JP2008080793A - Functioning sheet and method for production of functioning sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a functioning sheet uniformly, sustainably exerting functionality such as adsorptivity while keeping the shape as a sheet, and to provide a method for production of the functioning sheet. <P>SOLUTION: The functioning sheet 12 is produced by carrying on a substrate sheet 14, a powder-integrated resin particle 1 which has a granular carrier comprising a thermoplastic resin and a powder integrated on the surface of the granular carrier. In this case, the above integration process can be performed without needing the hardening or liquefying treatment of the resin. The resin particle 1 can also be prepared while optionally changing its form from powder to pebble so as to be easily processed in post-process such as twin screw extrusion. The granulation method for the powder-integrated resin particle includes using the thermoplastic resin 16 having its surface at least softened or melted, and obtaining the particle integrated with a functional material. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a functional sheet and a method for producing the same, and more particularly to a functional sheet provided with functionality such as adsorptivity and a method for producing the same.

  Many non-woven fabrics containing functional materials represented by zeolite have been developed for the purpose of improving the functionality such as adsorptivity. Patent Document 1 describes a microscale fine zeolite powder and a thermoplastic resin. A technique is disclosed in which a mixture is used and sandwiched between two nonwoven fabrics for molding.

  However, if a fine powder having an average particle size of about 1 to 100 μm is used as the zeolite powder, it tends to agglomerate as compared with a powder made of other substances, so that the non-woven fabric tends to be unevenly distributed. There is. Further, since the zeolite powder leaks from the gaps between the fibers of the nonwoven fabric, there is a problem in practical and functional aspects.

  In order to impart higher functions to the nonwoven fabric, when increasing the content of powder such as zeolite, the nonwoven fabric, nonwoven fabric and thermoplastic resin, or thermoplastic resin and powder integration process should be performed simultaneously. In addition, it was difficult to obtain this with strength that could withstand practical use.

In addition, when a mixture of zeolite powder and thermoplastic resin is used, the thermoplastic resin is biased and exposed due to non-uniform mixing due to the above-described action such as aggregation, resulting in poor adhesion between the nonwoven fabrics. There was a problem. However, when the ratio of the thermoplastic resin in the whole nonwoven fabric is increased to prevent this, there are practical problems of the nonwoven fabric such that the adsorption amount and adsorption rate of zeolite are reduced and the air permeability of the nonwoven fabric is deteriorated.
Japanese Patent Laid-Open No. 09-276897

  The present invention has been made in view of the above problems, and a functional sheet that uniformly and continuously exhibits functionality such as adsorptivity while maintaining its shape as a sheet, and production of the functional sheet It aims to provide a method.

  In the functional sheet according to the present invention, powder-integrated resin particles having a granular carrier made of a thermoplastic resin and a powder integrated on the surface of the granular carrier are supported on a base sheet. It is characterized by that. Thereby, the function can be exhibited without the powder, particularly the functional material, falling off the sheet.

  In the functional sheet according to the present invention, a powder-integrated resin particle having a granular carrier made of a thermoplastic resin and a powder integrated on the surface of the granular carrier between a plurality of substrate sheets. It is characterized by being supported. Thereby, it becomes possible to further prevent the powder-integrated resin particles from falling off.

  The functional sheet according to the present invention is characterized in that a layer made of a thermoplastic resin is further disposed between the base sheet and the powder-integrated resin particles. Thereby, carrying | support with a powder integrated resin particle is further accelerated | stimulated.

  In the functional sheet according to the present invention, the substrate sheet and the powder-integrated resin particles are supported by hot pressing. Thereby, the carrying | support of powder integrated resin particle is accelerated | stimulated.

  In the functional sheet according to the present invention, the weight of the powder is 30% by weight or more and 80% by weight or less based on the total weight of the functional sheet. Thereby, the functionality of the powder, particularly the functional material, and the degree of loading can be exhibited without excess or deficiency.

  In the functional sheet according to the present invention, the weight of the powder is from 50% by weight to 900% by weight with respect to the weight of the thermoplastic resin. Thereby, it becomes easy to maintain the form of the powder-integrated resin particles in the sheet.

  In the functional sheet according to the present invention, a volume ratio of the thermoplastic resin to the powder is 1: 1 to 1:20. Thereby, it becomes possible to fully exhibit the characteristics of the powder.

  In the functional sheet according to the present invention, the powder-integrated resin particles have an average particle size of 10 μm to 5 mm. Thereby, handling of the powder integrated resin particles becomes easy.

  In the method for producing a functional sheet according to the present invention, powder-integrated resin particles having a granular carrier made of a thermoplastic resin and a powder integrated on the surface of the granular carrier are formed on a base sheet. A method for producing a supported functional sheet, the step of applying heat to the granular carrier so that the surface of the granular carrier is at least softened; and a powder on the surface of the softened granular carrier. A step of attaching a body to obtain powder-integrated resin particles; and a step of supporting the obtained powder-integrated resin particles on a substrate sheet. Thereby, it becomes possible to obtain a sheet-like functional sheet by a simple method while exhibiting the function of the powder integrated resin particles.

  In the method for producing a functional sheet according to the present invention, the step of applying heat to the granular carrier is performed by frictional heat generated by contact between the rotary member that rotates in a sealed space and the granular carrier. It is characterized by being. This makes it possible to supply heat to the granular carrier by using the frictional heat generated during the process without the need for a further device, thereby reducing the complexity of the process. .

  ADVANTAGE OF THE INVENTION According to this invention, it becomes possible to exhibit the function derived from powder, maintaining the powder integrated resin particle which has the powder which has a fixed characteristic, without dropping | omitting from a base material sheet.

  Moreover, it becomes possible to complete simultaneously the integration process of the base material sheets, the base material sheet and the thermoplastic resin, and the thermoplastic resin and the powder, which have been considered difficult until now.

  Hereinafter, the present invention will be described in more detail.

<Functional sheet according to the present invention>
The functional sheet according to the present invention is characterized by having a sheet-like form in which powder-integrated resin particles are supported on a base sheet. The outline is shown in FIGS.

  As shown in FIG. 1, the functional sheet 12 according to the present invention may include a base sheet 14 and powder-integrated resin particles 1 supported on the base sheet. Moreover, as shown in FIG. 2, the functional sheet 12 according to the present invention further includes a thermoplastic resin layer 16 made of a thermoplastic resin between the base sheet 14 and the powder integrated resin particles 1. May be. Moreover, as shown in FIG. 3, the functional sheet 12 according to the present invention may be one in which the powder integrated resin particles 1 are supported between a plurality of substrate sheets 14.

  In the functional sheet according to the present invention, the weight of the powder constituting the powder-integrated resin particles is preferably 30% by weight to 80% by weight with respect to the total weight of the functional sheet. In particular, when zeolite is used as the powder, the desired adsorption effect cannot be obtained when the zeolite content is less than 30% by weight. On the other hand, when it exceeds 80% by weight, it becomes difficult for the thermoplastic resin to support the zeolite in the base sheet. In order to satisfy the above-described conditions, the weight of the nonwoven fabric to be used may be set as appropriate.

(Substrate sheet)
In the functional sheet according to the present invention, any known base sheet can be used without any particular limitation. For example, synthetic fibers such as aramid, cellulose, polyamide, polyvinyl alcohol, polyester, polyolefin, rayon, phenol, natural fibers such as cotton, silk, hemp, etc., and carbon fibers of these fibers are spunbonded and spun. Examples include those formed in the form of a cloth surface by tangling or adhering to each other by a physical method such as lace or needle punch, a chemical method such as resin bond, thermal bond, or a combination thereof. Moreover, the sheet-like base material which consists of synthetic resins, such as a polyethylene terephthalate (PET), polyethylene (PE), and polyvinyl chloride (PVC), may be sufficient. The type and weight of these components, and the aspect of the substrate sheet such as the number of voids inside the substrate sheet may be appropriately selected depending on the application, and examples thereof include nonwoven fabrics and sheet-like substrates. Examples of the base sheet include heat resistance at about 100 ° C. or higher, thermal stability, weight per unit area, air permeability (porous), thickness, and the like. Of the above, polyester, cotton, polyamide, aramid, and phenol are preferably used as the material constituting the base sheet. In addition, as a base material sheet, in the case of a sheet-like base material made of a synthetic resin, a known roughened surface such as a blast method may be used.

(Powder integrated resin particles)
In the functional sheet according to the present invention, the powder-integrated resin particles supported on the base sheet include a granular support made of a thermoplastic resin and a powder integrated on the surface of the granular support. And having a particulate form. In the present invention, the form of the powder-integrated resin particle is not particularly limited as long as it is particulate. For example, the form of the powder-integrated resin particles is not particularly limited, and the powder 4 is integrated on the surface of the granular carrier 2 as shown in FIG. Form may be sufficient.

  In this powder-integrated resin particle, the state “integrated on the surface of the granular carrier” means a temperature at which the thermoplastic resin and the powder constituting the granular carrier can make the thermoplastic resin into a solid state. , Refers to a state of continuous binding. As such a state, after applying heat to the thermoplastic resin constituting the granular carrier to change from a solid state to at least a molten state, the powder adheres to the surface of the molten thermoplastic resin. A state formed when the composition is set to a temperature at which the thermoplastic resin is in a solid state.

  In the powder integrated resin particles used in the functional sheet according to the present invention, the thermoplastic resin may be polyethylene (PE), low density polyethylene (LDPE), high density polyethylene (HDPE), chain low density polyethylene (LLDPE). , Polypropylene (PP), ethylene vinyl acetate (EVA), ethylene-methacrylic acid copolymer (EMAA), ethylene-methyl methacrylic acid copolymer (EMMA), ethylene-methyl acrylic acid copolymer (EMA), vinyl chloride , Vinyl acetate, vinyl chloride vinyl acetate copolymer, acrylic, methacrylic resin, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyacrylonitrile (PAN), and thermoplastic resin is a combination of these materials as appropriate It may be. Among these, PE, LDPE, LLDPE, PP, EVA, EMAA, EMMA, EMA, and acrylic resin are desirable for integration with the functional material. These thermoplastic resins are desirably those having a softening property at 200 ° C. or lower. By using the thermoplastic resin of these materials, fluidity and extensibility are imparted to the resin part, the dispersibility between the resin part and the powder, preferably the functional material, is increased, and the granular material made of the thermoplastic resin is further provided. It becomes possible to carry the functional material at a high concentration on the carrier.

  In the powder-integrated resin particles used in the functional sheet according to the present invention, the granular carrier made of the thermoplastic resin is not particularly limited as long as it can form a granular shape. And pebbles.

  In the powder integrated resin particles used in the functional sheet according to the present invention, the powder may be an inorganic compound or an organic compound as long as it can maintain a solid state when integrated with the following thermoplastic resin. Any of the compounds may be used. Among them, in the present invention, the functional material used as the powder is not particularly limited as long as it is an inorganic or organic substance having a function desired to be imparted to the powder-integrated resin particles. It may be a mixture. Here, examples of the function desired to be given include odor absorption, hygroscopicity, hydrophobicity, heat resistance, color development, hydrophilicity, adsorptivity, and impact resistance.

  In the powder integrated resin particles used in the functional sheet according to the present invention, the functional material that is the above inorganic compound or metal is silica, colloidal silica, zeolite, montmorillonite, hectorite, talc, aerosil, mica, bentonite, Known inorganic functional materials such as aluminum compounds, magnesium compounds, barium compounds, calcium carbonate, alumina, silicon nitride, boron nitride, iron oxide (valve), mercury sulfide (silica sand), amber, senna, kaolin, white mica Synthetic inorganic pigments such as natural mineral pigments such as cadmium yellow, nickel titanium, viridian, ultramarine, carbon black and lead white can also be used.

  In addition, examples of the functional material that is an organic substance include powdered ink toners used in copying machines and laser printers, phosphors, synthetic organic pigments such as phthalocyanine-based, azo-based, and polycyclic compounds, and natural organic pigments such as lakes. And thermosetting resins such as synthetic dyes, polyimides, urea resins, phenol resins, epoxy resins, urethane resins, melamine resins, unsaturated polyester resins, and alkyd resins.

  In the powder-integrated resin particles used in the functional sheet according to the present invention, the functional material used as the powder may be treated with a surface modifier such as a coupling agent so as to appropriately modify the characteristics. . Examples of such surface modifiers include methylating agents and silylating agents. For example, when zeolite is used as the powder and methylated, it is possible to impart hydrophobicity to the powder-integrated resin particles.

  In the powder integrated resin particles used in the functional sheet according to the present invention, the average particle size of the powder is usually 0.1 to 500 μm, particularly 1 to 100 μm. In addition, what is necessary is just to use well-known measuring methods, such as a wet method, for the measurement of this average particle diameter.

  The particle size of the powder integrated resin particles used in the functional sheet according to the present invention is 0.5 to 7 mm, and the average particle size of the powder integrated resin particles according to the present invention is 10 μm to 5 mm. It is particularly preferable that the thickness is 100 μm to 1.5 mm. When the average particle size is less than 10 μm, the entire amount cannot be automatically discharged when taken out from a sealed space where granulation is performed such as a granulation tank. On the other hand, when the average particle diameter exceeds 40 mm, the surface irregularities become conspicuous when the sheet is carried on a sheet, and good sheet characteristics cannot be obtained.

  Further, among the powder integrated resin particles used in the functional sheet according to the present invention, those having an average particle diameter of 1 to 30 mm may be used as they are for a desired use, and are particularly suitable for extrusion processing. It can be used for film formation and the like.

  In the powder integrated resin particles used in the functional sheet according to the present invention, the weight of the powder is not particularly limited, but is, for example, 50% by weight or more and 900% by weight or less with respect to the weight of the thermoplastic resin. It is preferably 80 to 100% by weight. If it is less than 50% by weight, the thermoplastic resin, which will be described later, is melted, and the surface of the powder-integrated resin particles becomes bullet marks, or the adhesion of the surface increases. It may adhere in the space to be used and cannot be removed from the granulation tank. On the other hand, if it exceeds 900% by weight, the integration of the thermoplastic resin and the powder may not proceed and granulation may not be possible.

  In the powder-integrated resin particles used in the functional sheet according to the present invention, the volume ratio of the thermoplastic resin to the powder of inorganic or organic functional material is preferably 1: 1 to 1:20. Outside these ranges, it may not be possible to remove from a space for granulation such as a granulation tank during production.

  The method for granulating powder-integrated resin particles used in the functional sheet according to the present invention is not particularly limited as long as it is a method capable of obtaining the above-described aspect of the powder-integrated resin particles. For example, in this granulation method, heat is applied to the granular carrier so as to at least soften the surface of the granular carrier made of the thermoplastic resin, and then the surface of the softened granular carrier is The powder described above, preferably a functional material, may be attached. As a result, the powder-integrated resin particles having a granular carrier made of a thermoplastic resin and a powder integrated on the surface of the granular carrier are obtained.

  In the granulation method of the powder-integrated resin particles, the granular carrier made of a thermoplastic resin and the powder exemplified by the functional material used for granulation of the powder-integrated resin particles are granulated during this method. It may be introduced as appropriate into the system for performing the granulation, and when performing the step of applying heat to the granular carrier, the powder exemplified by the functional material may already be introduced into the system. Or after performing this process, you may introduce | transduce powder into a system and perform the process which adheres powder to the surface of said granular carrier. Among them, the thermoplastic resin is first introduced for the purpose of suppressing the scattering of the powder exemplified as the functional material in the system for granulating and promoting the softening of the thermoplastic resin. It is preferable. The method for introducing these components into the system for granulation is not particularly limited, and a method of introducing a hopper for introduction at the top of the system for granulation to introduce into the system from the hopper, The method is appropriately selected from a method of directly entering the system manually. Further, the form of the granular carrier made of the above powder and thermoplastic resin introduced into the sealed space for granulation may be appropriately selected according to the desired form of the powder integrated resin particle. For example, examples of the form of the granular support made of a thermoplastic resin include pellets and granules.

  In the granulation method of the powder-integrated resin particles, the method of applying heat to the granular carrier is not particularly limited as long as it at least softens the surface of the granular carrier made of a thermoplastic resin. There is no. For example, a method of directly applying heat to the thermoplastic resin constituting the granular carrier may be used. In this case, for example, a method of introducing a granular carrier made of a thermoplastic resin into the sealed space and raising the temperature of the sealed space may be used. Also, it is introduced into a mixing granulator such as a Henschel mixer, and a rotating member such as a rotary blade that rotates in the sealed space of this machine is brought into contact with the granular carrier, and the granular carrier is caused by the frictional heat generated at this time. Heat may be applied to the body.

  In the granulation method of the powder-integrated resin particles, the temperature of the step of applying heat to the granular carrier depends on the thermoplastic resin used for granulation and the physical properties of the powder, the glass transition point, the melting temperature, etc. It may be selected as appropriate. For example, when heat is applied to a granular carrier made of polyethylene, polypropylene or the like as a thermoplastic resin, the temperature may be 80 ° C to 200 ° C. If it is lower than 80 ° C., it becomes difficult to at least soften the granular support made of the thermoplastic resin, and integration with the powder to be performed later does not proceed. On the other hand, when the temperature exceeds 200 ° C., the viscosity of the granular carrier is too low, and in the step of attaching the powder after the step of applying heat to the granular carrier, friction with the powder hardly occurs and it is difficult to contact. End up. Therefore, it becomes difficult to integrate the powder and the thermoplastic resin, and the particle size of the composition obtained by the process of adhering the powder increases, and various subsequent processes performed after this process. You may not be able to bring it in In addition to the above, the thermoplastic resin used in this temperature range includes polyethylene terephthalate, polycarbonate, and acrylic resin.

  Moreover, in the granulation method of the powder integrated resin particles, the temperature of the step of applying heat to the granular carrier may be a temperature lower than the melting point of the powder. Thereby, when heat is applied to the granular carrier, it is possible to prevent melting and integration with the thermoplastic resin.

  In the granulation method of the powder-integrated resin particles, the step of applying heat to the granular carrier is a known method of mixing and granulating a thermoplastic resin and preferably a powder exemplified by a functional material. You may carry out using a mixing granulator. As this mixing granulator, the mixing granulator provided with the granulation tank is mentioned, For example, a Henschel mixer is used suitably. The size of the granulation tank provided in such a mixing granulator may be appropriately selected according to the amount of components such as the thermoplastic resin and powder to be introduced, the specific gravity of the powder, etc. ~ 200 cm, height may be 80% to 200% of diameter.

  In the granulation method for powder-integrated resin particles, the step of applying heat to the granular carrier is caused by contact between the rotary member that rotates in a sealed space for granulation and the granular carrier. It may be performed by frictional heat. In particular, when performing a step of applying heat to the granular carrier using a Henschel mixer, contact with the granular carrier by a rotating member such as a rotary blade that rotates in the tank provided at the bottom of the granulation tank. May be performed by frictional heat generated by Thus, when granulation is performed using a Henschel mixer, it is preferable that the tip of the rotating member is performed so as to give a shearing force to the granular carrier. Here, the rotational speed of the rotating member may be appropriately selected according to the material of the granular carrier, the glass transition point, the melting temperature, and the like. For example, the rotational speed of the tip of the rotating member is 10 m / second to 100 m / second. You may set so that it may become second, especially 30m / sec-60m / sec. If it is such a range, it is preferable at the point which can raise the probability of contact with the powder illustrated by control of the softening temperature of a thermoplastic resin, and the functional material or functional pigment derived from an inorganic or organic.

  In addition, when performing the step of applying heat to the granular carrier using a Henschel mixer, the granulation tank is heated for the purpose of at least softening the surface of the granular carrier made of thermoplastic resin. Let it be done. In this case, the temperature of the granulation tank may be appropriately selected according to the material of the granular carrier, the glass transition point, the melting temperature, and the like. For example, when polyethylene, polypropylene, or the like is used as the thermoplastic resin, 80 ° C. -200 degreeC is mentioned. The method for controlling the temperature of the granulation tank may be a method of directly heating the granulation tank, or a method of achieving this temperature range by cooling the granulation tank. Good.

  In addition to rotating members such as rotary blades, the contact probability between the thermoplastic resin and the powder is increased, and the thermoplastic resin and powder rise in the tank as the rotary blade in the granulation tank rotates. In order to prevent this, a blade may be provided at a position vertically above the rotating member. This blade lowers the thermoplastic resin and the powder below the granulation tank in order to bring the powder exemplified by the thermoplastic resin and the functional material into contact with the rotating member provided at the lower part of the granulation tank. is there. Further, in order to improve the contact probability between the powder and the thermoplastic resin, a chopper having a particle crushing action may be installed from the side or upper part of the granulation tank, and one or more choppers may be installed. Good.

  In addition, as the size of the rotating member, those having a shape and strength sufficient to cut a softened thermoplastic resin are preferably used.

  Both of these rotating members and blades are installed at a position within a range of 20% to 60% of the height of the tank from the bottom of the granulation tank, so that the rotary blades and the blades are in parallel with each other in order from the bottom. May be installed.

  The chopper is installed for the purpose of disturbing the movement of the mixture of the thermoplastic resin and the functional material in the centrifugal direction generated by the rotating blade, and if this purpose is achieved, the installation method is not limited, but the tip from the top lid of the tank It is preferable to be installed so as to be directed toward the bottom. Moreover, if the said objective is achieved, the presence or absence of rotation will not be ask | required.

(Other ingredients)
The functional sheet according to the present invention may have various components within a range that does not affect the above aspect. In particular, as shown in FIG. 2, a thermoplastic resin layer 16 made of a thermoplastic resin may be provided between the base sheet 14 and the powder integrated resin particles 1. The thermoplastic resin is not particularly limited as long as it does not hinder the support of the powder integrated resin particles 1 and the base sheet 14, and the thermoplastic resin constituting the powder integrated resin particles 1 is not particularly limited. A resin is preferred.

(Process for producing a functional sheet according to the present invention)
Next, the manufacturing process of the functional sheet according to the present invention will be described with reference to FIG. FIG. 4 is a schematic view illustrating an example of a functional sheet manufacturing process.

  In the manufacturing process of the functional sheet according to the present invention, as shown in FIG. 4, first, the powder integrated resin particles are uniformly distributed from the feeder 44 onto the base sheet 14 supplied from the primary unwinding portion 41. To do. Thereafter, the base material sheet 14 having the powder-integrated resin particles uniformly distributed is, for example, the interior of the oven 46 in which heat is applied so that the powder-integrated resin particles are supported on the base material sheet 14. The whole base sheet may be preheated by passing through and may be hot pressed or pressed by the hot press roll 48. Thereafter, the obtained sheet may be wound up by the winding unit 49.

  In the production process of the functional sheet according to the present invention, as shown in FIGS. 1 and 2, when producing a product in which the powder integrated resin particles are exposed to the periphery, the powder integrated resin particles are fed from the feeder 44. Subsequent treatment may be carried out on the product obtained by uniformly spreading the powder.

  In the production process of the functional sheet according to the present invention, during the uniform distribution of the powder-integrated resin particles from the feeder 44 on the base material sheet 14 supplied from the primary side unwinding portion 41, a thermoplastic resin may be used as desired. A thermoplastic resin layer made of may be laminated on the base sheet 14. Further, a material obtained by previously laminating a thermoplastic resin layer on the base sheet 14 may be supplied from the primary side unwinding portion 41.

  In the manufacturing process of the functional sheet according to the present invention, the powder-integrated resin particles are uniformly distributed from the feeder 44 on the base sheet 14, and then transferred from the secondary side unwinding unit 42 before being conveyed to the oven 46. The same or different base material sheet 14 as that of the primary side unwinding portion 41 may be placed from above with respect to the spreading surface.

  In the manufacturing process of the functional sheet according to the present invention, the substrate sheet wound up by the winding unit 49 is supplied again to the primary-side unwinding unit 41, and each of the above steps is repeated, or heat pressing is performed from the feeder 44. Up to the roll 48 may be continuously arranged a plurality of times. Thereby, it is also possible to produce a functional sheet having a multilayer structure.

  In addition, the winding part 49 which is the final process may be omitted, and after pressing the base sheet obtained up to the hot-pressing roll 48, the sheet may be cut by a cutting machine or the like and sequentially laminated.

  What is necessary is just to select the heating temperature by the oven 46 suitably according to the kind of base material sheet and powder integrated resin particle to be used. For example, in the case of a base sheet made of synthetic fibers, it may be set in consideration of the glass transition point of the base sheet or powder-integrated resin particles, and the heating temperature is higher than the glass transition point of the powder-integrated resin particles. May be set so that the glass transition point of the base sheet is lower than the heating temperature. By adopting a heating temperature in this range, it becomes difficult to damage the substrate.

  The clearance distance between the hot press rolls 48 is not particularly limited.

  In the production process of the functional sheet according to the present invention, the line speed may be set according to the type of base material sheet and powder integrated resin particles to be used. If it is made favorable, it will not specifically limit.

  In addition, about the aspect which carries | supports a powder integrated resin particle on a base material sheet, although it described so that it may load with heat using the oven 46, the heat | fever pressurization roll 48, etc., it carries in this way. If it can achieve the aspect which does, it will not be limited to heat, For example, UV hardening, a high frequency, an ultrasonic wave, an electron beam is mentioned.

  EXAMPLES Hereinafter, although an Example and a comparative example are shown and this invention is demonstrated concretely, this invention is not restrict | limited to the following Example. In the examples, “parts” represents parts by weight.

(Examples 1-2, Comparative Examples 1-2)
About Examples 1-2, each component of Table 1 was pulverized under the following conditions using a Henschel mixer (manufactured by Mitsui Mining Co., Ltd.) to form powder integrated resin particles.

Rotational speed of blade edge of rotary blade 40m / second Crushing tank temperature 140 ° C
Grinding time 20 minutes Average particle size 2mm

  About Comparative Examples 1-2, after grind | pulverizing only the thermoplastic resin among each component of Table 1, it dry-blended with the molecular sieve 13X (made by Union Showa Co., Ltd.) of a zeolite as a functional material.

  As an example, powder-integrated resin particles (thermoplastic resin: polyethylene (PE)) are sandwiched between base sheets under the following hot press conditions to form a sheet, and the distribution workability at that time, the adhesion of the base sheet, Each was tested for hygroscopicity. As the base sheet, Escot Fine CO60NA02 (manufactured by Unitika Ltd.) was used. The results are shown in Table 1.

  In addition, as a comparative example, a composition obtained by dry blending zeolite powder and a thermoplastic resin (ethylene / vinyl acetate copolymer (EVA)) was sandwiched between base sheets in the same manner as in the example, and the sheet was formed. Were tested in the same manner. The results are shown in Table 1.

<Evaluation>
[Hot press conditions]
Oven temperature: 185 ° C
Clearance: L2 / L1 = 0.30
Line speed: 5m / min

[Distribution workability]
Spreading and measuring method: From the upper part of the feeder having a metal mesh installed in the base, a dry blend of functional material powder and thermoplastic resin or powder-integrated resin particles was added, and the spreading step was performed.

Evaluation criteria ○ ... uniformly distributed on the base sheet
× ... distributed unevenly on the base sheet

[Adhesiveness of base sheet]
Measurement method: The adhesion between 25 mm-wide substrate sheets was measured by using a tensile tester (manufactured by Toyo Seiki Co., Ltd.).

Evaluation criteria ○… Peeling at over 10N / 25mm
Δ: peeling at 5-10N / 25mm
X: Peeled at less than 5N / 25mm

  Table 1 shows the tensile strength at which the base material sheets peeled off.

[Hygroscopic]
The obtained base material sheet was cut into a 10 cm square and allowed to stand in an oven at a temperature of 40 ° C./relative humidity of 90% for 48 hours, and the weight increase due to moisture absorption was measured with an electronic balance.

Evaluation criteria ○… Increase of 20g or more
X: Increase less than 20g

(Examples 3-5, Comparative Examples 3-5)
About Examples 3-5, what used the molecular sieve 13X (made by Union Showa Co., Ltd.) of a zeolite as a functional material, and used polyethylene as a thermoplastic resin, respectively, and granulated by weight ratio 8: 2 was used. Moreover, about Comparative Examples 3-5, each was used independently. Using Escot Fine CO60NA02 (manufactured by Unitika Co., Ltd.) as a base sheet, hot pressing was performed under the following conditions based on the above hot pressing process to obtain a functional sheet.

[Hot press conditions]
Oven temperature: 130 ° C
Hot press temperature: 200 ° C
Line speed: 5m / min
Clearance: L2 / L1 = 0.30

  The obtained functional sheet was visually evaluated for the retention of zeolite in the base sheet and the appearance of the base sheet. The results are shown in Table 2.

(Examples 6-8 and Comparative Examples 6-8)
About Examples 6-8, each component of Table 3 was pulverized under the following conditions using a Henschel mixer (manufactured by Mitsui Mining Co., Ltd.) to form powder integrated resin particles.

Rotational speed of blade edge of rotary blade 40m / second Crushing tank temperature 140 ° C
Grinding time 20 minutes Average particle size 2mm

  The obtained powder-integrated resin particles were dropped on the landing surface described in Table 3 on the base material described in Table 3 (for PET / PE, each layer was formed by dry lamination). A functional sheet was obtained by pressing.

  About Comparative Examples 6-8, it replaced with the powder integrated resin particle of Examples 6-8, and carried out similarly to Examples 6-8 except having used the component of Table 3, and obtained the sheet | seat. .

  With respect to the functional sheet and the sheet thus obtained, the landing workability, the adhesion, the odor absorbing property and the moisture absorbing property were evaluated.

[Workability on landing]
Evaluation was performed in the same manner as the above [Distribution workability].

Evaluation criteria ○: Evenly distributed on the base sheet
Δ: There was a part that was partially unevenly distributed, but there was no problem in practical use.
×: distributed unevenly on the base sheet

[Adhesion (Abrasion resistance test)]
T-type peeling was performed at 1 N / m ² or more.

Evaluation criteria ○: No peeling of functional material
Δ: Slight peeling of functional material, but practically no problem
×: There is peeling of the functional material
XX: Almost no adhesion

[Odor absorption]
The obtained functional sheet or sheet and a tablet containing triethylamine (active ingredient content: 10%) were put in a sealed container and allowed to stand in an environment of a temperature of 25 ° C./relative humidity of 50% for 240 hours. Then, the presence or absence of adsorption | suction of a triethylamine component was detected using GC-MS apparatus (Automass, JEOL make), and the odor absorption property of the functional sheet or the sheet was evaluated. The results are shown in Table 3. In Table 3, a circle indicates that it has sufficient odor absorption.

[Hygroscopic]
The measurement was performed according to the [Hygroscopicity] evaluation method described in Example 1.

  The functional sheet according to the present invention can be suitably used mainly for filters for air-conditioning machines, medicines, desiccants for electronic and electrical members, and the like. In addition, since it is supported on a nonwoven fabric, it can be easily processed into a desired shape and can be applied to a wide range of fields.

It is the schematic which shows an example of the functional sheet by this invention. It is the schematic which shows an example of the functional sheet by this invention. It is the schematic which shows an example of the functional sheet by this invention. It is the schematic which shows an example of the manufacturing process of a functional sheet. It is the schematic which shows a powder integrated resin particle.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Powder integrated resin particle 2 Granular support body 4 Powder 12 Functional sheet 14 Base material sheet 16 Thermoplastic resin layer 41 Primary side unwinding part 42 Secondary side unwinding part 44 Feeder 46 Oven 48 Hot-pressing roll 49 Winding part

Claims (10)

  A functional sheet characterized in that powder-integrated resin particles having a granular carrier made of a thermoplastic resin and a powder integrated on the surface of the granular carrier are supported on a base sheet. .   Powder-integrated resin particles having a granular carrier made of a thermoplastic resin and a powder integrated on the surface of the granular carrier are supported between a plurality of substrate sheets. The functional sheet according to claim 1.   The functional sheet according to claim 1, wherein a layer made of a thermoplastic resin is further disposed between the base sheet and the powder integrated resin particles.   The functional sheet according to any one of claims 1 to 2, wherein the substrate sheet and the powder-integrated resin particles are supported by hot pressing.   5. The functional sheet according to claim 1, wherein the weight of the powder is 30% by weight to 80% by weight with respect to the total weight of the functional sheet.   The functional sheet according to any one of claims 1 to 5, wherein the weight of the powder is 50% by weight or more and 900% by weight or less based on the weight of the thermoplastic resin.   The functional sheet according to any one of claims 1 to 6, wherein a volume ratio of the thermoplastic resin and the powder is 1: 1 to 1:20.   The functional sheet according to any one of claims 1 to 7, wherein the average particle size of the powder-integrated resin particles is 10 µm to 5 mm. This is a method for producing a functional sheet in which powder-integrated resin particles having a granular carrier made of a thermoplastic resin and a powder integrated on the surface of the granular carrier are supported on a base sheet. And
Applying heat to the granular carrier so that the surface of the granular carrier is at least softened;
A step of attaching powder to the surface of the softened granular carrier to obtain powder-integrated resin particles;
Supporting the obtained powder-integrated resin particles on a substrate sheet;
A method for producing a functional sheet, comprising:   10. The step of applying heat to the granular carrier is a step performed by frictional heat generated by contact between a rotary member that rotates in a sealed space and the granular carrier. The manufacturing method of the functional sheet of description.

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