WO2020075669A1 - 積層体およびその製造方法 - Google Patents
積層体およびその製造方法 Download PDFInfo
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- WO2020075669A1 WO2020075669A1 PCT/JP2019/039475 JP2019039475W WO2020075669A1 WO 2020075669 A1 WO2020075669 A1 WO 2020075669A1 JP 2019039475 W JP2019039475 W JP 2019039475W WO 2020075669 A1 WO2020075669 A1 WO 2020075669A1
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- Prior art keywords
- molded body
- release agent
- adhesive
- coating
- mold
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Classifications
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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
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics 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
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
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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
- B32B27/00—Layered products comprising a layer of synthetic resin
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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
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
Definitions
- the present invention relates to a laminated body including a molded body and a coating material thereof, and a manufacturing method thereof.
- a release agent containing wax or silicone as a non-volatile component, or a mixture thereof is used.
- Various types of such release agents have been developed and marketed (for example, Patent Document 1).
- the molded body after molding is subjected to shot blasting treatment, sand blasting treatment, flame treatment, corona treatment, plasma treatment or the like or cleaning with a solvent such as alcohol, ketone, ester or hydrocarbon (for example, Patent Document 2).
- Shot blasting and sand blasting can give strong adherence, but it causes problems in the working environment and long processing time.
- Flame treatment has a risk of causing deformation, melting, ignition, and fire due to heat.
- the corona treatment is time consuming due to the vacuum, and the equipment cost is high.
- Cleaning with a solvent such as alcohol, ketone, ester, or hydrocarbon is easy, but depending on the type of the release agent, the molded product cannot have sufficient adherence.
- the use environment is limited by the use of dangerous substances.
- a resin molded body in which a coating is laminated is molded by molding a molded resin material using a mold release agent and removing the mold release agent adhering to the surface of the molded body from the mold after the mold release, as described above. After that, the molded article was laminated and coated with the coating material. That is, it was difficult to achieve both mold releasability and adhesiveness of the molded product without the post-treatment process.
- the present invention has been made in view of the above circumstances, and a method for achieving both mold releasability and adhesiveness of a molded body and efficiently manufacturing a laminate comprising the molded body and a coating thereof, and a manufacturing method thereof. It is an object of the present invention to provide a laminate manufactured by.
- the above object is achieved by a method for producing a laminate, which is characterized by the following production steps (1) to (6).
- (1) Release agent applying step of applying an aqueous release agent to the mold surface (2) A support raw material injecting step of injecting a support raw material of a molded body into the mold, (3) a curing and foaming step of curing the support material and optionally foaming it; (4) Molded body removing step of removing the molded body obtained in the curing and foaming step from the mold, (5) Subsequent to the step (4), an adhesive applying step of applying an adhesive to the molded body, and (6) a coating layer laminating step of stacking a coating on the molded body coated with the adhesive. .
- the present invention provides a novel method for producing a laminated body and a laminated body which have never existed before.
- the schematic sectional drawing of the layered product of the present invention The perspective view of the molded object A molded in the Example.
- An important aspect of the present invention is to provide a method for producing a laminate, which is characterized by the following production steps (1) to (6).
- (1) Release agent applying step of applying an aqueous release agent to the mold surface (2) A support raw material injection step of injecting a support raw material into the mold, (3) a curing and foaming step of curing the support material and optionally foaming it; (4) Molded body removing step of removing the molded body obtained in the curing and foaming step from the mold, (5) Subsequent to the step (4), an adhesive applying step of applying an adhesive to the molded body, and (6) a coating layer laminating step of stacking a coating on the molded body coated with the adhesive. .
- the method for producing a laminate of the present invention is, after taking out the molded body from the mold, a post-treatment that has been conventionally performed, that is, the molded body is shot blasted, sand blasted, flame treated, corona treated, plasma treated or alcohol.
- the adhesive is applied directly to the molded product taken out of the mold without any treatment such as cleaning with a solvent such as ketone, ester, hydrocarbon, etc., and a coating is applied to the molded product coated with this adhesive.
- the above-mentioned "(5) Step of applying an adhesive to the molded body after the step of (4)" means the steps in such an order.
- the laminate can be efficiently produced, and the obtained laminate has excellent adhesiveness between the molded body and the covering. It is possible to achieve both releasability and adhesiveness, which could never be achieved by conventional techniques.
- the water-based release agent used in the release agent coating step contains fine particles, and contains at least a release agent component, fine particles and water. Water constitutes at least the remaining part of the water-based release agent other than the release agent component and the fine particles.
- the release agent component waxes used in conventionally known water-based release agents, for example, paraffin wax, polyethylene wax, Fischer-Tropsch wax, microcrystalline wax, olefin polymer, higher fatty acid ester, oxidized wax Etc., a fluorine component, for example, a perfluoro group-containing hydrocarbon compound and / or a silicone component, for example, silicone oil, silicone resin, straight silicone, modified silicone, etc. may be used.
- the fluorine component and the silicone component are used to improve releasability. Only the wax component may be used, but it may be used together with the fluorine component and / or the silicone component.
- the fluorine component and / or silicone component is generally used in an amount of 0 to 300% by weight, preferably 2 to 100% by weight, based on the wax component.
- the fine particles contained in the water-based release agent are not particularly limited, and those conventionally used, for example, silica particles, acrylic particles, urethane particles, silicone rubber powder, plastic powder, PTFE powder, etc. can be used. Although the type thereof is not particularly limited, fine particles having a particle size of 100 nm to 20 ⁇ m, preferably 1 ⁇ m to 20 ⁇ m, more preferably 1 ⁇ m to 18 ⁇ m, still more preferably 2 ⁇ m to 15 ⁇ m are used. To do so. When the thickness is 100 nm or less, it becomes difficult to achieve the adhesiveness between the molded body and the coating material to be laminated in the subsequent step. If it is 20 ⁇ m or more, there is concern about the dispersion stability of the dispersion solution which is an aqueous release agent.
- the particle size as used in the present invention means an average particle size.
- the fine particles are 97: 3 to 20:80 (wax: fine particles), preferably 96: 4 to 25:75, and more preferably 95: 5 to 30 in weight ratio with the wax component in the release agent. : Use in the range of 70. The releasability at the time of molding is not impaired, and good adhesion between the molded body of the obtained laminate and the coating is achieved. As the amount of the fine particle component used increases, the adhesive force between the molded body and the coating tends to increase.
- the content of the release agent component in the water-based release agent is not particularly limited, and it may be used within the range conventionally known.
- the content of the release agent component in the water-based release agent is about 0.1 to 70% by weight, preferably 0.1 to 10% by weight, more preferably 0.1 to 5% by weight, still more preferably It may be used in an amount of 0.5 to 3% by weight.
- preservatives may be included in amounts within a range that does not impair the effects of the present invention.
- the amount thereof is usually about 0.1 to 300% by weight based on the wax component of the release agent.
- the mold used in the release agent coating step may be a conventionally existing or newly created desired mold, and the coating method and coating amount of the water-based release agent are not particularly limited. Instead, a conventionally known coating method, for example, spray coating, brush coating, dipping, etc., may be applied at a coating amount of, for example, 50 to 150 g / m 2 , preferably 70 to 120 g / m 2 .
- Support raw material injecting step the support raw material is injected into the mold.
- the raw material for the support a material obtained by curing a urethane resin raw material in a mold to obtain a resin molded body is preferable.
- Various urethane resin raw materials are known and commercially available. Known ones may be used.
- a thermosetting resin material that can be injected into the mold for example, an epoxy resin, a phenol resin, a styrene resin raw material, or a thermosetting resin material such as fiber reinforced prepreg can be used.
- the method of injecting the support material into the mold is not particularly limited, and a conventionally known injection method, for example, an injection machine or hand mixing may be used.
- the support material injected into the mold is cured and foamed if desired.
- the curing method, curing conditions, foaming method, foaming conditions, etc. are not particularly limited, and conventionally known methods and conditions may be applied.
- a foamable material when used as the support material, it may be foamed and cured according to the properties required for the final product.
- a urethane foam resin material when used, it is foamed to about 0.01 to 1.0 g / cm 3 and used as a support for a leather-wrapped handle laminate.
- the molded body obtained in the curing and foaming step is taken out from the mold. Extraction from the mold is not particularly limited, and a conventionally known extraction method may be adopted. Since the fine particles are added to the extent that the releasability is not impaired, the releasability of the molded product in the process of taking out the molded product is good because the conventional releasability is secured.
- Adhesive coating step In the adhesive coating step, an adhesive is applied to the molded body taken out, following the molded body taking out step.
- the adhesive is directly applied to the molded body taken out from the mold without post-processing the molded body taken out.
- the adhesive to be applied may be appropriately selected and used in consideration of the material of the support, the material of the coating to be laminated on the molded body and adhered to the adhesive in the subsequent coating layer laminating step, and is particularly limited. Not a thing.
- a chloroprene rubber adhesive or vinyl acetate adhesive can be used.
- the adhesive application method and conditions in the adhesive application step are not particularly limited, and conventionally known methods and conditions may be adopted.
- Coated material laminating step In the coated material laminating step, at least a part or all of the surface of the molded article coated with the adhesive obtained in the adhesive coating step is coated with, for example, leather, synthetic leather, cloth or glass. , Metal, resin, carbon fiber, various films, and the like, preferably leather, synthetic leather, cloth, and PET film are laminated.
- a method and conditions for laminating conventionally known methods and conditions may be adopted.
- the adhesive to be used is selected in consideration of the coating material, the molding material, and the laminating method.
- Another important aspect of the present invention is to provide a laminate obtained through the above manufacturing process. That is, a laminated body in which a molded body, an adhesive and a coating are laminated, wherein the molded body is a support made of resin, fine particles partially embedded in the support surface, the fine particle surface and the support surface.
- the above-mentioned laminated body is provided, which comprises a release agent attached to at least a part of each of the above.
- the laminated body 1 of the present invention has a structure in which a support body 2, a molded body 5 including fine particles 3 and a release agent 4, an adhesive 6 and a coating 7 are laminated.
- the molded body 5 is a molded body taken out from the mold in the molded body taking-out step.
- the support 2 is made by curing the support material and foaming it if desired.
- the fine particles 3 are fine particles contained in the water-based mold release agent applied to the surface of the mold, and the fine particles applied to the surface of the mold through the raw material injection step, the curing and foaming step, and the molded body unloading step are supported. It exists in a state where a part of it is embedded in the body surface.
- the mold release agent 4 is a mold release agent contained in the water-based mold release agent applied to the surface of the mold.
- the mold release agent 4 undergoes a raw material injection step, a curing and foaming step, and a molded body unloading step, and then the fine particle surface and the support surface It is a release agent such as wax that is transferred and attached to at least a part of each.
- Adhesive is the adhesive applied in the adhesive application process.
- the coating is a coating laminated in the coating laminating step.
- the layered product of the present invention has a release agent attached to at least a part of each of the surface of the fine particles and the surface of the support after molding due to the anchor effect of the fine particles 3 partially embedded in the surface of the support. Nevertheless, it is considered that the coating 7 adheres to the support 2 with sufficient strength via the adhesive 6.
- the laminated body of the present invention include a seat cushion, an armrest, a footrest, and a handle.
- existing equipment can be used and it can manufacture efficiently.
- Wax A In-house manufactured wax mixture
- Main component paraffin wax Wax B In-house manufactured wax mixture
- Main component microcrystalline wax Wax C In-house manufactured wax mixture
- Main component microcrystalline wax Fluorine In-house manufactured fluorine product
- Silicone Modified silicone oil
- the following fine particles A, B and C were used as fine particle components.
- the fine particles A are silicone rubber powder I (average particle size: 4 ⁇ m);
- the fine particles B are silicone rubber powder II (average particle diameter: 2 ⁇ m);
- the fine particles C are urethane beads (average particle diameter: 15 ⁇ m).
- the fine particles D are silica particles (average particle diameter: 15 nm);
- the fine particles E are plastic beads (average particle diameter: 40 ⁇ m).
- a water-based release agent was prepared by dispersing the above-mentioned release agent and fine particle components in water in an amount of the parts shown in Tables 1 to 5 using a surfactant.
- water was added so that the wax component was 2% by weight, and the wax component and the fine particle component were prepared in the range of 100: 0 to 10:90.
- a predetermined amount (100 g / m 2 ) of a mold release agent sample was applied to the inner wall surface of an aluminum test mold heated to 50 ° C. by using a spray gun (W-101 manufactured by Anest Iwata).
- a predetermined amount of a mixture of starting materials for a molded product is poured into the mold, the mold upper lid is closed, and the molded product A is cured for 90 seconds ( 2) and a molded body B (FIG. 3) were obtained.
- Adhesiveness evaluation Adhesive: Chloroprene rubber adhesive, vinyl acetate adhesive Coating: Leather, cloth (gold width 3), PET film Coating using the above adhesive and coating in the combinations shown in Table 1. About 1 g of the adhesive is applied to each of the adhesive surface of (1) and the adhesive surface 8 (FIG. 2) or the adhesive surface 9 (FIG. 3) of the molded body A or the molded body B, and dried for about 100 seconds. Sticked (laminated). The adhesive was applied uniformly to the coating and the bonding surface of the molded body A or molded body B in a range of 2.5 cm ⁇ 7 cm.
- Comparative Example 6 since the particle size of the particles used is too small, the releasability and adhesiveness are poor. In Comparative Example 7, the particle size of the particles used was too large, and therefore the stability of the aqueous release agent as a dispersion solution was lacking.
Abstract
Description
(1)金型表面に、水系離型剤を塗布する離型剤塗布工程、
(2)成型体の支持体原料を前記金型内に注入する支持体原料注入工程、
(3)前記支持体原料を硬化および所望により発泡させる硬化発泡工程、
(4)前記硬化発泡工程で得られた成型体を金型から取出す成型体取出工程、
(5)前記(4)の工程に続いて、前記成型体に接着剤を塗布する接着剤塗布工程、および
(6)前記接着剤が塗布された成型体に被覆物を積層する被覆物積層工程。
本発明により、従来にはなかった新規な積層体の製造方法および積層体が提供される。
(1)金型表面に、水系離型剤を塗布する離型剤塗布工程、
(2)支持体原料を前記金型内に注入する支持体原料注入工程、
(3)前記支持体原料を硬化および所望により発泡させる硬化発泡工程、
(4)前記硬化発泡工程で得られた成型体を金型から取出す成型体取出工程、
(5)前記(4)の工程に続いて、前記成型体に接着剤を塗布する接着剤塗布工程、および
(6)前記接着剤が塗布された成型体に被覆物を積層する被覆物積層工程。
本発明の積層体の製造方法により、効率よく積層体を製造することができ、かつ、得られた積層体は、成型体と被覆物との接着性に優れている。従来技術では決して果たせなかった、離型性と接着性の両立が達成できる。
離型剤塗布工程で使用する水系離型剤は、微粒子を含有するものであり、少なくとも離型剤成分、微粒子および水を含有する。
水は、該少なくとも離型剤成分、微粒子以外の水系離型剤の残余の部分を構成する。
離型剤成分としては、従来から知られている水系離型剤に使用されているワックス、例えば、パラフィンワックス、ポリエチレンワックス、フィッシャートロプシュワックス、マイクロクリスタリンワックス、オレフィン重合体、高級脂肪酸エステル、酸化ワックス等、フッ素成分、例えば、パーフルオロ基含有炭化水素化合物等および/またはシリコーン成分、例えば、シリコーンオイル、シリコーンレジン、ストレートシリコーン、変性シリコーン等を使用するようにすればよい。フッ素成分およびシリコーン成分は離型性の向上のために使用される。ワックス成分の使用のみでもよいが、フッ素成分および/またはシリコーン成分と共に使用されてもよい。フッ素成分および/またはシリコーン成分は、ワックス成分に対して、通常、0~300重量%、好ましくは2~100重量%程度使用される。
支持体原料注入工程においては、支持体原料を前記金型内に注入する。
支持体原料としては、ウレタン樹脂原料を金型内で硬化し、樹脂成型体として得られるものが好ましい。ウレタン樹脂原料は種々知られており、市販もされている。それらの公知のものを使用すればよい。
上記した支持体原料の他、金型内に注入できる熱硬化性樹脂材料、例えば、エポキシ樹脂、フェノール樹脂、スチレン樹脂原料、繊維強化プリプレグ等の熱硬化性樹脂材料も使用可能である。
硬化発泡工程においては、金型内に注入された支持体原料を硬化および所望により発泡させる。硬化方法、硬化条件、または、発泡方法、発泡条件等は、特に限定されるものではく、従来から知られている方法、条件を適用するようにすればよい。
例えば、支持体原料として発泡性材料を使用している場合は、最終製品に要求される特性に合わせて発泡硬化させればよい。例えば、発泡ウレタン樹脂原料を使用した場合は、0.01~1.0g/cm3程度に発泡され、革巻きハンドル積層品の支持体に使用される。
次に、成型体取出工程においては、前記硬化発泡工程で得られた成型体を金型から取出す。金型からの取出しは、特に、制限されるものではなく、従来から公知の取出し方法を採用するようにすればよい。離型性を損なわない範囲で微粒子が添加されているため、成型体取出工程における成型体の離型性は、従来の離型性が確保された良好なものである。
接着剤塗布工程においては、前記成型体取出し工程に続いて、取出した成型体に接着剤を塗布する。取出した成型体を後処理することなく、金型から取出した成型体に、接着剤を直接塗布する。
塗布する接着剤は、支持体原料、後の被覆物積層工程で成型体に積層され接着剤に接着される被覆物の材料を考慮して適宜選択して使用すればよく、特に、制限されるものではない。例えば、成型体が発泡ポリウレタンで、被覆物が合成皮革または革、布、PETフィルムの場合、例えば、クロロプレンゴム系接着剤、酢酸ビニル系接着剤を使用することができる。
被覆物積層工程
被覆物積層工程においては、接着剤塗布工程で得られた接着剤が塗布された成型体の表面の少なくとも一部または全部に、被覆物、例えば、革、合成皮革、布、ガラス、金属、樹脂、炭素繊維、各種フィルム等、望ましくは、革、合成皮革、布、PETフィルム等のフィルムを積層する。積層する方法、条件等は従来から公知の方法、条件を採用するようにすればよい。
上記したように、被覆物、成型体材料、積層する方法を考えあわせ、使用する接着剤が選ばれる。
積層体
即ち、成型体、接着剤および被覆物が積層された積層体であって、前記成型体が、樹脂よりなる支持体、支持体表面に一部が埋め込まれた微粒子、該微粒子表面および支持体表面のそれぞれの少なくとも一部に付着した離型剤よりなることを特徴とする、前記積層体が提供される。
本発明で提供される積層体の構造の概略断面図を図1に示す。
離型剤として以下のワックスA、B、C、フッ素、シリコーンを使用した。
ワックスA:自社製造ワックス混合物;主成分パラフィンワックス
ワックスB:自社製造ワックス混合物;主成分マイクロクリスタリンワックス
ワックスC:自社製造ワックス混合物;主成分マイクロクリスタリンワックス
フッ素:自社製造フッ素製品
シリコーン:変性シリコーンオイル
微粒子Aは、シリコーンゴムパウダーI(平均粒径:4μm);
微粒子Bは、シリコーンゴムパウダーII(平均粒径:2μm);
微粒子Cは、ウレタンビーズ(平均粒径:15μm)。
微粒子Dは、シリカ粒子(平均粒径:15nm);
微粒子Eは、プラスチックビーズ(平均粒径:40μm)。
50℃に加温したアルミニウム製試験用金型の内壁面に、離型剤サンプルをスプレーガン(アネスト岩田社製:W-101)を用いて所定量(100g/m2)塗布した。所定量の成型体原料撹拌混合物(イソシアネートおよびポリオールを50kg/m3になるように混合したもの)を前記金型内に注入し、金型上蓋を閉じ、90秒硬化させることで成型体A(図2),および成型体B(図3)を得た。
製造した離型剤サンプルを室温で1日間静置した後、離型剤サンプルの液状態を目視観察した。
液安定性は配合成分が均一に分散していれば「○」、不均一になっていたら「×」とランク付けした。
樹脂硬化後、金型の上蓋開放にかかる荷重をプッシュプルスケールで測定した。
結果を表1~表3に示す。
離型性は60N未満で「○」(良好)、60N以上で「×」(不良)とランク付けした。
接着剤:クロロプレンゴム系接着剤、酢酸ビニル系接着剤
被覆物:革、布(金巾3号)、PETフィルム
表1に示した組合せで上記接着剤、被覆物を使用し、被覆物の接着面および成型体Aまたは成型体Bの接着面8(図2)または接着面9(図3)に接着剤をそれぞれ約1g塗布し、100秒程乾燥させた後に被覆物と成型体を張り付けた(積層した)。
接着剤は被覆物および成型体Aまたは成型体Bの接着面に2.5cm×7cmの範囲に均一になるよう塗布した。
室温で約12時間静置後、被覆物の端部に輪状の金具を取り付け、プッシュプルスケールを用いて被覆物を成型体から剥離する際に要する荷重を測定した。
結果を表1~5中に示した。
接着性は、接着力が10N以上で「○」(良好)、10N未満で「×」(不良)とランク付けした。
比較例1、3、4、5、8は、微粒子を使用してないので、被覆物の成型体への接着力に劣る。比較例8においては、離型性にも劣る。
比較例2は、ワックス成分に対して微粒子成分の量が多すぎるため、被覆物の成型体への接着力は優れるものの、製造工程における成型体の離型性に劣る。
比較例6は、使用した粒子の粒径が小さすぎるため、離型性、接着性に劣る。
比較例7は、使用した粒子の粒径が大きすぎるため、分散溶液である水系離型剤の安定性に欠けるものである。
2:支持体
3;微粒子
4:離型剤
5:成型体
6:接着剤
7:被覆物
8:接着面
9:接着面
Claims (11)
- 成型体、接着剤および被覆物が積層された積層体であって、前記成型体が、樹脂よりなる支持体、支持体表面に一部が埋め込まれた微粒子、該微粒子表面および支持体表面のそれぞれの少なくとも一部に付着した離型剤よりなることを特徴とする、前記積層体。
- 微粒子が、100nm~20μmの粒子径を有する、請求項1に記載の積層体。
- 被覆物が革、合成皮革、布、ガラス、金属、樹脂、炭素繊維、またはフィルムである、請求項1または2に記載の積層体。
- 以下の製造工程(1)~(6)を経ることを特徴とする、積層体の製造方法:
(1)金型表面に、微粒子を含有する水系離型剤を塗布する離型剤塗布工程、
(2)成型体の支持体原料を前記金型内に注入する支持体原料注入工程、
(3)前記支持体原料を硬化および所望により発泡させる硬化発泡工程、
(4)前記硬化発泡工程で得られた成型体を金型から取出す成型体取出工程、
(5)前記(4)の工程に続いて、前記成型体に接着剤を塗布する接着剤塗布工程、および
(6)前記接着剤が塗布された成型体に被覆物を積層する被覆物積層工程。 - 水系離型剤が、離型剤成分、微粒子および水を含有する、請求項4に記載の積層体の製造方法。
- 離型剤がワックスを含有する、請求項5に記載の積層体の製造方法。
- ワックスと微粒子が、97:3~20:80(ワックス:微粒子)の重量比で含有されている、請求項6に記載の積層体の製造方法。
- 微粒子が、100nm~20μmの粒子径を有する、請求項5~7いずれかに記載の積層体の製造方法。
- 被覆物が革、合成皮革、布、ガラス、金属、樹脂、炭素繊維、またはフィルムである、請求項4~8いずれかに記載の積層体の製造方法。
- 請求項4~9いずれかに記載の製造方法により得られた積層体。
- 以下の製造工程(1)~(6)を経ることを特徴とする、請求項1~3いずれかに記載の積層体:
(1)金型表面に、水系離型剤を塗布する離型剤塗布工程、
(2)成型体の支持体原料を前記金型内に注入する支持体原料注入工程、
(3)前記支持体原料を硬化および所望により発泡させる硬化発泡工程、
(4)前記硬化発泡工程で得られた成型体を金型から取出す成型体取出工程、
(5)前記(4)の工程に続いて、前記成型体に接着剤を塗布する接着剤塗布工程、および
(6)前記接着剤が塗布された成型体に被覆物を積層する被覆物積層工程。
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