JPH0369632A - Pile-like cloth for vacuum molding - Google Patents

Abstract

PURPOSE:To obtain the title cloth suitable for interior material for vehicle such as automobile, stably moldable by vacuum molding, consisting of piled fiber part comprising polyester-based yarn and ground fabric part comprising synthetic yarn of polymer containing a vinyl chloride unit in a specific ratio. CONSTITUTION:At least one selected from the group consisting of polyester- based yarn, polyamide-based yarn and wool is used for piled fiber part and synthetic yarn comprising a polymer composed of >=60% vinyl chloride unit and/or vinylidene chloride part and preferably acrylonitrile unit is used as ground fabric part to give the objective cloth having >=0.2m<2> molding area of vacuum molding, readily moldable in vacuum at a temperature not causing reduction in quality such as scorching, efficiently and economically providing molded articles having excellent appearance.

Description

[Detailed description of the invention] [Industrial application fields] The present invention relates to a pile fabric for vacuum forming.

[Prior Art] Thermoforming is a molding method in which a plastic sheet or the like is softened by heat and then molded into a desired shape using a mold or the like. Molded products obtained using plastic sheets have flat surfaces and give a cheap impression, so thermoforming fabrics using fibers have been proposed as thermoforming materials that give a luxurious feel. As such a fabric for thermoforming, Japanese Patent Application Laid-open No. 54-
Pile fabrics described in JP-A-93183 and JP-A-55-128041 are suitable. The reason for this is that the pile fabric consists of a base fabric part and a raised part, and the appearance is determined by the raised part, so the base part should be made of a material that softens at the temperature used for thermoforming, and the raised part should be made of a material that does not soften at this temperature. This is because by using this, a fabric with an excellent appearance and which can be thermoformed can be obtained.

Now, a vacuum forming method is known as one of the thermoforming methods. To vacuum form a fabric for thermoforming, one or both sides of the fabric is heated with a heater, and then the fabric is placed in a mold and a vacuum is created between the mold and the fabric. The vacuum forming method has the advantage that the equipment is simple and pressure is applied only to one side of the fabric, so the appearance of the other side is not damaged. Since the fabric is small, it is necessary to uniformly heat the entire fabric unless it is heated to a very high temperature, and when it is formed at a temperature slightly higher than the temperature at which it can be formed. However, since a synthetic resin sheet or the like is attached to the fabric for vacuum forming in order to obtain a vacuum, it is very difficult to uniformly heat the synthetic resin sheet side of the fabric. For this reason, it is necessary to heat the fabric more than necessary, and even if a pile fabric suitable for thermoforming as described above is used, quality deterioration such as burning occurs in the raised part, and in extreme cases, the base fabric itself may be cut. There were some problems that occurred. This has been a problem, especially when searching for molded products or when molding products with large areas.

[Problems to be Solved by the Invention] The present invention has been made in view of the above-mentioned conventional problems, and an object of the present invention is to provide a pile fabric for vacuum forming that enables stable and good molding by vacuum forming. With the goal.

[Means for Solving the Problems] In the present invention, the raised portion is made of at least one type selected from the group consisting of polyester fibers, polyamide fibers, and wool, and the base fabric portion is made of vinyl chloride units and/or vinylidene chloride. The present invention relates to a pile fabric for vacuum forming made of a synthetic fiber made of a polymer containing 60% or more of units.

The piled fabric of the present invention is very suitable for vacuum forming. The reason for this is that polymer fibers mainly composed of vinyl chloride and/or vinylidene chloride are used in the base fabric, and these fibers are required to elongate to a certain level when heated, as described below. This is presumed to be because the stress is very small, the elongation until breakage is quite large, and the temperature range in which the stress required to generate a certain elongation is small is wide. Therefore, the pile-like fabric of the present invention becomes a pile-like fabric that is extremely useful for vacuum forming methods in which the stress applied to the object to be formed is small.

[Example] The pile-like fabric referred to in this specification refers to a fabric whose surface is pile-like, and is not particularly limited as long as it is such a fabric.

Specific examples of such pile fabrics include, but are not limited to, moquette, tricot, velvet, kohl pile, tuft pile, and raschel pile.

In addition, the pile-like fabric of the present invention uses the above-mentioned specific fibers as the base fabric, so that in the heated state as described above,
One of the characteristics of fabrics is that they stretch well and are easily formed even at low heating temperatures or with small forces, and maintain their shape after being formed by re-cooling. The effect is even more pronounced when applied to textiles, which have poor elasticity and are difficult to mold in the past.

The raised portion of the piled fabric of the present invention consists of polyester fibers,
It is composed of at least one type selected from the group consisting of polyamide fibers and wool (hereinafter also referred to as napped fibers).

The polyester fibers include, in addition to fibers consisting essentially only of ethylene terephthalate units such as polyethylene terephthalate fibers, polyester fibers consisting of copolymers containing repeating units other than ethylene terephthalate units, and furthermore, these fibers. Examples include fibers that are mixed with other fibers.

In addition, the polyamide fibers include fibers consisting essentially only of polyamide, such as nylon 6 fibers and nylon 66 fibers, as well as polyamide fibers consisting of these polymers containing other repeating units, and furthermore, these fibers. Examples include fibers that are mixed with other fibers.

The base fabric of the pile fabric of the present invention is composed of synthetic fibers (hereinafter also referred to as base fabric fibers) made of a polymer containing 60% or more of vinyl chloride and/or vinylidene chloride units. The base fabric made of fibers has sufficient thermoplasticity and can be easily stretched by heating even with a small force. Larger in comparison, making thermoforming easier. If it is less than the lower limit, the thermoplasticity of the base fabric portion will be insufficient, and if good moldability is to be achieved, excessive heating will tend to result in poor quality such as burnt fibers in the napped portion.

The base fabric portion fiber may be made of, for example, substantially only vinyl chloride units and/or vinylidene chloride units, but the portion other than vinyl chloride units and vinylidene chloride units is substantially acrylonitrile units. Preferably, synthetic fibers are used.

Furthermore, there are no particular limitations on the fineness of the synthetic fibers constituting the base fabric, the date and amount of the base fabric, etc.

In the pile-like fabric of the present invention, there are no particular limitations on the basis weight ratio between the napped portion fibers and the base fabric portion, and the manufacturing method thereof, and the ratio between the napped portion fibers and the base fabric portion is the same as that of a normal pile-like fabric. The fabric of the present invention having such a structure has the property of being able to stretch well with a weak force in a heated state (under molding conditions) and having a wide temperature range at which it stretches well. have.

In general, while vacuum forming is economical and easy, it also has a limit to the forming pressure.Therefore, the fabric of the present invention, which stretches well with weak force, is suitable for use in vacuum forming. .

In addition, especially when the molding area is large (for example, 0.2
d or higher), it is difficult to control the temperature distribution to make it uniform, but if the fabric of the present invention, which stretches well and has a wide temperature range, is used, strict temperature control becomes unnecessary, and even in the case of a large area,
Molding is easily achieved.

Using the piled fabric of the present invention, a synthetic resin sheet or the like is attached to the base fabric mainly to prevent air permeation, and then a plastic film or sheet is vacuum formed. By molding using the method described above, a molded product with a good appearance can be obtained.

The temperature, time, etc. for molding the molded article may be appropriately selected depending on the types of the napped fibers and base fabric constituting the pile fabric, the shape of the molded article, and the like.

The molded product produced as described above can be used as an interior material for vehicles such as automobiles, aircraft, and ships, and as an interior material for luxury goods storage cases, but is particularly useful for door linings, instrument panels, console boxes, etc. In the case of interior materials for automobiles, the effect of the present invention, which allows even large parts to be easily vacuum formed at relatively low temperatures, is more effectively exhibited.

Next, the present invention will be explained based on examples.

Example 1 and Comparative Examples 1 to 2 Synthetic fibers made of a polymer containing 70% polyvinyl chloride units and 30% acrylonitrile units were used as ground yarns, and polyester fibers (pile length 2) were used as pile yarns.
．． 0mm) moquette (20 wings, 35 pieces)
was produced and used as the fabric of Example 1.

For comparison, a fabric of Comparative Example 1 was prepared in the same manner as in Example 1, except that a synthetic fiber containing 50% polyvinyl chloride units and 50% acrylonitrile units was used as the ground yarn.

The fabrics (mockets) of Example 1 and Comparative Example 1 were tested using the test method of JI81098 (however, the width of the fabric was 1.5 mm).
The elongation at break (%) at each temperature according to
) and tensile strength (kg) were measured.

Figure 1 shows the value of (elongation/tensile strength) (vertical axis, %/kg)
The relationship between and temperature (horizontal axis, °C) is shown. From FIG. 1, the fabric of Example 1 shows clearly larger (elongation/tensile strength) values than the fabric of Comparative Example 1 even in the region below 60°C.
In particular, it can be seen that the contact value increases rapidly at 60 to 100°C.

This value (elongation/tensile strength) is an index showing how well the material can be elongated with a small amount of force.

Therefore, from this measurement result, the fabric of the present invention (Example 1) can be stretched well with a weak force in a heated state (under molding conditions), and can be stretched sufficiently and stretched well even at a temperature of about 60°C. It can be seen that the temperature range is wide.

Examples 2 to 3 Synthetic fibers containing 70% polyvinyl chloride units and 30% acrylonitrile units were used as the ground yarn, and polyethylene terephthalate fibers were used as the pile yarn on the ground yarn side of a moquette. Vinyl chloride (P
A sample of Example 2 was prepared by pasting a VC) sheet using an adhesive.

Also, instead of the polyvinyl chloride sheet, a thickness of 3111 mm
A sample of Example 3 was prepared in the same manner as Example 2 except that a polypropylene foam sheet expanded 20 times with In was used.

The obtained two samples were molded according to the procedure shown in FIGS. 2(a) to 2(c).

That is, a fabric (1
) is held by the clamp (2) (second figure),
Next, the heater (3) approached the fabric (1) and heated it (Figure 2 (b)).The fabric (1) and the heater (3)
) was approximately 20 cm apart.

During this heating step, the maximum fabric temperature on the surface of the raised portion and the surface of the synthetic resin sheet (hereinafter referred to as upper fabric salinity and lower fabric temperature, respectively) was measured using thermo paper.

After that, the fabric (1) and the heater (3) are separated, and after about 5 seconds, the mold (4) is pressed against the fabric (1), and the suction port (
5) The air between the fabric (1) and the mold (4) was sucked (Figure 2(c)).

Thereafter, the molded fabric (1) was cooled using a fan or the like and removed from the mold (4).

The heating conditions are shown in Table 1.

[Margins below] All of the samples of Examples 2 and 3 molded in this manner had good moldability and were free from burning and color change.

[Effects of the Invention] The pile fabric for vacuum forming of the present invention can be easily vacuum formed even at a temperature within a range that does not cause deterioration of quality such as burning, so molded products without appearance defects can be produced efficiently and economically. It will be done. Furthermore, since it does not require strict temperature distribution control compared to conventional fabrics, a large-area molded product without poor appearance can be easily obtained.

(4): mold

[Brief explanation of drawings]

Fig. 1 is a graph showing an example of the relationship between elongation/tensile strength and temperature of the fabric of the present invention, and Figs. 2(a) to 2(C) are explanatory diagrams showing an example of the vacuum forming process, respectively. . (Main symbols in the drawings) (1): Fabric (3): Heater';t'2a Diagram size 1 Figure ← - → Example 1 Figure 2b Figure 2C Temperature (0C)

Claims (1)

[Claims] 1. The raised portion is made of polyester fiber, polyamide fiber,
A pile fabric for vacuum forming, which is made of a synthetic fiber made of at least one type selected from the group consisting of wool, and whose base fabric part is made of a polymer containing 60% or more of vinyl chloride units and/or vinylidene chloride units. 2. The pile fabric according to claim 1, wherein the synthetic fiber used for the base fabric is a synthetic fiber made of a polymer containing vinyl chloride units and/or vinylidene chloride units and acrylonitrile units. 3. The piled fabric according to claim 1 or 2, wherein the piled fabric is a moquette. 4. The pile fabric according to claim 1, 2 or 3, wherein the forming area of the vacuum forming is 0.2 m^2 or more. 5. An interior material for an automobile manufactured by vacuum forming using the pile fabric according to claim 1. 6. The interior material for an automobile according to claim 5, which is at least one material selected from the group consisting of a door lining, an instrument panel, and a console box.