JPH04219230A - Resin sheet laminate - Google Patents

Abstract

PURPOSE:To provide a resin sheet laminate, in which the transfer formability of the grain pattern of a section having a complicate shape in an interior finish body such as an instrument panel is improved while a mold shrinkage factor is lowered, the generation of creases and looseness is prevented effectively and the interior finish body is softened at the same time. CONSTITUTION:A resin sheet laminate is composed of a first sheet layer, to which a grain pattern is transferred and formed and which consists of a thermoplastic synthetic resin, a second sheet layer as a draw-down preventive layer, which is made up of the thermoplastic synthetic resin, and laminated on said first sheet layer and obstructs a draw-down on a molding temperature, and a third sheet layer as a foaming layer, which is laminated on said second sheet layer and contains a primary foaming agent and a secondary foaming agent foamed at different periods by heating temperatures.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention relates to a resin sheet laminate, and more particularly, the present invention relates to a resin sheet laminate, and more particularly, improves grain transfer formability and shrinkage rate by using a sheet layer containing a chemical foaming agent capable of secondary foaming by heating during molding. The present invention relates to a resin sheet laminate that can reduce the amount of water and give flexibility to the product.

0002

[Prior Art] In recent years, interior bodies that incorporate automobile instrument panels, console boxes, etc. have become more flexible from the standpoint of safety and design, and delicate textures similar to natural leather have been used to give a sense of luxury. In many cases, an uneven pattern (grain pattern) is provided.

Various proposals have been made to provide this type of grain pattern. For example, JP-A-61-
No. 104848 has already disclosed a technical idea related to "a method for graining a synthetic resin sheet."

[0004] This technical idea is to polymerize a synthetic resin sheet heated at high temperature onto a pattern molded by electroforming so as to have a natural leather-like grain pattern and provide fine continuous pores. The synthetic resin sheet is vacuum-sucked in a pattern through the pores, thereby transferring the grain pattern onto the surface of the synthetic resin sheet.

[0005]

[Problems to be Solved by the Invention] Incidentally, interior bodies such as instrument panels, etc. have become noticeably larger and more complex in shape than before, and the above-mentioned conventional technology has made it possible to reduce the size of deep-drawn parts, especially It is difficult to reliably transfer a wrinkled pattern to a portion having an undercut portion.

[0006] Furthermore, since the synthetic resin sheet is molded and the wrinkled pattern is transferred while it is heated and softened, so-called drawdown occurs, and as a result, the alignment of the sheet layers constituting the synthetic resin sheet becomes difficult. This makes it difficult to maintain accuracy, and the problem is that wrinkles, slack, etc. occur on the surface.

[0007] Therefore, an object of the present invention is to improve the transfer formability of a mossori pattern in an interior body such as an instrument panel with a complicated shape, such as an undercut part, and to reduce the so-called molding shrinkage rate. It is an object of the present invention to provide a resin sheet laminate which effectively prevents the occurrence of wrinkles and slack, and which also has a flexible interior body.

[0008]

[Means for Solving the Problems] In order to achieve the above objects, the present invention provides a first sheet layer made of a thermoplastic synthetic resin, and a layer laminated to the first sheet layer made of a thermoplastic synthetic resin. a second sheet layer as a drawdown prevention layer for preventing excessive drawdown at the molding temperature, and a foaming material laminated on the second sheet layer and containing a secondary foaming agent that foams at the heating temperature. It is characterized by consisting of a third sheet layer as a layer.

The present invention also provides a first sheet layer made of a thermoplastic synthetic resin, laminated on the first sheet layer,
a second sheet layer as a foaming layer containing a secondary foaming agent that generates decomposition heat when heated and foams at the heating temperature;
A third sheet layer is laminated on the second sheet layer and is made of a woven or nonwoven fabric containing one or more types of thermoplastic fibers and serves as a fiber layer to prevent excessive drawdown at the molding temperature. It is characterized by consisting of.

Furthermore, the present invention provides a first sheet layer made of a thermoplastic synthetic resin, a woven or nonwoven fabric laminated on the first sheet layer and containing one or more types of thermoplastic fibers, and a It is characterized by comprising a second sheet layer as a foamed fiber layer that is integrated with a secondary foaming agent that generates decomposition heat and foams at heating temperature.

[0011]

[Operation] In the present invention, the foaming agent performs secondary foaming by heating the synthetic resin sheet laminate. The secondary foaming makes it possible to transfer and form the grain pattern efficiently and with high precision using the foaming pressure and resolution heat generated during foaming. In addition, the drawdown prevention layer lowers the molding shrinkage rate and effectively prevents wrinkles and slack from occurring.

0012

[Detailed description of the structure] In the resin sheet laminate according to the present invention, the hardness of the grain transfer layer on which the grain pattern of the mold is transferred is set to be Shore A60 or less. This is because if the shore A is 60 or more, softening of the molded product will be inhibited. The tensile strength at the molding temperature should be 2 gr/mm2 or less. This is because if it is 2 gr/mm2 or more, the softening of the molded product will be inhibited, and the transferability of the grain pattern will be reduced.

[0013] The raw materials for obtaining the above-mentioned physical properties include vinyl chloride resin (PVC) as the main material, ABS resin, M
At least one of the resin group consisting of olefin resins such as BS resin and EVA resin, and polyurethane resins such as copolymer resins of vinyl chloride and urethane is used alone or in a mixture.

Note that the above resin can be used even if it is partially crosslinked. Furthermore, if necessary, synthetic rubber such as NBR, a plasticizer, a stabilizer, a filler, an antioxidant, an ultraviolet absorber, etc. are added to the resin.

[0015] As the plasticizer, phthalic acid type, adipic acid type, epoxy type, sebacic acid type, polyester type polymerization plasticizer, etc. are used.

As the stabilizer, Ba--Zn type stabilizer, Sn type stabilizer, etc. are used. In addition, as a filler, for example, C
For example, BHT is used as the antioxidant, and a dihydroxybenzophenone ultraviolet absorbent is used as the ultraviolet absorber.

The drawdown prevention layer for preventing excessive drawdown is basically made of the same raw material as the grain transfer layer, but by changing the amount of plasticizer added or the mixing ratio of the resins used. Obtain the desired tensile strength.

[0018] In order to prevent excessive drawdown during heating and to hold each sheet layer in a proper position, the tensile strength at the molding temperature is set to 3 gr/mm2 or more and 5 gr/mm2 or less. If it is less than 3gr/mm2, drawdown will be promoted and molding will be difficult, and if it is less than 5gr/mm2,
This is because if it is 2 or more, the drawdown will be too small, resulting in increased distortion due to stretching during molding, and molding shrinkage will become too large.

The foam layer uses at least one type of vinyl chloride resin, ABS resin, EVA resin, polyurethane resin, vinyl chloride paste range, etc. as the main raw material. Further, a foaming agent that foams upon heating and generates heat of decomposition, a plasticizer, a stabilizer, a filler, and a foaming accelerator are added as necessary.

As the blowing agent, those commonly used for foaming polyolefin resins and vinyl chloride resins are used, but it is preferable to use azodicarbonan amide, azobisisobutyronitrile, and dinitrobentamethylenetetramine. be. It is also possible to use a mixture of multiple types of foaming agents, if necessary.

[0021] As a foaming agent, primary foaming is performed at 150°C;
A material that undergoes secondary foaming at around 190°C is used.

The plasticizer, stabilizer and filler used are the same raw materials as those used in the grain transfer layer.

[0023] The foam layer is formed by heating a sheet of the above composition to 150°C.
After foaming by heating, secondary foaming of about 10% to 25% is performed at a molding temperature of around 190°C.

[0024] Also, the tensile strength at the molding temperature is 2gr/mm.
Set to 2 or less. This is because when it is 2 gr/mm2 or more, the molding shrinkage rate increases.

The purpose of the fibrous layer, like the drawdown prevention layer, is to prevent excessive drawdown during heating and to maintain each sheet layer in a proper position to obtain moldability. The fiber layer is a woven or nonwoven fabric made of fibers made from at least one resin selected from acrylic resin, vinyl chloride resin, a copolymer of the above two resins, or polyester resin. It has plasticity.

The tensile strength at the molding temperature is 3 gr/mm2 or more, 5 gr/mm2 for the same reason as the drawdown prevention layer.
/mm2 or less.

[0027] Furthermore, the fiber diameter of the fiber is from 3d to 10d.
, preferably about 5d, and the basis weight is 20gr/m2 to 2
00gr/m2, preferably 70gr/m2 to 80
It is about gr/m2. Further, the fiber length is from 40 mm to 60 mm, preferably 50 mm.

The foamed fiber layer is a sheet layer in which a foamed resin capable of secondary foaming at the molding temperature is integrated with fibers made of woven or nonwoven fabric having the same thermoplasticity as the resin layer. The foamed fiber layer is made by impregnating the woven fabric or nonwoven fabric with a vinyl chloride resin such as plastisol or organosol to which a blowing agent has been added, and causing the foam to be firstly foamed in advance, and then to be secondarily foamed by heating during molding.

The foamed fiber layer has the same purpose as the drawdown layer and fiber layer. Therefore, the tensile strength at the molding temperature is set to 3 gr/mm2 or more and 5 gr/mm2 or less.

[0030]

EXAMPLES Next, preferred examples of the resin sheet laminate according to the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 shows a partial longitudinal sectional view of a resin sheet laminate according to a first embodiment. The resin sheet laminate 10
The first sheet layer 12 basically consists of a grain transfer layer.
, a second sheet layer 14 made of a drawdown prevention layer, and a third sheet layer 16 made of a foam layer.

The first sheet layer 12 contains 100 parts of polyvinyl chloride resin (P-1300) and 1 part of ABS modifier in weight ratio.
10, acrylic processing aid 10, phthalic acid plasticizer 13
0, epoxy plasticizer 10, Ba-Zn stabilizer 8, antimony flame retardant 3, ultraviolet absorber 0.5, antioxidant 0
．． A raw material having a blending ratio of 5.5 and filler 20 was used.

The second sheet layer 14 contains 100 parts of polyvinyl chloride resin (P-1300) and 1 part of ABS modifier in weight ratio.
50, acrylic processing aid 7, phthalic acid plasticizer 125
, an epoxy plasticizer of 10, a Ba-Zn stabilizer of 8, an antimony flame retardant of 3, an antioxidant of 0.5, and a filler of 20.

The third sheet layer 16 contains polyvinyl chloride resin (P-1100) 100% by weight, ethylene modifier 70%, urethane modifier 10%, NBR modifier 20%, and acrylic processing aid. Agent 4, Phthalic acid plasticizer 100, Ba-
Zn stabilizer 2, blowing agent (OBSH) 2, blowing agent (AD
A raw material having a blending ratio of 2 parts CA) and 1 part foaming aid (ZnO) was used.

In manufacturing the resin sheet laminate 10, first, the raw materials for each layer are mixed in a blender and kneaded with a mixing roll. Next, using a calender, divided sheets were obtained in which the first sheet layer 12 had a thickness of 0.3 mm, the second sheet layer 14 had a thickness of 0.6 mm, and the third sheet layer 16 had a thickness of 0.3 mm. Next, the third sheet layer 16 is
After primary foaming was performed at 0° C. to a thickness of 1.25 mm, the three sheet layers 12, 14, and 16 were heat-sealed to obtain a sheet laminate. The resin sheet laminate 10 was then vacuum-formed using a mold having a grain pattern for transferring the sheet laminate. Note that the molding temperature at this time is 180°C on the surface of the first sheet layer 12 to perform secondary foaming, and on the surface of the third sheet layer 16.
The surface temperature was set at 170°C.

FIG. 2 shows a partial longitudinal sectional view of a resin sheet laminate 20 according to a second embodiment. The resin sheet laminate 20 basically consists of a first sheet layer 22 consisting of a grain transfer portion, a second sheet layer 24 consisting of a foam layer, and a fibrous layer for preventing drawdown. It is composed of three sheet layers 26.

The first sheet layer 22 contains 100 parts by weight of polyvinyl chloride resin (P-1300) and 1 part by weight of ABS modifier.
10, acrylic processing aid 10, phthalic acid plasticizer 13
0, epoxy plasticizer 10, Ba-Zn stabilizer 8, antimony flame retardant 3, ultraviolet absorber 0.5, antioxidant 0
．． A raw material having a blending ratio of 5.5 and filler 20 was used.

The second sheet layer 24 contains polyvinyl chloride resin (P-1100) 100% by weight, ethylene modifier 70%, urethane modifier 10%, NBR modifier 20%, and acrylic processing aid. Agent 4, Phthalic acid plasticizer 100, Ba-
Zn stabilizer 2, blowing agent (OBSH) 2, blowing agent (AD
A raw material having a blending ratio of 2 parts CA) and 1 part foaming aid (ZnO) was used.

The third sheet layer 26 was made of a thermoplastic nonwoven fabric having a basis weight of 120 gr/m 2 and consisting of 75% of acrylic vinyl chloride resin fibers and 25% of polyester resin fibers in a weight ratio.

[0040] In manufacturing the resin sheet laminate 20, first, raw materials for each of the first sheet layer 22 and second sheet layer 24 are mixed using a blender and kneaded using a mixing roll. Next, using a calendar, the thickness of the first sheet layer 22 is 0.9 mm, and the thickness of the second sheet layer 24 is 0.3 m.
A dividing sheet of m was obtained. Furthermore, the second sheet layer 2
4 was primarily foamed at 150° C. to a thickness of 1.25 mm, and three sheet layers 22, 24, and 26 were then heat-sealed to obtain a sheet laminate. Next, the resin sheet laminate 20 was obtained by vacuum forming the sheet laminate using a mold having a grain pattern for transferring the sheet laminate.

The molding temperature at this time was set to 180° C. on the surface of the first sheet layer 22 and 170° C. on the surface of the third sheet layer 26 in order to perform secondary foaming.

FIG. 3 shows a partial longitudinal sectional view of a resin sheet laminate 30 according to a third embodiment. The resin sheet laminate 30 basically includes a first sheet layer 32 consisting of a grain transfer layer, a thermoplastic woven fabric or nonwoven fabric, and a foam layer.
It is composed of a second sheet layer 34 made of a foamed fiber layer integrated with a secondary foaming agent.

The first sheet layer 32 contains 100 parts by weight of polyvinyl chloride resin (P-1300) and 1 part by weight of ABS modifier.
10, acrylic processing aid 10, phthalic acid plasticizer 13
0, epoxy plasticizer 10, Ba-Zn stabilizer 8, antimony flame retardant 3, ultraviolet absorber 0.5, antioxidant 0
．． A raw material having a blending ratio of 5.5 and filler 20 was used.

The second sheet layer 34 is made by adding vinyl chloride paste (PSH-33 to
) 50, vinyl chloride paste (PCH-12) 50, phthalic acid plasticizer 60, Ba-Zn stabilizer 3, blowing agent (
0BSH) 2, foaming agent (ADCA) 1, foaming aid (Zn
O) It is impregnated with raw materials having a blending ratio of 1.

In manufacturing the resin sheet laminate 30, first, the raw materials for the first sheet layer 32 are mixed in a blender and kneaded with a mixing roll. Next, using a calendar, the first sheet layer 32 was made into a 0.9 mm thick sheet, and then the second sheet layer 34 was primarily foamed at 150° C., and then the two sheet layers 32 and 34 were heat-sealed. A sheet laminate was obtained. The resin sheet laminate 30 was then vacuum-formed using a mold having a grain pattern for transferring the sheet laminate. The molding temperature at this time was set to 180° C. on the surface of the first sheet layer 32 and 170° C. on the surface of the third sheet layer 36 in order to perform secondary foaming.

Resin sheet laminate 1 according to the first embodiment
0, the resin sheet laminate 20 according to the second embodiment, and the third embodiment.
An evaluation test was conducted on the resin sheet laminate 30 according to the example. In addition, as a comparative example, evaluation was performed with a resin sheet laminate molded using two examples of the prior art described below.

That is, in the first comparative example, a semi-rigid resin sheet is heated and molded using a scalpel, and then the resin sheet is set together with a foundation in a urethane injection mold, and urethane foam is injected as a cushioning material. This is a resin sheet laminate obtained by.

A second comparative example is a resin sheet laminate obtained by heating and vacuum forming a laminate made of a soft resin sheet and a polyolefin foam, and then injecting a hard resin for foundation. It is.

Table 1 shows the results of the evaluation test. From these results, it is easily understood that in all Examples, the flexibility and grain transfer formability of the molded products were improved, and the molding shrinkage rate was reduced.

[0050]

[Table 1]

[0051]

As described above, according to the resin sheet laminate according to the present invention, it is possible to improve the transfer formability of a grain pattern in a complex shape, for example, an undercut portion. Further, by reducing the molding shrinkage rate, it is possible to effectively prevent the occurrence of wrinkles and sagging. Furthermore, the molded product can be made more flexible.

[Brief explanation of the drawing]

FIG. 1 is a partial vertical sectional view of a resin sheet laminate used in a first preferred embodiment of the present invention.

FIG. 2 is a partial vertical sectional view of a resin sheet laminate used in a second preferred embodiment of the present invention.

FIG. 3 is a partial vertical sectional view of a resin sheet laminate used in a third preferred embodiment of the present invention.

[Explanation of symbols]

10, 20, 30... Resin sheet laminate 12, 22, 32... First sheet layer 1 as a grain transfer layer
4... Second sheet layer 16 as a drawdown prevention layer...
Third sheet layer 24 as a foam layer...Second sheet layer 26 as a foam layer...Third sheet layer as a fiber layer

Claims (4)

[Claims] 1. A first sheet layer made of a thermoplastic synthetic resin, and a drawdown prevention layer made of a thermoplastic synthetic resin and laminated on the first sheet layer to prevent excessive drawdown at molding temperature. It is characterized by consisting of a second sheet layer as a layer, and a third sheet layer as a foam layer laminated on the second sheet layer and containing a secondary foaming agent that foams at heating temperature. Resin sheet laminate. 2. A foaming layer containing a first sheet layer made of a thermoplastic synthetic resin and a secondary foaming agent that is laminated on the first sheet layer and generates decomposition heat when heated and foams at the heating temperature. and a second sheet layer laminated on the second sheet layer, comprising a woven or nonwoven fabric containing one or more types of thermoplastic fibers, for preventing excessive drawdown at the molding temperature. A resin sheet laminate comprising a third sheet layer as a layer. 3. A first sheet layer made of a thermoplastic synthetic resin, a woven or nonwoven fabric laminated on the first sheet layer and containing one or more types of thermoplastic fibers, which generates decomposition heat when heated. and a second sheet layer as a foamed fiber layer that is integrated with a secondary foaming agent that foams due to heating temperature;
A resin sheet laminate characterized by comprising: 4. The resin sheet laminate according to claim 2 or 3, wherein the thermoplastic fibers are made of an acrylic resin, a vinyl chloride resin, or a polyester resin.