JP2557864B2 - Molding laminate sheet and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a molding laminate sheet comprising a nonwoven sheet and a resin sheet, at least one surface of which has a smooth surface. More specifically, at least one surface has an average roughness of 70
The present invention relates to a laminate sheet having excellent thermoformability, which is a laminate of a semi-oriented polyester long-fiber non-woven sheet having a smooth surface of μ or less and a thermoplastic resin sheet, and a method for producing the same.

Such a laminate sheet has printability, decorativeness, heat resistance,
It has heat insulating properties and cushioning properties, and is used as a molding base material for foods, trays such as cosmetic boxes, automobile interior materials, and wall covering materials.

[Conventional technology]

It is known that a thermoplastic sheet material is molded and used as a molded product. As a molding method at that time, a pressing method using a die, a vacuum molding method, a pressure molding method, or the like is used. The pressing method generally requires the use of male and female dies, and the production rate is slow and inefficient. On the other hand, the vacuum forming method or the pressure forming method has an advantage that it can be efficiently processed by a simple apparatus, but it is necessary to use a thermoplastic sheet material having a low air permeability.

From this point of view, conventionally, a thermoplastic resin sheet has been widely used as a molding material. However, the thermoplastic resin sheet is inferior in printability, decorativeness, heat resistance and heat insulation. In order to improve these drawbacks, a known non-woven sheet and a resin sheet are used as a laminate in a molding material. In this case, what is important is that the fibrous structure of the non-woven sheet does not shift due to the stress at the time of molding so that the ground crack does not occur. When cracks in the ground occur, the wear resistance of the surface is reduced and fluffing easily occurs.
Further, if cracks in the ground occur, the aesthetics of the molded product are significantly reduced. On the other hand, if the fibrous structure is heat-sealed between the fibers or fixed with an adhesive in order to prevent the ground cracking, it becomes difficult to extend even when an external force is applied during the molding process, and the deep uneven shape and the complicated shape Molding becomes difficult.

As a method for improving the above-mentioned drawbacks, Japanese Patent Publication No. 56-39254 discloses a method of using a semi-stretched polyester fiber non-woven sheet which easily stretches against external force under heating. However, since this method is a non-woven sheet in which the semi-drawn yarn and the drawn yarn are composite or laminated, molding processability is slightly improved, but ground cracking cannot be completely prevented. Also, Japanese Patent Publication No. 55-7432 discloses a non-woven sheet using only the above semi-drawn yarn. However, simply using semi-stretched fibers causes various problems and cannot be said to be practical. For example, a known semi-stretched fiber has a property of shrinking when heated, and therefore, it is necessary to take measures to prevent heat shrinkability during lamination processing with a resin sheet and molding processing.
Measures such as clamping on all sides are taken. Therefore, when a laminate sheet of a nonwoven sheet and a resin sheet is used as a molding material, it has excellent moldability, that is, molding of deep unevenness or molding of a complicated shape over a wide temperature range. That the molded product is excellent in shape retention, that is, the molded product does not easily lose its shape due to external force, and the shape does not shrink or deform due to heating etc. To be done.

In addition, the laminated sheet used as a molding material must also have excellent practical properties after molding. Practical characteristics here are that the surface is smooth and printability is excellent so that even small characters, symbols, etc. can be printed clearly, and at least one end surface is made of a non-woven sheet, so the appearance becomes a fiber tone. Excellent in decorativeness such as touch, design,
It is required to have heat resistance so that it can be used even in a heating atmosphere of 180 ° C to 220 ° C, and to have heat insulation.

However, a molding laminate sheet having the above-mentioned properties has not yet appeared.

As a result of intensive studies to satisfy the above-mentioned required characteristics, the inventors of the present invention have obtained a laminate of a non-woven sheet obtained by heat-treating a semi-stretched polyester-based long fiber web under limited conditions and a thermoplastic resin sheet. However, they have arrived at the present invention by discovering that they are excellent in molding processability, shape retention of molded products, and practical properties.

[Problems to be solved by the invention]

The object of the present invention is to improve the drawbacks of a laminate of a non-woven sheet and a resin sheet using the above-mentioned known semi-stretched yarn, and to improve molding processability, shape retention of a molded product, and printability and decoration. sex,
It is an object of the present invention to provide a laminate which is excellent in practical properties such as heat resistance and heat insulation properties and can be applied with any molding method, and a manufacturing method thereof.

[Means for solving problems]

An object of the present invention is a laminate sheet of a non-woven sheet composed of polyester long fibers having a crystallinity index of 15% or more and 45% or less, and a thermoplastic sheet (excluding polyester resin), which comprises boiling water. The shrinkage is 10% or less, the breaking elongation at 120 ° C is 100% or more, the 30% elongation stress at 120 ° C is 70 kg / cm ² or less, and the nonwoven sheet has a substantially uniform fiber density. This is achieved by a molding laminate sheet characterized in that the average roughness of the surface of the non-woven sheet is 100 μ or less.

Further, the laminate sheet has a step of forming a nonwoven web made of polyester long fibers having a breaking elongation of 100% or more and a birefringence of 0.01 to 0.07; a partial thermocompression rate of the web using an embossing roll. Thermocompression bonding at 3 to 50%; the surface temperature of the thermocompression-bonded sheet containing water is 30 ° C. or more above the second-order transition point of the fiber and 60 above the melting point of the fiber.
Sandwiching the heating drum and the endless felt at a temperature of not higher than ℃ from both sides to suppress the area reduction and heat-treat to make the sheet surface smooth non-woven sheet; Laminating a plastic resin sheet (excluding polyester resin) (hereinafter, thermoplastic resin sheet has the same meaning), and a boiling water shrinkage rate of 10% or less at 120 ° C. Can be produced by using the method for producing a molding laminate sheet having a breaking elongation of 100% or more and a 30% elongation stress at 120 ° C. of 70 kg / cm ² or less.

As the non-woven sheet used in the present invention, a non-woven sheet proposed by the same applicant as in the present invention in Japanese Patent Application No. 61-121238, that is, a polyester type semi-stretched long fiber non-woven web is embossed with a roll. It is preferable to use a non-woven sheet characterized by a first step of performing partial thermocompression bonding, and then a second step of performing heat treatment by sandwiching it from both sides so as to suppress area reduction.

The laminate sheet for molding of the present invention is obtained by laminating the non-woven sheet thus obtained and the thermoplastic resin sheet.

The polymer for producing the polyester semi-drawn yarn used in the present invention is polyethylene terephthalate, or a copolymerized polyester mainly composed of repeating units of ethylene terephthalate, and has a second-order transition temperature substantially equal to or higher than room temperature. In addition, it is preferable to use a polymer that can stably produce an amorphous semi-drawn yarn and that can be crystallized by heat treatment. In particular, polyethylene terephthalate brings excellent results for the purpose of the present invention in terms of thermoformability, heat resistance of molded products, strength and the like.

In addition, other fibers, for example, fibers such as polyolefin and polyamide may be mixed as long as the object of the present invention is not impaired.

The fineness of the fiber is 30 denier or less, preferably 0.5 to 10
Denier.

The basis weight of the nonwoven sheet used in the present invention is preferably 30 to 600 g / m ² .

Hereinafter, the nonwoven sheet used in the present invention will be described in detail.

The non-woven sheet used in the present invention has a breaking elongation of 10 at a spinning speed of 1600 to 4000 m / min by a known spunbond method or the like.
The first step of partially thermocompressing a semi-stretched polyester continuous fiber web having a birefringence of 0.01% to 0.07 and 0% or more is performed. That is, the web is embossed at a surface temperature of the second-order transition point or more and the second-order transition point + 30 ° C. or less, the partial thermocompression bonding rate of 3 to 50%, and the partial thermocompression bonding projections being substantially evenly distributed. Partial thermocompression bonding is carried out using a roll (preferably, the size of each roll is 1 to 5 mm ² , and the distance between adjacent rolls is 1 to 10 mm).

The embossing pressure is 5 to 90 kg / cm. The nonwoven sheet that has undergone the first step has a boiling water shrinkage of 10% or more, has low physical properties, and has a fluffy surface. Such nonwoven sheets cannot be used directly for the purposes of the present invention.

If the second step is carried out without carrying out the first step, the fibers are moved while shrinking because the web is not fixed, the fiber dispersion in the non-woven sheet is deteriorated, and the basis weight fluctuation is caused. When the rate is 20% or more and a low basis weight, a phenomenon that holes are partially formed appears, which is not suitable for the purpose of the present invention.

Then, the following second step is performed. That is, it is carried out by using a normal felt calendar composed of a heating drum and an endless felt in contact with the heating drum. The surface temperature of the drum is set to a secondary transition point of + 30 ° C or higher and a melting point of -60 ° C or lower, and moisture is applied to the non-woven sheet of the first step by spraying, roll transfer, etc., and then heat treated through a felt calender. The non-woven sheet used in the present invention is obtained. The nonwoven sheet obtained by this second step has a crystallinity index of 15-45%, preferably 20-40%.
It has a boiling water shrinkage of 10% or less, a breaking elongation at 120 ° C of 100% or more, a 30% elongation stress at 120 ° C of 50 kg / cm ² or less, and an average apparent density of 0.25 to 0.60 g / cm ³ The average roughness of at least one surface is 100 μ or less. The crystallinity index is necessary for preventing thermal deterioration at the molding temperature, facilitating the molding, preventing deformation of the molded product, and achieving dimensional stability. When the crystallinity index is less than 15%, the nonwoven sheet is deteriorated, discolored, and fused to the mold at the temperature during molding. If it exceeds 45%, it becomes difficult to mold deep irregularities and complex shapes.

This non-woven sheet had a smooth surface, had an appearance quality similar to Japanese paper, and was able to be clearly printed by printing small letters or symbols by gravure printing, letterpress printing or the like. Furthermore, the surface has improved abrasion resistance and is less prone to fluffing, and has hardness and rigidity similar to those of paper patterns.

The molding laminate sheet of the present invention comprises a non-woven sheet which has been subjected to the heat treatment in the second step and a thermoplastic resin sheet by a known method such as extrusion lamination, lamination using an adhesive, or ultrasonic wave. It is obtained as a laminated body by a partial heat fusion laminating such as.

One of the objects of the present invention is to improve the decorative property to give the image of deplasticization of a molded product.

Therefore, the laminate sheet of the present invention, during the molding process,
It is preferable that the resin sheet surface is on the inside and the non-woven sheet is on the outside.

Therefore, the weight ratio of the non-woven sheet constituting the laminate sheet of the present invention to the thermoplastic resin sheet is preferably 0.1 to 20.

The thermoplastic resin sheet used in the present invention includes polyethylene, partially crosslinked polyethylene, polystyrene, rubber-modified polystyrene, acrylonitrile-styrene copolymer, methyl methacrylate-styrene copolymer, acrylic ester-vinylidene chloride. It is composed of a copolymer, a polyamide, and a vinylidene-based resin, and includes a simple substance thereof, a heterogeneous composite, or a foam thereof.

The thus obtained laminate sheet of the present invention is a known forming method, for example, vacuum forming, pressure forming, press forming using a concave-convex mold, extrusion forming, or the like, and by appropriately preheating the laminate sheet or the like. You can do it. At this time, it is preferable that the laminate sheet of the present invention is not peeled off.

The laminate sheet of the present invention has a boiling water shrinkage of 10% or less. This is because the laminate sheet causes shrinkage deformation at the time of heating during molding processing or preheating prior to it, resulting in distortion of the molded product. It is necessary to prevent the occurrence and to obtain a molded product of good quality.

Also, the breaking elongation at 120 ° C and the 30% elongation stress at 120 ° C are
It is directly related to moldability such as deformation during molding and familiarity with the mold, and in order to obtain excellent moldability, breaking elongation is 100% or more, 30% elongation stress is 70 kg / cm ² or less. This is necessary for deep concave and convex shapes and complex shapes.

Furthermore, it is desirable that the elongation stress at the temperature of use is large in relation to shape retention such as mold collapse during use of the molded product and dimensional stability.

In order to improve the decorativeness of the laminate sheet of the present invention,
It is preferable to perform printing on the smooth surface of the non-woven sheet before laminating the thermoplastic resin sheet. Since the average roughness of the non-woven sheet is 100 μ or less, the surface is smooth and has good printability, and even small letters and symbols can be printed extremely clearly.

A low average roughness indicates a smooth surface. When the average roughness is 100 μ or more, the irregularities are conspicuous, the printability is deteriorated, and the surface decoration is not good.

The values of the breaking elongation at 120 ° C. and 30% elongation stress at 120 ° C. of the moldable laminate sheet of the present invention are the same as the preferable values of the corresponding properties of the nonwoven sheet itself as described above.
This is because the thermoplastic resin sheet is more likely to be plasticized than the non-woven sheet under the heating conditions where the molding process is performed, and the thermoplastic resin sheet has the function of reducing the air permeability of the laminated sheet, This is due to the fact that it makes little contribution to the above properties.

Note that, as described above, the thermoplastic resin sheet is easily plasticized. That is, the thermal modulus is low. Therefore, if the thermoplastic resin sheet alone is molded, it may be partially expanded, and uniform molding cannot be performed. The composite laminate sheet according to the present invention is characterized in that the nonwoven sheet itself has a higher thermal modulus than the thermoplastic resin sheet, so that the entire sheet can be uniformly stretched and molded. On the other hand, since the laminate sheet according to the present invention uses the thermoplastic resin sheet, the air permeability becomes small, and the vacuum forming or the pressure forming which is difficult to use in the forming process of the nonwoven sheet alone can be used. Further, since the non-woven sheet imparts shape retention to the laminate sheet, it is possible to use a thinner sheet, for example, a sheet having a thickness of 100 μ or less, as compared with the case where a thermoplastic resin sheet alone is used to form a molded article. .

By using the moldable laminate sheet according to the present invention thus obtained for the molding process, the surface which has not been obtained hitherto has a fiber-like appearance and tactile sensation, and gives a beautiful appearance by printing. It is possible to obtain a molded product having excellent decorative properties, heat resistance, heat insulation properties, and the like.

〔Example〕

The present invention will be specifically described below with reference to examples. still,
The definition of the characteristics described in the examples and the measuring method are shown below.

◎ Average apparent density (according to JIS-L-1096) The unit weight is measured from a test piece of 20 cm x 20 cm, and the thickness is measured with a dial gauge (stylus diameter 10 mmφ, mass 80 g), and the weight per unit volume is calculated and expressed. .

◎ Birefringence The birefringence (Δn) is measured using a polarizing microscope Belex compensator under white light.

◎ Strength and Elongation (according to JIS-L-1096) Measured by Shimadzu's Auto Graph DSS-2000 type universal tensile tester with grasping length of 10 cm and pulling speed of 20 cm / min by changing ambient temperature.

The 30% elongation stress is represented by the value obtained by dividing the strength at 30% elongation by the cross-sectional area of the sample.

However, in the case of a single yarn, the initial load is 0.1 g / d.

◎ Breathability (according to JIS-L-1096) Measure using a Frajour tester.

◎ Abrasion resistance A vertical 20 cm × horizontal 3 cm test piece was rubbed 100 times with a friction tester type II (Gakushin type) at a load of 500 g, and then the appearance change of the test piece was judged according to the following criteria. However, it was used as a guide for wear resistance.

(Judgment criteria) Class A: No fuzz at all.

Class B: Some fluff, but not noticeable.

Class C: Conspicuous fuzz.

◎ Average Roughness Tokyo Seimitsu Co., Ltd. Surfcom surface roughness and contour measuring machine
The roughness of the surface of the sample is measured using 200B (measuring machine according to JIS-B-0651-76), the maximum peak value and the minimum peak value are obtained from the chart, and the difference between the average values is called the average roughness. .

◎ Boiled water shrinkage (nonwoven sheet) A sample of 25 cm x 25 cm is placed on each of the vertical and horizontal 20 cm positions, immersed in boiling water for 5 minutes, and then taken out to measure the dimensional change of the sample and the shrinkage of N = 5. The average value is shown.

◎ Crystallinity index The crystallinity index of X-ray diffraction intensity in the equatorial direction is determined by the equatorial reflection method.

The X-ray diffraction intensity is the X-ray generator (RU-200P manufactured by Rigaku Denki Co., Ltd.).
L) and a goniometer (SG-9R), a scintillation counter for the measuring tube, and a wave height analyzer for the counting unit.
Cu / Kα rays monochromatic with a nickel filter (wavelength = 1.
5418A). The fiber sample is set in an aluminum sample holder so that the fiber axis is perpendicular to the X-ray diffraction plane. At this time, the thickness of the sample is set so as to be about 0.5 m / m. Operates X-ray generation at 30kV, 80mA, scanning speed 1 ° / min, chart speed 10mm /
Minutes, time constant 1 second, divergence slit 1/2 °, receiving slit 0.3 m / m, scattering slit 1/2 °, 2θ is recorded from 35 ° to 7 °. The full scale of the recorder is set so that the diffraction intensity curve is within the scale. Polyethylene terephthalate fiber generally has an equatorial line diffraction angle of 2θ = 17.
It has three major reflections in the range of ° to 26 ° [low angle side (100) (010) (110) plane]. FIG. 1 shows an example of an X-ray diffraction intensity curve of polyethylene terephthalate fiber.
(In the figure, a represents a crystal part and b represents an amorphous part.) The crystallinity index is 2 from the obtained X-ray diffraction intensity curve.
A straight line connects the diffraction intensity curves between θ = 7 ° and 2θ = 35 to form a baseline. As shown in FIG. 1, a valley near 2θ = 20 ° is set as a peak, and a straight line is connected along the skirts of the base angle side and the high angle side to separate the crystal part and the amorphous part, and the area method is calculated according to the following formula.

◎ Basis weight fluctuation rate It is a standard to show the uniformity of filament distribution of the sheet, and it is sampled from 30 places with a width of 25 mm and a length of 100 mm, and the weight of each sampling is measured. Ask by.

It can be said that the uniformity of the filament distribution is excellent when the variation in unit weight is less than 20%.

◎ Thermal deterioration After leaving in a 105 ° C hot air dryer for 300 hours, perform a tensile test and measure the breaking elongation. The elongation retention is calculated from the elongation at break before and after exposure at 105 ° C.

◎ Tear strength (according to JIS L-1096) Obtain a test piece of 5 cm x 15 cm in the vertical and horizontal directions using the tensile tester. (Single tongue method).

Example 1 Using a rectangular spinneret having a hole diameter of 0.25 mm and 1000 holes, polyethylene terephthalate having an intrinsic viscosity of 0.75 was spun at a melting temperature of 290 ° C. at a discharge rate of 850 g / min, and the position was 800 mm directly below the spinneret. By changing the air pressure of a certain towing air soccer,
The long fiber web (weight per unit area: 150 g / m ² ) was taken out on the wire mesh conveyor at a spinning speed of 2000 m / min, 2500 m / min, and 3000 m / min. The physical properties of the fibers constituting the obtained web are shown in Table 1.

As a comparative example, long fiber webs having a spinning speed of 1200 m / min and 5200 m / min were sampled and shown in Table 1.

Part of each fiber web having the characteristics shown in Table 1 with a pair of embossing rolls set to have a unit area of the convex portion of the embossing roll of 2 m ² , a crimping area ratio of 24%, an upper and lower roll temperature of 80 ° C, and a linear pressure of 20 kg / cm. Thermobonding to obtain the first step nonwoven sheet,
This characteristic is shown in Table 2. Then, the non-woven sheet of the first step is uniformly sprayed with 3% by weight of water by a spraying method, and a felt calender having a drum diameter of 1800 mm is used to perform heat treatment at a temperature of 130 ° C. and a processing speed of 15 m / min. A second step nonwoven sheet was obtained, the properties of which are shown in Table 3.

From the results shown in Table 2, the non-woven sheet of the first step cannot be used as the non-woven sheet for the purpose of the present invention because it has a large boiling water shrinkage and a low physical property.

From the results shown in Table 3, the non-woven sheet of the second step has a low boiling water shrinkage rate, a high elongation at break of 120 ° C of 100% or more, and a 30% elongation stress of 120 ° C of 50 kg. It is as low as / cm ² or less and has good moldability. It also shows high elongation stress at operating temperature around room temperature, and the molded product obtained by molding has excellent shape retention. understood. Furthermore, the average roughness is 100μ or less, the surface is very smooth,
It was found that the wear resistance and heat deterioration were good.

On the other hand, Comparative Example Experiment No. is a non-woven sheet made of unstretched yarn, so it is brittle, inferior in extensibility, heat deterioration, etc. and is not suitable as a molding material at all, and is fused to the felt calender drum. As a result, there are many problems in the process such as the sheet being rolled.

Further, Comparative Example Experiment No. was a non-woven sheet having a large 30% elongation stress at 120 ° C., a small elongation at break, and poor moldability because it was composed of a yarn having a high degree of drawing.

Example-2 A web composed of the fibers of Example Experiment No. shown in Table 1 was subjected to the heat treatment of the first step and the second step in the same manner as in Example 1, and the basis weight variation rate was measured to be 18%. Thus, a non-woven sheet having a good appearance quality with no noticeable unevenness of weight was obtained.

On the other hand, as a comparison, when the same fibrous web is used and the first step of partial thermocompression bonding is omitted and the second step of heat treatment is directly carried out, the basis weight variation rate is 53%, and the appearance unevenness is considerably conspicuous. It was extremely bad.

Example 3 A 25μ polyamide sheet and a 30μ aluminum foil were laminated with a 50μ polypropylene sheet interposed therebetween. On the polyamide sheet side of this laminated sheet, the third sheet of Example 1
The non-woven sheets of Table and Experiment No. were laminated and joined. For the joining, a room-temperature reaction type urethane adhesive (Takeda Chemical Industries, two-liquid reaction type) was used in all cases. The obtained laminate sheet was heated to a temperature of 180 ° C., and molded with a rectangular parallelepiped concave-convex mold having a length of 10 cm × a width of 10 cm × a depth of 3 cm. However, the forming process should be such that the non-woven sheet is on the outside.

Next, the molded product was heated in an oven for 30 minutes at a temperature of 180 ° C., and the dimensional change and deformation state of the molded product before and after heating were observed, but both the dimensional change and the deformation were negligible. Moreover, when taking it out, it could be taken out sufficiently by hand.

As a result of the above, the laminate sheet of the present invention has molding processability,
It was proved that the molded product has excellent shape retention and heat resistance.

〔The invention's effect〕

The moldable laminate sheet of the present invention is a polyester-based long-fiber non-woven fabric which has a small thermal shrinkage and easily expands in a wide molding temperature range and has appropriate rigidity at a temperature near room temperature. Since it is a laminated body of a sheet and a thermoplastic resin sheet, it is possible to form a deep concave and convex shape and a complicated shape, and the molded product has excellent shape retention. Furthermore, because of its excellent printability on the surface, decorativeness of deplasticized image, heat resistance, heat insulation, etc., it can be widely used as a substitute for molded plastic that has been widely used in the past.
Since it has unprecedented functions, it can be applied to fields where general-purpose plastics had problems. For example, it can be widely used as a molding material for various trays such as foods and cosmetic boxes, interior materials for automobiles, wall covering materials, and packaging materials.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI technical display location B29L 9:00

Claims (4)

(57) [Claims] 1. A laminate sheet comprising a non-woven sheet made of polyester filaments having a crystallinity index of 15 to 45% and a thermoplastic resin sheet (excluding the polyester resin sheet), the laminate sheet comprising: Boiling water shrinkage of body sheet is 10% or less, 12
The elongation at break at 0 ° C is 100% or more, the 30% elongation stress at 120 ° C is 70 kg / cm ² or less, and the nonwoven sheet has an average apparent density of 0.25 to 0.60 g / cm ³ , A laminated sheet for molding, characterized in that the average roughness of its surface is 100 μ or less. 2. The molding laminated sheet according to claim 1, wherein the weight ratio of the non-woven sheet and the thermoplastic resin sheet is in the range of 0.1 to 20. 3. The laminated sheet for molding according to claim 1, wherein the thermoplastic resin sheet is a film composed of a single layer or a heterogeneous multilayer or a combination thereof. 4. A breaking elongation of 100% or more and a birefringence of 0.01 to
Forming a long fiber web of 0.07 polyester long fibers; thermocompressing the web with an embossing roll at a partial thermocompression rate of 3 to 50%; When the surface temperature of the sheet after pressure bonding is 30 ° C or higher than the second-order transition point of the fiber and the melting point of the fiber
It is heat-treated by sandwiching it between the heating drum at 60 ° C or less and the endless belt from both sides to suppress the area reduction, and the fiber has a crystallinity index of 15 to 45% and an average apparent density of 0.25.
-0.60 g / cm ³ , a step of forming a smooth surface non-woven sheet having a surface roughness of 100 μ or less; and the non-woven surface smooth sheet and a thermoplastic resin sheet (excluding a polyester resin sheet) For molding with boiling water shrinkage of 10% or less, breaking elongation at 120 ° C of 100% or more and 30% elongation stress of 120 ° C of 70 kg / cm ² or less, characterized by including a step of laminating Laminated sheet manufacturing method.