JP2018034388A - Molded article using fabric and manufacturing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a new material having an unprecedented design and texture in order to respond to the diversification of designs in recent years. SOLUTION: After alternately stacking a cloth and a thermoplastic resin film, the cloth is impregnated with a molten thermoplastic resin by heating and pressurizing, and then the thermoplastic resin is solidified by cooling while pressing. The obtained solidified product is cut to expose the cut surface. As a result, a molded product obtained by laminating five or more fabrics having different color tones and adhering them with a thermoplastic resin, characterized in that a striped pattern is formed on the cut surface of the molded product. Goods are obtained. [Selection diagram] FIG. 7

Description

  The present invention relates to a molded article having excellent design properties, in which fabrics are laminated and bonded with a thermoplastic resin, and a method for producing the same.

  Various materials such as fabric, wood, paper, leather, glass, metal, plastic, etc., are used depending on the application as materials for interior products, stationery, decorative accessories, etc. Accordingly, new materials having unprecedented design and texture are being demanded.

  Among the above-mentioned materials used in the past, fabrics can express various colors and have a gentle texture, so interior products such as curtains, carpets, wallpaper, sofa fabrics, stationery and decorative accessories It is also widely used. Since fabrics are flexible, they are mostly used for applications that require flexibility.

  On the other hand, it is widely practiced to stack a plurality of thin fabrics into a thick laminate. In that case, it is also known to laminate using an adhesive. Patent Document 1 describes a fabric molded product obtained by overlapping a fabric soaked with an adhesive to form a plate-shaped molded product and then compressing and drying the fabric, and can be used instead of a building material or the like. Has been. However, it takes time to dry the adhesive, and there is no description of its design properties.

Japanese Patent Laid-Open No. 11-77838

  In recent years, in order to cope with the diversification of design, it is required to provide a new material having unprecedented design and texture.

  The above-described problem is a molded product in which five or more fabrics having different color tones are laminated and bonded with a thermoplastic resin, and a striped pattern is formed on the cut surface of the molded product. It is solved by providing a molded article.

  At this time, it is preferable that the cut surface is inclined. It is also preferable that the cut surface is a curved surface. It is also preferable that the fabric in the molded product is curved. It is also preferred that at least one surface is covered with a fabric.

  In addition, the above-mentioned problem is that the fabric and the thermoplastic resin film are alternately stacked, and then the molten thermoplastic resin is impregnated in the fabric by heating and pressing, and then the thermoplastic resin is solidified by cooling while pressing. It is also possible to solve the problem by providing a method for producing the molded product, wherein the solidified product obtained is cut to expose the cut surface.

  At this time, it is preferable to polish the cut surface after exposing the cut surface. It is also preferable that the cloth in the molded product is curved by being solidified by cooling while being pressurized with a mold having a curved surface. By repeating the operation of impregnating the melted thermoplastic resin into the fabric by heating and pressurizing the fabric and the thermoplastic resin film alternately, increasing the overall thickness, and then cooling by pressurizing and cooling. It is also preferable to solidify the plastic resin. In addition, it is also preferable to use a fabric containing cellulose fibers and heat it with microwaves.

  Since the molded article of the present invention has an unprecedented design and texture, it can provide a new material in the fields of interior products, stationery, decorative accessories and the like. Further, according to the manufacturing method of the present invention, it is possible to manufacture a molded product having excellent design properties in response to various design requirements.

In Example 1, it is an external appearance of the solidified material obtained by hot pressing. In Example 1, it is the cut surface which cut | disconnected the solidified material perpendicularly with the electric circular saw. In Example 1, it is the cut surface grind | polished with the sandpaper. 2 is an enlarged photograph of a cut surface after polishing in Example 1. FIG. 2 is a curved cut surface cut using a circular chisel in Example 1. FIG. It is the external appearance of the solidified product which both surfaces obtained by hot pressing in Example 2. It is the cut surface after grinding | polishing when a cutting direction is changed in Example 2. FIG. 2 is an appearance of a photo frame produced in Example 2.

  The molded product of the present invention is a molded product in which five or more fabrics having different color tones are laminated and bonded with a thermoplastic resin.

The fabric used in the present invention is not particularly limited. Any of woven fabric, knitted fabric and non-woven fabric can be used. Among them, it is preferable to use a woven fabric in order to obtain a high-strength molded product having excellent rigidity. The basis weight of the fabric is not particularly limited and is appropriately selected depending on the application, but is usually 50 to 1000 g / m ² . The fiber material constituting the fabric is not particularly limited, and synthetic fibers such as polyester, nylon, acrylic, and vinylon, semi-synthetic fibers such as rayon and acetate, natural fibers such as cotton, hemp, wool, and silk can be used. . A fabric including a plurality of types of fibers may be used. Also, a laminate may be obtained by using a plurality of types of fabrics containing different fibers and stacking them.

  When synthetic fibers are used, the melting point or softening point thereof needs to be higher than the melting point or glass transition point of the thermoplastic resin used for bonding. Specifically, the melting point or softening point of the synthetic fiber is preferably 200 ° C. or higher, and more preferably 230 ° C. or higher. Here, if the synthetic fiber has a clear melting point, the melting point should satisfy the above condition, and if not, the softening point should satisfy the above condition. Among synthetic fibers, polyester is preferably used because of its high melting point and high strength.

  Natural fibers and semi-synthetic fibers are preferably used in the present invention because they usually do not soften below 230 ° C. In many cases, these fibers degrade by heating to higher temperatures. Among these, cellulose fibers such as cotton and hemp are preferably used when heated by microwaves because the fibers contain moisture and have good heat resistance.

  As the fabric used in the present invention, a new good product may be used, but it is preferable from the viewpoint of cost to use a non-standard product or a recycled product. Non-standard products include those in which the color of the dyed fabric deviates from the product standards, those in which defects have occurred during weaving, and those that have been damaged or soiled during product handling. In addition, examples of recycled products include fabrics of stock products that have not been subjected to sewing processing, surplus fabric at the time of cutting, stock products after sewing processing, and recycled products after use by consumers. In the molded product of the present invention, except for one piece of fabric on the surface, the fabric does not appear on the appearance except for the cut surface, so various non-standard products and recycled products can be used without any problems. By using non-standard products and recycled products, waste can be reduced, so it can be said that it is an environmentally friendly molded product.

  In the molded product of the present invention, five or more fabrics having different color tones must be laminated. By laminating five or more fabrics and bonding them with a thermoplastic resin, it is possible to obtain a molded product having excellent rigidity and a molded product having excellent cut surface design. The number of fabrics to be laminated is preferably 10 or more, and more preferably 20 or more. The upper limit of the number of laminated fabrics is not particularly limited, but is usually 1000 or less in consideration of productivity. Here, “the colors are different from each other” means that not all the fabrics have the same color. Fabrics having different color tones may be arranged randomly or regularly. What is necessary is just to stack | paste the fabric from which a color tone differs so that the stripe pattern of the target design may be formed in a cut surface. In order to express rich colors, it is preferable to use a fabric of three or more colors, and it is more preferable to use a fabric of four or more colors.

  The method for producing the molded product of the present invention is not particularly limited, but the fabric and the thermoplastic resin film are alternately stacked, and then the fabric is impregnated with the molten thermoplastic resin by heating and pressing, and then cooled while being pressurized. Thus, a method of solidifying the thermoplastic resin is preferable. By doing so, the fiber aggregate in the fabric is impregnated with the thermoplastic resin, and the fabrics are firmly bonded to each other.

  The thermoplastic resin film overlapped with the fabric has a melting point or glass transition point lower than the melting point or softening point of the fibers contained in the fabric. Here, when the thermoplastic resin film has a clear melting point, the melting point should satisfy the above condition, and the glass transition point should satisfy the above condition. In order not to reduce the strength of the fiber during heating and pressurization, the melting point or glass transition point of the thermoplastic resin film is preferably 40 ° C. or more lower than the melting point or softening point of the fiber contained in the fabric. It is more preferable that the temperature is lower by at least ° C. The melting point or glass transition point of the thermoplastic resin contained in the film is preferably 60 to 180 ° C, and more preferably 80 to 160 ° C. When the melting point or glass transition point of the thermoplastic resin is included in the above range, the fabric can be bonded while suppressing the decrease in fiber strength, and the heat resistance of the molded product can be ensured.

  As the thermoplastic resin used for the thermoplastic resin film, polyolefin, polyester, nylon, polycarbonate, acrylic resin, polyvinyl chloride, polystyrene, ABS resin, AS resin, or the like can be used. Of these, polyolefins having a relatively low melting point and being inexpensive are preferably used. Polyolefins generally do not have good adhesion to other resins, but in the present invention, a fiber assembly in a fabric is impregnated with a thermoplastic resin melted by heating and pressurizing. Adhesion can be sufficiently strong. As the polyolefin, polyethylene such as low density polyethylene and high density polyethylene, and polypropylene can be used. An ethylene-propylene copolymer can also be used. Among these, low-density polyethylene is preferably used because it has a low melting point and is inexpensive. Here, the low density polyethylene includes not only low density polyethylene of a high pressure method but also linear low density polyethylene (LLDPE).

  The thickness of the thermoplastic resin film disposed between the fabrics is not particularly limited, and is usually 10 to 500 μm, and preferably 20 to 300 μm. The thickness of the film is adjusted according to the basis weight or thickness of the fabric to be overlaid. The film sandwiched between the fabrics may be only one sheet or a plurality of films. In the case of a plurality of films, the total thickness may be included in the above thickness range.

After the fabric and the thermoplastic resin film are alternately stacked, the fabric is impregnated with the thermoplastic resin melted by heating and pressing. Although the pressurization method is not particularly limited, pressurization can be performed using a press device or the like. Pressing may be performed while heating in a press device or the like, or a preheated laminate may be pressed with a press device or the like. The heating temperature at this time is higher than the melting point or glass transition point of the thermoplastic resin film and lower than the melting point or softening point of the fibers contained in the fabric. Next, the thermoplastic resin is solidified by cooling while being pressurized. By solidifying the melted thermoplastic resin under pressure, the melted thermoplastic resin is solidified in a state where the melted thermoplastic resin is sufficiently impregnated in the gaps of the fibers in the fabric, and the fabrics are firmly bonded to each other. What is necessary is just to adjust suitably the pressure added to a laminated body according to the use of a molded article, and what is necessary is just the pressure of 0.5 N / cm < ² > or more, as long as it is made to adhere only to such an extent that it does not peel by cutting. The inventor has confirmed that adhesion is possible even at a pressure of 1 N / cm ² . To more firmly adhered is preferably pressing pressure is 5N / cm ² or more, more preferably 10 N / cm ² or more. The upper limit value of the pressing pressure is not particularly limited, but it is realistic to set it to 10000 N / cm ² or less in consideration of the cost of equipment and energy.

  When a hot press apparatus is used, the molten thermoplastic resin can be impregnated in the fabric by pressurizing simultaneously with heating. In the case of heating using a hot press device, the laminate must be heated by heat transfer from a hot platen, but the fabric has a low heat transfer coefficient because it contains air inside. Therefore, when the thickness of the molded product is large, it takes a long time to melt the thermoplastic resin film at the center. In such a case, a series of operations in which a small number of fabrics and thermoplastic resin films are alternately stacked and then impregnated into the fabric by heating and pressurizing are repeated a plurality of times, It is preferable to solidify the thermoplastic resin by gradually increasing the number of fabrics and the overall thickness and then cooling while applying pressure.

  In addition, the laminate can be heated using a microwave. Thereby, even when the thickness of the molded product is large, it is possible to efficiently heat the center part. However, in this case, the laminate needs to contain moisture, and it is necessary to use fibers having a high moisture content such as cellulose fiber, wool, silk, and nylon. Among these, cellulose fibers are suitable for heating with microwaves because the fibers contain moisture and have good heat resistance. After heating with microwaves, the thermoplastic resin is solidified by cooling while being pressurized.

  Thus, the thickness of the molded product obtained by solidifying the thermoplastic resin is not particularly limited, and is appropriately set according to the application. Considering the ease of observing the striped pattern, the thickness of the molded product is preferably 2 mm or more, more preferably 5 mm or more. On the other hand, considering the productivity, the thickness of the molded product is usually 300 mm or less.

  In the molded product of the present invention, five or more fabrics having different color tones are laminated and bonded with a thermoplastic resin. The molded product of the present invention can be cut without peeling because the fabrics are firmly bonded to each other. And the striped pattern excellent in the designability is formed in the cut surface exposed by cutting. At this time, it is a great feature of the molded article of the present invention that a unique striped pattern rich in changes derived from the difference in color tone of the fabric exposed on the cut surface is formed.

  In the molded product of the present invention, the method for forming the cut surface is not particularly limited, and it may be cut with a blade such as a saw, chisel, canna, or carving sword, lathe, milling machine, drilling machine, electric drill, electric grinder, etc. It may be cut by a cutting machine or a grinding machine. Note that the cutting here also includes grinding to expose the cut surface by peeling off the surface. Moreover, it can also cut | disconnect with a water jet or a laser processing machine.

  The cut surface may be perpendicular to the surface or may be inclined. When the cut surface is inclined, the cut surface is widened and the interval between the stripe patterns is widened. Therefore, it is easy to observe the stripe pattern, which is advantageous in terms of design in many cases. Further, the cut surface may be a flat surface or a curved surface. When the cut surface is a flat surface, the cutting operation is easy. When the cut surface is a curved surface, the striped pattern appearing on the cut surface is bent depending on the viewing angle, so that the design can be varied.

  It is also preferred that the fabric in the molded product is curved. In this case, even if the cut surface is a plane, a curved striped pattern is formed, and a pattern like a grain can be obtained. The method for curving the fabric in the molded product is not particularly limited, but a method for solidifying the thermoplastic resin by cooling with a mold having a curved surface is preferable. The shape to be curved is not particularly limited, but the laminate may be greatly bent so as to form a part of a spherical surface or a cylindrical shape, or may be bent into a corrugated shape.

  In the molded article of the present invention, at least one surface is preferably covered with a fabric. Thereby, the molded article of the characteristic design which has both the surface covered with the fabric and the cut surface in which the striped pattern was formed can be provided. At this time, both surfaces may be covered with the cloth, or only one surface may be covered with the cloth, and the cut surface may be exposed on the other surface. Further, only one surface may be covered with a fabric and the other surface may be covered with a thermoplastic resin. Furthermore, the cut surfaces may be exposed on both surfaces. These configurations can be appropriately selected according to the target design.

  In the molded article of the present invention, it is also preferable to polish the cut surface after exposing the cut surface. In the molded article of the present invention, the fiber aggregate in the fabric is impregnated with the thermoplastic resin, and the fabrics are firmly bonded to each other. Can be obtained. Thereby, it becomes possible to clearly observe the stripe pattern of the cut surface, and it is also possible to obtain a smooth cut surface that does not seem to be a laminate of fabrics. The polishing method is not particularly limited, and sandpaper, an electric grinder, or the like can be used.

  You may further color the molded article of this invention. Thereby, the color tone can be further adjusted while taking advantage of the color tone of the cloth of the raw material. The coloring method is not particularly limited, but it is preferable to use a dye for fiber dyeing. In that case, it is possible to impregnate the dyeing solution to dye the whole, or to apply the dyeing solution to dye all or part of it. In addition, although a coating can be applied, in this case, a transparent coating that can observe a stripe pattern in a cross section is preferable.

  The use of the molded article of the present invention thus obtained is not particularly limited. Taking advantage of the design of the striped pattern on the cut surface and the texture of the fabric, it can be used for various purposes such as interior products, stationery and decorative accessories. Interior accessories include picture frames, wall decorations, door knobs, desk tops, and so on. Stationery includes pen trays, pen stands, staple covers, measure covers, and paper weights. Examples of ornamental accessories include mobile phone straps, key chains, smartphone covers, and accessories. Depending on the application, it can be bonded to other members, or can be drilled or screwed.

Example 1
As the fabric, a twill woven fabric containing 65% by mass of polyester and 35% by mass of cotton and having a basis weight of 255 g / m ² was used. A low-density polyethylene film having a thickness of 70 μm was used as the thermoplastic resin film. The woven fabric and the film were each cut into a size of 30 cm × 30 cm, and 20 woven fabrics and 19 films were alternately stacked so that the woven fabrics were arranged on the lowermost surface and the uppermost surface. The woven fabrics used here include ones having different color tones, and were appropriately arranged and stacked according to a desired cross-sectional design. The obtained laminate was sandwiched between iron plates and hot pressed with a press for 10 minutes. The pressing temperature was 160 ° C. and the pressing pressure was 0.1 N / cm ² .

  10 sheets of woven fabric and 10 sheets of film are alternately stacked so that the woven fabric is arranged on the lowermost surface, and the laminate immediately after the hot press molding including 20 woven fabrics is placed thereon, and further Then, 10 sheets of woven fabric and 10 sheets of film were alternately stacked so that the woven cloth was arranged on the uppermost surface, and these were put together in an iron plate and hot pressed under the same conditions as described above. As a result, a high-temperature laminate including 40 woven fabrics was obtained. Also at this time, woven fabrics having different color tones were appropriately selected and stacked according to the desired cross-sectional design.

This operation was further repeated three times to obtain a high-temperature laminate including 100 woven fabrics, the lowermost surface and the uppermost surface being woven fabrics. The woven fabric used here contained twelve colors having different color tones. This laminate was sandwiched between cooling presses having a press pressure of 50 N / cm ² to solidify the polyethylene, and then the load was removed to obtain a solidified product having a thickness of 30 mm with the woven fabric exposed on both surfaces. The obtained solidified product was hard and had sufficient rigidity. Further, each layer was firmly adhered, and it was not peeled off even in subsequent cutting or polishing, and was not peeled off when a force was applied by hand. Here, since the basis weight of the low-density polyethylene (density 0.92 / cm ³ ) film having a thickness of 70 μm is 65 g / m ^2, it contains 20% by mass of low-density polyethylene with respect to the weight of the entire molded product. . The appearance of the laminate thus obtained is shown in FIG.

  When the obtained solidified product was cut vertically with an electric circular saw, colorful stripes appeared on the cut surface, but fuzz was conspicuous (FIG. 2). When this cut surface was polished with No. 400 sandpaper, it was possible to obtain a glossy cut surface, and a clearer stripe pattern could be observed (FIG. 3). An enlarged photograph of the cut surface after polishing is shown in FIG. It can be seen that the fiber aggregate in the fabric is impregnated with the thermoplastic resin, and that the cut surface is smooth without fluffing. When the solidified material was cut obliquely, the area of the cut surface increased and the pitch of the stripe pattern increased. In addition, when it was cut using a round chisel to create a curved cut surface with traces of the blade, a colorful striped pattern curved to show a unique design (FIG. 5). The woven fabric is exposed on both surfaces of the resulting molded product, and while it has a so-called fabric texture, a unique striped pattern is formed on the cut surface, giving it a unique texture Goods were obtained.

Example 2
The same woven fabric and film as in Example 1 were cut into a size of 30 cm × 30 cm, and 20 woven fabrics and 19 films were alternately stacked so that the woven fabrics were arranged on the lowermost surface and the uppermost surface. . The woven fabric used here includes five colors having different color tones, which are appropriately arranged and stacked according to a desired cross-sectional design. The obtained laminate was sandwiched between iron plates, lightly sandwiched without pressing with a press, and heated at 160 ° C. for 10 minutes.

  10 sheets of woven fabric and 10 sheets of film are alternately stacked so that the woven fabric is arranged on the lowermost surface, and the laminate immediately after heating including 20 woven fabrics is placed thereon, and further, 10 sheets of woven fabric and 10 sheets of film were placed alternately so that the woven fabric was placed on the uppermost surface, and these were put together in an iron plate and heated without pressing under the same conditions as above. . As a result, a high-temperature laminate including 40 woven fabrics was obtained. Also at this time, woven fabrics having different color tones were appropriately selected and stacked according to the desired cross-sectional design.

This operation was further repeated three times to obtain a high-temperature laminate including 100 woven fabrics, the lowermost surface and the uppermost surface being woven fabrics. This was sandwiched between a pair of corrugated wooden molds fitted together, and then sandwiched between cooling presses having a press pressure of 50 N / cm ² and cooled over 20 minutes. After the polyethylene was solidified, the load was removed to obtain a solidified product having a waved thickness on both surfaces of 30 mm (FIG. 6). When the obtained solidified product was cut with an electric circular saw and polished with No. 400 sandpaper, a curved stripe pattern appeared depending on the cutting direction even though the cut surface was flat (FIG. 7). . Further, the obtained solidified product was cut out to a predetermined size and shaped with fleas, and the cut surfaces of the obtained molded products were sequentially polished with No. 180-1600 sandpaper to smooth the surface. The molded product was then assembled into a photo frame shape. Subsequently, the frame was immersed in a solution obtained by diluting 30 ml of black selenium dye with 1 liter of water until the solution was sufficiently penetrated, and then air-dried. As a result, a photo frame with a heavy color tone could be obtained (FIG. 8).

Example 3
The same woven fabric and film as in Example 1 were cut into dimensions of 20 cm × 20 cm, and 100 woven fabrics and 99 films were alternately stacked so that the woven fabrics were arranged on the lowermost surface and the uppermost surface. . This was put into a microwave oven, heated at 500 W for 7 minutes, sandwiched between iron plates, and hot-pressed for 10 minutes with a press in the same manner as in Example 1. The pressing temperature was 160 ° C. and the pressing pressure was 0.1 N / cm ² . Thereafter, the polyethylene was solidified by cooling with a cooling press in the same manner as in Example 1, and then the load was removed to obtain a solidified product having a thickness of 30 mm with the woven fabric exposed on both surfaces. When the solidified product was cut, a striped pattern was observed on the cut surface as in Example 1.

Claims (10)

  A molded product obtained by laminating five or more fabrics having different color tones and bonded with a thermoplastic resin, wherein a striped pattern is formed on a cut surface of the molded product.   The molded article according to claim 1, wherein the cut surface is inclined.   The molded product according to claim 1, wherein the cut surface is a curved surface.   The molded article according to any one of claims 1 to 3, wherein the fabric in the molded article is curved.   The molded article according to any one of claims 1 to 4, wherein at least one surface is covered with a fabric.   The fabric and the thermoplastic resin film are alternately stacked, and then the molten thermoplastic resin is impregnated into the fabric by heating and pressurizing, and then the thermoplastic resin is solidified by cooling with pressurization and the obtained solidification is obtained. The method for producing a molded product according to any one of claims 1 to 5, wherein the product is cut to expose the cut surface.   The manufacturing method of the molded article according to claim 6, wherein the cut surface is polished after the cut surface is exposed.   The method for producing a molded product according to claim 6 or 7, wherein the fabric in the molded product is curved by being solidified by cooling while being pressurized with a mold having a curved surface.   By repeating the operation of impregnating the melted thermoplastic resin into the fabric by heating and pressurizing the fabric and the thermoplastic resin film alternately, increasing the overall thickness, and then cooling by pressurizing and cooling. The method for producing a molded product according to any one of claims 6 to 8, wherein the plastic resin is solidified. The method for producing a molded product according to any one of claims 6 to 9, wherein a fabric containing cellulose fibers is used and heated by microwaves.