JP7127982B2 - Decorative molding using embroidered artificial leather and its manufacturing method - Google Patents

Description

TECHNICAL FIELD The present invention relates to a decorative molding in which embroidered artificial leather is integrated with the surface of a resin molding.

A decorative molding is known in which artificial leather is integrated with the surface of a resin molding. Such a decorative molded article is manufactured by insert molding (also referred to as in-mold molding) in which artificial leather or a preform molded from it is placed in a mold cavity and injection molded. It is manufactured by manually attaching a preform molded body to the surface of a molded resin molded body.

For example, Patent Literature 1 below discloses that an insert material having a suede-like or silver-like tactile feel in which a reinforcing sheet is bonded to the back surface of artificial leather is preformed into a three-dimensional shape, punched into a required shape, and injected into an injection molding die. Disclosed is a molded body obtained by molding a resin molded body by injecting a molten resin from the reinforcing sheet side of the insert material after being placed in a cavity in a mold and integrating the insert material on the surface thereof.

By the way, a technique of applying embroidery to artificial leather is known. However, when the artificial leather is embroidered, there are problems such as tearing at the embroidered seams and a significant decrease in strength. As a technique for solving such problems, Patent Document 2 below discloses that ultrafine fibers of 0.8 denier or less and a hard-twisted yarn fabric having a twist number of 1200 T/m to 4000 T/m are non-separably and integrally entangled, Disclosed is a suede-like artificial leather that is held by an elastic polymer and that is embroidered on the surface of the napped surface of the napped and dyed napped sheet.

JP 2006-281592 A JP-A-10-273886

Embroidered artificial leather, which is an artificial leather with embroidery, is placed in a cavity in an injection mold, and injection molding is performed to manufacture a decorative molded product that integrates the artificial leather with the surface of a resin molded product by insert molding. However, due to the resin pressure of the molten resin of injection molding, the resin penetrates the embroidered seams of the embroidered artificial leather, causing resin leakage on the embroidered surface, and the artificial leather stretching due to the resin pressure. The fabric may tear at the seams or wrinkle due to the difference in elongation between the embroidered part and the non-embroidered part.

The present invention provides a decoration using embroidered artificial leather that suppresses resin leakage on the embroidered surface, tearing at seams, and wrinkles when used for insert molding. An object is to provide a molded article .

One aspect of the present invention is a laminate obtained by laminating an artificial leather, an adhesive layer, and a backer layer in order from the surface side , obtained by insert molding using embroidered artificial leather. It is a decorated molded body . According to such an embroidered artificial leather, since the adhesive layer and the backer layer are provided, when it is used for insert molding, the embroidered surface may leak resin, tear at the seams, and the embroidered part may be damaged. It is possible to suppress the occurrence of wrinkles due to the difference in elongation between the embroidered portion and the portion other than the embroidered portion.

The backer layer comprises at least one sheet selected from the group consisting of non-woven fabrics, woven fabrics, knitted fabrics and artificial leather base fabrics, in particular, artificial leather obtained by imparting macromolecular elasticity to non-woven fabrics of ultrafine fibers having an average fineness of 1 dtex or less. It is preferable that the base fabric is included because the effect of suppressing resin leakage is high.

Another aspect of the present invention includes a step of manufacturing a laminate by laminating artificial leather, an adhesive, and a backer material in order and pressing them, and making the laminate so that the embroidery thread penetrates the laminate. , applying embroidery, and a method for manufacturing an embroidered artificial leather. According to such a manufacturing method, the embroidered artificial leather as described above can be easily manufactured.

In another aspect of the present invention, there is provided a step of accommodating any of the above-mentioned embroidered artificial leather or a preform molded body thereof in a cavity of an injection molding die, and injecting a molten resin into the injection molding die. and forming a decorative molded article by integrating the embroidered artificial leather on the surface of the injection molded article to be molded. According to this method of manufacturing a decorative molded product, the embroidered surface is less likely to leak resin, is less likely to be torn at the seams, and is less likely to be wrinkled. A molded body is obtained.

According to the present invention, it is possible to provide an embroidered artificial leather which, when used for insert molding, suppresses resin leakage on the embroidered surface, tears at seams, and wrinkles.

FIG. 1 is a schematic diagram for explaining the embroidered artificial leather of the embodiment. FIG. 2 is an explanatory diagram for explaining each step of hot press molding for molding a preform molded body. FIG. 3 is an explanatory diagram illustrating a method of manufacturing a decorative molded body by insert molding. FIG. 4 is a schematic diagram for explaining the decorative molding of the embodiment.

The embroidered artificial leather of this embodiment will be described with reference to FIG.

1A and 1B are schematic diagrams for explaining the embroidered artificial leather 5 of the present embodiment, where (a) is a top view and (b) is a cross-sectional view taken along the line B-B' of (a). In FIG. 1, 1 is an artificial leather, 2 is an adhesive layer, 3 is a backer layer, and 4 is embroidery. In the embroidered artificial leather 5, a floral pattern is formed as the embroidery 4 with a large number of embroidery threads. Moreover, the artificial leather 1 and the backer layer 3 form a laminated body bonded with the adhesive layer 2 .

As shown in FIG. 1(b), the embroidery 4 is formed so that the embroidery thread penetrates the laminate composed of the artificial leather 1, the adhesive layer 2, and the backer layer 3. As shown in FIG.

In the embroidered artificial leather 5, the backer layer 3 adhered to the artificial leather 1 with the adhesive layer 2 prevents the artificial leather 1 from stretching. This prevents seams from tearing due to stretching of the artificial leather. In addition, in insert molding, the backer layer 3 makes it difficult for the molten resin to enter the holes of the seams forming the embroidery 4 .

As the artificial leather, raised artificial leather obtained by raising the surface of artificial leather greige obtained by imparting polymeric elastic material to non-woven fabric, and grained artificial leather obtained by forming a resin layer on the surface of artificial leather greige are used.

Specific examples of resins forming fibers of nonwoven fabric of artificial leather include polyethylene terephthalate (PET), modified PET, polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polytriethylene terephthalate, and polyhexamethylene. Aromatic polyester resins such as terephthalate, polypropylene terephthalate, and polyethylene naphthalate; Polyester resin; polyamide resin such as polyamide 6, polyamide 66, polyamide 610, polyamide 10, polyamide 11, polyamide 12, polyamide 6-12; polypropylene, polyethylene, polybutene, polymethylpentene, chlorine-based polyolefin, ethylene vinyl acetate Polyolefin-based resins such as polymers and styrene-ethylene copolymers; modified polyvinyl alcohol-based resins formed from modified polyvinyl alcohol containing 25 to 70 mol% of ethylene units; and polyurethane-based elastomers, polyamide-based elastomers, and polyester-based resins. Examples include thermoplastic resins such as crystalline elastomers such as elastomers. These may be used alone or in combination of two or more. In addition, the fineness of the fibers forming the nonwoven fabric is not particularly limited. It may be fineness.

Specific examples of the elastic polymer applied to the nonwoven fabric include various polyurethanes such as polycarbonate-based polyurethane, polyester-based polyurethane, and polyether-based polyurethane; Synthetic rubber etc. are mentioned. Among these, polyurethane is preferable because of its excellent adhesion and mechanical properties. The content of the elastic polymer is preferably 0.1 to 50% by mass, more preferably 5 to 35% by mass, and particularly preferably 8 to 30%. If the content of the elastic polymer is too high, the formability tends to be lowered.

Raised artificial leather can be obtained by raising one surface of artificial leather greige obtained by imparting high molecular weight elastic material to non-woven fabric. Further, grain-finished artificial leather can be obtained by laminating a grain-like resin layer on one surface of an artificial leather greige obtained by imparting a polymeric elastic material to a non-woven fabric. As a method of forming the napped artificial leather, there is a method of forming a raised suede-like or nubuck-like decorative surface by buffing the surface of the artificial leather greige. The buffing process is a process in which the surface of the raw artificial leather is rubbed with sandpaper, a brush, or the like to raise the fibers. In addition, as a method of forming grain artificial leather, a method of forming a grain-like resin layer containing polymeric elastic material such as polyurethane on the surface of artificial leather greige by a method such as a dry surface forming method or a direct coating method. are mentioned. As the polymeric elastic material for forming the grainy resin layer, it is possible to use polyurethane, acrylic elastomers, and the like, which have conventionally been used to form grainy resin layers.

As the backer material for forming the backer layer, entangled nonwoven fabrics, papermaking nonwoven fabrics, woven fabrics, knitted fabrics, sheets containing fiber materials such as artificial leather base fabrics, especially, nonwoven fabrics of ultrafine fibers with an average fineness of 1 dtex or less and polymer It is preferable to use an artificial leather base fabric to which an elastic body has been added, because it is highly effective in suppressing resin leakage. Although the thickness of the backer layer is not particularly limited, it is preferably 0.1 to 1 mm, more preferably 0.35 to 0.8 mm.

In addition, the adhesive that forms the adhesive layer is not particularly limited, but hot-melt adhesives such as hot-melt polyurethane, polyvinyl butyral (PVB) adhesives, and the like can be mentioned. Although the thickness of the adhesive layer is not particularly limited, it is preferably 0.03 to 0.3 mm, more preferably 0.05 to 0.2 mm.

The embroidered artificial leather as described above is manufactured by sequentially laminating the artificial leather, the adhesive film, and the backer material and pressing them to produce a laminate, and the artificial leather is formed so that the embroidery thread penetrates the laminate. It can be manufactured by applying embroidery that appears on the surface of the leather.

The type of embroidery thread used for embroidery is not particularly limited, but examples include polyester thread and rayon thread. Among these, polyester yarn is preferred because it has a high elongation (for example, about 16%) and is more easily elongated than rayon yarn (for example, about 14%).

Further, the embroidery area can be, for example, 5 to 80%, and the embroidery density can be exemplified in the range of about 10 to 300 lines/cm ² .

Next, a decorative molded body obtained by integrating the above-described embroidered artificial leather with the surface of a resin molded body will be described. From the standpoint of productivity, the method for producing the decorative molded article is to place the embroidered artificial leather or its preform molded article into the cavity of the injection molding die, and inject the molten resin into the injection molding die. Therefore, a manufacturing method employing insert molding is preferable, in which the embroidered artificial leather is integrated with the surface of the injection-molded article to be molded.

As a method for producing a decorative molded article of the present embodiment, after manufacturing a preform molded article by preforming an embroidered artificial leather in a shape that matches the cavity of the mold used for injection molding, the preform is placed in the mold cavity. A manufacturing method by insert molding in which a molded body is accommodated and injection molded will be described.

FIG. 2 is an explanatory diagram for explaining each step of hot press molding for molding a preform molded body of embroidered artificial leather. In FIG. 2, 5 is an embroidered artificial leather, 21 is a male mold for heat press, 22 is a female mold for heat press, 21a is the core of the male mold 21, and 22a is the cavity of the female mold 22. . Further, 9 is a preform molded body before trimming, 10 is a preform molded body, and 8 is an unnecessary portion of the trimmed embroidered artificial leather 5 .

First, the embroidered artificial leather 5 is arranged between the female mold 22 and the male mold 21, as shown in FIG. 2(a). At this time, the female mold 22 and the male mold 21 are heated to a predetermined temperature that softens the embroidered artificial leather 5 . Then, as shown in FIG. 2(b), the female mold 22 and the male mold 21 are clamped with a predetermined pressure. At this time, the embroidered artificial leather 5 is sandwiched between the core 21a of the male mold 21 and the cavity 22a of the female mold 22 and shaped.

Then, as shown in FIG. 2(c), the female mold 22 and the male mold 21 are opened and cooled to obtain the preform molded body 9 before trimming. Then, the preform molded body 9 before trimming is taken out from the female mold 22 and the male mold 21, and the unnecessary part 8 of the embroidered artificial leather 5 is trimmed to obtain the preform molded body 10. FIG.

The preform molded body thus obtained is integrated with the surface of the resin molded body to form a decorative molded body. As a method for integrating the preform molded body with the resin molded body, insert molding is preferably used in which the preform molded body is integrated with the resin molded body molded by injection molding. With reference to FIG. 3, a method of manufacturing a decorative molding 20 obtained by integrating the embroidered artificial leather 5 on the surface of the injection-molded resin molding 7 by insert molding will be described.

In FIG. 3, 10 is a preform molding of embroidered artificial leather, 12a is a movable side mold, 12b is a fixed side mold, 13 is an injection part main body of an injection molding machine, 13a is a nozzle, 13b is a cylinder, and 13c is an in-line screw. , 14 is a gate, 7 is a resin molding, 7a is a molten resin, and 20 is a decorative molding. The movable side mold 12a and the fixed side mold 12b are paired to form an injection mold 12 that forms a cavity c. In this embodiment, the movable side mold 12a is a female mold for injection molding, and the fixed side mold 12b is a male mold for injection molding.

First, as shown in FIG. 3(a), the preform molding 10 of embroidered artificial leather is accommodated in the concave portion for forming the cavity of the movable side mold 12a. At this time, the artificial leather 1 side of the embroidered artificial leather 5 faces the recess for forming the cavity, and the backer layer 3 side is arranged in such a direction that the melted resin is filled. In the present embodiment, an example of using a preform molded body of embroidered artificial leather molded in advance so as to conform to the shape of the cavity of the injection mold will be described, but the embroidered artificial leather is inserted as it is. It may be subjected to molding.

Next, as shown in FIG. 3B, the movable side mold 12a and the fixed side mold 12b are clamped. Then, as shown in FIG. 3(c), the molten resin 7a is filled into the cavity c formed in a state where the movable side mold 12a and the fixed side mold 12b are clamped. Specifically, the injection section 13 of the injection molding machine is advanced, the nozzle 13a is brought into contact with the gate 14 formed in the fixed side mold 12b, and the molten resin 7a is injected by the in-line screw 13c in the cylinder 13b to melt the resin. The cavity c is completely filled with the resin 7a at a predetermined filling pressure.

Injection molding conditions are conditions that allow complete filling according to the thermal properties and melt viscosity of the resin to be injected, the shape of the molded body, and the thickness of the resin (resin temperature, mold temperature, injection pressure, injection speed, retention after injection pressure, cooling time) are appropriately set.

Specific examples of injection-molded resins include ABS resins, acrylic resins such as PMMA resins, polystyrene resins, polycarbonate resins, polyolefin resins such as polypropylene, polyethylene terephthalate (PET), and polybutylene terephthalate. polyester resins such as (PBT), various polyamide resins, COP resins, and the like. Moreover, these may be compound products containing fillers or the like, or mixed products obtained by alloying or blending a plurality of types of resins. These are appropriately selected depending on the application. In addition, the thickness of the injection molded body to be molded is not particularly limited, and is appropriately selected according to the application and moldability. is preferred.

Then, in the cooling step, the resin molded body 7 is molded in a cavity c formed by clamping the movable side mold 12a and the fixed side mold 12b, and the embroidered artificial leather plastic is laminated on the resin molded body 7. After cooling for a predetermined time in a state in which the reformed molded body 10 is integrated, as shown in FIG. A decorative molding 20 is taken out, in which the molded body 7 and the preform molded body 10 of the embroidered artificial leather laminated on the resin molded body 7 are integrated.

FIG. 4 shows the decorative molding 20 manufactured in this manner. 4A and 4B are schematic diagrams for explaining the decorative molded body 20 obtained by insert molding as described above, where (a) is a top view and (b) is a cross-sectional view of the BB' cross section of (a). is. The decorative molding 20 is formed by integrating an embroidered artificial leather 5, which is obtained by applying embroidery 4 to a laminate in which an artificial leather 1, an adhesive layer 2, and a backer layer 3 are laminated in order, on the surface of a resin molding 7. formed by The embroidery 4 is formed so that the embroidery thread penetrates the laminate composed of the artificial leather 1 , the adhesive layer 2 and the backer layer 3 . According to the decorative molding 20 obtained by insert molding using such an embroidered artificial leather 5, the backer layer 3 suppresses the artificial leather 1 from stretching during the insert molding. Therefore, it is possible to suppress the occurrence of tearing in the seams due to stretching of the artificial leather 1 due to resin pressure from insert molding. Further, the existence of the backer layer 3 makes it difficult for molten resin to enter the holes of the seams forming the embroidery 4 during insert molding. In addition, since the artificial leather 1 is adhered and supported by the backer layer, it is possible to suppress the occurrence of wrinkles due to the difference in elongation between the part on which the embroidery 4 is formed and the part on which the embroidery 4 is not formed. be.

EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples. In addition, the scope of the present invention is not limited at all by the examples.

(Example 1)
140 mm long x 140 mm wide, 0.5 mm thick, 0.9 dtex fineness, _Tg 100 ° C. An artificial leather base fabric with an apparent density of 0.50 g / cm ³ containing ultrafine fibers of modified PET and polyurethane, As a grain layer, a grain-finished artificial leather was prepared by forming a grained dry surface layer having a thickness of 0.11 mm and using a silicone-modified polycarbonate-based polyurethane resin as the surface layer. The 50% elongation stress at 20° C. in the vertical direction of this grained artificial leather was 170 N/25 mm.

Also, a polyurethane hot-melt film (Tg 100° C.) having a length of 140 mm and a width of 140 mm and a thickness of 50 μm was prepared. Furthermore, as a backer material, an artificial leather base fabric having an apparent density of 0.50 g/cm ³ and containing ultrafine fibers of modified PET having a fineness of 0.9 dtex and a _Tg of 100° C. and polyurethane was prepared. The 50% elongation stress at 20° C. in the warp direction of the artificial leather base fabric was 140 N/25 mm.

Then, the artificial leather with grain, the polyurethane hot-melt film, and the backing material were stacked in order and adhered by hot pressing to obtain a laminate.

Then, the laminate was embroidered with a floral pattern as shown in FIG. 1 so that the embroidery thread penetrated the laminate. The number of needles for embroidery was 50 to 100/cm ² and the embroidery area was 12 cm ² . Embroidered artificial leather A was obtained by embroidering the laminate in this manner.

Then, the embroidered artificial leather A is hot-press molded at a mold temperature of 100° C. and a press pressure of 100 kg/cm ² using a press mold for shaping into a shape corresponding to the injection mold described later. , to form a preform. At this time, the preform molding of the embroidered artificial leather A retained a firm shape according to the pattern.

Insert molding was performed using the embroidered artificial leather A trimmed into a predetermined shape. Specifically, in the state where the movable side mold and the fixed side mold of the injection mold mounted on the electric injection molding machine (SE-100 manufactured by Sumitomo Heavy Industries, Ltd.) are opened, The embroidered artificial leather A was positioned and arranged on the cavity forming surface of the movable side mold. Then, the movable side mold and the fixed side mold were clamped. The shape of the cavity of the injection mold was 2 mm in thickness, 80 mm in diameter, and 10 mm in height, with a circular outer periphery and a trapezoidal cross section as shown in FIG.

Then, under the conditions of a resin temperature of 230° C. and a mold temperature of 40° C., the ABS resin was injected to fill the cavity. After complete filling, the mold was opened after cooling. In this way, a decorative molded article in which the embroidered artificial leather A was integrated with the surface of the ABS resin molded article was obtained. The obtained decorative molding had a good appearance with no resin leakage, breakage, or wrinkles.

(Example 2)
A decorative molded article was obtained in the same manner as in Example 1, except that a papermaking nonwoven fabric was used as the backer material instead of the artificial leather base fabric. The obtained decorative molding had a good appearance with no resin leakage, breakage, or wrinkles.

(Example 3)
A decorative molded article was obtained in the same manner as in Example 1, except that a polyvinyl butyral (PVB) adhesive was used in place of the polyurethane hot-melt film. The obtained decorative molding had a good appearance with no resin leakage, breakage, or wrinkles.

(Example 4)
A decorative molded article was obtained in the same manner as in Example 1, except that a polyvinyl butyral (PVB) adhesive was used in Example 2 instead of the polyurethane hot-melt film. The obtained decorative molding had a good appearance with no resin leakage, breakage, or wrinkles.

(Comparative example 1)
A grained artificial leather similar to that of Example 1 was prepared. Then, a floral pattern was embroidered in the same manner as in Example 1 so that the embroidery thread penetrated the grained artificial leather. Thus, an embroidered artificial leather B was obtained.

In the same manner as in Example 1, except that the embroidered artificial leather B was used instead of the embroidered artificial leather A, the embroidered artificial leather B was integrated with the surface of the ABS resin molding by performing insert molding. A decorative molding was obtained. In the obtained decorative molding, leakage of resin was observed from the needle holes of the embroidery, tears were observed between the needle holes, and wrinkles were generated.

1 artificial leather 2 adhesive layer 3 backer layer 4 embroidery 5 embroidered artificial leather 7 resin molded body 10 embroidered artificial leather preform molded body 12 injection mold 20 decorative molded body c cavity

Claims (3)

A decorative molding that is an insert molding, comprising a resin molding and an embroidered artificial leather laminated on the surface of the resin molding,
The embroidered artificial leather is
A laminate in which an artificial leather, an adhesive layer, and a backer layer are laminated in order from the surface side,
The artificial leather includes an artificial leather greek obtained by imparting a first polymer elastic body to a first nonwoven fabric, and a napped artificial leather obtained by raising the surface of the artificial leather greek, or a resin on the surface of the artificial leather greek It is a layered grained artificial leather,
The backer layer comprises a fiber sheet containing at least one selected from the group consisting of a second nonwoven fabric, a woven fabric, and a knitted fabric,
A decorative molding characterized in that all embroidery threads of seams have embroidery applied so as to penetrate the laminate. 2. The decorative molded article according to claim 1, wherein the backer layer includes an artificial leather base fabric obtained by imparting a second elastic polymer to the second nonwoven fabric, which is a nonwoven fabric of ultrafine fibers having an average fineness of 1 dtex or less. A laminate in which artificial leather, an adhesive layer, and a backer layer are laminated in order from the surface side, and embroidery is applied so that all the embroidery threads of the seams penetrate the laminate. a step of preparing an artificial leather;
a step of housing the artificial leather with embroidery or a preform molded body thereof in the cavity of the injection molding mold so that the side of the artificial leather faces the cavity surface of the injection molding mold;
A step of injecting a molten resin into the injection mold to form a decorative molded body in which the embroidered artificial leather is integrated on the surface of the injection molded body to be molded,
The artificial leather includes an artificial leather greek obtained by imparting a first polymer elastic body to a first nonwoven fabric, and a napped artificial leather obtained by raising the surface of the artificial leather greek, or a resin on the surface of the artificial leather greek It is a layered grained artificial leather,
A method for producing a decorative molded article, wherein the backer layer includes at least one fiber sheet selected from the group consisting of a second nonwoven fabric, a woven fabric, and a knitted fabric.

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