JP2023022462A - Perforated laminated sheet and manufacturing method thereof - Google Patents

Abstract

To provide a perforated laminated sheet having a pattern.SOLUTION: A perforated laminated sheet according to the embodiment of the invention is manufactured by processing a raw laminated sheet in which at least one layer of resin sheet is placed between a first cloth on the front side and a second cloth on the back side, and the first cloth, the second cloth, and the resin sheet are stuck together. The perforated laminated sheet has a plurality of supersonic punching holes PH penetrating from the first cloth to the second cloth and has a pattern formed by difference in thickness caused by distribution density of the plurality of supersonic punching holes PH at least on either one of the front surface and the back surface of the raw laminated sheet.SELECTED DRAWING: Figure 7

Description

The present invention relates to a perforated laminated sheet and a method for producing the same.

In the conventional punching process, a punch is placed at a desired position on the fabric, and a large amount of pressure is applied to punch it out. Conventional punching has been applied only to non-woven fabrics, synthetic leather, natural leather, etc., which are entwined with fibers.

However, woven fabrics and knitted fabrics, which are currently the mainstream of sheet materials, are frayed from the cross section of the punched hole when conventional punching is applied, resulting in a decrease in strength and no practical performance.
It is also conceivable to use a laminated sheet consisting of an outer material, urethane foam, and a lining as the surface material of automobile chairs to improve air permeability, reduce the energy consumption of air conditioning, and improve the fuel efficiency of automobiles. there is Such a thick laminated sheet material has a large resistance during processing and cannot be processed (only so-called thin materials can be punched). In this way, the punching process can only be applied to so-called thin materials, so it is limited to planar patterns (patterns), and air permeability is improved by applying materials with highly designed patterns with a sense of unevenness to car seats. Therefore, it is impossible to reduce fuel consumption.

Patent Literature 1 discloses a method for manufacturing a sheet member. This manufacturing method uses a piercing pin whose base is supported by a piercing pin support 12 and which is arranged to face a drilling table. The piercing pin is pierced from the surface of the sheet member supplied to the piercing table to pierce the sheet member with fine holes. Further, in this method, the elastic member fitted around the piercing pin is brought into contact with the surface of the sheet member laminated on the liner member and supplied to the drilling table, thereby fixing the sheet member to the drilling table. , the piercing pin unit is lowered to penetrate the sheet member with the piercing pin, thereby piercing the sheet member with fine holes. Furthermore, in this method, the burrs formed on the periphery of the fine holes are made to bite into the surface of the liner member, the sheet member and the liner member are laminated and integrated, the piercing pin unit is lifted, and the piercing pin is removed from the sheet member, After releasing the sheet member fixed to the drilling table by the elastic member from the drilling table, the liner member is separated.

Further, Patent Document 2 discloses a method for manufacturing a laminated sheet material, which is characterized by forming a three-dimensional uneven pattern on the laminated sheet material using a rotation receiving roll having an uneven pattern formed on the rotating peripheral surface. ing. Specifically, in the gap formed between the rotation receiving roll and the horn of the ultrasonic device arranged facing the rotation receiving roll, the thick first sheet material and the first sheet A sheet material is supplied so as to be laminated with a second sheet material having a thickness thinner than that of the second sheet material, and a pressure member provided in the vicinity of the gap pushes the sheet material to the rotation receiving roll side immediately before the sheet material is supplied to the gap. is pressed to transfer the uneven pattern of the rotation receiving roll, and only the portions that are in contact with the convex portions of the rotation receiving roll are softened by generating frictional heat with an ultrasonic device, and then partially ultrasonically bonded and laminated. Sheet material. At this time, the thickness of the laminated sheet material is reduced only at the joint portion, and the laminated sheet material is kept thick without being joined at the non-joined portion, thereby forming a three-dimensional uneven pattern on the laminated sheet material.

Further, Patent Document 3 discloses a laminated sheet. This laminated sheet is a laminated sheet of at least three layers, in which an adhesive sheet located in the middle and nonwoven fabrics located on the front and back sides are laminated and integrated. The laminated sheet has embossed uneven portions, and the overlapping sheets are fitted and joined only at the embossed uneven portions.

Further, Patent Document 4 discloses an ultrasonic punching device capable of punching clean holes by ultrasonic punching.

JP 2017-19028 A JP 2015-93391 A JP 2018-89833 A JP 2020-19073 A

Embodiments of the present invention provide perforated laminate sheets having a pattern.

In the perforated laminated sheet according to the embodiment of the present invention, at least one layer of resin sheet is interposed between the first cloth on the front surface and the second cloth on the back surface, and the first cloth and the second cloth are separated from each other. A perforated laminated sheet obtained by processing the original laminated sheet in which the cloth and the resin sheet are adhered, and has a plurality of ultrasonic punching holes penetrating from the first cloth to the second cloth, At least one of the front surface and the rear surface of the original laminated sheet has a pattern formed by a thin thickness due to the distribution density of a plurality of ultrasonic punching holes.

In the perforated laminated sheet according to the present invention, the resin sheet is a urethane foam sheet.

In the perforated laminated sheet according to the present invention, the first cloth is any one of woven fabric, knitted fabric, nonwoven fabric, synthetic leather, and natural leather, and the second fabric is any one of nonwoven fabric, woven fabric, and knitted fabric. characterized by being

The perforated laminated sheet according to the present invention is characterized in that the resin sheet has a thickness of 3 mm or more.

The perforated laminated sheet according to the present invention is characterized in that the perforated regions having ultrasonically punched holes and the non-punched regions having no ultrasonically punched holes are different in height or thickness.

In the perforated laminated sheet according to the present invention, the ultrasonic punching holes are provided in the punching hole region at a distribution density of 4 mm or more and 8 mm or less in the vertical and horizontal directions, and in the non-punching region, the ultrasonic punching holes are formed in a belt-like region having a width of 3 mm or more. It is characterized by having no ultrasonic punching holes.

In the method for producing a perforated laminated sheet according to the present invention, at least one layer of resin sheet is interposed between the first cloth on the front surface and the second cloth on the back surface, and the first cloth and the second cloth are separated from each other. A perforated laminated sheet manufacturing method for manufacturing a perforated laminated sheet by processing an original laminated sheet in which the cloth and the resin sheet are adhered, wherein a plurality of ultrasonic punching holes are formed in the perforated laminated sheet. A mold having a plurality of convex portions corresponding to each is brought into contact with the front surface or the back surface of the original laminated sheet, and an ultrasonic horn for transmitting ultrasonic vibration is provided at a position facing the surface of the mold, The original laminated sheet is movably sandwiched between the mold and the ultrasonic horn, and ultrasonic vibration is transmitted from the ultrasonic horn toward the convex portion of the mold, whereby the ultrasonic horn and the mold The perforated laminated sheet is produced by moving the original laminated sheet between the mold and the ultrasonic horn while fusing the original laminated sheet by frictional heat generated at the interface between the two.

In the method for manufacturing a perforated laminated sheet according to the present invention, the mold has convex portions corresponding to the ultrasonic punching holes in the punching hole region having the ultrasonic punching holes in the perforated laminated sheet. and no convex portion is formed in the non-convex portion area corresponding to the non-punching region having no ultrasonic punching holes.

In the method for manufacturing a perforated laminated sheet according to the present invention, in the mold, in the part corresponding to the punching hole region, the convex parts are provided with a distribution density of intervals of 4 mm or more and 8 mm or less in the vertical and horizontal directions, and the non- The area corresponding to the punched area is characterized in that there is no protrusion in the belt-like area with a width of 3 mm or more.

FIG. 2 is a side view of an original laminated sheet used for manufacturing a perforated laminated sheet according to an embodiment of the present invention; BRIEF DESCRIPTION OF THE DRAWINGS The whole block diagram of the manufacturing apparatus of the perforated laminated sheet which concerns on the 1st Embodiment of this invention. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view showing the arrangement of molds used in the perforated laminated sheet manufacturing apparatus according to the first embodiment of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view of an example of a mold used in the perforated laminated sheet manufacturing apparatus according to the first embodiment of the present invention; FIG. 2 is a perspective view of an example of a convex portion in a mold used in the perforated laminated sheet manufacturing apparatus according to the first embodiment of the present invention. 5A and 5B are a front view and a cross-sectional view of the convex portion of the mold shown in FIG. BRIEF DESCRIPTION OF THE DRAWINGS The top view of an example of the perforated lamination sheet which concerns on embodiment of this invention. BRIEF DESCRIPTION OF THE DRAWINGS The top view of an example of the perforated lamination sheet which concerns on embodiment of this invention. FIG. 8 is a cross-sectional view taken along line II of the perforated laminated sheet shown in FIG. 7; BRIEF DESCRIPTION OF THE DRAWINGS The top view which expanded and showed the principal part of an example of the perforated laminated sheet which concerns on embodiment of this invention. FIG. 5A is a front view and cross-sectional view of a projection formed on the mold shown in FIG. FIG. 4 is a front view of several examples of convex portions formed on a mold used in the apparatus for manufacturing a perforated laminated sheet according to the first embodiment of the present invention. 1 is a perspective view of an example of an ultrasonic horn in a mold used in a perforated laminated sheet manufacturing apparatus according to a first embodiment of the invention; FIG.

EMBODIMENT OF THE INVENTION With reference to an accompanying drawing, embodiment of the manufacturing method of the perforated laminated sheet and the perforated laminated sheet which concerns on embodiment of this invention is described below. In each figure, the same components are denoted by the same reference numerals, and overlapping descriptions are omitted. It should be noted that the present invention is not intended to be limited to the configurations described below, and each configuration can be changed as appropriate without departing from the gist of the invention. In addition, in each figure, the hole diameters of the ultrasonically punched holes in the perforated laminated sheet are not strictly reproduced in relation to the size relationship in the actual perforated laminated sheet, and are appropriately exaggerated for the sake of easy understanding. It is. FIG. 1 shows an original laminate sheet 100 prior to making an apertured laminate sheet according to an embodiment of the present invention.

The original laminated sheet 100 is composed of a front fabric 101 that is a first cloth on the surface, a lining 102 that is a second fabric on the back, and a resin sheet 103 interposed between the front fabric 101 and the lining 102. be done. The resin sheet 103 is at least one layer (one sheet). Therefore, the resin sheet 103 may have two layers (two sheets) or more. The outer material 101, the lining material 102, and the resin sheet 103 are adhered to each other by thermal adhesion, an adhesive agent, or the like, and are integrated.

Any one of woven fabric, knitted fabric, non-woven fabric, synthetic leather, and natural leather can be adopted for the outer material 101, which is the first cloth. Synthetic leather can include polyurethane synthetic leather and PVC leather, and natural leather can include split leather. The outer material 101 may be colored with dyes or pigments. The types of dyes and pigments are not limited.

The fiber material constituting the outer material 101 is not particularly limited, but thermoplastic fibers are preferable from the viewpoint of durability. Examples of thermoplastic fibers include synthetic fibers such as polyester, polypropylene and nylon, and semi-synthetic fibers such as acetate and triacetate. These can be used individually by 1 type or in combination of 2 or more types. Among them, synthetic fibers are more preferable, and polyester is even more preferable, because of their excellent physical properties, particularly strength, abrasion resistance, and heat resistance. The fiber material is preferably composed mainly of thermoplastic fibers, but fibers other than thermoplastic fibers, such as natural fibers and regenerated fibers, may be blended or blended within a range that does not affect their physical properties. They may be combined by a technique such as weaving, twisting, weaving, or knitting.

In addition, although the lining 102, which is the second cloth, is not particularly limited, either a woven fabric or a knitted fabric can be adopted. The fiber material constituting the lining 102 is not particularly limited, but synthetic fibers are preferable, and nylon or polyester is more preferable.

Although the resin sheet 103 is not particularly limited, a urethane foam sheet (soft polyurethane foam) can be adopted. The thickness of the resin sheet 103 can be 3 mm or more.

FIG. 2 shows an overall configuration diagram of a perforated laminated sheet manufacturing apparatus according to the first embodiment. In this first embodiment, a mold 11 having a length shorter than the width of the original laminated sheet 100 is used. The length of this mold 11 is, for example, 20 cm, and the width of the original laminated sheet 100 is, for example, 150 cm. These lengths are merely examples, and it goes without saying that other lengths may be used.

The perforated laminated sheet manufacturing apparatus includes a punching section 10 for punching the original laminated sheet 100 and the recovery resin sheet 22 between a mold 11 and an ultrasonic horn 12 . The ultrasonic horn 12 is provided with a vibrator 13 connected thereto for vibrating the ultrasonic horn 12 to generate ultrasonic vibrations from the ultrasonic horn 12 . The transducer 13 is connected to an ultrasonic oscillator 14 that transmits high-frequency power of a predetermined frequency to the transducer 13 . The resin of the recovery resin sheet 22, which will be described later, is a resin sheet for adhering and recovering pieces that have been melted and removed from the original laminated sheet 100 by ultrasonic vibration at the hole portion, and is an OPP. A film (polypropylene film) or the like can be used.

As shown in FIG. 3, a plurality of molds 11 are arranged side by side in the horizontal direction. In addition, they are arranged in a plurality of rows in the vertical direction. When the molds 11 are arranged in a plurality of rows, the molds 11 are arranged in a zigzag pattern. Here, the lateral direction corresponds to the width direction of the original laminated sheet 100 . The longitudinal direction coincides with the conveying direction of the original laminated sheet 100 . The molds 11 arranged in a zigzag pattern are slightly overlapped at the ends, and are configured so that the pattern of holes formed in the original laminated sheet 100 is continuous. A shaft 16 passes through each mold 11 . A long drive shaft 17 arranged so as to sandwich each mold 11 is rotated by a motor (not shown). A drive shaft 17 and shafts 16, 16 at both ends of each mold 11 are provided with gears, which are connected by chains 18, 18 and driven. A reference numeral 19 denotes a bearing for the shaft 16, which is fixed, for example, to a main body (not shown).

An ultrasonic horn 12 having approximately the same length as the mold 11 (for example, (length of mold 11)+1 cm) is associated with each mold 11 and provided below mold 11. It is Therefore, a plurality of sets of the mold 11 and the ultrasonic horn 12 are arranged side by side in the width direction of the original laminated sheet 100 . A set of the mold 11 and the ultrasonic horn 12 is arranged in a zigzag pattern in the direction in which the original laminated sheet 100 is conveyed.

The mold 11 has a cylindrical shape as shown in FIG. 4, and is used in a laterally elongated state. Protrusions 15 corresponding to the holes formed in the original laminated sheet 100 are formed on the surface of the mold 11 . In this embodiment, the ultrasonic vibrations transmitted toward the surface including the protrusions 15 of the mold 11 melt the portions of the original laminated sheet 100 corresponding to the portions of the protrusions 15 of the mold 11 as holes. A driving source is provided for driving the ultrasonic horn 12 so as to pull out (fuse) it. This drive source is composed of the vibrator 13 and the ultrasonic oscillator 14 shown in FIG.

The protruding portion 15 has a thin, substantially rod-like tip, and as shown in FIG. It has a tip portion 15a formed in a tapered truncated cone shape or a truncated pyramid shape. Alternatively, as shown in FIG. 5(b), the convex portion 15 is formed by a prism (or The tip portion 15a of the cylinder) may have a shape in which a plurality of stages are stacked. The size of the head of the tip portion 15a is appropriately selected depending on the size of the ultrasonic punching hole PH, but in the mold 11 shown in FIG. 4, the diameter is 1 mm.

Further, in the front end portion 15a of the protrusion 15 shown in FIG. 5B, a concave portion 15h is formed in a rectangular frame shape as shown in FIG. 5A(a) when the front end portion 15a is viewed from the front. The cross-sectional shape of the recess 15h may be square as shown in FIG. 5A(b).

The completed perforated laminated sheet 21A of this embodiment is as shown in FIG. That is, the sheet has a pattern in which the punched hole areas RA having ultrasonic punched holes (indicated by black dots in FIG. 6) are surrounded by the non-punched areas RB having no ultrasonic punched holes. In FIG. 6, the dashed lines in FIG. 6 that do not actually exist in the perforated laminated sheet 21A are used. It refers to the area outside the square, which is the strip-shaped white portion in FIG. 6 . Therefore, the completed perforated laminated sheet 21A of the present embodiment is a sheet having a pattern in which a plurality of hexagons are repeated and interspersed in a plane on a plane. The shape of the punched area RA is not limited to a hexagon, and various patterns such as a polygon, circle, star, and heart can be used.

FIG. 7 is an enlarged view of a part of the perforated laminated sheet 21A of FIG. PH cannot be established. As shown in FIG. 8, which is a cross-sectional view taken along the line II of FIG. 7, the outer material 101, the resin sheet 103, and the lining 102 are compressed in the thickness direction and welded together at the ultrasonic punching holes PH. Therefore, the punched hole area RA is the thickness of the outer material 101, the thickness of the lining material 102, and the slight thickness of the crushed resin sheet 103. FIG. On the other hand, since there is no ultrasonic punching hole PH in the non-punching region RB, the original thickness of the resin sheet 103 remains as it is without being crushed. Therefore, the perforated laminated sheet 21A has a pattern formed on at least one of the front surface and the rear surface of the laminated sheet by the thin thickness of the laminated sheet due to the distribution density of the plurality of ultrasonic punching holes PH. That is, in the perforated laminated sheet 21A, the punched hole regions RA having the ultrasonic punching holes PH and the non-punching regions RB having no ultrasonic punching holes PH are different in height or thickness. With this configuration, the perforated laminated sheet 21A of the present embodiment has a three-dimensional effect and a feeling of unevenness, making it possible to obtain a sheet with excellent design.

The distribution density of the plurality of ultrasonically punched holes PH in the perforated laminated sheet 21A will be described. FIG. 9 shows a plan view of essential parts of the perforated laminated sheet 21A. In this embodiment, the mold 11 shown in FIG. 4 is used, the size of the head of the tip portion 15a of the mold 11 is 1 mm in diameter, and the hole diameter of the ultrasonic punching hole is approximately 1 mm. . The interval (horizontal interval) between the ultrasonic punching holes PH1 and PH2 formed in the same punching hole area RA in this embodiment is 4 mm, and the ultrasonic punching holes PH1 (or PH2) and The distance from the ultrasonic punching hole PH3 is 4 mm. Here, the distance between the holes PH1 and PH2 is the distance from the center of the hole PH1 to the center of the hole PH2.
A line segment connecting the center of the ultrasonic punching hole PH1, the center of the ultrasonic punching hole PH2, and the center of the ultrasonic punching hole PH3 forms an equilateral triangle. In the present embodiment, the vertical interval of the ultrasonic punching holes refers to, for example, the distance from the ultrasonic punching holes PH3 to the line segment connecting the ultrasonic punching holes PH1 and PH2. In other words, the vertical interval is the length of a perpendicular drawn from the vertex PH3 of the equilateral triangle to the base PH1-PH2 of the equilateral triangle (the height of the equilateral triangle), and the horizontal interval is the length of the equilateral triangle. is the length of the base. In this embodiment, the longitudinal interval is approximately 4 mm (2×√3 mm).
Regarding the ultrasonic punching holes in the punching hole area RA of the perforated laminated sheet, the vertical and horizontal intervals of the ultrasonic punching holes are not particularly limited, but the distribution of the intervals of the ultrasonic punching holes in the vertical and horizontal directions is 4 mm or more and 8 mm or less. It is preferably provided with a density, and more preferably set to 4 mm or more and 5 mm or less. The vertical interval (dimension) and horizontal interval (dimension) of the ultrasonic punching holes are merely an example, and other values can be adopted, and can be appropriately set in consideration of the hole diameter and design of the ultrasonic punching holes. It is possible. Also, regarding the hole diameter of the ultrasonic punching holes, the dimension of "approximately 1 mm" is merely an example.

In the non-punching region RB of the present embodiment, a configuration is adopted in which there is no ultrasonic punching hole PH in a band-like region (non-punching region RB) having a width of 7 mm or more. That is, in the example of FIG. 9, the width w of the non-punching region RB is approximately 7 mm, and the two ends of the ultrasonic punching hole (eg PH3) and the end of the ultrasonic punching hole (eg PH4) sandwiching this width w. was set slightly longer than 7 mm.
In the non-punched perforated area of the perforated laminated sheet, the width of the belt-like area is not particularly limited, but is preferably set to 3 mm or more, more preferably 7 mm or more. Other values can be adopted for the width of the non-punching region, and the width can be appropriately set in consideration of the hole diameter and design of the ultrasonic punching holes.

As shown in FIG. 4, the mold 11 for manufacturing the perforated laminated sheet 21A as described above is, as shown in FIG. A convex portion 15 is formed corresponding to the hole PH. Further, in the mold 11, the convex portion 15 is not formed in the non-convex portion area NT corresponding to the non-punching region RB having no ultrasonic punching holes PH.

Further, in the present embodiment, the mold 11 has the projections 15 spaced vertically and horizontally at approximately 4 mm intervals (vertically from the center of the tip 15a of the projections 15) corresponding to the ultrasonic punching holes PH in the punching hole area RA. (distance to the center of the tip portion 15a of the convex portion 15 adjacent in the direction or lateral direction), and is projected in a band-like region (non-convex area NT) with a width of 7 mm corresponding to the non-punching region RB. It is configured without the part 15 . The vertical and horizontal “vertical” are the rotating directions of the mold 11 (conveying direction of the original laminated sheet 100), and the vertical and horizontal “horizontal” are the length directions of the mold 11 (the width direction of the original laminated sheet 100). is.
As described above, in the perforated laminated sheet of the present embodiment, the ultrasonically punched holes are provided in the vertical and horizontal directions at a distribution density of intervals of 4 mm or more and 8 mm or less, and in the non-punched region, the ultrasonic wave is formed into a belt-like region having a width of 3 mm or more. Since the sonic punching hole is not provided, in the mold of the embodiment, the projections 15 are provided at a distribution density of 4 mm or more and 8 mm or less in the vertical and horizontal directions corresponding to the punching hole area. In the region corresponding to the non-punching region, the band-shaped region having a width of 3 mm or more is formed with no protrusions. That is, the positions of the convex portions of the mold are set according to the vertical and horizontal intervals of the ultrasonically punched holes and the dimensions of the belt-like regions in the non-punched regions having no ultrasonically punched holes in the perforated laminated sheet.
The width direction of the perforated laminate sheet 21A coincides with the length direction of the mold 11 described above. The longitudinal direction (conveyance direction) of the perforated laminated sheet 21A follows the rotation of the mold 11 described above. The direction of the horizontal spacing of the ultrasonic punching holes coincides with the width direction of the perforated laminated sheet 21A. The direction of the longitudinal spacing of the ultrasonic punching holes coincides with the length direction (conveyance direction) of the perforated laminated sheet 21A.

5(a), the tip 15a of the projection 15 is formed flat without any recess as shown in FIG. 10(a) when viewed from the front. The cross-sectional shape of the portion 15 can be configured similarly to the cross-sectional view of a truncated cone as shown in FIG. 10(b). 5(a), the tip 15a of the projection 15 is formed with an annular recess 15h as shown in FIG. 10(c) when the tip 15a is viewed from the front. The cross-sectional shape of 15h may be an inverted conical shape as shown in FIG. 10(d).

Further, the shape of the tip portion 15a is any desired shape such as a circle, square, triangle, rectangle, rhombus, etc., as shown in FIGS. be able to. Of course, a shape whose outline is composed of curved lines, such as a heart shape or a four-leaf clover shape, may be used. The hole pattern is formed by forming holes of the above-described shape on the original laminated sheet 100 at a constant pitch in the vertical and horizontal directions, or providing portions with moderately different pitches, or forming several straight lines extending in an oblique direction with a desired inclination. It can be formed by, for example, arranging them at predetermined intervals. Of course, the pattern is not limited.

Also, the depth of the hole in the center of the recess 15h and the length (height) of the tip portion are appropriately selected depending on the thickness of the original laminated sheet 100 forming the hole pattern and the size of the ultrasonic punching hole PH. be done. It is desirable that the size (diameter, etc.) of one hole be approximately 0.8 mm or more. Also, the distance between the two protrusions 15 corresponding to the vertical and horizontal intervals of the adjacent ultrasonic punching holes PH is 4 mm or more and 8 mm or less, preferably 4 mm or more and 5 mm or less.

As shown in FIG. 12, the ultrasonic horn 12 includes a rectangular parallelepiped base portion 31 and a rectangular parallelepiped distal end portion 32 continuously formed on the upper side thereof. A slit 33 is formed from the base portion 31 toward the tip portion 32 side and penetrates from the front side to the back side to induce vertical vibration due to ultrasonic waves.

With the above configuration, the holes in the hole pattern are melted and punched by ultrasonic vibration, and the holes in the hole pattern are neatly and surely formed one by one, so that the punching can be performed reliably. In this case, it is possible to obtain a processed sheet in which the peripheral surface of the drilled hole is once melted and fixed by ultrasonic vibration, and the hole pattern is accurately formed.

As shown in FIG. 2, the mold 11 and the ultrasonic horn 12 are sandwiched, and on one side, an original sheet roller 35 around which the original laminated sheet 100 before being ultrasonically punched is wound. is provided. At a position below the original fabric roller 35 and close to the ultrasonic horn 12, a recovery resin sheet 22 is wound to adhere and recover pieces of the original laminated sheet 100 from which holes have been removed. A resin sheet roller 42 is provided.

The collecting resin sheet 22 is superimposed under the original laminated sheet 100 at a position where the conveying rollers 48 are provided in the conveying path along which the original laminated sheet 100 reaches between the mold 11 and the ultrasonic horn 12. It is sent between the mold 11 and the ultrasonic horn 12 . The original laminated sheet 100 is ultrasonically punched between the mold 11 and the ultrasonic horn 12 and sent out between them. When ultrasonically punched and sent out, the original laminated sheet 100 becomes a perforated laminated sheet 21A. The perforated laminated sheet 21A and the recovery resin sheet 22 are sandwiched between pressing rollers 43 and 44 and further transported forward.

Separation rollers 45U and 45D are provided in front of the pressing rollers 43 and 44 in the conveying direction. The collecting resin sheet 22 conveyed from the pressing rollers 43 and 44 and the perforated laminated sheet 21A are separated by separation rollers 45U and 45D. That is, the perforated laminate sheet 21A and the recovery resin sheet 22 are separated into two sheets before reaching the separation rollers 45U and 45D, and the perforated laminate sheet 21A stacked above is brought into contact with the separation roller 45U. , and reaches the product take-up roller 46 . In addition, the collection resin sheet 22 stacked downward is wound up by the collection sheet roller 47 via the rollers 52 and 53 so as to go around part of the separation roller 45D. Above the rollers 52 and 53, a scaffolding board 51 used for inspection and the like is provided so as not to hinder the rotation of the rollers 52 and 53. - 特許庁In the above, the constituent elements provided on the forward side in the conveying direction of the pressing rollers 43 and 44 constitute a piece collecting and conveying mechanism 40 for separating the collecting resin sheet 22 and the perforated laminated sheet 21A.

In addition, the conveying path from the raw fabric roller 35 and the resin sheet roller 42 to between the mold 11 and the ultrasonic horn 12, the mold 11, the ultrasonic horn 12, the vibrator 13, and the ultrasonic oscillator 14 are As shown, the original laminated sheet 100 and the recovery resin sheet 22 are passed between the mold 11 and the ultrasonic horn 12 to perform punching by ultrasonic irradiation.

In the perforated laminated sheet manufacturing apparatus configured as described above, the original laminated sheet 100 of the original fabric roller 35 and the recovery resin sheet 22 wound around the resin sheet roller 42 are transported through the conveying path as described above. It is guided between the metal mold 11 and the ultrasonic horn 12, and is passed through the gap to perform ultrasonic punching by ultrasonic vibration transmission. That is, in the method for manufacturing a perforated laminated sheet according to the present embodiment, at least one layer of resin sheet is interposed between the first cloth on the front surface and the second cloth on the back surface, and the first cloth and the A method for manufacturing a perforated laminated sheet by processing an original laminated sheet 100 in which the second cloth and the resin sheet are adhered to produce a perforated laminated sheet.

In the method for manufacturing a perforated laminated sheet according to the present embodiment, a mold 11, which is a mold having a plurality of convex portions 15 corresponding to a plurality of ultrasonic punching holes formed in the perforated laminated sheet, is used for the original lamination. An ultrasonic horn 12 that is brought into contact with the surface or the back surface of the sheet 100 and transmits ultrasonic vibrations is provided at a position facing the surface of the mold 11, and the original laminated sheet 100 is connected to the mold 11 and the ultrasonic wave. While being movably sandwiched between the horns 12 , ultrasonic vibrations are transmitted from the ultrasonic horn 12 to the projections of the mold 11 , and the original laminated sheet 100 is moved between the mold 11 and the ultrasonic horn 12 . A perforated laminate sheet 21A is produced by moving between the two.

With the above configuration, the superimposed original laminated sheet 100 and the recovery resin sheet 22 should form holes in the hole pattern of the original laminated sheet 100 corresponding to the convex portions 15 of the mold 11 when the ultrasonic punching process is performed. The parts are melted by the frictional heat of the ultrasonic vibration and punched out, and the parts of the recovery resin sheet 22 corresponding to the holes in the hole pattern of the original laminated sheet 100 are also melted by the frictional heat of the ultrasonic vibration. At this time, the pieces pulled out from the holes of the perforated laminated sheet 21A, which is the sheet obtained by processing the original laminated sheet 100, are recovered immediately after the overlapping recovery resin sheets 22 are melted by receiving frictional heat due to ultrasonic vibration. It will be in a state of being fused and solidified to the resin sheet 22 for use. In this state, the recovery resin sheet 22 and the perforated laminated sheet 21A are transported by the pressing rollers 43 and 44 in the direction of the product take-up roller 46 and the recovery sheet roller 47, and are guided to the separation rollers 45U and 45D. separated.

After the separation by the separation rollers 45U and 45D, the pieces extracted from the holes of the perforated laminated sheet 21A adhere to the melted and solidified recovery resin sheet 22, or are conveyed together with the recovery resin sheet 22 in an integrated state. be. On the other hand, the perforated laminated sheet 21A, in which the pieces removed from the holes of the perforated laminated sheet 21A are removed by the recovery resin sheet 22 and are no longer there, is taken up by the product take-up roller 46, and the removed piece adhered to the perforated laminated sheet 21A is collected. The resin sheet 22 is wound up by the collection sheet roller 47 .

Therefore, the perforated pattern was accurately formed without the scraped pieces remaining in the holes of the perforated laminated sheet 21A or becoming dust adhering to other parts of the perforated laminated sheet 21A. A perforated laminated sheet 21A in the state can be obtained. The perforated laminated sheet 21A is produced by processing a laminated sheet composed of an outer material, urethane foam, and a lining material by the above-described manufacturing method. It is also possible to reduce the energy consumption of air-conditioning and heating, aiming to improve the fuel efficiency of automobiles. In addition, the perforated laminated sheet 21A is made of a material having a highly designed pattern with an uneven feeling, and is applied to chairs of transportation vehicles (automobiles, buses, aircraft, trains, etc.) to improve breathability. It is extremely effective in its application.

REFERENCE SIGNS LIST 10 Punching part 11 Mold 11a Base surface 12 Ultrasonic horn 13 Transducer 14 Ultrasonic oscillator 15 Projection 16 Shaft 17 Drive shaft 18 Chain 21A Perforated laminated sheet 22 Recovery resin sheet 31 Base part 32 Tip part 33 Slit 35 Raw fabric roller 40 Sampling collecting and conveying mechanism 42 Resin sheet rollers 43, 44 Pressing rollers 45D, 45U Separating roller 46 Product winding roller 47 Collecting sheet roller 48 Conveying rollers 52, 53 Rollers 100 Original laminated sheet 101 Outer material 102 Lining material 103 Resin sheet RA Punching hole area RB Non-punching area PH Ultrasonic punching hole NT Non-convex area

Claims (9)

An original laminated sheet in which at least one layer of resin sheet is interposed between the first cloth on the surface and the second cloth on the back, and the first cloth, the second cloth, and the resin sheet are adhered. , which has a plurality of ultrasonically punched holes penetrating from the first cloth to the second cloth, and the original laminated sheet is formed by the distribution density of the plurality of ultrasonically punched holes A perforated laminate sheet characterized by having a thin pattern formed on at least one of the surface and the back surface of the sheet. 2. The perforated laminated sheet according to claim 1, wherein the resin sheet is a urethane foam sheet. The first cloth is any one of woven fabric, knitted fabric, non-woven fabric, synthetic leather, and natural leather, and the second fabric is any one of non-woven fabric, woven fabric, and knitted fabric. 2. The perforated laminated sheet according to 2. 4. The perforated laminated sheet according to any one of claims 1 to 3, wherein the resin sheet has a thickness of 3 mm or more. 5. The perforated laminated sheet according to any one of claims 1 to 4, wherein the perforated area having ultrasonically punched holes and the non-punched area having no ultrasonically punched holes are different in height or thickness. In the punching hole region, ultrasonic punching holes are provided in the vertical and horizontal directions at a distribution density of intervals of 4 mm or more and 8 mm or less, and in the non-punching region, there is no ultrasonic punching hole in a belt-like region with a width of 3 mm or more. The perforated laminated sheet according to claim 5. An original laminated sheet in which at least one layer of resin sheet is interposed between the first cloth on the surface and the second cloth on the back, and the first cloth, the second cloth, and the resin sheet are adhered. A perforated laminated sheet manufacturing method for manufacturing a perforated laminated sheet by processing the , an ultrasonic horn that is brought into contact with the front surface or the back surface of the original laminated sheet and transmits ultrasonic vibration is provided at a position facing the surface of the mold, and the original laminated sheet is connected to the mold and the ultrasonic horn in a state of being movably sandwiched by the ultrasonic horn, ultrasonic vibration is transmitted from the ultrasonic horn toward the convex portion of the mold, and the original laminated sheet is melted and cut by frictional heat generated at the interface between the ultrasonic horn and the mold. A method for manufacturing a perforated laminated sheet, characterized in that the original laminated sheet is moved between the mold and the ultrasonic horn while the perforated laminated sheet is produced. The mold has convex portions corresponding to the ultrasonic punching holes in the punching hole area having the ultrasonic punching holes in the perforated laminated sheet, and the non-punching area without the ultrasonic punching holes. 8. The method for producing a perforated laminated sheet according to claim 7, wherein no projection is formed in the non-projection area corresponding to . In the mold, convex portions are provided with a distribution density of intervals of 4 mm or more and 8 mm or less in the regions corresponding to the punching hole regions, and in the regions corresponding to the non-punching regions, the regions are belt-shaped with a width of 3 mm or more. 9. The method for producing a perforated laminated sheet according to claim 8, wherein no projections are formed in the region.

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