JPS6040537B2 - fabric for molding - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a fabric for molding, and more specifically, a composite sheet is formed by laminating a fabric and a plastic sheet or by subbing plastic on the back side of the fabric, The present invention relates to a molding cloth used for integral molding of a cloth band and plastics, such as manufacturing three-dimensional molded products having various curved surfaces from the composite sheet.

Conventionally, it is known that interior materials for vehicles and houses are manufactured by molding plastic sheets into three-dimensional structures with various curved surfaces.However, when molding plastic sheets alone, the appearance and feel are flat. , only those with a cold and hard feel can be obtained.

In order to solve these drawbacks, fabric strips have been attached to the surface of the single plastic sheet molded product, but this method has problems with the systematic elongation of the fabric and the fibers or threads that make up the fabric. Since the elongation is not sufficient, in order to attach the sweetfish along the three-dimensional curve, it is necessary to cut and sew pieces of cloth in advance and paste them together, which is a long and complicated process. The external appearance of the above composite molded product also has poor commercial value. Also, the appearance,
In order to improve the feel, some attempts have been made to bond the cloth to a plastic sheet and then mature it, but the molding requires excessive pressure and temperature, and the cloth has a large resilience after molding, making it difficult to peel off. There are problems such as deformation of the composite molded product. This is thought to be due to the high deformation stress and low thermoplasticity of the fabric band under the molding conditions. For this reason, if a sufficient temperature is applied to allow the fabric belt to ripen, the fibers will be compressed and will not recover, resulting in a disadvantage that the appearance and feel will be significantly deteriorated. For this reason, attempts have been made to use nonwoven fabrics mainly made of thermoplastic fiber materials with a low softening point, but nonwoven fabrics have a paper-like surface and lack a luxurious feel.

The inventors of the present invention have arrived at the fabric of the present invention as a result of intensive research in order to obtain a fiber sheet suitable for use in composite molding materials that does not have the above-mentioned drawbacks. That is, in the present invention, the back surface portion is mainly composed of fiber A having a softening point of 80 to 22,000 and a breaking elongation of 50% or more (excluding fibers made of polyester mainly composed of ethylene terephthalate repeating units), and the surface portion is This is a fabric belt for molding, characterized in that it is mainly composed of high softening point fiber B having a softening point 20 degrees higher than that of fiber A.

The term "back surface part" used in relation to the molding fabric of the present invention is:
It refers to the ground part in pile knitted fabrics, the part that exists at the bottom of the raised part in raised woven and knitted fabrics, the part that mainly consists of the ground yarn part in other woven and knitted fabrics, the bottom layer of nonwoven fabrics, etc. It shows the pile part of pile knitted fabrics, the raised part of raised woven and knitted fabrics, the surface layer part of other woven and knitted fabrics, and the surface layer part of nonwoven fabrics.

The Futake of the present invention usually has a low softening point and high elongation fiber A.
(hereinafter abbreviated as A-fiber) is laminated by laminating a plastic sheet or plate on the side of the fabric, or the back side of the fabric is undercoated with plastic to form a composite sheet, which is then molded. The operation is simple, and it is possible to obtain a molded article at low temperature and low pressure, and the high softening point fiber B (hereinafter abbreviated as B fiber) on the surface of the fabric retains its fiber shape.

In addition, since the back surface of Nunobata has sufficient elongation under molding conditions, it does not cause delamination or deformation even in three-dimensional molded products with curved surfaces, making it an integrally molded product with excellent appearance and texture. is obtained. To explain the cloth pad of the present invention in more detail, in the cloth pad of the present invention, the back surface portion for cloth is mainly composed of A fibers, and the regular surface portion of the cloth is mainly composed of B fibers, but at least under molding conditions. It is important that when the A fibers are stretched along the curved surface of the molded product, they can bear the load and stretch sufficiently. Fibers with sufficient elongation even at room temperature, such as fibers with a softening point and high elongation, are used. For example, when heating 150qo, 20
Fibers exhibiting elongation of 0% or more, particularly 300% or more are preferred. On the other hand, it is important that the high softening point binding material does not lose its fiber form under the molding conditions, and that it has a structure that is bent in advance in a plane or three-dimensional manner within the fabric so that it does not bear any load. For example, in a pile or raised structure of a woven or knitted fabric, a preferable example is when the structure that becomes the ground part is mainly composed of A fibers, and the pile or raised part is mainly composed of B fibers. It may also be a fabric of a three-dimensional structure such as tissue. However, in order to obtain two-dimensional (two-dimensional) elongation properties, knitted fabrics are particularly preferred, and knitted fabrics with surface effects such as pile or napping are particularly preferable because the see-through of the fabric at bends is less noticeable. For example, circular knit single velor, tricot pile green space, etc. are more preferable. Furthermore, knitted fabrics in which A fibers are used for the ground warp and ground weft and B fibers are used for the pile or wool warp are also effective because two-dimensional elongation can be obtained. A fibers include polyamide, copolyamide, polyester (
(excluding polyesters mainly consisting of ethylene terephthalate repeating units), copolymerized polyesters, polyacrylonitrile, copolymerized polyacrylonitrile, polyolefins, polyvinyl chloride, polyvinylidene chloride, polyclar, and other thermoplastic polymers alone, in mixtures, or in combination. Examples include fibers manufactured by weaving yarn, but they usually have a softening point of 80~80.
Preferably, the fiber is 220qC, more preferably 100 to 200oo, and the fiber is spun to have an elongation of at least 50%.

Furthermore, it is important to select the fiber appropriately depending on the combination with the B fiber. The difference in softening point between the A fiber and the B fiber is usually preferably at least 20% or more, more preferably 50oo or more.

In addition, the A fiber is a fiber having a breaking elongation of at least 50%, preferably 100% or more, particularly preferably 150% or more, and a softening point of 80 to 22,000. For this purpose, fiber-forming thermoplastic polymers such as polyester elastic fibers, polyurethane elastic fibers, polypropylene, polyesters (excluding polyesters mainly composed of ethylene terephthalate repeating units), and polyamides are usually heated at a rate of about 1000 to 500 impressions/min. Examples include highly oriented undrawn fibers obtained by high-speed spinning, and semi-drawn fibers obtained from ordinary paper yarn. A
Particularly preferable fibers are the above-mentioned highly oriented undrawn fibers or semi-drawn fibers. B fibers can also be mixed with A fibers in an amount and usage that do not inhibit the effects of the present invention. For example, a covered yarn in which A fibers are covered with B fibers is exemplified.

B fibers include natural fibers such as cotton, rayon, hemp, and wool; synthetic fibers such as polyester, polyamide, aramid, and phenol/formaldehyde; thermoplastic synthetic fibers treated with melt-resistant melamine resin, etc.; Examples include mixed fibers and mixed systems.

Further, the softening point is preferably at least 170 qo or higher, particularly preferably 22,000 or higher.
The above A fibers and/or B fibers, particularly the B fibers, have flame retardant properties, antistatic properties, stain resistance, dyeability, water resistance, water repellency, oil properties,
Modification treatments such as anti-pilling properties, antibacterial properties, elasticity, flexibility, heat and light stability, etc., or coloring may be applied, or processing that imparts these properties after striped weaving, or polyurethane, etc. Coloring by elastic processing, dyeing, textile printing, etc. may be performed.

Each fabric thus obtained is laminated by laminating the A fiber (back side) side with a plastic sheet, or the A fiber (back side) side of the fabric is undercoated with plastic to form a composite sheet. It is integrally molded into the desired shape by summer molding, press molding, etc. In addition, lamination with plastics can be done by extruding melt polymer and laminating it on the back side of the fabric.
Although this can be done by overlapping and pressing a plastic sheet on the back side of the fabric, it is usually done by adhering using an adhesive. Examples of plastic sheets include plastic sheets and plates, and examples of plastics include a wide range of common thermoplastic materials such as vinyl chloride resin, ABS resin, and polyolefin resin. The material is selected from materials having a forming temperature such that the dotted line is thermoformed with sufficiently low force and the high softening point fibers are unlikely to be permanently deformed by the temperature and pressure during processing. The adhesive to be used is one that has a high affinity with A fibers and plastic sheets and has sufficient adhesive strength. Generally, adhesives that are thermoplastic during molding are used, but adhesives that harden due to the heat during molding can also be used. Of course, any adhesive can be used, such as film, non-woven fabric, powder, solution, melt, etc., but it is possible to use film, non-woven fabric, powder, molten, etc. to bond the fabric sheet and plastic sheet together during molding. It is also possible to mold while adhering.

Preferred adhesives include polyurethane adhesives, polyvinyl adhesives, carboxyl-modified olefin resins, carboxy-modified synthetic rubbers, copolymerized polyamide resins, copolymerized polyester resins, Q-olefin/vinyl acetate copolymer resins, and vinyl chloride resins. However, it is not limited to these. Additionally, plasticizers, retardants, antistatic agents, inorganic fillers, stabilizers, adhesion improvers, foaming agents, and the like may be added to the plastic sheet material and adhesive, if desired. Molded products made integrally using the fabric of the present invention have excellent appearance and texture, and are therefore suitable for use in automobiles, ships, wheels, aircraft and other interior parts, furniture, building materials, interior parts, toys, etc. be.

The present invention will be explained below with reference to Examples. The Europeanization point of the fiber in the present invention refers to the temperature at which the fiber becomes easily deformed rapidly when heated at a constant rate, and was measured by the following method. 0 for one fiber or yarn with textbook facing east
．． When a load of 0.01 g/d is applied and the temperature is increased at a rate of 1° C./min in air, contraction occurs when a certain temperature range is reached, but the shrinkage is performed so that the load remains constant.

The relationship between the dimensional change of the sample fiber and temperature at this time was plotted as a graph, and the temperature at which the change occurred rapidly was defined as the softening point. Further, the cutting elongation of the elastic yarn was measured by the following method.

Using a constant speed extension type tensile testing machine with a self-recording device, a hook-shaped chuck was attached and the distance between the hooks was set to 5 meters. A sample folded into a loop shape five times is set on the hook, and the elongation rate at the time of tension cutting is read from the chart at a tensile speed of 500 per minute. Further, the cutting elongation of fibers other than elastic yarns was measured according to JIS L-1070-78.

Example 1 Isotac polypropylene (intrinsic viscosity 1.65) was spun to 110 denier/3 at a melting temperature of 240 qo at high speed.
A 6-filament highly oriented drawn multifilament yarn (softening point of about 13,000, elongation of about 250%) was obtained.

This thread is used as the ground part, while the pile part has 15
0 denier/48 filament highly oriented polyester multifilament drawn false twist crimped yarn (softening point 2
A velor structure was knitted using a single circular knitting machine using 4000) to obtain a pile paper fabric with a basis weight of 300 g/m. In this knitted fabric, highly oriented undrawn polypropylene fibers form a ground portion to maintain the dimensional stability of the striped fabric, and highly oriented drawn polyester fibers form a pile portion that is bent. When this was thermoformed, the former yarn easily and large elongation occurred in the yarn axis direction during molding, while the latter did not cause any substantial elongation of the yarn but was superior because the bent yarn approached a straight shape. It has two-dimensional extensibility and can provide good moldability. That is, after dyeing and water-repelling the obtained knitted fabric, a commercially available two-component reactive urethane adhesive was applied to a thickness of 30 mm in solid content, and a 0.7 mm thick adhesive was applied. After laminating with the ABC resin plate, drying to produce a laminate (composite sheet), and heating this laminate to 180 qo,
Vacuum forming was performed using a vacuum forming mold having a curved surface shape. The polyester fibers in the gland part elongate more than three times at this molding temperature, and the stress generated at that time is extremely small, allowing for easy molding even into curved shapes, resulting in a beautiful finish with no distortion after molding. Ta. In addition, the highly oriented drawn polyester fibers in the pile part are stretched on the curved surface, but the stress is evenly distributed, which is sufficient to prevent peeling (see-through of the fabric), and because it does not cause thermal deformation, the appearance A three-dimensional molded product with excellent properties was obtained.

This molded product is durable enough to be used as an interior panel for automobiles.
It had an excellent appearance and texture. Example 2 Dimethyl terephthalate and dimethyl isophthalate in a molar ratio of 8
Polyester (intrinsic viscosity 0.60) obtained by copolymerizing this with ethylene glycol and butylene glycol at a molar ratio of 5 to 50 is
Melting point 199qC (softening point 170qC)
A copolymerized polyester multifilament yarn having a cutting elongation of 55% and a 150 denier/48 filament was obtained.

This yarn is used as a striped yarn, and a drawn false-twisted crimped yarn of polyester multifilament with a filament melting point of 26000 (softening point 240q○) is used as a pile warp. A copolymerized polyester multifilament yarn of filaments is used as the ground warp, and the pile warp and the ground warp are arranged in a ratio of 1:3, and the warp density is 90/2.
A single-sided pile fabric with 5 ribs, striped yarn density of 90 threads/25 ribs, and fabric weight of 20 females was woven.

In this woven fabric, copolymerized polyester fibers with a melting point of 19 o (softening point 170 qo) form striped yarns and ground warp yarns to maintain the dimensional stability of the woven fabric.
℃) polyester fibers form pile warps and are bent. When this is aged, the former yarn has a large elongation in the yarn axis direction during molding, while the latter yarn has no substantial elongation, but the bent yarn approaches a straight line, resulting in a large amount of elongation. It exhibits two-dimensional extensibility and can provide good moldability. That is, after dyeing this fabric, it was backed with vinyl chloride resin at a thickness of 0.6 to form a laminated sheet, and this laminated sheet was vacuum-formed at 160 oo as a furniture decoration board. The resulting molded product had a superior appearance and feel compared to conventional products made only of plastic sheets, and could be processed much more efficiently than conventional methods. Example 3 20 denier polyurethane spandex type (softening point 1
65oo, cutting elongation approximately 550%) 70 denier/24
Spandex core yarn covered with filament polypropylene false twisted yarn was used for the ground part, while 140 denier/48 filament nylon 6,6 false twisted yarn (softening point 230°C) was used for the pile part. Then, a knitted fabric was knitted in the same manner as in Example 1.

Claims (1)

[Claims] 1 The back side of the fabric is mainly composed of fiber A having a softening point of 80 to 220°C and a breaking elongation of 50% or more (excluding fibers made of polyester mainly composed of ethylene terephthalate repeating units), and the front side is mainly composed of Fiber A
1. A fabric for molding, characterized in that it is composed of high softening point fiber B having a softening point 20° C. or more higher than that of the fiber B.