JPH04352882A - Leather-like sheet-shaped laminate and formed body thereof - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a leather-like sheet-like laminate that can be well shaped by thermoforming and a molded product thereof.

0002

BACKGROUND OF THE INVENTION Hitherto, leather-like sheet materials have been heat-formed to produce camera cases, cases, and bags. For example, in the 1970s, it was possible to form camera cases by laminating artificial leather with lining fabric and applying high frequency processing.
3-65322, JP-A No. 2-21804, JP-A-2 No.
This method has been proposed in, for example, Publication No.-21805.

0003

[Problems to be Solved by the Invention] When manufacturing a molded article by drawing a conventional leather-like sheet material such as artificial leather, it is necessary to heat the leather-like sheet material to a temperature high enough to thermoform it. This is done by pressing the material to be molded under high pressure. As a result, molded products that place emphasis on shapeability are products that significantly lose their leather-like appearance and have a hardened feel and texture.

[0004] An object of the present invention is to provide an excellent leather-like sheet-like molded product that can be easily heat-formed at low temperatures, has good formability, and does not impair its leather-like appearance.

[0005]

[Means for Solving the Problems] The present invention provides a laminate comprising a surface layer of a leather-like sheet, a resin intermediate layer, and a backing layer, wherein the intermediate layer has a molding temperature at least 3 times higher than that of the other layers.
This is a leather-like sheet-like laminate characterized by being made of a resin whose molding temperature is 0°C lower.

The present invention also provides a laminate comprising a surface layer of a leather-like sheet, a resin intermediate layer, and a backing layer, wherein the intermediate layer is made of an ionomer resin and the temperature is at least 30° C. higher than the molding temperature of the other layers. This is a leather-like sheet-like laminate characterized by being made of a resin with a low molding temperature.

The present invention also provides a molded article of a leather-like sheet-like material laminate, which is obtained by thermoforming the leather-like sheet-like material laminate described above.

[0008] The leather-like sheet material used in the present invention is a knitted fabric, a woven fabric, a non-woven fabric made of synthetic fibers and/or regenerated fibers or natural fibers, or an integrated fiber aggregate of a knitted fabric and a non-woven fabric. On fabrics or those fabrics,
For example, fibrous sheets such as fabrics containing elastic polymers such as polyurethane elastomers, acrylonitrile-butadiene polymers, styrene-butadiene polymers,
In particular, the base layer is a soft and heavy fibrous sheet made of fiber-entangled nonwoven fabric of synthetic fibers with a fineness of 3 deniers or less containing a polymer mainly composed of polyurethane elastomer, and one side of the fibrous sheet is made of polyurethane elastomer, A sheet material obtained by applying a surface coating layer of a porous layer or a non-porous layer of a polymer mainly composed of a polymer with high bending fatigue resistance such as plasticized polyvinyl chloride is finished, and a colored coating layer is applied. smooth or textured surface,
This is a so-called silvered leather-like sheet material, or a so-called suede-like leather-like sheet material made by forming a raised fiber surface on one side of the above-mentioned fibrous sheet. The thickness of these leather-like sheets is appropriately determined depending on the intended use of the product, but the usual thickness is 0.5 to 3.0 mm.

[0009] The resin constituting the intermediate layer has a molding temperature that is at least 30°C lower than the molding temperature of the surface layer and the backing layer, and usually has a molding temperature in the range of 80 to 170°C. Resins with high molding temperatures require high thermoforming temperatures to obtain good shaping properties, resulting in molded products that are no different from conventional thermoforming of leather-like sheet materials and have many defects.On the other hand, with resins with low molding temperatures, Deformation may occur due to heat treatment applied in a subsequent process, such as curing the adhesive. The molding temperature referred to in the present invention is determined by comparing the sheet materials constituting each layer at a temperature at which the heat fixation rate measured in accordance with JIS K-6546 "Test method for hemispherical plasticity of leather" is 40% or more. An intermediate layer resin having a thermoforming temperature difference of at least 30°C, preferably 40°C or more is used. Examples of such resins include polyethylene, ethylene copolymer, polypropylene, ethylene vinyl acetate copolymer or partially saponified products thereof, polybutylene terephthalate, polyhexamethylene terephthalate, 6-nylon, 11-nylon, and 12-nylon. In terms of shape stability after molding, the bending elastic modulus of the resin at room temperature is 1500 kg/cm2 or more,
It is preferable to use one with a weight of 2000 Kg/cm2 or more. However, even if the resin meets the above requirements, resins that do not maintain heat fixability over a long period of time, such as isoprene rubber and butadiene rubber, are outside the scope of the present invention, but polyurethane elastomers By selecting the segments, a resin having a composition that satisfies the above requirements can be obtained.

[0010] Furthermore, it is an object of the present invention to provide a molded product which imparts especially good formability and toughness to the leather-like sheet-like material laminate of the present invention, and which does not impair the appearance, feel, etc. of the leather-like sheet-like material. In some cases, for example, olefins such as ethylene and propylene or compositions of olefins and other vinyl monomers are copolymerized with 3 to 10 mol% of metal salts such as methacrylic acid or acrylic acid, or vinyl monomers that form metal crosslinks. By using an ionomer resin obtained by crosslinking the obtained copolymer with metal ions for the intermediate layer, a laminate that can be thermoformed at low temperature and has good shape stability can be obtained. The thickness of these resin layers is appropriately selected depending on the thickness of the leather-like sheet material and the thickness of the laminate, but they are usually films or sheets with a thickness of 20 to 500 .mu.m. If the thickness is outside this range, a sufficient fixing effect will not be obtained or the thermoforming cycle will become longer, which is undesirable.

[0011] The backing material of the leather-like sheet-like laminate is selected as appropriate depending on the intended use of the molded product, but is usually a knitted fabric made of synthetic fibers and/or recycled fibers or natural fibers,
Fabrics such as woven fabrics, non-woven fabrics, or integrated fiber aggregates of knitted woven fabrics and non-woven fabrics, or these fabrics are coated with elastic polymers such as polyurethane elastomers, acrylonitrile-butadiene polymers, styrene-butadiene polymers, etc. A material selected from the group consisting of fibrous sheets containing polyester, polyethylene, polypropylene, polyamide, ethylene vinyl acetate or partially saponified products thereof, and synthetic resin films and sheets such as vinyl chloride polymers is used. In particular, when a leather-like sheet containing an elastic polymer in a nonwoven fabric is used as the backing material, deep drawing becomes possible, and the appearance of the laminate becomes a leather-like sheet itself, giving the molded product a luxurious feel. is obtained.

[0012] Next, the method for forming a leather-like sheet-like laminate and manufacturing a molded product made from the same involves applying a resin film or a sheet-like material and a backing material to the back side of a desired leather-like sheet-like material, and forming an intermediate resin layer. the temperature at which it softens or melts,
Preferably, a leather-like sheet laminate is prepared in advance by hot plate pressing or hot roll pressing at a temperature of 170° C. or lower, or a resin for the intermediate layer is melted between the back surface of the leather-like sheet and the backing material. A method of extruding a laminate by roll pressing and then thermoforming a molded product of a desired shape at the molding temperature of the intermediate resin layer, or adding a resin film or a sheet material and a backing layer to the back of the desired leather-like sheet material. Place the material in the mold and set the molding temperature of the intermediate resin layer,
Preferably, it is a method of thermoforming at a temperature of 170° C. or lower to form a molded product of a desired shape made of a leather-like sheet-like material laminate all at once.

[0013] Moldings of leather-like sheet-like laminates include cases, bags/travel bags, school bags, shoes, daily necessities, furniture, interior decoration goods, sporting goods, automobiles, etc.
It is processed and used as interior materials for vehicles, parts for clothing design, etc. It is particularly suitable as a deep drawn product.

Next, the leather-like sheet-like material laminate of the present invention will be explained with reference to the drawings. FIG. 1 is a schematic cross-sectional view of a leather-like sheet-like material laminate, and FIG. 1 (1) is a leather-like sheet-like material laminate consisting of a surface layer of a leather-like sheet-like material 2 with silver, a resin intermediate layer 4, and a backing layer 5. FIG. 1(2) shows a leather-like sheet-like laminate consisting of a surface layer of a suede-like leather-like sheet-like material 3, a resin intermediate layer 4, and a backing layer 5.

[0015]

[Operation] The present invention provides a laminate consisting of a surface layer of a leather-like sheet, a resin intermediate layer, and a backing layer, in which the intermediate layer contains a resin whose molding temperature is at least 30°C lower than the molding temperature of the other layers. By using an ionomer resin, the leather-like sheet-like laminate can be thermoformed at low temperatures and has good formability and toughness, improving the appearance and feel of the leather-like sheet. It is possible to obtain a molded article that does not impair the properties.

[0016]

[Example] Next, embodiments of the present invention will be explained with reference to Examples. In addition, parts and percentages in the examples refer to weight unless otherwise specified.

Example 1, Comparative Example 1 The surface of the fibrous base layer consisting of an entangled nonwoven fabric of nylon ultrafine fiber bundles and polyester/polyether polyurethane elastomer was finished with a napped surface of ultrafine fibers, and dyed and finished. The obtained suede-like leather-like sheet material with a thickness of 0.8 mm (heat treatment temperature 140°C with a heat fixation rate of over 40%)
An ionomer resin film (metallic crosslinked product of ethylene-methacrylic acid copolymer, heat treatment temperature 65°C with a heat fixation rate exceeding 40%) with an average thickness of 100 μm is applied as an intermediate layer to the back side of the above fibrous base layer. A laminate in which a sheet-like material sliced into 0.4 mm thickness (heat treatment temperature 140°C or higher with a heat fixation rate of over 40%) was applied as a backing material was heat-treated from the backing surface at a heat treatment drum surface temperature of 95°C, A leather-like sheet-like laminate was obtained by pressing at a gauge pressure of 1.5 kg/cm2.

[0018] This leather-like sheet-like material laminate is used as the outer material of a handbag, and the product is cut into the shape of the desired handbag, which is shaped and fixed by ironing at a low temperature, and then sewn and parts are attached. The product obtained is
A good product was obtained that had excellent mold cohesion and shape retention, and did not lose its suede-like, heavy-feeling appearance, textured appearance, and elastic touch.

For comparison, a leather-like sheet laminate in which the suede-like leather-like sheet of Example 1 and sliced sheets were laminated with a polyurethane adhesive was used and similarly processed into a handbag. As a result, it turned out that the molds were not cohesive because the molding could not be done sufficiently.

Example 2 A colored porous coating layer of polyester polyurethane elastomer was formed on the surface of a fibrous base layer consisting of an entangled nonwoven fabric of polyethylene terephthalate ultrafine fiber bundles and polyester polyurethane elastomer, and colored and embossed. A silver-plated leather-like sheet material with a thickness of 1.2 mm (heat treatment temperature exceeding 40% with a heat fixation rate of 14%)
An ionomer resin film (metallic crosslinked material of ethylene-methacrylic acid copolymer, heat-treated at 65°C with a heat fixation rate of over 40%) with an average thickness of 100 μm is placed on the surface of the base layer (0°C or higher).
) and nylon tricot (heat treatment temperature 140°C or higher with a heat fixation rate of over 40%) was applied as a backing material, the laminate was heat treated from the backing surface at a heat treatment drum surface temperature of 95°C, and the gauge pressure was 1.5Kg/ A leather-like sheet-like laminate was obtained by pressing at cm2. This leather-like sheet-like laminate was molded into a camera lid using a vacuum drawing machine at a molding temperature of 145°C.

[0021] The obtained molded product has excellent mold cohesion and shape retention, has a solid appearance with a leather-like surface, has a good elastic feel, etc., and is good even after repeated use. A product with excellent bending fatigue resistance was obtained.

Example 3, Comparative Example 2 The silvered leather-like sheet material of Example 2 was used as the surface layer, and the intermediate layer resin was an unstretched film of polyhexamethylene terephthalate-based polyester film with an average thickness of 150 μm (heat setting rate: 40). The laminate, in which a heat treatment temperature of 75°C exceeding The bag obtained by attaching reinforcing materials to the bag body, handles, etc. has excellent shape retention and shape retention, and has a solid appearance with a leather-like sheet on the surface, and has elasticity. The tactile sensation was not impaired and was good.

For comparison, nylon tricot was laminated on the silvered leather-like sheet of Example 2 via a polyurethane adhesive, and deep drawing was performed at a forming temperature of 150°C, but sufficient drawing was not possible. The mold was not well organized and the shape retention was also poor. Therefore, in order to obtain a molded product with the same degree of cohesiveness and shape retention as in Example 3, the molding temperature was raised to 185°C and deep drawing was carried out. As a result, the entire molded product was hardened and had a leather-like appearance. , the tactility was impaired, resulting in a vinyl-like product.

[0024]

Effects of the Invention: The leather-like sheet-like laminate of the present invention can be thermoformed at low temperatures, has good formability and toughness, and has a solid feel to the leather-like sheet. It is possible to obtain a leather-like sheet-like molded article that does not impair good appearance and feel, has a stable form, has high delamination strength, and has high resistance to bending fatigue.

[Brief explanation of drawings]

FIG. 1 is a schematic cross-sectional view of a leather-like sheet-like material laminate of the present invention.

[Explanation of symbols]

1 Leather-like sheet-like material laminate, 2　Silver-like leather-like sheet material, 3 Suede-like leather-like sheet material, 4 Resin intermediate layer, 5 Backing material layer.

Claims (3)

[Claims] Claim 1: A laminate comprising a surface layer of a leather-like sheet, a resin intermediate layer, and a backing layer, wherein the intermediate layer is made of a resin whose molding temperature is at least 30°C lower than the molding temperature of the other layers. A leather-like sheet-like laminate characterized by: 2. A leather-like sheet-like material laminate according to claim 1, wherein the resin intermediate layer is made of an ionomer resin. 3. A molded article of a leather-like sheet-like material laminate, which is obtained by thermoforming the leather-like sheet-like material laminate according to claim 1 or 2.