body used in the in-mold molding is large enough to be stretched so that the surface area when it is integrated with the resin molded body is increased by 5 to 40%. It is preferable to be formed into a shape having a thickness.
- FIG. 28 is an explanatory diagram for explaining a change in the area of the decorative surface in in-mold molding. As shown in FIG. 28, in the preform molded body 162, the surface area of the decorative surface 9b is 5 to 40% than the surface area of the decorative surface 9b of the textile-like resin molded body 160 formed by in-mold molding. It is necessary to mold so as to be small.
- in-mold molding is performed using a preform molded body having a decorative surface 9b having a surface area 5 to 40% smaller than the surface area of the decorative surface 9b when integrated with the textile-like resin molded body 160.
- the preform molded body is integrated while being stretched by being stretched so that the surface area of the decorative surface is increased by 5 to 40% so as to be integrated. Wrinkles are less likely to occur on the decorative surface.
- the surface area of the decorative surface of the preform molded body relative to the surface area of the decorative surface when integrated with the decorative molded body is 5 to 40%, more preferably 10 to 35%, especially 15 to 30%. % Smaller is preferred.
- the surface area of the decorative surface of the preform molded body is smaller than 5% with respect to the surface area of the decorated surface when integrated with the decorative molded body, wrinkles are likely to occur. This seems to be because the preform molded body stretches too much during injection molding and cannot follow the thermal shrinkage of the resin molded body during cooling.
- the surface area of the decorative surface of the preform molded body is smaller than 40% with respect to the surface area of the decorative surface when integrated with the decorative molded body, the height of the deep drawn shape is large. In the case of producing a decorative molded body having a difference, the formability is lowered.
- Nonwoven fabric A is a dense non-woven fabric obtained by removing sea components from the fiber entanglement of long-fiber sea-island composite fibers obtained by the spunbond method.
- Non-woven fabric A comprises a fiber entangled fiber having an apparent density of 0.53 g / cm 3 entangled with a fiber bundle (average 25 fibers / bundle) of ultrafine fibers having a fineness of 0.08 dtex, and an impregnated crosslinked non-foamed polyurethane.
- a nonwoven fabric having a thickness of 500 ⁇ m and a basis weight of 310 g / m 2 .
- the ultrafine fiber was made of isophthalic acid-modified PET having a Tg of 110 ° C., and the mass ratio of non-foamed polyurethane / fiber entangled body was 12/88. Moreover, the mass reduction
- Nonwoven fabric C is a dense nonwoven fabric similar to the above except that foamed polyurethane is used in place of the crosslinked non-foamed polyurethane of nonwoven fabric A.
- Nonwoven fabric E is a papermaking nonwoven fabric (PY-100-60 manufactured by Awa Paper Co., Ltd.) having an apparent density of 0.40 g / cm 3 , a thickness of 240 ⁇ m, and a basis weight of 95 g / cm 2 .
- the non-woven fabric F is a resin-containing non-woven fabric obtained by impregnating the PVB-based adhesive into the gaps between the fibers of the non-woven fabric E.
- Artificial leather is artificial leather in which a suede-like napped surface is formed as a decorative surface by buffing the surface of the nonwoven fabric A and then dyeing it with a disperse dye using a liquid dyeing machine.
- the evaluation methods used in this example are summarized below.
- the surface tactile sensation of the textile-like resin molding was determined according to the following criteria.
- D The textile material was embedded in the resin molding and became a smooth surface.
- Preform formability The corners of the preform molded body were visually observed, and the preform moldability was determined according to the following criteria. A: The corners were sharp as usual. B: The corners were rounded.
- Example 1 A PVB adhesive was applied to the release surface of the release paper so that the thickness after adhesion was 75 ⁇ m, thereby forming a second adhesive layer. Specifically, first, a 10% methanol solution of a PVB adhesive was prepared. And the 75-micrometer 2nd adhesive bond layer was formed by repeating the process of apply
- a transparent acrylic film (trade name Technoloy made by Sumitomo Chemical Co., Ltd.) with a thickness of 30 ⁇ m to be a surface protective layer to the second adhesive layer of the release paper with the second adhesive layer, only the release paper is used.
- the transparent acrylic film with a 2nd adhesive bond layer was obtained by peeling.
- the textile material was piled up on the 2nd adhesive bond layer of the transparent acrylic film with a 2nd adhesive bond layer, and it pressure-bonded, heating.
- a lace knitted fabric with a lattice pattern having a line width of about 4 mm was prepared.
- the 1st adhesive bond layer was formed by further apply
- the nonwoven fabric A was piled up on the surface of the 1st adhesive bond layer, and it pressure-bonded, heating. In this way, an in-mold sheet A1 having a surface protective layer was obtained.
- a preform molded body was molded using a mold having a three-dimensional cavity.
- the in-mold sheet A1 is disposed so that the surface protective layer faces the female mold of the press mold heated to 150 ° C., and the press mold is pressed at a pressure of 0.4 MPa. It went by. In this way, a preform formed body A2 was obtained.
- the obtained preform A2 was placed in the recess of the cavity of the mold for in-mold so that the surface protective layer faces the surface of the movable mold. Then, an ABS resin was injection molded under the conditions of a resin temperature of 235 ° C. and a mold temperature of 30 to 50 ° C. By performing in-mold molding in this way, a textile-like resin molded body A3 having a shape as shown in FIGS. 18A to 18C was obtained. And it evaluated according to the above evaluation methods. The results are shown in Table 1.
- Example 2 It is a PVA film having a thickness of 30 ⁇ m for forming a temporary adhesive layer on the surface of a 50 ⁇ m-thick amorphous PET film (trade name G440E manufactured by Mitsubishi Plastics Co., Ltd.) that becomes a surface temporary protective layer ( A PVA film (Kuraray Poval film) manufactured by Kuraray Co., Ltd. was placed. And after pressure-bonding a PVA-type film and an amorphous PET film through a release paper while heating, only the release paper was peeled off to obtain an amorphous PET film with a temporary adhesive layer.
- a PVA film having a thickness of 30 ⁇ m for forming a temporary adhesive layer on the surface of a 50 ⁇ m-thick amorphous PET film (trade name G440E manufactured by Mitsubishi Plastics Co., Ltd.) that becomes a surface temporary protective layer ( A PVA film (Kuraray Poval film) manufactured by Kuraray Co., Ltd. was placed. And after pressure-bonding a PVA
- a first adhesive layer was formed by applying a PVB-based adhesive to a textile material having a lattice pattern similar to that in Example 1 so that the thickness after bonding was 100 ⁇ m.
- the nonwoven fabric A was piled up on the surface of the 1st adhesive bond layer, and it pressure-bonded, heating.
- the amorphous PET film with a temporary adhesive layer was piled up on the textile material so that a temporary adhesive layer might face, and it pressure-bonded, heating. In this way, an in-mold sheet B1 having a surface temporary protective layer was obtained.
- Example 1 preform molding was performed in the same manner except that the in-mold sheet B1 was used instead of the in-mold sheet A1, and further in-mold molding was performed.
- the surface temporary protective layer and the temporary adhesive layer was removed from the obtained in-mold molded product.
- textile-like resin molding B3 was evaluated like Example 1.
- FIG. The results are shown in Table 1.
- Example 3 The in-mold sheet C1 was obtained by peeling the surface temporary protective layer and the temporary adhesive layer from the in-mold sheet B1 similar to that manufactured in Example 2.
- Example 1 instead of using the in-mold sheet A1, the preform molding is performed in the same manner except that the in-mold sheet C1 is used, and further, the textile-like resin molded body C3 is obtained by performing the in-mold molding. Obtained.
- the textile-like resin molded body C3 was evaluated in the same manner as in Example 1. The results are shown in Table 1.
- Example 4 In the same manner as in Example 1, a transparent acrylic film with a second adhesive layer was obtained. And the textile material of the lattice pattern similar to Example 1 was piled up on the adhesive layer of the transparent acrylic film with a 2nd adhesive layer, and it pressure-bonded, heating. In this way, an in-mold sheet D1 was obtained.
- Example 1 instead of using the in-mold sheet A1, the preform molding is performed in the same manner except that the in-mold sheet D1 is used, and further, the textile-like resin molded body D3 is obtained by performing the in-mold molding. Obtained. And textile-like resin molding D3 was evaluated like Example 1. FIG. The results are shown in Table 1.
- Example 5 In the same manner as in Example 2, an amorphous PET film with a temporary adhesive layer was obtained. And the textile material of the lattice pattern similar to Example 1 was piled up on the temporary adhesive layer of the amorphous PET film with a temporary adhesive layer, and it pressure-bonded, heating. In this way, an in-mold sheet E1 having a temporary surface protective layer was obtained.
- Example 2 a textile-like resin molded body E3 was obtained in the same manner except that the in-mold sheet E1 was used instead of the in-mold sheet B1. And the textile-like resin molding E3 was evaluated like Example 1. FIG. The results are shown in Table 1.
- Example 6 In Example 1, instead of using the in-mold sheet A1 using a lattice lace knitted fabric as a textile material, a woven fabric printed so that small patterns having a diameter of about 8 mm are dispersed in a dot shape is used as the textile material. In the same manner, an in-mold sheet F1 was obtained.
- Example 1 instead of using the in-mold sheet A1, the preform molding is performed in the same manner except that the in-mold sheet F1 is used. Further, by performing in-mold molding, the textile-like resin molded body F3 is obtained. Obtained. The textile-like resin molded product F3 was evaluated in the same manner as in Example 1. The results are shown in Table 1.
- Example 1 the in-mold sheet A1 and the preform molded body A2 were used.
- the comparative example only a textile material having a lattice pattern similar to that in Example 1 is placed in the concave portion of the cavity cavity of the mold for in-molding, and injection molding is performed under the same conditions as in Example 1, thereby producing a textile-like material.
- a resin molded body G3 was obtained.
- the textile-like resin molded product G3 was evaluated in the same manner as in Example 1. The results are shown in Table 1.
- a textile-like resin molded article obtained by performing preform molding using the in-mold sheet provided with the fiber sheet layer containing the nonwoven fabric obtained in Examples 1 to 3 and 6, and in-mold molding is provided.
- the textile material was not embedded in the resin molded body, and a texture with a rich three-dimensional feel was obtained.
- Example 7 In Example 2, in the same manner as in Example 1, except that non-woven fabric A containing ultrafine fibers of isophthalic acid-modified PET having a Tg of 110 ° C. was used instead of non-woven fabric A containing ultrafine fibers of isophthalic acid-modified PET having a Tg of 110 ° C. Sheet H1 was obtained. In Example 2, a textile-like resin molded body H3 was obtained in the same manner except that the in-mold sheet H1 was used instead of the in-mold sheet B1. The textile-like resin molded body H3 was evaluated in the same manner as in Example 1. The results are shown in Table 2.
- Example 8 In Example 2, an in-mold sheet J1 was obtained in the same manner except that the nonwoven fabric C containing uncrosslinked foamed polyurethane was used instead of the nonwoven fabric A containing crosslinked non-foamed polyurethane. In Example 2, a textile-like resin molded product J3 was obtained in the same manner except that the in-mold sheet J1 was used instead of the in-mold sheet B1. The textile-like resin molded product J3 was evaluated in the same manner as in Example 1. The results are shown in Table 2.
- Example 9 In Example 2, instead of the non-woven fabric A which is a dense non-woven fabric containing a fiber-entangled body having an apparent density of 0.53 g / cm 3 entangled with a fiber bundle of ultrafine fibers having a fineness of 0.08 dtex, a fineness of 2.5 dtex An in-mold sheet K1 was obtained in the same manner except that the nonwoven fabric D containing a fiber entangled body having an apparent density of 0.45 g / cm 3 entangled with regular fibers was used. In Example 2, a textile-like resin molded body K3 was obtained in the same manner except that the in-mold sheet K1 was used instead of the in-mold sheet B1. And textile-like resin molding K3 was evaluated like Example 1. FIG. The results are shown in Table 2.
- Example 10 In Example 2, instead of the non-woven fabric A, which is a dense non-woven fabric containing a fiber-entangled body having an apparent density of 0.53 g / cm 3 entangled with a fiber bundle of ultrafine fibers having a fineness of 0.08 dtex, a paper-making non-woven fabric is used.
- An in-mold sheet L1 was obtained in the same manner except that the nonwoven fabric E was used.
- a textile-like resin molded body L3 was obtained in the same manner except that the in-mold sheet L1 was used instead of the in-mold sheet B1.
- textile-like resin molding K3 was evaluated like Example 1.
- FIG. The results are shown in Table 2.
- Example 11 In Example 2, in place of the non-woven fabric A, which is a dense non-woven fabric containing a fiber-entangled body having an apparent density of 0.53 g / cm 3 entangled with a fiber bundle of ultrafine fibers having a fineness of 0.08 dtex, An in-mold sheet M1 was obtained in the same manner except that the nonwoven fabric F, which was a papermaking nonwoven fabric impregnated with a PVB adhesive, was used. In Example 2, a textile-like resin molded body M3 was obtained in the same manner except that the in-mold sheet M1 was used instead of the in-mold sheet B1. The textile-like resin molded body M3 was evaluated in the same manner as in Example 1. The results are shown in Table 2.
- the textile-like resin moldings obtained by performing preform molding using the in-mold sheet provided with the fiber sheet layer which is the nonwoven fabric layer obtained in Examples 7 to 11 and in-mold molding are all textile materials. Was not embedded in the resin molding.
- in-mold moldability was slightly inferior to Example 2 when using an isophthalic acid-modified polyethylene terephthalate ultrafine fiber having a Tg of 130 ° C. in Example 7.
- the nonwoven fabric impregnated with the uncrosslinked foamed polyurethane of Example 8 was used, the corners of the preform molded body were rounded compared to Example 2.
- Example 9 In the case of Example 9 in which the nonwoven fabric D containing regular fibers having a fineness of 2.5 dtex was used, the resin entered the textile material, resulting in a hard resin texture. Moreover, also in Example 10 using the papermaking nonwoven fabric E, the resin entered the textile material, resulting in a slightly hard resin texture.
- the non-woven fabric F which is a paper-making non-woven fabric obtained by impregnating the PVB-based adhesive into the gaps between the fibers, the textile material has a three-dimensional effect, and the texture of the fiber feeling is maintained.
- Example 12 A 30 ⁇ m-thick PVA film (Co., Ltd.) for forming a temporary adhesive layer on the surface of a 75 ⁇ m-thick biaxially stretched PET film (trade name Lumirror manufactured by Toray Industries, Inc.) that becomes a surface temporary protective layer Kuraray product name Kuraray Poval Film) was placed. And after pressure-bonding a PVA-type film and an amorphous PET film through a release paper while heating, only the release paper was peeled off to obtain an amorphous PET film with a temporary adhesive layer. And the amorphous PET film with a temporary adhesive layer was accumulated so that the temporary adhesive layer might face the decorative surface of artificial leather, and it pressure-bonded, heating. Thus, an artificial leather-like in-mold sheet N1 having a temporary surface protective layer was obtained.
- a preform molded body was molded using a mold having a three-dimensional cavity using the in-mold sheet N1.
- the in-mold sheet N1 is disposed so that the surface temporary protective layer faces the female mold of the press mold heated to a temperature of 150 ° C., and the press mold is pressed at a pressure of 0.4 MPa. Was done.
- a preform molded body N2 was obtained.
- the preform molded body N2 had a decorated surface having a surface area equivalent to the surface area of the decorated surface of the textile-like resin molded body N3 finally obtained by in-mold molding.
- the resulting preform molded body N2 was placed in the concave portion of the cavity of the in-mold mold so that the surface temporary protective layer faces the surface of the movable mold. Then, an ABS resin was injection molded under the conditions of a resin temperature of 235 ° C. and a mold temperature of 30 to 50 ° C. By performing in-mold molding in this way, a textile-like resin molded body N3 having a shape as shown in FIGS. 1, 22 and 23 was obtained. And it evaluated according to the above evaluation methods. The results are shown in Table 3.
- Example 13 to 16 In the production of the preform molded body of Example 12, as shown in Table 3, the decorative surface is 5 to 50% smaller than the surface area of the decorative resin molded surface finally obtained by in-mold molding. A leather-like textile-like resin molded body was obtained and evaluated in the same manner as in Example 12 except that a preform molded body having the above was manufactured. The results are shown in Table 3.
- the surface area of the decorative surface is 5 to 40 in in-mold injection molding.
- % of the leather-like textile-like resin moldings obtained in Examples 13 to 15 that were stretched so as to be larger than each other the boundary between the protruding portion and the flat portion was sharp as usual.
- the surface area of the decorative surface is 50% larger in in-mold injection molding.
- the decorative molded body obtained in the stretched Example 16 was particularly poor in shaping.
- the present invention can decorate the surface of a mobile terminal (smartphone, tablet PC) and accessories such as a case and a cover, a casing of an electronic device, a vehicle interior material, a resin molded body such as a cosmetic case in a textile style.
- a mobile terminal smart phone, tablet PC
- accessories such as a case and a cover, a casing of an electronic device, a vehicle interior material, a resin molded body such as a cosmetic case in a textile style.
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Abstract
Description
以下、第1実施形態を図面を参照しながら詳述する。
図1は第1実施形態のテキスタイル調樹脂成形体(ハウジング)10の斜視模式図である。図1において、テキスタイル調樹脂成形体10は逆盆構造の底部に1つの突出部Pと1つの開口部Hを有する。また、図2は、図1のII-II’断面、図3は図1のIII-III’断面における模式断面図である。
図1は第2実施形態のテキスタイル調樹脂成形体(ハウジング)20の斜視模式図である。また、図7は、図1のII-II’断面、図8は図1のIII-III’断面における模式断面図である。なお、第1実施形態で示した符号と同じ符号の要素は、第1実施形態で説明したものと同様の要素を示す。
図1は第3実施形態のテキスタイル調樹脂成形体(ハウジング)30の斜視模式図である。また、図10は、図1のII-II’断面、図11は図1のIII-III’断面における模式断面図である。なお、第1~第2実施形態で示した符号と同じ符号の要素は、第1~第2実施形態で説明したものと同様の要素を示す。
質量減少率(%)=(1-DMF浸漬後の重量/DMF浸漬前の重量)×100、により算出される。
図1は第4実施形態のテキスタイル調樹脂成形体(ハウジング)40の斜視模式図である。また、図15は、図1のII-II’断面、図16は図1のIII-III’断面における模式断面図である。なお、第1~第3実施形態で示した符号と同じ符号の要素は、第1~第3実施形態で説明したものと同様の要素を示す。
図1は第5実施形態のテキスタイル調樹脂成形体(ハウジング)50の斜視模式図である。また、図19は、図1のII-II’断面、図20は図1のIII-III’断面における模式断面図である。なお、第1~第4実施形態で示した符号と同じ符号の要素は、第1~第4実施形態で説明したものと同様の要素を示す。
図1は第6実施形態の人工皮革をテキスタイル素材として用いたテキスタイル調樹脂成形体(ハウジング)60の斜視模式図である。また、図22は、図1のII-II’断面、図23は図1のIII-III’断面における模式断面図である。なお、第1~第5実施形態で示した符号と同じ符号の要素は、第1~第5実施形態で説明したものと同様の要素を示す。
以上、第1実施形態~第6実施形態のインモールド用シート、プレフォーム成形体及びテキスタイル調樹脂成形体の好ましい実施形態を説明した。第7実施形態では、インモールド用シートを用いてテキスタイル調樹脂成形体を製造する好ましい方法について詳しく説明する。なお、第7実施形態においては、第6実施形態で説明したインモールド用シート61を用いる例について代表的に説明する。しかしながら、その他のインモールド用シートを用いた場合にも同様の効果が得られる。
〈不織布A〉
不織布Aはスパンボンド法で得られた長繊維の海島型複合繊維の繊維絡合体から海成分を除去することにより得られた次のような緻密不織布である。不織布Aは、繊度0.08dtexの極細繊維の繊維束(平均25本/束)を絡合させた見掛け密度0.53g/cm3の繊維絡合体と、含浸付与された架橋された非発泡ポリウレタンを含む、厚さ500μm、目付310g/m2の不織布である。なお、極細繊維はTg110℃のイソフタル酸変性PETからなり、非発泡ポリウレタン/繊維絡合体の質量比は12/88であった。また、非発泡ポリウレタンのDMF浸漬に対する質量減少率は0.5質量%であった。
〈不織布B〉
不織布Bは、不織布AのTg110℃のイソフタル酸変性PETの極細繊維の代わりに、Tg130℃の変性PETの極細繊維を用いた以外は同様の緻密不織布である。
〈不織布C〉
不織布Cは不織布Aの架橋された非発泡ポリウレタンの代わりに発泡ポリウレタンを用いた以外は同様の緻密不織布である。
〈不織布D〉
不織布Dは、繊度2.5dtexのレギュラー繊維を絡合させた見掛け密度0.68g/cm3の繊維絡合体に、架橋された非発泡ポリウレタンを含浸付与して形成された厚さ500μm、目付380g/cm2の不織布である。
〈不織布E〉
不織布Eは、見掛け密度0.40g/cm3、厚さ240μm、目付95g/cm2の抄紙系不織布(阿波製紙(株)製のPY-100-60)である。
〈不織布F〉
不織布Fは、不織布Eの繊維間の空隙にPVB系接着剤を含浸させた樹脂含有不織布である。
〈人工皮革〉
人工皮革は、不織布Aの表面をバフィング処理した後、液流染色機で分散染料を用いて染色することにより、加飾面としてスエード調の立毛面を形成した人工皮革である。
(テキスタイル調樹脂成形体の表面触感)
テキスタイル調樹脂成形体の表面触感を以下の基準で判定した。
A:テキスタイル素材が樹脂成形体に埋め込まれず、立体感に優れ、繊維感や人工皮革の風合いが高く維持されていた。
B:テキスタイル素材の立体感がある程度あり、繊維感や人工皮革の風合いも維持されていた。
C:テキスタイル素材に樹脂が侵入し、硬質の樹脂感のある風合いになった。
D:テキスタイル素材が樹脂成形体に埋め込まれて平滑な表面になっていた。
テキスタイル調樹脂成形体の表面外観を以下の基準で目視により判定した。
A:テキスタイル素材が樹脂成形体の定位置に正確に貼り合わされ、シワや柄の歪みもなかった。
B:テキスタイル素材が樹脂成形体の定位置に正確に貼り合わされていたが、シワがあるか、または、模様が変形していた。
C:テキスタイル素材が樹脂成形体の定位置に正確に貼り合わされなかった。
プレフォーム成形体の角部を目視により観察し、プレフォーム成形性を以下の基準で判定した。
A:角が型どおりにシャープであった。
B:角が丸みを帯びていた。
JIS L 0849に記載の摩擦試験機I型(クロックメーター型)の摩擦子の代りに、測定試料との接触面が4.0mm×2.0mmの長方形形状を有するステンレス製摩擦子を取り付けた。そして、荷重200gをかけて、毎分30回の往復速度でテキスタイル調樹脂成形体の表面を1分間摩擦処理することにより、耐傷付性を以下の基準で評価した。
A:表面外観が変わらなかった。
B:テキスタイル素材の剥れもしくは破れが見られた。
テキスタイル調樹脂成形体の直径20mm、高さ5mmの半球状の突出部を形成する部分を目視により観察し、インモールド成形性を以下の基準で判定した。
S:突出部と平坦部との境界が正確でシャープであった。
A:突出部と平坦部との境界がほぼ型どおりにシャープであった。
B:突出部と平坦部との境界が丸みを帯びている部分が少しあった。
C:突出部と平坦部との境界が殆ど丸みを帯びていた。
離型紙の離型面に、接着後の厚さが75μmになるようにPVB系接着剤を塗布することにより第二接着剤層を形成した。具体的には、はじめに、PVB系接着剤の10%メタノール溶液を調製した。そして、離型面に接着剤溶液を塗布し、70℃で乾燥する工程を複数回繰り返すことにより、75μmの第二接着剤層を形成した。このようにして第二接着剤層付離型紙を得た。そして、第二接着剤層付離型紙の第二接着剤層に表面保護層になる厚さ30μmの透明アクリルフィルム(住友化学(株)製の商品名テクノロイ)を圧着した後、離型紙のみを剥離することにより、第二接着剤層付透明アクリルフィルムを得た。そして、第二接着剤層付透明アクリルフィルムの第二接着剤層にテキスタイル素材を重ね、加熱しながら圧着した。テキスタイル素材としては、線幅が約4mmの格子柄のレース編物を準備した。そして、テキスタイル素材の表面に厚さが50μmになるようにPVB系接着剤をさらに塗布することにより第一接着剤層を形成した。そして、第一接着剤層の表面に不織布Aを重ね、加熱しながら圧着した。このようにして、表面保護層を有するインモールド用シートA1を得た。
表面仮保護層になる厚さ50μmの非晶性PETフィルム(三菱樹脂(株)製の商品名G440E)の表面に、仮接着剤層を形成するための厚さ30μmのPVA系フィルムである(株)クラレ製のPVAフィルム(クラレポバールフィルム)を載置した。そして、離型紙を介してPVA系フィルムと非晶性PETフィルムとを加熱しながら圧着した後、離型紙のみを剥離することにより、仮接着剤層付非晶性PETフィルムを得た。一方、実施例1と同様の格子柄のテキスタイル素材に、接着後の厚さが100μmになるようにPVB系接着剤を塗布することにより第一接着剤層を形成した。そして、第一接着剤層の表面に不織布Aを重ね、加熱しながら圧着した。そして、テキスタイル素材に、仮接着剤層が面するように仮接着剤層付非晶性PETフィルムを重ね、加熱しながら圧着した。このようにして、表面仮保護層を有するインモールド用シートB1を得た。
実施例2において製造されたものと同様のインモールド用シートB1から表面仮保護層及び仮接着剤層を剥離することにより、インモールド用シートC1を得た。
実施例1と同様にして、第二接着剤層付透明アクリルフィルムを得た。そして、第二接着剤層付透明アクリルフィルムの接着剤層に実施例1と同様の格子柄のテキスタイル素材を重ね、加熱しながら圧着した。このようにしてインモールド用シートD1を得た。
実施例2と同様にして、仮接着剤層付非晶性PETフィルムを得た。そして、仮接着剤層付非晶性PETフィルムの仮接着剤層に実施例1と同様の格子柄のテキスタイル素材を重ね、加熱しながら圧着した。このようにして、表面仮保護層を有するインモールド用シートE1を得た。
実施例1において、テキスタイル素材として格子柄のレース編物を用いたインモールド用シートA1を用いた代わりに、テキスタイル素材として直径8mm程度の小紋がドット状に分散するように捺染された織物を用いた以外は同様にしてインモールド用シートF1を得た。
実施例1においては、インモールド用シートA1及びプレフォーム成形体A2を用いた。一方、比較例においては、実施例1と同様の格子柄のテキスタイル素材のみをインモールド用金型のキャビティキャビティの凹部に配置し、実施例1と同様の条件で射出成形することにより、テキスタイル調樹脂成形体G3を得た。そして、テキスタイル調樹脂成形体G3を実施例1と同様にして評価した。結果を表1に示す。
実施例2において、Tg110℃のイソフタル酸変性PETの極細繊維を含有する不織布Aの代わりに、Tg130℃のイソフタル酸変性PETの極細繊維を含有する不織布Bを用いた以外は同様にしてインモールド用シートH1を得た。そして、実施例2において、インモールド用シートB1を用いる代わりにインモールド用シートH1を用いた以外は同様にして、テキスタイル調樹脂成形体H3を得た。そして、テキスタイル調樹脂成形体H3を実施例1と同様にして評価した。結果を表2に示す。
実施例2において、架橋された非発泡ポリウレタンを含有する不織布Aの代わりに、未架橋型の発泡ポリウレタンを含有する不織布Cを用いた以外は同様にしてインモールド用シートJ1を得た。そして、実施例2において、インモールド用シートB1を用いる代わりにインモールド用シートJ1を用いた以外は同様にして、テキスタイル調樹脂成形体J3を得た。そして、テキスタイル調樹脂成形体J3を実施例1と同様にして評価した。結果を表2に示す。
実施例2において、繊度0.08dtexの極細繊維の繊維束を絡合させた見掛け密度0.53g/cm3の繊維絡合体を含有する緻密不織布である不織布Aの代わりに、繊度2.5dtexのレギュラー繊維を絡合させた見掛け密度0.45g/cm3の繊維絡合体を含有する不織布Dを用いた以外は同様にしてインモールド用シートK1を得た。そして、実施例2において、インモールド用シートB1を用いる代わりにインモールド用シートK1を用いた以外は同様にして、テキスタイル調樹脂成形体K3を得た。そして、テキスタイル調樹脂成形体K3を実施例1と同様にして評価した。結果を表2に示す。
実施例2において、繊度0.08dtexの極細繊維の繊維束を絡合させた見掛け密度0.53g/cm3の繊維絡合体を含有する緻密不織布である不織布Aの代わりに、抄紙系不織布である不織布Eを用いた以外は同様にしてインモールド用シートL1を得た。そして、実施例2において、インモールド用シートB1を用いる代わりにインモールド用シートL1を用いた以外は同様にして、テキスタイル調樹脂成形体L3を得た。そして、テキスタイル調樹脂成形体K3を実施例1と同様にして評価した。結果を表2に示す。
実施例2において、繊度0.08dtexの極細繊維の繊維束を絡合させた見掛け密度0.53g/cm3の繊維絡合体を含有する緻密不織布である不織布Aの代わりに、繊維間の空隙にPVB系接着剤を含浸させた抄紙系不織布である不織布Fを用いた以外は同様にしてインモールド用シートM1を得た。そして、実施例2において、インモールド用シートB1を用いる代わりにインモールド用シートM1を用いた以外は同様にして、テキスタイル調樹脂成形体M3を得た。そして、テキスタイル調樹脂成形体M3を実施例1と同様にして評価した。結果を表2に示す。
表面仮保護層になる厚さ75μmの2軸延伸PETフィルム(東レ(株)製の商品名ルミラー)の表面に、仮接着剤層を形成するための厚さ30μmのPVA系フィルム((株)クラレ製商品名クラレポバールフィルム)を載置した。そして、離型紙を介してPVA系フィルムと非晶性PETフィルムとを加熱しながら圧着した後、離型紙のみを剥離することにより、仮接着剤層付非晶性PETフィルムを得た。そして、人工皮革の加飾面に仮接着剤層が面するように仮接着剤層付非晶性PETフィルムを重ね、加熱しながら圧着した。このようにして、表面仮保護層を有する人工皮革調のインモールド用シートN1を得た。
実施例12のプレフォーム成形体の製造において、表3に記載したように、最終的にインモールド成形で得られるテキスタイル調樹脂成形体の加飾面の表面積によりも5~50%小さい加飾面を有するプレフォーム成形体を製造した以外は実施例12と同様にして皮革調のテキスタイル調樹脂成形体を得、評価した。結果を表3に示す。
2 表面保護層(保護フィルム)
3 接着剤層(第二接着剤層)
4 表面仮保護層
5 樹脂成形体
6 接着剤層(仮接着剤層)
7 繊維シート層
8 接着剤層(第一接着剤層)
9 人工皮革層
9a 緻密不織布
9b 加飾面
10,20,30,40,50,60,62,130,140,150 テキスタイル調樹脂成形体
11,21,31,41,51,61,103 ,104 インモールド用シート
162a 予備成形体
12,22,32,42,52,62,162 プレフォーム成形体
13 射出成形機
13a シリンダ
13b ノズル部
13c スクリュー
13d ホッパ
15 樹脂
17,117 プレフォーム金型(プレス金型)
17a,117a メス金型
17b,117b オス金型
18,118 インモールド用金型
18a,118a 可動側金型
18b,118b 固定側金型
18c,118c 樹脂注入口
118d ストリッパプレート
23 (トリミング処理された)プレフォーム成形体
24 溶融樹脂
25 離型紙
26 接着剤層付離型紙
132 ランナー
28 接着剤含浸不織布
P 突出部
H 開口部
Claims (40)
- インモールド成形により溶融樹脂を射出して成形される樹脂成形体に一体化されるテキスタイル調インモールド用シートであって、
前記樹脂成形体に一体化される側になる第1面と、前記第1面に対する裏面になる第2面と、を有し、
前記第1面から前記第2面に向かって順に、繊維シート層,第一接着剤層,及びテキスタイル素材層,を少なくとも有するテキスタイル調インモールド用シート。 - 前記テキスタイル素材層は、織物,編物,または不織布を含む請求項1に記載のテキスタイル調インモールド用シート。
- 前記繊維シート層は、前記インモールド成形において前記テキスタイル素材に前記溶融樹脂を浸透させないためのバリア層である請求項1に記載のテキスタイル調インモールド用シート。
- 前記繊維シート層が、不織布を含む請求項1に記載のテキスタイル調インモールド用シート。
- 前記不織布は、繊度2.0dtex以下の極細繊維の不織布である請求項4に記載のテキスタイル調インモールド用シート。
- 前記繊度2.0dtex以下の極細繊維が、繊度0.9dtex以下の極細繊維である請求項5に記載のテキスタイル調インモールド用シート。
- 前記極細繊維の不織布は、その内部空隙に付与されたポリウレタンをさらに含み、前記極細繊維は、ガラス転移温度(Tg)100~120℃のポリエステルを含む請求項5に記載のテキスタイル調インモールド用シート。
- 前記ポリウレタンは、N,N-ジメチルホルムアミドに24時間浸漬して乾燥した後の、浸漬前の質量に対する質量減少率が5質量%以下である架橋された非発泡ポリウレタンである請求項7に記載のテキスタイル調インモールド用シート。
- 前記不織布が、抄紙系不織布である請求項4に記載のテキスタイル調インモールド用シート。
- 前記抄紙系不織布は、その内部空隙に含浸付与された熱可塑性樹脂をさらに含む請求項9に記載のテキスタイル調インモールド用シート。
- 前記熱可塑性樹脂はポリビニルアセタール樹脂である請求項10に記載のテキスタイル調インモールド用シート。
- 前記ポリビニルアセタール樹脂がポリビニルブチラール樹脂である請求項11に記載のテキスタイル調インモールド用シート。
- 前記第一接着剤層は、ポリビニルアセタール樹脂を含む請求項1に記載のテキスタイル調インモールド用シート。
- 前記ポリビニルアセタール樹脂がポリビニルブチラール樹脂である請求項13に記載のテキスタイル調インモールド用シート。
- 前記第2面の側に、前記テキスタイル素材層を覆う表面樹脂層をさらに備える請求項1に記載のテキスタイル調インモールド用シート。
- 前記表面樹脂層は、前記テキスタイル素材層に接着された表面保護層である請求項15に記載のテキスタイル調インモールド用シート。
- 前記表面保護層は、アクリル系透明樹脂層またはメタクリル系透明樹脂層である請求項16に記載のテキスタイル調インモールド用シート。
- 前記アクリル系透明樹脂層またはメタクリル系透明樹脂層は、エラストマーを含む請求項17に記載のテキスタイル調インモールド用シート。
- 前記表面保護層は、前記テキスタイル素材層にポリビニルアセタール樹脂を含む第二接着剤層を介して接着されている請求項16に記載のテキスタイル調インモールド用シート。
- 前記ポリビニルアセタール樹脂がポリビニルブチラール樹脂である請求項19に記載のテキスタイル調インモールド用シート。
- 前記表面樹脂層は、前記テキスタイル素材層に剥離可能に仮接着された表面仮保護層である請求項15に記載のテキスタイル調インモールド用シート。
- 前記インモールド成形後に、前記表面仮保護層が剥離される請求項21に記載のテキスタイル調インモールド用シート。
- 前記表面仮保護層は、ポリエステルフィルム層である請求項21に記載のテキスタイル調インモールド用シート。
- 前記ポリエステルフィルム層は、非晶性PETを含む請求項23に記載のテキスタイル調インモールド用シート。
- 前記表面仮保護層は、ポリビニルアルコール樹脂を含む仮接着剤層を介して前記テキスタイル素材層に仮接着されている請求項21に記載のテキスタイル調インモールド用シート。
- 前記表面仮保護層は、粘着層を介して前記仮接着剤層に接着されている請求項25に記載のテキスタイル調インモールド用シート。
- インモールド成形により溶融樹脂を射出して成形される樹脂成形体に一体化されるテキスタイル調インモールド用シートであって、
前記樹脂成形体に一体化される第1面と、前記第1面に対する裏面になる第2面と、を有し、
前記第1面から前記第2面に向かって順に、テキスタイル素材層,及び前記テキスタイル素材層に仮接着された表面仮保護層を少なくとも有するテキスタイル調インモールド用シート。 - 前記テキスタイル素材層は、織物,編物,または不織布を含む請求項27に記載のテキスタイル調インモールド用シート。
- 前記テキスタイル素材層は、繊度2.0dtex以下の極細繊維の不織布を含む請求項27に記載のテキスタイル調インモールド用シート。
- 前記繊度2.0dtex以下の極細繊維が、繊度0.9dtex以下の極細繊維である請求項29に記載のテキスタイル調インモールド用シート。
- 前記繊度0.9dtex以下の極細繊維の不織布は、その表面に立毛形成、または銀面調樹脂層を積層されて人工皮革を形成している請求項30に記載のテキスタイル調インモールド用シート。
- 前記極細繊維の不織布は、その内部空隙に付与されたポリウレタンをさらに含み、前記極細繊維は、ガラス転移温度(Tg)100~120℃のポリエステルからなる請求項29に記載のテキスタイル調インモールド用シート。
- 前記表面仮保護層は、ポリエステルフィルム層である請求項27に記載のテキスタイル調インモールド用シート。
- 請求項1~33の何れか1項に記載のテキスタイル調インモールド用シートに賦形して形成されたプレフォーム成形体。
- 請求項34に記載のプレフォーム成形体と、前記プレフォーム成形体の前記第1面の側に積層一体化された前記インモールド成形により成形された前記樹脂成形体と、を含むテキスタイル調樹脂成形体。
- インモールド成形用金型のキャビティ内に、前記第1面の側に溶融樹脂が射出されるように請求項34に記載のプレフォーム成形体を配置する第1工程と、
前記金型内に溶融樹脂を射出することにより、前記第1面の側で前記プレフォーム成形体に一体化された前記樹脂成形体を成形する第2工程と、を備えるテキスタイル調樹脂成形体の製造方法。 - 前記プレフォーム成形体は、前記第2工程において、前記第2面の表面積が5~40%大きくなるように延伸される請求項36に記載のテキスタイル調樹脂成形体の製造方法。
- 前記プレフォーム成形体は、前記テキスタイル調樹脂成形体の輪郭を形成するように予めトリミング処理されている請求項37に記載のテキスタイル調樹脂成形体の製造方法。
- 請求項38に記載の製造方法により得られた、前記輪郭の端面に切断面がないテキスタイル調樹脂成形体。
- 請求項27に記載のテキスタイル調インモールド用シートを製造する方法であって、
テキスタイル素材を準備する工程と、
前記テキスタイル素材に、ポリビニルアルコール系フィルムを介在させて前記表面仮保護層を形成するためのフィルムを配置し、前記テキスタイル素材に配置された前記ポリビニルアルコール系フィルム及び前記表面仮保護層を形成するためのフィルムをプレスする工程を備えるテキスタイル調インモールド用シートの製造方法。
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KR20160048096A (ko) | 2016-05-03 |
EP3040177A1 (en) | 2016-07-06 |
EP3040177B1 (en) | 2020-06-03 |
US20180154563A1 (en) | 2018-06-07 |
EP3718731A1 (en) | 2020-10-07 |
KR102271406B1 (ko) | 2021-06-30 |
TW201518092A (zh) | 2015-05-16 |
US20160214293A1 (en) | 2016-07-28 |
CN105492181A (zh) | 2016-04-13 |
CN108995131A (zh) | 2018-12-14 |
TWI554397B (zh) | 2016-10-21 |
US11000980B2 (en) | 2021-05-11 |
JP6587541B2 (ja) | 2019-10-09 |
CN105492181B (zh) | 2018-08-07 |
EP3040177A4 (en) | 2017-04-26 |
EP3718731B1 (en) | 2022-12-28 |
JPWO2015029453A1 (ja) | 2017-03-02 |
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