JP2003225913A - Method for producing laminate with coat formed thereon - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a laminate with a coat formed thereon which is useful as a waterproofing seal material, etc., easily and inexpensively without requiring a complex apparatus, know-how, etc., with quality kept constant. <P>SOLUTION: A reaction mixed solution L containing a polyol, an isocyanate, and a catalyst is applied on a release sheet S, the solution L is heated from the application side S2 of the sheet S to accelerate the curing of the solution L, and a base material B of foam is mounted on the surface of the solution L under curing. After that, by finishing the curing of the solution L, the laminate P in which the coat C formed by the curing of the solution L is fitted on the surface of the base material B is obtained. In this way, the laminate P in which the surface shape of the base material B is kept constant, and the density change of the base material B is controlled and which has constant quality can be obtained. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a laminate having a coating film formed thereon.

[0002]

2. Description of the Related Art Conventionally, a product having a film formed on the surface of a foam has been used in various fields by utilizing its properties. One example is the use of waterproof sealing materials. In this waterproof sealing material, the sealing surface is required to be impermeable to moisture, and the requirement for the sealing surface can be satisfied by the coating. Further, the waterproof sealing material is often used in a state of being sandwiched between two objects, and it is generally required that the waterproof sealing material be compressed and deformed at that time, but the requirement can be satisfied by the foam. it can.

As a conventional method for producing a product in which a film is formed on the surface of the foam, a method of injecting a foaming raw material into a foaming mold to carry out foaming, and a side wall provided on both sides in the width direction of the transfer conveyor. Then, a method is known in which a foaming raw material is continuously injected onto the transfer conveyor between the side walls to perform foam molding.

However, in the former manufacturing method, since the shape and size of the product are determined by the shape and size of the foaming mold, there is little freedom in product size, and if the size of the product is large, the cost of manufacturing the foaming mold is low. There is a problem that becomes very high. Further, since the foam molding is performed in a closed space called a foam molding die, there is a problem that the density of the foam increases, the amount of foaming raw material used increases, and the product cost increases.

On the other hand, in the latter manufacturing method, since foaming is performed with the upper part of the transfer conveyor being open,
There is a problem that the top surface shape of the product is not uniform and the density is different in the vertical direction, which makes it difficult to achieve a uniform quality.

Further, in JP-A-9-183963, a raw material composed of an isocyanate-terminated prepolymer containing at least a tackifier is made into a fluid state by heating and then cast on a release sheet to form a film. There is disclosed a method for producing a waterproof sealing material by pressing a polyurethane foam onto the coating while the coating is in a fluid state and then curing the isocyanate-terminated prepolymer.

However, the isocyanate-terminated prepolymer which has been made into a fluid state by the heating is solidified at the temperature-decreasing portion when the temperature falls below a predetermined temperature before the pressure-bonding of the polyurethane foam after being cast on the release sheet. As a result, the adhesiveness decreases or disappears. Therefore, in order to uniformly and surely integrate the polyurethane foam and the film, the temperature of the release sheet on which the isocyanate-terminated prepolymer is cast must be maintained at a predetermined temperature and the temperature distribution should be uniform. Therefore, considerable equipment, know-how and precision are required for process control.

[0008]

SUMMARY OF THE INVENTION The present invention has been made in view of the above points, and provides a laminated body having a coating film suitable as a waterproof sealing material or the like with a constant quality and at a low cost.
In addition, the present invention provides a method that can be easily manufactured without requiring complicated equipment and know-how.

[0009]

According to the present invention, a reaction mixture containing a polyol, an isocyanate and a catalyst is coated on a release sheet, and the reaction mixture is heated from the side not coated with the reaction mixture of the release sheet. To accelerate the curing of the reaction mixture,
By placing a base material made of a foam on the surface of the reaction mixture during curing, and then completing the curing of the reaction mixture, a film formed by curing the reaction mixture is formed on the base material. The present invention relates to a method for producing a laminate having a coating film formed on the surface thereof.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described in detail below with reference to the accompanying drawings. FIG. 1 is a schematic view showing an example of an apparatus used in a method for producing a laminate having a coating film according to the present invention. Manufacturing apparatus 10 shown in FIG.
Is composed of a release sheet supply device 11, a discharge device 15, a doctor knife 17, a heating device 19, a base material supply device 25, and a pressing device 31.

The release sheet feeding device 11 includes a release sheet S.
The release sheet S is continuously fed in one direction from the release sheet roll 12 wound with, in this example, a horizontal direction,
The release sheet take-up roll 13 is rotated by a drive motor (not shown). The release sheet S has a surface S1 which is an upper surface when the release sheet S is supplied.
Is a paper or plastic sheet (including what is called a film) treated so as to have no or poor adhesion. The width of the release sheet S is appropriately determined according to the size of the target product. Further, between the release sheet roll 12 and the release sheet take-up roll 13, a support member such as a support roll or a support plate for contacting the lower surface of the release sheet S to support the release sheet S ( (Not shown) may be provided.

The discharging device 15 includes a surface S1 of the release sheet S.
A low-pressure injection device, etc., which is used as a device for discharging a polyurethane raw material, for discharging the reaction liquid mixture L onto the above,
Known ones are used. In the discharge device 15 of this example, a discharge nozzle 16 is arranged above the mold release sheet roll 12 and discharges the reaction mixture liquid L onto the mold release sheet surface S1.

The reaction mixture L is a film-forming raw material, contains a polyol, an isocyanate and a catalyst, and is made of a polyurethane raw material which forms polyurethane by the reaction. The polyol used is not limited. An example is polyetherpolyol. Further, the isocyanate used is not limited, but in the present invention, since the reaction mixture liquid L is heated via the release sheet S, MDI having low volatility is used.
Is preferred. As the catalyst, a catalyst used in the synthesis of polyurethane, which exhibits a catalytic ability under a certain condition after mixing the reaction mixture is used. Particularly, in the present invention, a temperature-sensitive catalyst that exhibits catalytic ability under temperature conditions is suitable. As an example of a temperature-sensitive catalyst, a block catalyst obtained by partially or wholly neutralizing an amine catalyst with a carboxylic acid, or a compound which is a sealing agent at all times and whose activity is blocked or suppressed, is heated by heat. Examples thereof include heat-activated catalysts in which amine catalysts are formed, and heat-sensitive catalysts in which the catalytic activity rapidly increases due to reduction of steric hindrance in the molecular structure of the catalyst by heating, proximity of electron pair to nitrogen atom, reduction of hydrogen bond and the like. Specifically, 1,
5-Diazabicyclo [4,3,0] nonene-5 octylate (DBN octylate) is particularly preferred. Other appropriate additives may be added.

The proportions of polyol, isocyanate, catalyst, and additives added as appropriate in the reaction mixture L are as follows:
The value is such that polyurethane can be formed by the reaction, and is determined by the polyol, isocyanate, catalyst, etc. used. Further, the reaction mixture L is the release sheet S.
2 for the reason that the doctor knife 17 can apply a uniform thickness to the surface S1 of the
It is preferable that the viscosity at 0 ° C. is 0.5 to 500 Pa · S. Further, the coating thickness by the doctor knife 17 is
Although it is appropriate, it is particularly preferably about 50 μm to 500 μm from the viewpoint that a coating film having appropriate flexibility and excellent waterproofness can be obtained.

The doctor knife 17 is used to uniformly apply the reaction mixture L discharged onto the surface S1 of the release sheet S as described above to the surface S1 of the release sheet S, and is made of a known material. It is arranged above the release sheet S between the discharge nozzle 16 and the base material mounting position E described later. The distance between the lower end of the doctor knife 17 and the surface S1 of the release sheet S is set according to the coating thickness of the reaction mixture liquid L.

The heating device 19 heats the reaction mixture liquid L applied to the surface S1 of the release sheet S in a required thickness from the reaction mixture liquid non-application side of the release sheet S, that is, the lower surface side. The first heating device 21 is used in this example.
And the second heating device 23.

The first heating device 21 performs first heating on the reaction mixture liquid L applied on the surface S1 of the release sheet S before the base material is placed on the release sheet S, It accelerates the curing of the reaction mixture L. The position of the first heating device 21 is preferably between the doctor knife 17 and the substrate mounting position E. In this way, the uniform application of the reaction mixture L by the doctor knife 17 is not hindered by the acceleration of the curing of the reaction mixture L, and the reaction mixture L having a low viscosity before starting the curing is excessive on the substrate. Can be prevented. Further, it is preferable that the first heating device 21 is arranged below the release sheet S so that the first heating is performed from the reaction mixture non-application side S2 of the release sheet S. In this way, the release sheet S
If the first heating is performed from the reaction mixture liquid non-application side S2, the laminated surface side of the reaction mixture liquid L with the base material is not directly heated, so that the curing proceeds too much and the adhesion or adhesion with the base material It is possible to realize strong integration with the base material without impairing the property.

The second heating device 23 is for second heating of the reaction mixture liquid L after the substrate is placed, and the curing of the reaction mixture liquid L is completed by this second heating. The position of the second heating device 23 is located downstream of the substrate mounting position E along the supply direction Q of the release sheet, and more preferably, the substrate and the reaction mixture L by the pressing device 31 described later are more preferable. It is on the downstream side of the crimping position F with. This is because when the second heating is performed on the upstream side of the pressure bonding position F, the curing of the reaction mixture L further progresses, and the adhesiveness or the tackiness of the substrate mounting surface in the reaction mixture L decreases. Then, even if the reaction mixture L is pressure-bonded to the base material at the pressure-bonding position F, the reaction mixture L does not exhibit sufficient adhesiveness or tackiness, and it is difficult to obtain the effect of increasing the bonding strength by pressure bonding. Further, the second heating device 23 is provided on the side S of the release sheet S on which the reaction mixture is not applied.
It is preferable to arrange it under the release sheet S so that the second heating can be performed from 2. This is because if the second heating is performed from the base material side, the heat insulation of the foam constituting the base material is hindered, and the reaction mixture liquid L cannot be efficiently heated.

The first heating device 21 and the second heating device 2
For 3, a known heating device such as an electric heater or a hot air device is used. Further, the heating temperature is set to a temperature at which the reaction mixture liquid L can proceed with curing, and varies depending on the composition of the reaction mixture liquid L and the like, but an example is about 50 to 150 ° C.

The base material supply device 25 is for supplying the base material B to the base material mounting surface L1 constituted by the upper surface of the reaction mixture liquid L applied to the surface of the release sheet S, In this example, the base material roll 26 wound with a series of base material B and the upper surface of the base material B supplied from the base material roll 26 come into contact with each other and rotate in accordance with the supply direction Q of the release sheet S. It comprises rotating rolls 27 and 28. The rotating rolls 27, 28
At least one of them is rotated by a drive motor or the like, whereby the series of base materials B is supplied in the same direction as the supply direction F of the release sheet S.

The base material B is made of foam. The foam constituting the base material B is appropriately selected, but elastically deformable is preferable. Examples include rubber sponge, polyolefin foam, polyurethane foam and the like.
Especially, the number of cells is 20 to 100 per inch,
More preferably 20 to 60 pieces / rubber sponge
Inches and polyurethane foams of 50 to 100 / inch are preferred. By using the foam having the number of cells in this range as the base material B, not only the waterproof property of the base material B itself becomes good, but also the base material B is impregnated with a part of the reaction liquid mixture L. An impregnation layer is formed between the material B and the impregnation layer, and the waterproof property of the product is further improved.

The pressing device 31 is arranged between the first heating device 21 and the second heating device 23 in this example, and presses the base material B toward the release sheet S, whereby the base material B reacts. It is pressed against the surface of the mixed liquid L. The pressing device 31 in this example is configured by a pressure roll, but may be another pressure plate or the like.

As another device, a product winding device may be provided, or a cutting device for cutting the product to a required size may be provided at a position downstream of the second heating device 23.

Next, a method for manufacturing a laminate having a coating film according to the present invention will be described using the manufacturing apparatus 10.
First, a series of release sheets S is continuously supplied from the release sheet roll 12 in one direction, in this example, a horizontal direction, and the release sheet take-up roll 13 continues to wind the release sheet S. Then, the reaction mixture L is continuously discharged from the discharge nozzle 16 onto the surface S1 of the release sheet S supplied from the release sheet roll 12, and the discharged reaction mixture L is the doctor knife 17. The release sheet S having a required thickness is evenly coated by the method.

Then, by the first heating device 21,
The reaction mixture liquid L is first heated from the reaction mixture liquid non-application side S2 of the release sheet S to accelerate the curing of the reaction mixture liquid L. Then, the base material B is supplied from the base material roll 26, and the base material B is mounted on the base material mounting surface L1 formed by the upper surface of the reaction mixture liquid L after the first heating. As a result, the reaction mixture liquid L that has started to be cured and the base material B are sequentially laminated on the release sheet S, and the pressing device 3 is in the laminated state.
Continuously sent to 1. Then, the base material B is pressed downward by the pressing device 31 and pressure-bonded to the reaction mixture liquid L, and the reaction mixture liquid L in the middle of curing and the base material B are surely brought into close contact with each other. At that time, if a foam having a number of cells within the above range is used as the foam constituting the base material B, a part of the reaction mixture liquid L is impregnated into the base material B and the surface of the base material B on the reaction mixture liquid L side. A reaction mixture impregnated layer is formed in the vicinity.

Then, by the second heating device 23,
The reaction mixture liquid L is secondly heated from the reaction mixture liquid non-application side S2 of the release sheet S to complete the curing of the reaction mixture liquid L. As a result, the reaction liquid mixture L becomes a coating C, which is firmly bonded and integrated with the base material B, and the laminated body P having the coating formed thereon is formed on the surface of the release sheet S.

After that, only the release sheet S is wound up on the release sheet take-up roll 13 to obtain the laminate P having the coating film as a product.

(Example) As a polyol, Curapol F3010 (OH value: 56, average number of functional groups: 3, manufactured by Kuraray Co., Ltd.) and Pracel 220AL (OH number: 56, average number of functional groups: 2, Daicel Chemical Industries, Ltd.) were used. , As an isocyanate, Coronate 1050 (NCO%: 23%, M
DI prepolymer, manufactured by Nippon Polyurethane Industry Co., Ltd., and Ucat1102 (DBN octylate, manufactured by San-Apro Co., Ltd.) were used as a temperature-sensitive catalyst. Were mixed with each other to prepare a reaction liquid mixture L of Examples 1 and 2.

[0029]

[Table 1]

Using the reaction mixture L of Examples 1 and 2,
Using the apparatus shown in FIG. 1, laminates having the coatings of Examples 1 and 2 were produced. At that time, each of the reaction mixture liquids L was applied onto the release sheet S by the doctor knife 17 so as to have a thickness of 100 μm. A PET film coated with silicon is used as the release sheet S, and a seal flex ESH (a urethane foam having 60 to 80 cells / inch, manufactured by Inoac Corporation) is used as the base material B with a thickness of 10 mm. What was done was used. Far-infrared heaters are used as the first heating device 21 and the second heating device 23, the first heating device 21 is set to 60 ° C. to perform the first heating, and the second heating device is set to 130 ° C. Second heating was performed. The pressure applied by the pressing device 31 is 9/1 for the base material B.
It was compressed to 0.

The laminated bodies having the coating films of Examples 1 and 2 had a plane dimension of 100 by cutting after the second heating.
It was set to 0 × 2000 mm. In the example products thus obtained, the thickness of the coating film was 50 μm, and the impregnation layer was formed between the coating film and the substrate in the range of 30 to 50 μm.

Further, according to the water stopping test method called the U-shaped test method, the above-mentioned example product was punched into a test piece having a U-shape with a width of 15 mm, and the test piece was sandwiched between acrylic resin plates. When the test was performed by compressing the material B to 50%, it was possible to hold the material B at a water pressure of 100 mmAq for 24 hours. Furthermore, it was possible to retain the water pressure of 200 mmAq for 24 hours, and it was confirmed that the water resistance was excellent.

In the description of the above embodiment, the case where the series of base materials are continuously supplied to continuously manufacture the product has been described, but the present invention is not limited to this, and is shown in FIG. Like the manufacturing apparatus 40, the base material B1 having a required size by cutting or the like may be placed on the surface of the reaction mixture liquid L which is first heated on the release sheet S.

[0034]

As shown and described above, according to the method for producing a laminate having a coating film of the present invention, it is possible to easily produce products of different sizes by changing the size of the release sheet. Since it is not necessary to recreate the foaming mold as in the conventional case, the product can be obtained easily and at low cost. Further, a product is manufactured by placing a preformed substrate on the surface of the reaction mixture on a release sheet, and freely foam-molded on a transfer conveyor with an open upper side as in the conventional case. Therefore, a product having a constant surface shape can be obtained. In addition, the product density does not change in the vertical direction at the time of foaming as in the conventional case, and the quality of the product does not fluctuate, and a product of constant quality can be obtained. Further, the required manufacturing equipment is not complicated, and the product can be manufactured rationally.

Further, in the present invention, the heating of the reaction mixture is carried out in two steps, that is, the first heating is performed before the substrate is placed on the surface of the reaction mixture and the second heating is performed after the substrate is placed. If you go
By the first heating, the reaction mixture can be in a proper impregnation state into the base material and in a curing progress state that achieves good adhesion or viscous state, and further, the second heating completely cures the reaction mixture. By doing so, the coating can be formed and the coating and the base material can be firmly and efficiently integrated.

Further, in the present invention, if the base material is pressure-bonded to the surface of the reaction mixture after the base material is placed on the surface of the reaction mixture, the contact between the base material and the reaction mixture is ensured. It is possible to form a coating film having a high bonding strength with the base material on the surface of the base material.

In the present invention, if a temperature-sensitive catalyst is used as the catalyst, the curing reaction of the reaction mixture can be easily controlled, and the product can be efficiently manufactured.

Further, in the present invention, if the reaction mixture is applied onto the release sheet with a doctor knife, the thickness of the coating film formed on the surface of the substrate can be made uniform, and the quality of the product can be made more uniform. Can be

Further, in the present invention, the release sheet is continuously supplied to continuously coat the reaction mixture on the release sheet, and the substrate is continuously coated on the surface of the reaction mixture being cured. By placing the laminate, it is possible to continuously produce a laminated body having a film formed thereon, and it is possible to obtain a product extremely reasonably and economically.

[Brief description of drawings]

FIG. 1 is a schematic view of an embodiment of a manufacturing apparatus used in the present invention.

FIG. 2 is a schematic view of a manufacturing apparatus when another base material is used.

[Explanation of symbols]

10 Manufacturing equipment 12 Release sheet roll 13 Release sheet take-up roll 16 discharge nozzles 17 doctor knife 21 First heating device 23 Second heating device 31 Pressing device B base material C coating L reaction mixture Laminate with P coating S release sheet S2 Reaction mixture non-coated side

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Claims (6)

[Claims] 1. A reaction mixture containing a polyol, an isocyanate and a catalyst is coated on a release sheet, and the reaction mixture is heated from the side not coated with the reaction mixture of the release sheet to cure the reaction mixture. By accelerating and placing a substrate made of a foam on the surface of the reaction mixture during curing, and then completing the curing of the reaction mixture, a film formed by curing the reaction mixture is formed. A method for producing a laminated body having a coating film formed on the surface of a base material. 2. The heating of the reaction mixture is carried out in two steps: first heating before placing the substrate on the surface of the reaction mixture and second heating after placing the substrate. A method for producing a laminate having the coating according to claim 1 characterized. 3. A laminate having a coating film according to claim 1 or 2, wherein the substrate is placed on the surface of the reaction mixture after the substrate is placed on the surface of the reaction mixture. Production method. 4. The method for producing a laminated body having a coating film according to claim 1, wherein the catalyst is a temperature-sensitive catalyst. 5. The method for producing a laminate having a coating film according to any one of claims 1 to 4, wherein the reaction mixture is applied onto a release sheet with a doctor knife. 6. A release sheet is continuously supplied, a reaction mixture is continuously applied onto the release sheet, and a base material is continuously placed on the surface of the reaction mixture during curing. The manufacturing method of the laminated body in which the coating film of any one of Claim 1 to 5 was formed.