JPH0446223B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (a) Field of Industrial Application The present invention relates to a novel method for manufacturing a laminate. More specifically, it relates to a method for producing a laminate that has excellent properties such as flexibility, water absorption, oil absorption, and cushioning properties and is useful as interior materials for vehicles, pine materials, packaging materials, civil engineering materials, etc. .

(b) Prior Art Vehicle interior materials, packaging materials, containers, etc. using paper or synthetic resin cardboard have been proposed.

An example of such an interior material is an interior material that uses a synthetic resin cardboard with a thermoplastic resin sheet bonded to one or both sides of the core material, which is a textured thermoplastic resin sheet that has been textured.

For example, Japanese Utility Model Application Publication No. 49-172 proposes a curved panel for interior use in which a thermoplastic resin nonwoven fabric or synthetic leather layer is laminated on the surface of a thermoplastic resin air-filled corrugated board. Kaisho 49-64915
Similar interior materials have also been proposed in Japanese Utility Model Publication No. 53-82019.

In both of these methods, first a synthetic resin cardboard board is molded, then the cushioning material and skin material are layered via an adhesive layer, and then each layer is bonded using heat and pressure using a press molding machine or vacuum molding machine. A method has been adopted to do so.

This method has problems in terms of productivity because the steps are complicated and discontinuous. Also,
In the bonding process, insufficient heat and pressure will cause poor adhesion between the layers of the laminate, while excessive heat and pressure will cause deformation and deterioration of the synthetic resin cardboard or skin material. It has the problem of being narrow and prone to producing defective products.

Further, a proposal for improving the drawbacks of the above-mentioned method to some extent is disclosed in Japanese Patent Application Laid-Open No. 55-67444.

In this method, a single-sided corrugated board consisting of a core and a first surface layer is used in advance, and a second surface layer is laminated to produce a double-sided corrugated board, while the second surface layer is still in a molten state. The synthetic resin cardboard board and the skin material are thermally bonded by supplying an adhesive film and/or skin material to the surface and softening the adhesive film or skin material using the melting heat of the second surface layer. That is.
All of these interior materials have rigidity but lack flexibility, so they always require secondary processing such as press molding or vacuum forming for molding, and they have the disadvantage of being difficult to handle. Also,
Manufacturing costs will also be high.

On the other hand, when packaging mechanical parts for knock-down export, they are immersed in oil to prevent rust.
Some methods include wrapping the product in plastic film, etc., and shipping it overseas after packaging. At that time, the oil soaked in the package accumulates on the bottom of the package, making it difficult to dispose of the oil, and there is a need for packaging materials that are effective in dealing with this problem.

(c) Problems to be solved by the invention As mentioned above, in the conventional technology, the manufacturing process is complicated, productivity is low, the range of appropriate processing conditions for the bonding process is narrow, and defective products are likely to occur. However, there are various problems such as the resulting product has poor flexibility and requires secondary processing such as molding, the manufacturing cost is high, and it is not suitable for packaging for knock down export. are doing.

In view of these points, the present invention is relatively lightweight and flexible, and can be used in fields that do not require much rigidity, such as interior materials for vehicle trunks, or because it does not have a conventional liner layer. When manufacturing laminates that can be used for knock-down packaging materials that require water or oil absorption, civil engineering materials, pine materials that require cushioning properties, etc., conventional It is an object of the present invention to provide a method for simplifying the complicated steps in manufacturing cardboard and manufacturing a laminate at low cost.

(d) Means for Solving the Problems The present invention provides at least two sheets in which a breathable base material is directly heat-sealed to the base surface of a textured sheet made of thermoplastic resin.
A method for manufacturing a laminate consisting of layers, that is, a breathable base material and a molten thermoplastic resin sheet are laminated, and while the molten thermoplastic resin sheet is in a softened state, suction is applied from the surface of the molten thermoplastic resin sheet to continuously produce the laminate. The present invention provides a method for manufacturing a laminate, which is characterized by subjecting the laminate to irregularities.

The thermoplastic resin used in the present invention includes high, medium, and low density ethylene homopolymers, ethylene-butene-1 copolymers, and ethylene-butene-1 copolymers.
Hexene-1 copolymer, ethylene-octene-1
Copolymers with α-olefins mainly composed of ethylene, such as copolymers, or copolymers with other α-olefins mainly composed of polypropylene, propylene, polybutene-1, poly-4-methylpentene -1 and other polyolefin resins, and graft-modified products of these with very small amounts of polar monomers such as unsaturated carboxylic acids such as acrylic acid and maleic acid or derivatives thereof, nylon-6, nylon-
6,6, polyamide resins such as nylon-12, polyvinyl alcohol resins, polyester resins, polystyrene resins, saponified products of ethylene-vinyl acetate copolymers, polycarbonate resins,
Polyvinyl chloride resins, polyvinylidene chloride resins, and mixtures thereof, which have relatively high crystallinity and good processability, are used. Among these resins, polyolefin resins are preferred because they are versatile, inexpensive, and have good processability.

In addition, these thermoplastic resins may be added with inorganic or organic fillers such as calcium carbonate, talc, and glass fiber, as well as conventional additives such as ultraviolet absorbers, antioxidants, pigments, foaming materials, lubricants, and antistatic agents. Additives such as flame retardants, fillers, rubbers, etc. may be added.

The breathable base material of the present invention includes the above-mentioned polyethylene,
Thermoplastic resins such as polypropylene, polyamide, and polyester are extruded into a network, or various filaments spun from the above resins, synthetic fibers, and natural fibers are bonded together by spinning, adhesion, and fusion, as needed. Examples include woven fabrics or nonwoven fabrics processed by needle punching or the like, split woven nonwoven fabrics of resin films, paper, felt, cardboard waste, synthetic pulp, and the like. The present invention also includes inorganic breathable materials made of metals or minerals, such as net-like bodies made of flexible thin films, punched foils, and metal fibers.

(E) Effect As mentioned above, in the method for manufacturing a laminate of the present invention, a thermoplastic resin sheet is used, and while the sheet is in a softened state, an uneven process is applied to the sheet, and at the same time, the process is performed without using an adhesive. Breathable substrates can be directly fused. Therefore, the laminate can be manufactured easily and at low cost.

In addition, both materials are lightweight and flexible, so
The laminate is lightweight and has cushioning properties, has a wide range of uses, and can be rolled into a roll, making it convenient for storage and transportation.

In addition, since the breathable base material is porous, it adheres well to the thermoplastic resin sheet, and furthermore, the breathable base material also acts as a filter, so it can be used as drainage material or knock-down export packaging material, etc. as described later. It can also be used for other purposes.

(f) Examples The present invention will be further explained in detail based on the drawings.

FIG. 1 is a perspective view of one embodiment of a laminate manufactured by the method of the present invention. A laminate 1 includes a textured sheet 2 having a large number of recesses 3 and a breathable base material 4.
It consists of at least two layers. The textured sheet 2 is made of the thermoplastic resin mentioned above, and the breathable base material 4 is made of the various breathable materials mentioned above, and is directly thermally fused to the base surface 5 of the textured sheet 2.

The above heat welding is carried out by thermocompression bonding the breathable base material while the resin is in a softened state when the thermoplastic resin is subjected to the uneven processing.

Further, if necessary, a suitable liner 7 such as a thermoplastic resin sheet or a melt-extruded film can be attached to the convex surface 6 (outer surface of the concave surface 3) to increase the rigidity of the laminate 1.

FIG. 2 is a schematic explanatory diagram of the manufacturing process of the laminate of the present invention. The molten thermoplastic resin 12 extruded from the T-die 11 is laminated with a breathable base material 13 and introduced onto a circulating forming belt 14. This forming belt 14 has a large number of through holes of arbitrary diameters. When the molten thermoplastic resin side of the two layers is suctioned by the suction box 15 through the forming belt 14, the softened thermoplastic resin 12 is textured and a large number of recesses 3 (first A laminate having a two-layer structure consisting of a layer of thermoplastic resin 12 and an air-permeable base material 13 is obtained.

Furthermore, if necessary, in order to bond a liner to the convex surface 6, a thermoplastic resin sheet (a molten sheet may be used) is introduced, and after being pressed and bonded by thermocompression with a thermocompression roll 17, annealing is performed as necessary. After removing the strain, the laminate 18 can be manufactured continuously. Furthermore, since the laminate of the present invention is flexible, it can also be wound up into a roll as a product.

(g) Effects of the invention As mentioned above, in the method for manufacturing a laminate of the present invention, two components, a thermoplastic resin sheet and an air-permeable base material, are used.
By suctioning the layers, uneven processing and fusion are performed simultaneously, and compared to conventional manufacturing methods,
It can be manufactured easily and inexpensively.

Furthermore, when using the laminate produced using the method of the present invention for interior materials for the trunk or other parts of a vehicle, it can be used as is without the need for secondary processing such as press forming or vacuum forming. It not only has good properties but is also easy to handle.

Furthermore, since the laminate can be rolled up and handled, it is convenient for storage and transportation.

Furthermore, even in cases where oil is a problem, such as in knock-down export packaging, the laminate of the present invention has recesses, and the oil collects in the recesses through the breathable base material, making it easier to handle the packaged items. becomes easier.

On the other hand, since the laminate of the present invention has cushioning properties,
It can also be used as a carpet-like product such as a golf practice mat, a vehicle floor mat, or a general floor mat.

In addition, a laminate consisting of three layers with a liner bonded to the convex surface is made by creating a large number of pores in the base surface, which is the bonding surface between the thermoplastic resin and the breathable base material.
The breathable base material acts as a filter and can also be used as a drainage material with good drainage.

Furthermore, the manufacturing method of the present invention has various advantages, such as being able to manufacture without using adhesives and thus preventing contamination by solvents.

[Brief explanation of the drawing]

FIG. 1 is a partial perspective view of an embodiment of the laminate of the present invention, and FIG. 2 is a schematic illustration of the manufacturing process of the laminate of the present invention. 1... Laminated board, 2... Textured sheet, 3...
Recessed portion, 4... Breathable base material, 5... Base surface, 6... Convex surface, 7... Liner, 11... T-die, 12...
Molten thermoplastic resin, 13... Breathable base material, 14...
...Molding belt, 15...Suction box, 1
6... Thermoplastic resin sheet, 17... Pressure roll, 18... Laminate board.

Claims (1)

[Claims] 1. A breathable base material and a molten thermoplastic resin sheet are laminated, and while the molten thermoplastic resin sheet is in a softened state, the surface of the molten thermoplastic resin sheet is continuously suctioned. A method for producing a laminate comprising at least two layers, the method comprising applying an uneven finish. 2. The method for manufacturing a laminate according to claim 1, wherein the thermoplastic resin is a polyolefin resin. 3 The breathable base material and the molten plastic resin sheet are laminated, and while the molten thermoplastic resin sheet is in a softened state, the surface of the molten thermoplastic resin sheet is suctioned to continuously form an uneven surface. 2. The method for producing a laminate according to claim 1, wherein a thermoplastic resin sheet is laminated on the convex surface.