JP2017144662A - Method for manufacturing laminate, laminate, and method for manufacturing laminate product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a laminate capable of imparting desired characteristics to a laminate according to the application of the laminate; a laminate; and a method for manufacturing a laminate product.SOLUTION: A method for manufacturing a laminate includes: preparing a plurality of substrate sheets formed of at least one selected from B group formed using a stretched or non-stretched linear body formed of at least one selected from A group; selecting at least two substrate sheets from the plurality of prepared substrate sheets; determining one substrate sheet as a first substrate sheet and determining the other substrate as a second substrate sheet; forming an uncompressed laminated sheet formed by laminating the first substrate sheet and the second substrate sheet; thermocompression bonding the uncompressed laminated sheet; and then cooling the uncompressed laminated sheet. The A groups is a flat yarn, a multifilament, a monofilament or a staple fiber. The B group is a fabric, a crossed bonding cloth, Warifu, knitted fabric or a one-direction resin sheet.SELECTED DRAWING: None

Description

  The present invention relates to a laminate manufacturing method, a laminate, and a laminate product manufacturing method.

  Patent Document 1 describes a method of manufacturing a laminated polymer product by interposing an adhesive layer between a woven fabric and a thermocompression bonding and completely dissolving the adhesive layer.

Japanese Patent No. 5138222

In the prior art, there may have been a situation where the rigidity is not sufficient or, on the contrary, depending on the product, the rigidity is unnecessarily high.
Recently, the use of laminates in a wide range of fields has been studied, and it is required to provide laminates suitable for various applications. The laminated body suitable for various uses is a laminated body in which the weight, rigidity, etc. of the laminated body are optimized for the intended use.
Thus, development of the manufacturing method of a laminated body which can provide a desired characteristic according to the use of a laminated body, a laminated body, and the manufacturing method of a laminated body product is desired.

  Then, the subject of this invention is providing the manufacturing method of a laminated body which can provide a desired characteristic according to the use of a laminated body, a laminated body, and the manufacturing method of a laminated body product.

  Other problems of the present invention will become apparent from the following description.

  The above problems are solved by the following inventions.

1.
Prepare a plurality of substrate sheets made of at least one selected from the following group B formed using stretched or non-stretched filaments made of at least one selected from the following group A,
Select at least two substrate sheets from the prepared plurality of substrate sheets,
One of the sheets is a first base sheet, the other is a second base sheet,
Forming an uncompressed laminated sheet formed by laminating the first base sheet and the second base sheet;
Next, the uncompressed laminate sheet is thermocompression-bonded and then cooled, and then the laminate is produced.
[Group A]
Flat yarn, multifilament, monofilament or staple fiber (Group B)
1. Woven fabric, cross-bonded fabric, burif, knitted fabric or unidirectional resin sheet
Prepare a plurality of substrate sheets made of at least one selected from the following group B formed using stretched or non-stretched filaments made of at least one selected from the following group A,
Select at least two substrate sheets from the prepared plurality of substrate sheets,
One of the sheets is a first base sheet, the other is a second base sheet,
An intermediate layer made of a thermoplastic resin is provided between the first base sheet and the second base sheet, and the first base sheet, the intermediate layer, and the second base sheet To form a non-bonded laminated sheet,
Next, the unbonded laminated sheet is thermocompression bonded at a temperature equal to or higher than the melting point of the thermoplastic resin, and then cooled.
[Group A]
Flat yarn, multifilament, monofilament or staple fiber (Group B)
2. woven fabric, cross-bonded fabric, warif, knitted fabric or unidirectional resin sheet
Prepare a plurality of substrate sheets made of at least one selected from the following group B formed using stretched or non-stretched filaments made of at least one selected from the following group A,
Select at least two substrate sheets from the prepared plurality of substrate sheets,
One of the sheets is a first base sheet, the other is a second base sheet,
Between the first base sheet and the second base sheet, an intermediate layer containing a high melting point resin component of a thermoplastic resin is provided in the low melting point resin component of the thermoplastic resin, Forming an uncompressed laminate sheet formed by laminating the base material sheet 1, the intermediate layer, and the second base material sheet,
Next, the uncompressed laminated sheet is thermocompression-bonded at a temperature not lower than the melting point of the low melting point resin component and lower than the melting point of the high melting point resin component, and then cooled.
[Group A]
Flat yarn, multifilament, monofilament or staple fiber (Group B)
3. woven fabric, cross-bonded fabric, warif, knitted fabric or unidirectional resin sheet
Prepare multiple base sheets made of nonwoven fabric,
Select at least two substrate sheets from the prepared plurality of substrate sheets,
One of the sheets is a first base sheet, the other is a second base sheet,
Forming an uncompressed laminated sheet formed by laminating the first base sheet and the second base sheet;
Next, the uncompressed laminate sheet is thermocompression-bonded and then cooled, and then the laminate is produced.
5.
Prepare multiple base sheets made of nonwoven fabric,
Select at least two substrate sheets from the prepared plurality of substrate sheets,
One of the sheets is a first base sheet, the other is a second base sheet,
An intermediate layer made of a thermoplastic resin is provided between the first base sheet and the second base sheet, and the first base sheet, the intermediate layer, and the second base sheet To form a non-bonded laminated sheet,
Next, the unbonded laminated sheet is thermocompression bonded at a temperature equal to or higher than the melting point of the thermoplastic resin, and then cooled.
6).
Prepare multiple base sheets made of nonwoven fabric,
Select at least two substrate sheets from the prepared plurality of substrate sheets,
One of the sheets is a first base sheet, the other is a second base sheet,
Between the first base sheet and the second base sheet, an intermediate layer containing a high melting point resin component of a thermoplastic resin is provided in the low melting point resin component of the thermoplastic resin, Forming an uncompressed laminate sheet formed by laminating the base material sheet 1, the intermediate layer, and the second base material sheet,
Next, the uncompressed laminated sheet is thermocompression-bonded at a temperature not lower than the melting point of the low melting point resin component and lower than the melting point of the high melting point resin component, and then cooled.
7).
A plurality of substrate sheets made of at least one selected from the following group B formed using stretched or non-stretched filaments made of at least one selected from the following group A are prepared, and at least one of them Selecting a single base sheet as the first base sheet,
Preparing a plurality of substrate sheets made of non-woven fabric, selecting at least one of the substrate sheets as a second substrate sheet,
Forming an uncompressed laminated sheet formed by laminating the first base sheet and the second base sheet;
Next, the uncompressed laminate sheet is thermocompression-bonded and then cooled, and then the laminate is produced.
[Group A]
Flat yarn, multifilament, monofilament or staple fiber (Group B)
7. Woven fabric, cross-bonded fabric, burif, knitted fabric or unidirectional resin sheet
A plurality of substrate sheets made of at least one selected from the following group B formed using stretched or non-stretched filaments made of at least one selected from the following group A are prepared, and at least one of them Selecting a single base sheet as the first base sheet,
Preparing a plurality of substrate sheets made of non-woven fabric, selecting at least one of the substrate sheets as a second substrate sheet,
An intermediate layer made of a thermoplastic resin is provided between the first base sheet and the second base sheet, and the first base sheet, the intermediate layer, and the second base sheet To form a non-bonded laminated sheet,
Next, the unbonded laminated sheet is thermocompression bonded at a temperature equal to or higher than the melting point of the thermoplastic resin, and then cooled.
[Group A]
Flat yarn, multifilament, monofilament or staple fiber (Group B)
8. Woven fabric, cross-bonded fabric, warif, knitted fabric or unidirectional resin sheet
A plurality of substrate sheets made of at least one selected from the following group B formed using stretched or non-stretched filaments made of at least one selected from the following group A are prepared, and at least one of them Selecting a single base sheet as the first base sheet,
Preparing a plurality of substrate sheets made of non-woven fabric, selecting at least one of the substrate sheets as a second substrate sheet,
Between the first base sheet and the second base sheet, an intermediate layer containing a high melting point resin component of a thermoplastic resin is provided in the low melting point resin component of the thermoplastic resin, Forming an uncompressed laminate sheet formed by laminating the base material sheet 1, the intermediate layer, and the second base material sheet,
Next, the uncompressed laminated sheet is thermocompression-bonded at a temperature not lower than the melting point of the low melting point resin component and lower than the melting point of the high melting point resin component, and then cooled.
[Group A]
Flat yarn, multifilament, monofilament or staple fiber (Group B)
9. Woven fabric, cross-bonded fabric, warif, knitted fabric or unidirectional resin sheet
The laminate according to any one of 4 to 9 above, wherein the nonwoven fabric is formed by a fleece forming method such as spun bond or melt blow, a thermal bond, a chemical bond, a needle punch, a spun lace fleece bonding method, or the like. Body manufacturing method.
11.
When forming the unbonded laminated sheet,
8. The method for producing a laminate according to 1, 4, or 7, wherein a laminate material selected from the following group C is laminated between the first substrate sheet and the second substrate sheet. .
[Group C]
Foam;
Non-woven fabric;
Resin film or resin sheet;
paper;
Natural leather or artificial leather;
Honeycomb structure;
11. Metal sheet such as aluminum, iron or copper
The intermediate layer is further provided between the first base sheet and a laminate material selected from the group C and / or between the laminate material selected from the group C and the second base sheet. 12. The method for producing a laminate according to 11 above.
13.
When forming a laminate formed by laminating a plurality of the uncompressed laminate sheets,
10. The method for producing a laminate according to 2, 3, 5, 6, 8, or 9, wherein a laminate material selected from the following group C is laminated between the uncompressed laminate sheets.
[Group C]
Foam;
Non-woven fabric;
Resin film or resin sheet;
paper;
Natural leather or artificial leather;
Honeycomb structure;
Metal sheet such as aluminum, iron or copper14.
14. The method for producing a laminate according to 13, wherein the intermediate layer is further provided between the uncompressed laminate sheet and a laminate material selected from the group C.
15.
When forming a laminate formed by laminating the unbonded laminate sheet and the first base sheet or the second base sheet,
2. The above-mentioned 2, 3, 5, 6 characterized in that a laminate material selected from the following group C is laminated between the unbonded laminate sheet and the first substrate sheet or the second substrate sheet. The manufacturing method of the laminated body of 8 or 9.
[Group C]
Foam;
Non-woven fabric;
Resin film or resin sheet;
paper;
Natural leather or artificial leather;
Honeycomb structure;
15. Metal sheet such as aluminum, iron or copper
Between the unbonded laminated sheet and the laminated material selected from the group C and / or between the laminated material selected from the group C and the first base sheet or the second base sheet, the intermediate 16. The method for producing a laminate according to 15 above, further comprising a layer.
17.
When forming the unbonded laminated sheet,
A laminate material selected from the following group C is laminated between the first base sheet and the intermediate layer and / or between the second base sheet and the intermediate layer, The manufacturing method of the laminated body of 2, 3, 5, 6, 8, or 9.
[Group C]
Foam;
Non-woven fabric;
Resin film or resin sheet;
paper;
Natural leather or artificial leather;
Honeycomb structure;
Metal sheet such as aluminum, iron or copper 18.
The intermediate layer is further provided between the first base sheet and a laminated material selected from the group C and / or between the second base sheet and the laminated material selected from the group C. 18. The method for producing a laminated body according to 17 above.
19.
The manufacturing method of the laminated body in any one of said 1-18 whose resin which comprises a said 1st base material sheet and a said 2nd base material sheet is the same kind of composition.
20.
The said 1st base material sheet, the said 2nd base material sheet, and resin which comprises the said intermediate | middle layer are in any one of said 2, 3, 5, 6, 8, 9, 12-19 which are the same kind of compositions. The manufacturing method of the laminated body.
21.
A laminate manufactured by the method for producing a laminate according to any one of 1 to 20 above.
22.
A laminate having a laminate material selected from the following group D is laminated on one or both sides of the laminate described in 21 above.
[Group D]
Foam;
Non-woven fabric;
Resin film or resin sheet;
paper;
Natural leather or artificial leather;
Honeycomb structure;
Metal sheet such as aluminum, iron or copper23.
23. The laminate according to item 22, further comprising the intermediate layer between the laminate and a laminate material selected from the group D.
24.
A method for producing a laminate product, comprising producing a laminate product selected from the following group E using the laminate as described in 21 above.
[Group E]
Chair or bench parts such as backrest, seat, frame or armrest;
Springs for sofas, beds, cushions or pillows;
Wheelchair parts such as wheels, leg supports, footrests, armrests;
Ski or snowboard parts such as ski shoes, ski boot parts or snowboard shoes, snowboard shoe parts, skis or snowboard boards, stocks;
Sports protectors such as helmets, elbow pads, knee pads, shin pads or chest pads;
Motorcycle protectors such as helmets, elbow pads, knee pads, shin pads or chest pads;
Safety protectors such as helmets, elbow pads, knee pads, shin pads or chest pads;
Disaster protectors such as helmets, elbow pads, knee pads, shin pads or chest pads;
Surfboard or bodyboard;
Accessories such as yachts, kayaks, canoes or boat wall boards, bottom boards, frame materials or boat oars;
Fishing rod, floating;
Sports rackets for tennis, badminton, etc .;
Shoe insole or shoe sole plate;
Prosthetic hand, prosthetic leg or cast;
Medical supporter core materials such as waist, shoulders, elbows, knees and ankles;
Cases or covers for mobile devices such as laptops and smartphones;
Appliance housings such as refrigerators, washing machines, vacuum cleaners, TVs;
Bicycle parts such as hoods, frames, cranks or pedals;
Automotive interior or exterior materials;
Aircraft components;
Speaker cone;
Umbrella bone, middle rod (shaft) or hand (handle);
Crossing bars, crossing bars such as ETC;
Building materials such as roofs, floors and wall panels;
Industrial spring materials such as leaf springs;
Containers such as trays and boxes;
Aqueduct pipe for agricultural water introduction for house, tunnel ground temperature adjustment, etc .;
Soft ground reinforcement sheet;
Water stop plate;
A herbicidal or rooting sheet;
Protectors such as bulletproof vests or prevention of injury;
Safety shoe parts such as toe cores and piercing prevention plates;
cargo;
Exterior materials such as suitcases, attache cases, musical instrument cases;
Heel core material, school bag core material, shoulder belt core material or underwear core material;
Core material for bags or core material for all-purpose bags;
Frames for tents, etc .;
Playground equipment for skateboards, roller skates, etc.

  ADVANTAGE OF THE INVENTION According to this invention, according to the use of a laminated body, the manufacturing method of a laminated body which can provide a desired characteristic, a laminated body, and the manufacturing method of a laminated body product can be provided.

Conceptual diagram representing an example of fabric Conceptual diagram showing an example of cross-bonded fabric Conceptual diagram showing an example of a knitted fabric Conceptual diagram showing an example of unidirectional resin sheet The conceptual diagram showing an example of the laminated body of this invention

  Below, the form for implementing this invention is demonstrated.

1. 1st aspect The manufacturing method of the laminated body of a 1st aspect is initially at least 1 chosen from the following B group formed using the extending | stretching or non-stretched linear body which consists of at least 1 sort (s) chosen from the following A group. Prepare a plurality of seed sheets made of seeds.

[Group A]
Flat yarn, multifilament, monofilament or staple fiber

[Group B]
Woven fabric, cross-bonded fabric, burif, knitted fabric or unidirectional resin sheet

  Preferred examples of Group A filaments include polyolefins such as polypropylene and polyethylene; polyesters such as polyethylene terephthalate. Flat yarns, multifilaments, monofilaments or staple fibers formed using these resins are used as the filaments.

  The filaments may be stretched or unstretched, but are preferably stretched to improve the strength of the product. As the stretching means, for example, uniaxial or biaxial stretching can be employed.

  As the striatum, a single-layer structure, a laminated structure, or a core-sheath structure can be used.

  When the linear body has a single layer structure, the resin constituting the linear body is made of a thermoplastic resin having a melting point higher than the temperature of thermocompression bonding. At this time, a thermoplastic resin having a melting point lower than the temperature of thermocompression bonding can also be included.

  When the striate has a laminated structure, a surface layer made of a thermoplastic resin having a melting point lower than that of the base layer can be laminated on one side or both sides of the base layer with the striate having a single layer structure as a base layer.

  When the striatum has a core-sheath structure, a surface layer made of a thermoplastic resin having a melting point lower than that of the base layer can be covered with the striate having a single layer structure as a base layer. Examples of such a linear body include flat yarns, multifilaments, monofilaments, and staple fibers.

  When a laminated structure is used as the striated body, means for forming a laminated film as a molding material is not particularly limited, but (1) a film that becomes a base layer and a film that becomes a surface layer are previously formed and dried. Means for making a multilayer using a laminating method or a thermal laminating method, (2) a method of coating a thermoplastic resin to be a surface layer on the surface of a film to be a base layer, (3) a surface to a film to be a preformed base layer It can be appropriately selected from means such as a method of extruding a layer, or (4) a method of extruding as a laminated film by a multilayer coextrusion method.

  When the core-sheath structure is used as the filamentous body, the forming means is not particularly limited, but prepares a resin as a base layer and a resin as a surface layer in advance, and introduces it into a compound spinning apparatus equipped with an extruder, Each resin can be melted and passed through separate pipes of the extruder, merged and extruded by a composite spinning die, and a means such as a method of cooling it can be used.

  The thickness of the striatum can be arbitrarily selected according to the purpose. However, in the case where the striatum has a single layer structure or a laminated structure, it is generally in the range of 50 to 10,000 decitex (dt). In the case where the striate body has a core-sheath structure, generally, a range of 1 to 10000 dtex (dt) is desirable.

  The woven fabric of group B may be a plain weave shown in FIG. 1 (A), a twill weave shown in FIG. 1 (B), or a satin weave shown in FIG. 1 (C). The cross-bonded cloth may be any of a biaxial cross-bonded cloth shown in FIG. 2 (A), a triaxial cross-bonded cloth shown in FIG. 2 (B), and a four-axis cross-bonded cloth shown in FIG. 2 (C). The knitted fabric may be either a horizontal knitting shown in FIG. 3 (A) or a vertical knitting shown in FIG. 3 (B). The unidirectional resin sheet is a resin sheet in which the filaments are aligned in one direction (see FIG. 4).

  Next, at least two substrate sheets are selected from the prepared plurality of substrate sheets, one of which is a first substrate sheet, and the other is a second substrate sheet.

  In the present invention, two substrate sheets may be selected, so the number of sheets to be selected may be three or four or more.

It is also preferable to provide an intermediate layer made of a thermoplastic resin between the first base sheet and the second base sheet.
In one embodiment of the present invention, an uncompressed laminated sheet is formed by laminating the first base sheet and the second base sheet in this order.
In another aspect of the present invention, an uncompressed laminated sheet is formed by laminating the first base sheet, the intermediate layer, and the second base sheet in this order.

  Even when three or more sheets are selected, an unbonded laminated sheet may be formed by providing an intermediate layer between each base sheet.

  In the aspect in which the intermediate layer is disposed between the first base sheet and the second base sheet, the intermediate layer may be formed of a single thermoplastic resin, or the thermoplastic resin. The low melting point resin component may be formed of a thermoplastic resin containing a high melting point resin component.

  In particular, when the intermediate layer is a low melting point resin component of a thermoplastic resin containing a high melting point resin component of a thermoplastic resin, the intermediate layer includes a first base sheet and a second base sheet. It is preferable because it can function as a rigidity improving layer that improves the rigidity of the resulting laminate.

  In the present specification, the “melting point” is a temperature measured as a melting peak temperature by DSC measurement (differential scanning calorimetry). Therefore, the high melting point resin component has a higher melting peak temperature than the low melting point resin component.

The thermoplastic resin used for the intermediate layer is not particularly limited, but preferred examples include polyolefins such as polypropylene and polyethylene, and polyesters such as polyethylene terephthalate.
On the other hand, when the intermediate layer contains a low melting point resin component and a high melting point resin component, the low melting point resin component and the high melting point resin component are not particularly limited. Preferred examples include polyolefins such as polyethylene and polyesters such as polyethylene terephthalate. As the high melting point resin component used, any resin having a higher melting point than the low melting point resin component may be used, and preferred examples include polyolefins such as polypropylene and polyethylene, and polyesters such as polyethylene terephthalate.

  In the embodiment in which the low-melting resin component and the high-melting resin component are contained in the intermediate layer, when the low-melting resin component and the high-melting resin component to be used are selected from polypropylene, for example, random polypropylene is used as the low-melting resin component. Homopolypropylene can be used as the high melting point resin component.

  Random polypropylene is other than propylene as monomer components and propylene such as α-olefin (for example, ethylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-heptene, 1-octene, etc. Of the α-olefin) are randomly copolymerized.

  In addition, as another embodiment in which the low melting point resin component and the high melting point resin component used for the intermediate layer are each selected from polypropylene, a relatively low melting point random polypropylene is used as the low melting point resin component, and the high melting point resin is used. Random polypropylene having a relatively high melting point can also be used as a component.

  Examples of the intermediate layer include, but are not limited to, a film formed by kneading pellets of a low melting point resin component and pellets of a high melting point resin component at a temperature equal to or higher than the melting points of both resin components, and by inflation molding or the like. be able to.

  In the intermediate layer, the content of the high melting point resin component is preferably in the range of 5% by weight to 50% by weight, for example, and more preferably in the range of 10% by weight to 30% by weight. The weight ratio of the low melting point resin component to the high melting point resin component in the intermediate layer is preferably in the range of 5:95 to 50:50, and more preferably in the range of 10:90 to 30:70.

  The thickness of the intermediate layer is not limited because it can be appropriately set according to, for example, the thickness of the base sheet and the thickness of the striatum, but is preferably in the range of 10 μm to 100 μm, 20 μm More preferably, it is in the range of ˜60 μm.

  Various additives can be added to the striatum or intermediate layer depending on the purpose. Specifically, organic phosphorus-based, thioether-based antioxidants; hindered amine-based light stabilizers; benzophenone-based, benzotriazole-based, benzoate-based ultraviolet absorbers; anti-static agents; bisamide-based, wax-based, Dispersants such as organic metal salts; lubricants such as amides and organic metal salts; flame retardants such as bromine-containing organic, phosphoric acid, melamine cyanurate, and antimony trioxide; low density polyethylene, linear low Examples include stretching aids such as density polyethylene; organic pigments; inorganic pigments; inorganic fillers; organic fillers; metal ion-based inorganic antibacterial agents, organic antibacterial agents, and the like.

Next, the uncompressed laminated sheet is subjected to thermocompression bonding and then cooled to produce a laminated body.
In particular, in the case of an uncompressed laminated sheet having the intermediate layer, heat is applied at a temperature not lower than the melting point of the thermoplastic resin forming the intermediate layer, or not lower than the melting point of the low melting point resin component and lower than the melting point of the high melting point resin component. It is preferable to crimp and then cool. By this manufacturing method, the obtained laminate has an effect of excellent rigidity.

  Although the method of thermocompression bonding is not particularly limited, for example, a hot press machine or the like can be used, and the pressure is not particularly limited, and can be appropriately set according to the thickness of each layer, for example, 0.5 MPa to 20 MPa. Preferably, it is in the range of 2 MPa to 15 MPa.

  The thermocompression bonding time is not particularly limited as long as it can be thermocompression bonded, but is preferably in the range of 1 minute to 20 minutes, for example.

  The cooling after thermocompression bonding may be natural cooling or forced cooling. In the case of forced cooling, it is possible to employ a technique of maintaining the pressure-bonding state during thermocompression bonding and lowering the temperature to the cooling temperature. In this case, a cooling press method can be employed.

The pressure of the cooling press is not particularly limited, and can be set as appropriate according to the thickness of each layer. For example, the pressure is preferably in the range of 0.5 MPa to 20 MPa, and more preferably in the range of 2 MPa to 15 MPa. .
The cooling time is not particularly limited as long as it can be cooled, but is preferably in the range of 10 seconds to 20 minutes, for example.

The laminated body manufactured by this invention has the effect which is excellent in rigidity.
The reason why the laminate of the above aspect is excellent in rigidity is that it is not melted at the time of thermocompression bonding, or even if it is melted, a high melting point resin component that is melted in a very small amount causes a crystalline state of the resin. It is estimated that the improvement is contributed. More specifically, when the melted low melting point resin component is recrystallized, the unmelted high melting point resin component functions as a crystal nucleating agent, and is suitable for imparting rigidity to the cloth laminate. Presumed to form a state.
In the present specification, “high rigidity” more specifically means that the flexural modulus (MPa) measured in accordance with, for example, JIS K 7171 is high.

2. Second Aspect In the first aspect, a nonwoven fabric is used as the first base sheet and the second base sheet. Since the other structure is the same as that of a 1st aspect, those description is used.

  The nonwoven fabric used in this embodiment may be a nonwoven fabric formed by a fleece forming method such as spunbond or melt blow, or a nonwoven fabric formed by a thermal bond, chemical bond, needle punch, spunlace fleece bonding method or the like. It can also be used.

3. 3rd aspect In the 1st aspect, from at least 1 sort chosen from the following B group formed using the extending | stretching or unstretched linear body which consists of at least 1 sort chosen from the following A group as a 1st base material sheet. This is a mode in which a nonwoven fabric is used as the second base sheet.
[Group A]
Flat yarn, multifilament, monofilament or staple fiber (Group B)
Woven fabric, cross-bonded fabric, warif, knitted fabric, or unidirectional resin sheet The rest of the configuration is the same as that in the first aspect, and thus the description thereof is incorporated.

4). 4th aspect In the said 1st aspect and 2nd aspect, it is preferable that resin which comprises a 1st base material sheet and a 2nd base material sheet is the same kind of composition.
Furthermore, in the aspect which has an intermediate | middle layer of the said 1st aspect and the 2nd aspect, it is preferable that resin which comprises a 1st base material sheet, a 2nd base material sheet, and an intermediate | middle layer is the same kind of composition. .
For example, it means that the resins constituting the first base sheet, the second base sheet, and the intermediate layer are all polyethylene resins, or all are polypropylene resins, which have the same composition.

5. 5th aspect In the said aspect, when forming an uncrimped laminated sheet or when forming the laminated body formed by laminating | stacking this uncrimped laminated sheet, the laminated body further laminated | stacked by the laminated material chosen from C group is also provided. preferable.

  Examples of the laminated material selected from Group C include foam; nonwoven fabric; resin film or resin sheet; paper; natural leather or artificial leather; honeycomb structure; and metal sheet such as aluminum, iron, or copper.

As illustrated in FIG. 5A, a laminate material selected from Group C can be laminated between the first base sheet and the second base sheet.
As shown in FIG. 5 (2), when forming a laminate formed by laminating a plurality of uncompressed laminate sheets, a laminate material selected from Group C can be laminated between the uncompressed laminate sheets. .
As shown in FIG. 5 (3), when forming an uncompressed laminate sheet and a laminate formed by laminating the first substrate sheet or the second substrate sheet, A laminated material selected from Group C can be laminated between the first base sheet or the second base sheet.
As shown in FIG. 5 (4), when forming an uncompressed laminated sheet, between the first base sheet and the intermediate layer and / or between the second base sheet and the intermediate layer, A laminate material selected from Group C can be laminated.

  5 (1) to (4) above, between the first base sheet or the second base sheet and a laminate material selected from group C, or from the non-compression laminate sheet and group C An intermediate layer may be further provided between the selected laminate materials.

6). 6th aspect The laminated body of this aspect is a laminated body by which the laminated material chosen from D group was laminated | stacked on the single side | surface or both surfaces of the laminated body manufactured in the said aspect.

  Examples of the laminated material selected from Group D include foams; nonwoven fabrics; resin films or resin sheets; paper; natural leather or artificial leather; honeycomb structures; and metal sheets such as aluminum, iron, and copper.

  A laminate in which such a laminate material is laminated not only has excellent rigidity, but also exhibits excellent effects depending on the use by selecting the laminate material according to various uses.

  If it is a foam, the outer surface is excellent in flexibility and the inside can be provided with a laminate excellent in rigidity. If it is a resin film or a resin sheet, the laminated body excellent in surface protection can be provided. If it is paper, the laminated body excellent in the decorating property can be provided by forming various patterns on paper. If it is natural leather, a high-class laminate can be provided. If it is a metal sheet, the laminated body which gives the profound feeling that the whole was formed with the metal can be provided.

7). 7th aspect In this invention, the laminated body product chosen from E group can be manufactured using the laminated body obtained by the manufacturing method of said laminated body.

Examples of the laminate product selected from Group E include the following products, but are not necessarily limited.
Chair or bench parts such as backrest, seat, frame or armrest;
Springs for sofas, beds, cushions or pillows;
Wheelchair parts such as wheels, leg supports, footrests, armrests;
Ski or snowboard parts such as ski shoes, ski boot parts or snowboard shoes, snowboard shoe parts, skis or snowboard boards, stocks;
Sports protectors such as helmets, elbow pads, knee pads, shin pads or chest pads;
Motorcycle protectors such as helmets, elbow pads, knee pads, shin pads or chest pads;
Safety protectors such as helmets, elbow pads, knee pads, shin pads or chest pads;
Disaster protectors such as helmets, elbow pads, knee pads, shin pads or chest pads;
Surfboard or bodyboard;
Accessories such as yachts, kayaks, canoes or boat wall boards, bottom boards, frame materials or boat oars;
Fishing rod, floating;
Sports rackets for tennis, badminton, etc .;
Shoe insole or shoe sole plate;
Prosthetic hand, prosthetic leg or cast;
Medical supporter core materials such as waist, shoulders, elbows, knees and ankles;
Cases or covers for mobile devices such as laptops and smartphones;
Appliance housings such as refrigerators, washing machines, vacuum cleaners, TVs;
Bicycle parts such as hoods, frames, cranks or pedals;
Automotive interior or exterior materials;
Aircraft components;
Speaker cone;
Umbrella bone, middle rod (shaft) or hand (handle);
Crossing bars, crossing bars such as ETC;
Building materials such as roofs, floors and wall panels;
Industrial spring materials such as leaf springs;
Containers such as trays and boxes;
Aqueduct pipe for agricultural water introduction for house, tunnel ground temperature adjustment, etc .;
Soft ground reinforcement sheet;
Water stop plate;
A herbicidal or rooting sheet;
Protectors such as bulletproof vests or prevention of injury;
Safety shoe parts such as toe cores and piercing prevention plates;
cargo;
Exterior materials such as suitcases, attache cases, musical instrument cases;
Heel core material, school bag core material, shoulder belt core material or underwear core material;
Core material for bags or core material for all-purpose bags;
Frames for tents, etc .;
Playground equipment for skateboards, roller skates, etc.

Claims (24)

Prepare a plurality of substrate sheets made of at least one selected from the following group B formed using stretched or non-stretched filaments made of at least one selected from the following group A,
Select at least two substrate sheets from the prepared plurality of substrate sheets,
One of the sheets is a first base sheet, the other is a second base sheet,
Forming an uncompressed laminated sheet formed by laminating the first base sheet and the second base sheet;
Next, the uncompressed laminate sheet is thermocompression-bonded and then cooled, and then the laminate is produced.
[Group A]
Flat yarn, multifilament, monofilament or staple fiber (Group B)
Woven fabric, cross-bonded fabric, burif, knitted fabric or unidirectional resin sheet Prepare a plurality of substrate sheets made of at least one selected from the following group B formed using stretched or non-stretched filaments made of at least one selected from the following group A,
Select at least two substrate sheets from the prepared plurality of substrate sheets,
One of the sheets is a first base sheet, the other is a second base sheet,
An intermediate layer made of a thermoplastic resin is provided between the first base sheet and the second base sheet, and the first base sheet, the intermediate layer, and the second base sheet To form a non-bonded laminated sheet,
Next, the unbonded laminated sheet is thermocompression bonded at a temperature equal to or higher than the melting point of the thermoplastic resin, and then cooled.
[Group A]
Flat yarn, multifilament, monofilament or staple fiber (Group B)
Woven fabric, cross-bonded fabric, burif, knitted fabric or unidirectional resin sheet Prepare a plurality of substrate sheets made of at least one selected from the following group B formed using stretched or non-stretched filaments made of at least one selected from the following group A,
Select at least two substrate sheets from the prepared plurality of substrate sheets,
One of the sheets is a first base sheet, the other is a second base sheet,
Between the first base sheet and the second base sheet, an intermediate layer containing a high melting point resin component of a thermoplastic resin is provided in the low melting point resin component of the thermoplastic resin, Forming an uncompressed laminate sheet formed by laminating the base material sheet 1, the intermediate layer, and the second base material sheet,
Next, the uncompressed laminated sheet is thermocompression-bonded at a temperature not lower than the melting point of the low melting point resin component and lower than the melting point of the high melting point resin component, and then cooled.
[Group A]
Flat yarn, multifilament, monofilament or staple fiber (Group B)
Woven fabric, cross-bonded fabric, burif, knitted fabric or unidirectional resin sheet Prepare multiple base sheets made of nonwoven fabric,
Select at least two substrate sheets from the prepared plurality of substrate sheets,
One of the sheets is a first base sheet, the other is a second base sheet,
Forming an uncompressed laminated sheet formed by laminating the first base sheet and the second base sheet;
Next, the uncompressed laminate sheet is thermocompression-bonded and then cooled, and then the laminate is produced. Prepare multiple base sheets made of nonwoven fabric,
Select at least two substrate sheets from the prepared plurality of substrate sheets,
One of the sheets is a first base sheet, the other is a second base sheet,
An intermediate layer made of a thermoplastic resin is provided between the first base sheet and the second base sheet, and the first base sheet, the intermediate layer, and the second base sheet To form a non-bonded laminated sheet,
Next, the unbonded laminated sheet is thermocompression bonded at a temperature equal to or higher than the melting point of the thermoplastic resin, and then cooled. Prepare multiple base sheets made of nonwoven fabric,
Select at least two substrate sheets from the prepared plurality of substrate sheets,
One of the sheets is a first base sheet, the other is a second base sheet,
Between the first base sheet and the second base sheet, an intermediate layer containing a high melting point resin component of a thermoplastic resin is provided in the low melting point resin component of the thermoplastic resin, Forming an uncompressed laminate sheet formed by laminating the base material sheet 1, the intermediate layer, and the second base material sheet,
Next, the uncompressed laminated sheet is thermocompression-bonded at a temperature not lower than the melting point of the low melting point resin component and lower than the melting point of the high melting point resin component, and then cooled. A plurality of substrate sheets made of at least one selected from the following group B formed using stretched or non-stretched filaments made of at least one selected from the following group A are prepared, and at least one of them Selecting a single base sheet as the first base sheet,
Preparing a plurality of substrate sheets made of non-woven fabric, selecting at least one of the substrate sheets as a second substrate sheet,
Forming an uncompressed laminated sheet formed by laminating the first base sheet and the second base sheet;
Next, the uncompressed laminate sheet is thermocompression-bonded and then cooled, and then the laminate is produced.
[Group A]
Flat yarn, multifilament, monofilament or staple fiber (Group B)
Woven fabric, cross-bonded fabric, burif, knitted fabric or unidirectional resin sheet A plurality of substrate sheets made of at least one selected from the following group B formed using stretched or non-stretched filaments made of at least one selected from the following group A are prepared, and at least one of them Selecting a single base sheet as the first base sheet,
Preparing a plurality of substrate sheets made of non-woven fabric, selecting at least one of the substrate sheets as a second substrate sheet,
An intermediate layer made of a thermoplastic resin is provided between the first base sheet and the second base sheet, and the first base sheet, the intermediate layer, and the second base sheet To form a non-bonded laminated sheet,
Next, the unbonded laminated sheet is thermocompression bonded at a temperature equal to or higher than the melting point of the thermoplastic resin, and then cooled.
[Group A]
Flat yarn, multifilament, monofilament or staple fiber (Group B)
Woven fabric, cross-bonded fabric, burif, knitted fabric or unidirectional resin sheet A plurality of substrate sheets made of at least one selected from the following group B formed using stretched or non-stretched filaments made of at least one selected from the following group A are prepared, and at least one of them Selecting a single base sheet as the first base sheet,
Preparing a plurality of substrate sheets made of non-woven fabric, selecting at least one of the substrate sheets as a second substrate sheet,
Between the first base sheet and the second base sheet, an intermediate layer containing a high melting point resin component of a thermoplastic resin is provided in the low melting point resin component of the thermoplastic resin, Forming an uncompressed laminate sheet formed by laminating the base material sheet 1, the intermediate layer, and the second base material sheet,
Next, the uncompressed laminated sheet is thermocompression-bonded at a temperature not lower than the melting point of the low melting point resin component and lower than the melting point of the high melting point resin component, and then cooled.
[Group A]
Flat yarn, multifilament, monofilament or staple fiber (Group B)
Woven fabric, cross-bonded fabric, burif, knitted fabric or unidirectional resin sheet   The nonwoven fabric is formed by a fleece forming method such as spun bond or melt blow, thermal bond, chemical bond, needle punch, spun lace fleece bonding method or the like. A manufacturing method of a layered product. When forming the unbonded laminated sheet,
The laminate material according to claim 1, 4 or 7, wherein a laminate material selected from the following group C is laminated between the first substrate sheet and the second substrate sheet. Method.
[Group C]
Foam;
Non-woven fabric;
Resin film or resin sheet;
paper;
Natural leather or artificial leather;
Honeycomb structure;
Metal sheet such as aluminum, iron or copper   The intermediate layer is further provided between the first base sheet and a laminate material selected from the group C and / or between the laminate material selected from the group C and the second base sheet. The manufacturing method of the laminated body of Claim 11 characterized by these. When forming a laminate formed by laminating a plurality of the uncompressed laminate sheets,
The method for producing a laminate according to claim 2, 3, 5, 6, 8, or 9, wherein a laminate material selected from the following group C is laminated between the uncompressed laminate sheets.
[Group C]
Foam;
Non-woven fabric;
Resin film or resin sheet;
paper;
Natural leather or artificial leather;
Honeycomb structure;
Metal sheet such as aluminum, iron or copper   The method for producing a laminate according to claim 13, further comprising the intermediate layer between the uncompressed laminate sheet and a laminate material selected from the group C. When forming a laminate formed by laminating the unbonded laminate sheet and the first base sheet or the second base sheet,
A laminate material selected from the following group C is laminated between the uncompressed laminate sheet and the first substrate sheet or the second substrate sheet. A method for producing a laminate according to 6, 8, or 9.
[Group C]
Foam;
Non-woven fabric;
Resin film or resin sheet;
paper;
Natural leather or artificial leather;
Honeycomb structure;
Metal sheet such as aluminum, iron or copper   Between the unbonded laminated sheet and the laminated material selected from the group C and / or between the laminated material selected from the group C and the first base sheet or the second base sheet, the intermediate The method for producing a laminate according to claim 15, further comprising a layer. When forming the unbonded laminated sheet,
A laminate material selected from the following group C is laminated between the first base sheet and the intermediate layer and / or between the second base sheet and the intermediate layer. Item 10. The method for producing a laminate according to Item 2, 3, 5, 6, 8, or 9.
[Group C]
Foam;
Non-woven fabric;
Resin film or resin sheet;
paper;
Natural leather or artificial leather;
Honeycomb structure;
Metal sheet such as aluminum, iron or copper   The intermediate layer is further provided between the first base sheet and a laminated material selected from the group C and / or between the second base sheet and the laminated material selected from the group C. The manufacturing method of the laminated body of Claim 17 characterized by these.   The method for producing a laminate according to any one of claims 1 to 18, wherein the resins constituting the first base sheet and the second base sheet have the same composition.   Resin which comprises said 1st base material sheet, said 2nd base material sheet, and said intermediate | middle layer is the same kind of composition, In any one of Claim 2, 3, 5, 6, 8, 9, 12-19 The manufacturing method of the laminated body of description.   A laminate produced by the laminate production method according to claim 1. The laminated body characterized by laminating | stacking the laminated material chosen from the following D group on the single side | surface or both surfaces of the laminated body of Claim 21.
[Group D]
Foam;
Non-woven fabric;
Resin film or resin sheet;
paper;
Natural leather or artificial leather;
Honeycomb structure;
Metal sheet such as aluminum, iron or copper   The laminate according to claim 22, further comprising the intermediate layer between the laminate and a laminate material selected from the group D. A method for producing a laminate product, comprising producing a laminate product selected from the following group E using the laminate according to claim 21.
[Group E]
Chair or bench parts such as backrest, seat, frame or armrest;
Springs for sofas, beds, cushions or pillows;
Wheelchair parts such as wheels, leg supports, footrests, armrests;
Ski or snowboard parts such as ski shoes, ski boot parts or snowboard shoes, snowboard shoe parts, skis or snowboard boards, stocks;
Sports protectors such as helmets, elbow pads, knee pads, shin pads or chest pads;
Motorcycle protectors such as helmets, elbow pads, knee pads, shin pads or chest pads;
Safety protectors such as helmets, elbow pads, knee pads, shin pads or chest pads;
Disaster protectors such as helmets, elbow pads, knee pads, shin pads or chest pads;
Surfboard or bodyboard;
Accessories such as yachts, kayaks, canoes or boat wall boards, bottom boards, frame materials or boat oars;
Fishing rod, floating;
Sports rackets for tennis, badminton, etc .;
Shoe insole or shoe sole plate;
Prosthetic hand, prosthetic leg or cast;
Medical supporter core materials such as waist, shoulders, elbows, knees and ankles;
Cases or covers for mobile devices such as laptops and smartphones;
Appliance housings such as refrigerators, washing machines, vacuum cleaners, TVs;
Bicycle parts such as hoods, frames, cranks or pedals;
Automotive interior or exterior materials;
Aircraft components;
Speaker cone;
Umbrella bone, middle rod (shaft) or hand (handle);
Crossing bars, crossing bars such as ETC;
Building materials such as roofs, floors and wall panels;
Industrial spring materials such as leaf springs;
Containers such as trays and boxes;
Aqueduct pipe for agricultural water introduction for house, tunnel ground temperature adjustment, etc .;
Soft ground reinforcement sheet;
Water stop plate;
A herbicidal or rooting sheet;
Protectors such as bulletproof vests or prevention of injury;
Safety shoe parts such as toe cores and piercing prevention plates;
cargo;
Exterior materials such as suitcases, attache cases, musical instrument cases;
Heel core material, school bag core material, shoulder belt core material or underwear core material;
Core material for bags or core material for all-purpose bags;
Frames for tents, etc .;
Playground equipment for skateboards, roller skates, etc.

Images