JP4330606B2 - Carbon cloth-like sheet and manufacturing method thereof - Google Patents

Description

  The present invention relates to a carbon cloth-like sheet simulating a carbon cloth, which is a woven fabric made of carbon fibers, and a method for producing the same.

  Carbon cloth is a woven fabric made of carbon fiber, and is lightweight and extremely strong. Therefore, it is used for the base of airplane wings and the cockpit of F1 cars. Moreover, it is not used as an interior material (for example, an instrument panel, etc.) of an ordinary automobile, but is used as a decoration for the appearance sportiness.

  For this reason, for example, a carbon cloth-like sheet in which a carbon cloth is sandwiched with an acrylic resin or a carbon cloth pattern printed on a synthetic resin sheet has been proposed.

  However, a carbon cloth sandwiched with an acrylic resin is not very often used as an interior material for ordinary automobiles because the carbon cloth itself is very expensive and difficult to mold.

  A carbon cloth-like sheet in which a carbon cloth pattern is printed on a synthetic resin sheet is inexpensive and is used as an automobile interior material. However, it does not have a three-dimensional effect and has a poor appearance. The actual carbon cloth looks like black and silver with the warp and weft depending on the angle of light, and it looks bright and shining, whereas the printed carbon cloth-like sheet has no three-dimensional effect and does not look very good.

  An object of the present invention is to provide a carbon cloth-like synthetic resin sheet having a stereoscopic effect and brightness closer to those of a genuine carbon cloth.

  The carbon cloth-like sheet of the present invention has a black base layer made of a thermoplastic resin and a transparent transparent layer made of a thermoplastic resin laminated thereon, and carbon is formed on the boundary surface between the base layer and the transparent layer. A cross-like uneven pattern is formed, and 0.1 wt% to 10 wt% of a pearl pigment or metal powder is kneaded into the underlayer.

  Further, the method for producing a carbon cloth-like sheet of the present invention comprises a carbon cloth-like unevenness on the surface of a base layer made of a black thermoplastic resin in which 0.1 wt% to 10 wt% of a pearl pigment or metal powder is kneaded. A carbon cloth-like concavo-convex pattern is transferred using a squeezing roll or press plate having a pattern, and a transparent layer made of a thermoplastic resin is formed thereon.

  Furthermore, the method for producing a carbon cloth-like sheet according to the present invention uses a squeezing roll or a press plate having a carbon cloth-like uneven pattern on the lower surface of a transparent sheet made of a thermoplastic resin to be a transparent layer, so that the carbon cloth-like uneven pattern is used. And a base layer made of a black thermoplastic resin in which 0.1% by weight to 10% by weight of a pearl pigment or metal powder is kneaded is formed on the lower surface side of the transparent layer.

  According to the present invention, a carbon cloth-like sheet having a three-dimensional feeling and brightness close to those of a real carbon cloth can be obtained.

  FIG. 1 is a cross-sectional view of a carbon cloth-like sheet 1 of the present invention. A transparent layer 3 made of a thermoplastic resin is laminated on a black base layer 2 made of a thermoplastic resin, and the base layer 2 and the transparent layer 3 are transparent. A carbon cloth-like uneven pattern 4 is formed on the boundary surface with the layer 3. A backing layer 5 is formed on the lower surface of the underlayer 2.

  The underlayer 2 is made of a moldable resin, and for example, ABS resin, polystyrene, polyethylene, polypropylene, acrylic resin, polyvinyl chloride, polycarbonate, polyamide, polyester and other known thermoplastic resins can be used. The underlayer 2 is preferably black in order to reproduce carbon cloth. The thickness of the underlayer 2 is preferably 100 μm to 1000 μm.

  In order to increase the brightness so that the carbon cloth-like uneven pattern 4 has a three-dimensional effect, a pearl pigment or metal powder such as aluminum powder may be kneaded into the resin constituting the underlayer 2. The amount to be kneaded is preferably 0.1% by weight to 10% by weight, and more preferably 1% by weight to 5% by weight. If the amount to be kneaded is less than 0.1% by weight, there is no effect of increasing the luminance, and if it exceeds 10% by weight, the blackness of the underlayer becomes weak.

  In order to enhance the three-dimensional effect, a high brightness layer 6 made of a paint containing a pearl pigment or metal powder such as aluminum powder may be formed on the entire surface of the carbon cloth-like uneven pattern 4 as shown in FIG. The high luminance layer 6 may be formed only on the convex / concave pattern 4a as shown in FIG. 3 or the concave / convex pattern 4b as shown in FIG.

  The transparent layer 3 is made of a thermoplastic resin and can be selected from resins that can be used as the base layer 2, but different resins may be used for the base layer 2 and the transparent layer 3. The transparent layer 3 may be completely transparent or translucent, such as a smoky transparent (these are collectively referred to herein as “transparent”). The thickness of the transparent layer 3 is preferably 50 μm to 1500 μm.

  The backing layer 5 may be provided as necessary, and the material can be selected from resins used as a transparent layer and a base layer.

  In order to produce the carbon cloth-like sheet of the present invention, the surface of the black thermoplastic resin sheet used as the underlayer 2 is a diaphragm having a carbon cloth-like concavo-convex pattern made by transferring from a real carbon cloth. The carbon cloth-like concavo-convex pattern 4 is transferred using a roll or a press plate. The transparent layer 3 is formed by heat-sealing a transparent thermoplastic resin sheet on the base layer to which the concavo-convex pattern has been transferred, or by casting the resin.

  In order to enhance the three-dimensional effect of the uneven pattern 4, a metal powder such as a pearl pigment or aluminum powder may be kneaded into the resin constituting the base layer 2. Also, after transferring the concavo-convex pattern 4 to the underlayer 2 or before transferring, a high brightness layer is formed by applying or printing a coating containing a pearl pigment or metal powder such as aluminum powder on the entire surface of the concavo-convex pattern 4. Also good. For coating and printing, known methods such as gravure, offset, spray coater, roll coater and knife coater can be used. In addition, the coating or printing of a paint containing metal powder such as pearl pigment or aluminum powder is applied only to the convex portion 4a (FIG. 3) or the concave portion 4b (FIG. 4) of the concavo-convex pattern 4 to form the high luminance layer 6. Also good.

  Further, the uneven pattern 4 may be formed on the lower surface of the transparent layer 3 without being formed on the surface of the underlayer 2. That is, the carbon cloth-like uneven pattern 4 is transferred to the lower surface of the transparent thermoplastic resin sheet to be the transparent layer 3 using a squeeze roll or a press plate, and the lower surface of the transparent layer 3 on which the uneven pattern 4 is formed. The base layer 2 may be formed by thermally fusing a thermoplastic resin sheet to be the base layer 2 on the side, or by casting a resin.

  When the concave / convex pattern 4 is formed on the lower surface side of the transparent layer 3, the high-luminance layer 6 is formed on the concave / convex pattern 4 of the transparent layer 3, but is transparent over the entire surface of the thermoplastic resin sheet to be the base layer 2. You may form in a convex part or a recessed part according to the uneven | corrugated pattern 4 of the layer 3. FIG.

  The backing layer 5 is formed by heat-sealing a thermoplastic resin sheet or casting a resin. However, even when the foundation layer and the transparent layer are laminated, the foundation layer is laminated on the transparent layer. It may be before.

<Example 1>
Carbon black 2% by weight and par pigment 2% by weight were added to a soft vinyl chloride compound (plasticizer 40PHR), and a sheet serving as an underlayer having a thickness of 300 μm was prepared by a calendering method. Next, using a press plate having a carbon cloth-like concavo-convex pattern created by transferring from a real carbon cloth, the concavo-convex pattern is transferred to this sheet by pressing at a temperature of 180 ° C. and a pressure of 50 kg / cm ^2. did.

A transparent soft vinyl chloride sheet with a thickness of 300 μm is placed on the surface of the sheet with the uneven pattern, and heat-sealed at a temperature of 150 ° C. and a pressure of 10 kg / cm ² using a mirror-shaped press plate. -A Boncross sheet was created.

<Example 2>
A chlorinated polypropylene primer was applied to a polypropylene sheet having a film thickness of 200 μm as an underlayer and dried at 70 ° C. for 3 minutes, and then a polyurethane paint (solid content 10% by weight, Carbon black 0.3% by weight and aluminum powder 0.2% by weight) was applied to a dry film thickness of 20 μm and dried at 80 ° C. for 5 minutes.

Next, using a press plate having a rugged pattern of carbon cloth prepared by transferring from a genuine carbon cloth, the rugged pattern was transferred to a sheet by pressing at a temperature of 180 ° C. and a pressure of 50 kg / cm ² .

A 200 μm thick acrylic film (PMMA) serving as a transparent layer is placed on the side of the sheet with the uneven pattern, and heat fusion is performed at a temperature of 150 ° C. and a pressure of 10 kg / cm ² using a mirror-like press plate. Thus, a carbon cloth-like sheet was prepared.

<Example 3>
Carbon black 2% by weight and par pigment 2% by weight were added to a soft vinyl chloride compound (plasticizer 40PHR), and a sheet serving as an underlayer having a thickness of 300 μm was prepared by a calendering method. Next, using a press plate having a carbon cloth-like concavo-convex pattern created by transferring from a real carbon cloth to a 200 μm thick acrylic film (PMMA) as a transparent layer, a temperature of 180 ° C. and a pressure of 50 kg / The uneven pattern was transferred to an acrylic film by pressing at cm ² .

A sheet serving as the base layer is disposed on the surface of the acrylic film having a concavo-convex pattern, and is heat-sealed at a temperature of 150 ° C. and a pressure of 10 kg / cm ² using a mirror-shaped press plate, and then carbon cloth is used. A tone sheet was created.

  Each of the carbon cloth-like sheets obtained in Examples 1 to 3 had a three-dimensional effect like a real carbon cloth and had a feeling close to the real one.

1 is a cross-sectional view of a carbon cloth-like sheet according to the present invention. Sectional drawing of another carbon cloth tone sheet. Sectional drawing of another carbon cloth tone sheet. Sectional drawing of another carbon cloth tone sheet.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Carbon cloth-like sheet | seat 2 Underlayer 3 Transparent layer 4 Concave / convex pattern 4a Convex part 4b Concave part 5 Backing layer 6 High brightness layer

Claims (3)

It has a black base layer made of a thermoplastic resin and a transparent transparent layer made of a thermoplastic resin laminated thereon, and a carbon cloth tone uneven pattern is formed on the boundary surface between the base layer and the transparent layer. cage, wherein the carbon cloth regulating sheet 0.1 wt% to the base layer 5 wt% Pearl Pigments are kneaded. Pearl Pigments to the surface of the base layer consisting of 0.1 wt% to 5 wt% kneaded crowded by comprising black thermoplastic resin, carbon cloth tone with grain roll or pressing plate having an uneven pattern of carbon cloth tone A method for producing a carbon cloth-like sheet in which a concavo-convex pattern is transferred and a transparent layer made of a thermoplastic resin is formed thereon. Using a squeezing roll or press plate with a carbon cloth-like concavo-convex pattern on the lower surface of a transparent sheet made of a thermoplastic resin as a transparent layer, the carbon cloth-like concavo-convex pattern is transferred to the lower surface side of this transparent layer. method for producing a carbon cloth pitch seat which faces charges forming a base layer consisting of 0.1 wt% to 5 wt% prepared by incorporating a black thermoplastic resin.

Images