JP2007301965A - Solid forming method and its molded article in heat-resistant resin film material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a medical treatment with higher safety, and social welfare services, and to induce resources of a product twisted reusable, and an environment or very big social merits, such as damping of medical expenses cost which continues expanding at the present time. <P>SOLUTION: A manufacturing process of a film molding which makes core airtight liquid-tightness integrity comprises the steps of heating beforehand a super-high heatproof resin film obtained by performing extrusion molding to a film shape of a predetermined thermoplastic resin which undergoes an improvement modification of the refractory by performing extrusion molding to the film shape to raise a temperature beforehand and a mold of high-frequency welder which kept it warm to carry out a prescribed time contact, and raising it to a predetermined temperature in a solid forming method with a heat-resistant resin film material, and adhering/welding it by furthermore applying a high frequency. Further, a manufacturing process of a chemical fiber integral film molding carries out direct extrusion molding of the fused elastomer resin to a chemical fiber rear surface. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for producing a film molded body using a heat-resistant resin film material, and a molded product obtained by the production method.

Among various sterilization methods currently used in the medical field, there is a high-pressure steam sterilization process.
In this method, all pathogens can be obtained by placing machinery and equipment to be sterilized in a high-pressure steam sterilizer (autoclave) and performing high-temperature and high-pressure treatment of 132 ° C / 5 minutes (121 ° C / 20 minutes, 114 ° C / 45 minutes) This sterilization method is officially instructed by the Ministry of Health and Welfare and the World Health Organization (WHO) as a sterilization method for AIDS and hepatitis, and is completely effective in preventing infections of all pathogenic bacteria and viruses. To do. However, products of natural and chemically synthesized resins such as plastic and rubber have a low melting point of around 100 ° C., and plastic deformation occurs due to the above-mentioned high-pressure steam sterilization. Was not available. For this reason, at present, most of the various resin products used in the medical field are not disposable because they are regarded as “disposable”. However, there is a problem that the cost is high. Or, as another method, sterilization with disinfectant, ethylene oxide gas or ozone is performed, but sterilization with each disinfectant is often incomplete, and harmful disinfectant remains. There are concerns, and the sterilization method using ethylene oxide gas or ozone has many disadvantages compared to the high-pressure steam sterilization method, such as a high risk to the human body due to residual components such as gas.

In addition, the resin films currently used in the medical field are used as various resin parts, but the resin used in them is not much different from the resins used in general. In any material, plastic deformation, melting, or deterioration deformation occurs at around 100 ° C. This is because the surface area of contact with the external environment in the shape of a film is very large compared to other resin molded products, and it is easily affected by external heat and humidity. This is because the product is particularly weak in durability and is in a severe condition.
Therefore, especially high-pressure steam sterilization of film resin products manufactured by the welder molding method, such as conventional sphygmomanometer wristbands, air mats for medical beds, and various medical covers, regardless of their size, shape, etc. There was a strong demand from the market to be able to handle it.

  Furthermore, a method for obtaining a synthetic composite resin film obtained by laminating an elastomer film and a fiber material obtained in accordance with the present invention, which are necessary at the time of producing various products, has also been demanded.

  In order to solve these problems, various elastomers have been developed. For example, as seen in JP-A-2004-107559 and JP-A-2003-136660, a polyester resin having a relatively high melting point or a crosslinking treatment is used. Many attempts have been made to solve the problem by a technique such as obtaining a high melting point resin by providing a molecular cross-linking structure. However, these are used as various packaging materials that require the mechanical strength and rigidity of the film, and are sufficient as post-processability for products related to medical products such as adhesiveness, or as essential conditions for the purpose of use on the human body. There is a problem that it cannot be used due to lack of flexibility.

References

JP 2004-107559 A JP2003-136660

  In addition to solving the above problems, in particular, in view of many improvements such as ease of use and cost of resin product equipment related to medical care, a method for producing a film molded body using a heat-resistant resin film material and a molded body obtained by the manufacturing method are provided. It is to be.

In order to solve the above-described problems, the present invention performs molding of a predetermined thermoplastic resin into a film shape (extrusion molding such as calendar molding and T-die molding) in a three-dimensional formation method using a heat-resistant resin film material. The temperature of the high-frequency welder mold itself is preheated to a predetermined temperature and kept in contact with these molds for a predetermined time to increase to a predetermined temperature. This is a method for producing a film molded body that is welded so as to be able to approach the matching point of the high-frequency welder more smoothly so as to be in an airtight and liquidtight state.

  The thermoplastic resin is based on a thermoplastic polyurethane elastomer (TPU) for molding, and a special polyurethane elastomer having improved heat resistance by compounding (mixing) a predetermined amount of polycarbonate in a molten state at a predetermined temperature; It is to be.

  In addition, various types of heat-synthesized chemically synthesized fibers for high-pressure steam sterilization treatment, or a urethane-based adhesive is uniformly applied to at least one surface of the synthetic fiber, or melted to the coated surface A method for producing a synthetic fiber film molded body in which an elastomer resin is extruded is also conceivable.

  Moreover, this invention is a molded article obtained by the manufacturing method made with the special polyurethane-type elastomer which improved the heat-resistant performance and the molded article obtained by the manufacturing method of the said film molded object.

  Furthermore, this invention is a molded article obtained by the same manufacturing method made with the special polyurethane type elastomer which improved the heat resistant performance and the molded article obtained by the manufacturing method of the said synthetic fiber composite film molded object.

As described above, according to the present invention, all the existing resin film products, welder processed products (not hollow bodies, gas- or liquid-filled products with airtight or liquid honey, and open solids with a predetermined pressure), and The hollow body by the welding process can be subjected to high-pressure steam sterilization.
In addition, the present invention can be applied to a sewn product of these reinforced cloth-like resins by pasting with a synthetic fiber fabric having a peel strength of 8 N / cm to 15 N / cm. For example, it is considered that it can be used as medical waterproof cloth, sterilization, antifouling cloth, predetermined medical clothes, apron, curtain, etc., as well as predetermined pressure release type air mat etc. Diversion is possible.

Compared to the prior art, which uses sewing as a processing method, the present invention enables welder processing, and therefore, by realizing high airtightness that cannot be achieved conventionally, various fillings such as gas or liquid are filled inside. It can be used without leaking, and it can be used for sphygmomanometer armbands, complex-shaped seat cushions, water pillows, hot water bottles, etc. It has also become possible to form structures.
Furthermore, to lower-level products (for example, products that only support up to 120 ° C, products that do not have sufficient peel strength and break immediately, or have a limited number of times of high-pressure steam sterilization) There is also a lot of potential for application.

For example, as described in [Production of Elastomer Film] having the above-described structure, a method of increasing the degree of the sublimation structure and increasing the heat resistance by irradiating the resin with an olefin elastomer resin or an inexpensive vinyl chloride elastomer resin, etc. Also, the coating method such as dipping or topping calendering method (both placing the resin on the fabric surface and stretching it with a spatula) can be used for laminating the resin to a film or synthetic fabric without using the laminating method. It is also possible to produce a waterproof / antifouling fabric having a hard resin film and capable of high-pressure steam sterilization using a system technology.
Since the film pressure is not uniform, the amount of resin in the melted part is not uniform, so it is suitable for hollow bodies that require high airtightness and tear strength on the welder surface, such as high-frequency welding and heat sealing. However, it is sufficiently possible to create a conventional sewn product considering only waterproofness such as bed sheets.

  In addition, when considering cost reduction, the standardization of this high-pressure steam sterilization product will lower the level of technology, or conversely, for applications and products that do not require special flexibility, select an appropriate resin. -By selecting the fabric, it is considered possible to produce even higher heat-resistant films, and it is fully possible that these technologies will be derived.

  Examples of these include operating tables in operating rooms, covers for precision machinery and equipment, practitioners' apron, etc., which are frequently contaminated with blood and drugs and always require high-pressure steam sterilization. Covers for used sheets, wheelchair cushions, air pillows, posture change / holding pads, etc. for patients who are at risk of infection even in the nursing / nursing field, as well as ventilation pressure air mats and treatment for preventing floor rubbing At present, it is possible to produce all instruments and articles that cannot be properly sterilized, such as ozone for use and medicine ejection mats.

  Therefore, the present invention produces extremely great social merits such as providing safer medical / welfare services and resources / environment due to product reusability, or reducing medical costs that are currently expanding. .

With the success of these development and establishment of manufacturing methods, plastic films or resin film bonded fabrics (chemical fibers), such as sphygmomanometer armbands, air mattresses, mats, and cushions that can be sterilized with high-pressure steam, were established. It is possible to manufacture welder processed products made of unitary resin film), and to perform “complete sterilization” methods approved by WHO for these products. With these realizations, it is possible to sterilize by a more reliable, simple and inexpensive method without using a sterilization method that may cause adverse effects on the human body due to residues, etc., and improve safety at the medical site. Conceivable. Furthermore, because of the physical properties of the material, a film product that has been “disposable” in the past can be reused, which has a great effect on cost reduction of medical costs.

  By studying and improving as much as possible using conventional resins and various additives as much as possible, the required and sufficient required performance can be satisfied, the cost can be reduced, and a device and processing method with a simple structure. With the goal of achieving the above, the present invention has solved the problems and achieved the object.

As the material for the special heat-resistant resin, the high heat-resistant (PH) series, which is a special grade of high-functionality (P) grade, from the Resamine series of thermoplastic polyurethane elastomers (TPU) for molding used by Daiichi Seika Kogyo. These generally have high heat resistance, and have high pressure resistance, low strain, low temperature deformation and little change in altitude due to low temperatures. Of the resamine PH grades, the present invention selects resamine PH 890 having a hardness of 90 degrees, and further improves the viscosity characteristics in order to improve blocking resistance.
This is because the special heat-resistant resin thus completed has both flexibility and high heat resistance compared with conventional polyester elastomers such as Toilet Du Pont's Hytrel and Toyobo's Perprene.

Embodiments of the present invention will be described with reference to the drawings. FIG. 1 is an explanatory view of the production process of the ultra-high heat resistant resin film of the present invention. This is mainly a T-die molding method which is a kind of extrusion molding.
As shown in FIG. 1, a sheet 11 having a thickness of about 2 mm to 0.3 mm from a slot-like extrusion port 12 by a screw 11 provided with a molten material (mixture of polyurethane resin and polycarbonate) in a resin container 1 at the bottom of the container. Solidified to form. The obtained still hot sheet is fed as close as possible to the position (the distance from the resin extrusion port 12 to the cloth or release paper P which is the landing point is about 33% of the normal position). It is brought into contact with the pattern paper P and adjusted to a predetermined thickness of 0.15 mm to 0.2 mm while being rolled by the rolling roller 22 while being fed by the heat roller 21 set at about 70 degrees in advance. The finished product F. Thereafter, it is sent to the winding roller 3 in the next step.
In addition, when the cloth shape of the strength resistance or the appearance is not required, a release paper is used instead of the cloth, and the heat roller 21 for heating the cloth may be at room temperature.

  The reason why the still hot sheet was set as close as possible (the distance from the resin extrusion port 12 to the dough or release paper P as the landing point is about 33% of the normal position) is that of the selected Rezamin PH890. Then, because of its extremely high heat resistance as a resin characteristic, the temperature during extrusion molding is very high, and since the surface area ratio to the volume is very large for processing into a thin film, the synthetic fiber material during T-die molding When the resin material is dropped, the resin material tends to cause a sudden temperature drop. This is because it causes a decrease.

  The high heat resistant elastomer film, which is the finished product F, has a very stable and high heat resistance as a physical property itself, and therefore has a high melting point in each processing step, and the conventional welder joining method does not melt sufficiently and cannot be processed. Therefore, a new processing method was required.

  FIG. 2 is an explanatory view showing a new processing method of the present invention. As shown in FIG. 2, at least a temperature at which a heat sheet welder action in normal resin molding is started by a heat source such as a nichrome heater 52 attached to the mold 51 (about 90 degrees to about 120 degrees). In a state where the mold 51 is heated in advance and the heat-resistant resin film 53 to be processed is brought into contact with the mold 51 on the base sheet 54 and is kept at a sufficient predetermined temperature (about 90 degrees). Simultaneously or immediately after, high-frequency welder processing is performed to promote internal heat generation so as to reach a higher temperature, and the welded resin portion 55 is obtained on the laminated film to ensure welding.

FIG. 3 is an explanatory view showing a conventional molding method, in which the upper part (a) is a high-frequency welder and the lower part (b) is a heat-sealing method.
In conventional high-frequency welder molding, materials can be joined by melting and fusing materials by adjusting the conditions of the frequency, amperage, energization time, and cooling time to be applied, depending on the thickness and material type. However, although the molded product is constituted, the high heat resistance TPU according to the present invention cannot be fused and bonded only by such a conventional high-frequency welder.

The reason is considered to be due to the composition of the material (high heat resistance = high molecular purity or extremely high melting point), and when trying to process only by welding, higher energy (high current and voltage) than usual. Welding is required. However, when the resin itself has high heat resistance, such as the material of the present invention, or when the material has a volume or thickness, the matching point (conduction resistance changes rapidly when the material is melted) when simply adding high energy. This is because it is difficult to determine the point (melting equilibrium point), and if an excessive amount of current is applied even at several milliamperes, a short circuit (energization short circuit) occurs, causing a serious accident such as ignition or burning of the material.
Therefore, after various studies and a lot of research, we invented a method of using the heat seal processing method together with the high frequency welder.

  The heat-sealing method is a processing method in which films that melt at a relatively low temperature are conventionally brought into contact with a heat source to easily bond and form the films. The temperature of the mold itself is heated to about 90 ° C. to 120 ° C., the mold is brought into contact with the material in advance, and the matching point of the high frequency welder can be approached more smoothly by applying a high frequency. In this way, the high heat resistant film of the present invention can be melted and bonded.

  Furthermore, in the present invention, the final purpose is to enable the development of a hollow welder product having high heat resistance, but when pressure resistance and strength are required depending on the type and application of the product to be created, sewing processing In some cases, the film alone cannot be used to improve the appearance with a soft cloth feeling (because the film alone tears due to pinholes during sewing) In view of the above, a method for producing a synthetic composite film in which these elastomer films and fiber products (fabrics) are bonded together has been completed.

In order to use these high-pressure products or sewing products that require sewing, it was necessary to create a fabric with a high heat-resistant film for each application strength depending on the application. For this purpose, a method was adopted in which a urethane-based adhesive was uniformly applied to the back surface of the synthetic fiber, and the heat-resistant elastomer resin in a melted state was directly extruded onto the coated surface.
The adhesive may be used as necessary. When the finished film F does not require high peel strength, the synthetic fiber film may be prepared by impregnating and fixing the molten resin directly to the synthetic fiber.

  In addition, the rapid decrease in the resin temperature after extrusion may reduce the peel strength between the synthetic fabric and the film, so the contact surface of the chemical fiber should be removed using a heat roller (heating device) immediately before contact with the resin. It is to heat and heat up to about 80 ° C. to 90 ° C. to stably bond the films.

  These chemical fiber materials used are required to have high heat resistance for the same reason as the elastomer resin, and therefore, fiber products (nylon 6, polyester, etc.) having these are used.

As described above, by developing a high heat-resistant film alone and a cloth with a high heat-resistant film, blood pressure monitor armbands, pressure ulcer prevention air mats, and waterproof covers, which are molded products of main objects, were produced.

  As a result of testing the sphygmomanometer wristband of the finished molded product described above, the peel strength in the case of the high heat resistance resin of the present invention when there is no custom setting for reducing the heat roller and the resin drop distance is 8 to 3 N / cm. It has succeeded in obtaining the performance equivalent to the peel strength normally obtained by laminate sheeting of TPU of ˜15 N / cm, and in the welder molded product using these, the internal pressure of 1.5 to 2.0 bar is actually Holding is possible.

In addition, although not shown in the figure, a film formed product filled with a cooling agent or a heat insulating material may be considered.
For example, it can also be used in local cold bags or socks for replacing ice packs and strong compresses.

  The heat-resistant resin bonding / welding method according to the present invention is not limited to the above-described embodiment, and does not depart from the spirit of the heat-resistant resin, that is, a high-frequency welder that has conventionally been impossible due to its high heat resistance. It is widely included in heat-resistant resin materials in general. For example, it is a very effective method including a polyester elastomer.

It is manufacturing process explanatory drawing of the ultra-high heat-resistant resin film of this invention. It is explanatory drawing which shows the new processing method of this invention. It is explanatory drawing which shows the conventional forming method.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Molten resin container 11 Screw 12 Resin extrusion port 2 Feed roller 21 Heat roller 22 Rolling roller 3 Winding roller L Molten material (resin)
F Finished film P Fabric or release paper 51 Mold 52 Heater 53 Heat resistant resin film 54 Base sheet 55 Fusion resin part H Heat W High frequency

Claims (6)

In the three-dimensional forming method using heat-resistant resin film material, heat-resistant resin film obtained by extruding a predetermined thermoplastic resin into a film shape is stacked, and the temperature of the mold of the high-frequency welder itself is preheated to a predetermined temperature. And the manufacturing method of the film molding formed by making it contact with those metal molds for a predetermined time, raising to predetermined temperature, and also applying a high frequency and welding.   The specific thermoplastic resin according to claim 1, wherein the predetermined thermoplastic resin is a special polyurethane-based elastomer having a heat resistant performance improved by compounding (mixing) a predetermined amount of polycarbonate with a molding thermoplastic polyurethane elastomer (TPU) as a base. A method for producing a film molded body.   A method for producing a synthetic fiber film molded body by extruding various types of laminates or a special polyurethane-based elastomer resin melted on at least one surface of the synthetic fiber at least for heat-resistant steam sterilization treatment .   A high heat-resistant resin film obtained by extruding a predetermined thermoplastic resin into a film shape is overlaid, the temperature of the high-frequency welder mold itself is heated and kept at a predetermined temperature in advance, and the molds are subjected to a predetermined time. A molded product obtained by a method for producing a film molded body which is brought into contact and raised to a predetermined temperature, and is further welded by applying a high frequency.   Based on a thermoplastic polyurethane elastomer (TPU) for molding, the specified thermoplastic resin is a special polyurethane-based elastomer whose heat resistance is improved by compounding (mixing) a specified amount of polycarbonate into a film shape The heat-resistant resin film obtained by extrusion molding is stacked on top of each other, and the temperature of the high-frequency welder mold itself is heated and kept at a predetermined temperature in advance and brought into contact with these molds for a predetermined time to increase to a predetermined temperature. In addition, a molded product obtained by a method for producing a film molded body formed by welding by applying a high frequency.   A predetermined thermoplastic resin, which is a special polyurethane-based elastomer whose heat resistance is improved by compounding (mixing) a predetermined amount of polycarbonate based on a thermoplastic polyurethane elastomer (TPU) for molding, at least, Obtained by extruding the special polyurethane-based elastomer resin in a state of melting various types of chemically synthesized fibers having heat resistance for high-pressure steam sterilization treatment or melting on at least one surface of the synthetic fiber into a film shape. Overlay the synthetic fiber high heat-resistant resin film, heat the temperature of the high-frequency welder mold itself to a predetermined temperature and keep it in contact with the mold for a predetermined time to increase the temperature to a predetermined temperature, and then apply a higher frequency. Manufacturing of film moldings formed by welding Molded article obtained by law.

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