JP3020840B2 - Process paper for manufacturing flexible urethane foam - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a process paper for producing a flexible urethane foam.

[0002]

2. Description of the Related Art Various methods have been known for continuous production of urethane foam blocks which have been industrialized. A typical example of such a method is shown in FIG. A support 105 made of special process paper is laid in a toy shape on a conveyor belt 104 provided at the bottom of a mold 103 having both side walls 101 and 102 to cover the inside of the mold. There is a method of obtaining a urethane foam molded article by casting M, foaming and curing, and then peeling off process paper from the molded urethane foam block.

As a process paper having such a special structure, the present applicant has already disclosed in Japanese Patent Publication No. 54-20227 a base paper and a polyolefin-based synthetic resin laminate film layer laminated on the base paper. Adhesive strength is
The synthetic resin laminate layer is temporarily laminated on the base paper so as to be smaller than the adhesive strength between the urethane foam and the synthetic resin laminate film layer generated by foaming the polyurethane resin on the synthetic resin laminate film layer. Thereby, the process paper as the support is configured to be capable of separating between two layers, and only one layer (synthetic resin laminated film layer) is completely adhered on the urethane foam surface to cover the foam surface. In addition to providing process paper for manufacturing,
JP-A-64-44712 has provided a method for producing urethane foam using the process paper.

[0004]

The raw materials used for urethane foam include furniture such as beds, mattresses, sofas and cushions, automobiles, filters, and the like.
For soft urethane such as packing, hard urethane such as heat insulating material, cushioning material, etc.,
No. 2,227, a process paper obtained by extruding and laminating a polyethylene layer on a base paper in a temporarily attached state can be used.

However, soft urethanes for medical use, sanitary materials and the like are used, for example, in gather rubbers for disposable diapers and the like. In addition to the fact that the modulus of elasticity of polyethylene is different from that of polyethylene, there is a problem.Because flexible urethane foams for medical and hygiene materials are often used for small products, polyethylene If any residue remains, the urethane foam must be cut off to remove the polyethylene, and there is a problem in cost, non-defective rate, and the like.

Conventionally, flexible urethane foam has been used without using the above-mentioned polyethylene process paper.
Although an unstretched polypropylene (CPP) film having good releasability from a flexible urethane foam is used,
During the foaming process, as shown in FIG. 3, the CP is placed on a conveyor belt disposed at the bottom in a mold having a bottom and both side walls.
When laying in a toy shape to cover the inside of the mold with the P film as a support, it is very difficult to lay because wrinkles, slacks, breaks, tears, and tears occur because of the film shape, As a result, the productivity and the rate of non-defective products have been reduced.

Therefore, in consideration of such circumstances, the present invention can be used as a process paper in the production of flexible urethane foam, and after the production of the urethane foam, the entire process paper can be used from the outer surface of the urethane foam. It is an object of the present invention to provide a process paper for producing a peelable urethane foam.

[0008]

SUMMARY OF THE INVENTION The present invention has been made to achieve the above-mentioned objects and objects of the prior art, and the gist thereof is as follows.

(1) Base paper and laminated on the base paper
Composed of a polypropylene laminate film layer
A flexible polyurethane foam production for process paper, wherein the poly
The propylene laminate film layer has a medium thickness in the width direction.
The polypropylene is formed so as to be larger in the center.
Foamed soft polyurethane resin on laminate film layer
From the urethane foam generated by the
Paper through the polypropylene laminate film layer
Soft urethane foam characterized in that it is detachable
Process paper for manufacturing

(2) Process paper for producing a flexible urethane foam, wherein the polypropylene is a polypropylene having a Vicat softening point of 139 ° C. to 155 ° C.

(3) a base paper and a polyolefin-based synthetic resin laminate film layer laminated on the base paper;
A non-stretched polypropylene (CPP) film layer laminated on the synthetic resin laminate film layer, and the process paper is formed from urethane foam generated by foaming a flexible polyurethane resin on the unstretched polypropylene film layer. A process paper for producing a flexible urethane foam, characterized in that it can be peeled off via a stretched polypropylene film layer.

[0012]

Embodiments of the present invention will be described below in detail with reference to the drawings.

First, FIG. 1 is a partially enlarged sectional view of a first embodiment of a process paper for producing urethane foam of the present invention.

In FIG. 1, reference numeral 1 indicates a process paper for producing a flexible urethane foam of the present invention (hereinafter simply referred to as “process paper”).
It comprises a laminated film layer 3 laminated on a base paper 2.

Here, kraft paper or the like can be used as the base paper 2 in consideration of strength and economy, and its thickness can be 50 to 50 basis weight in consideration of strength and economy.
It is preferably 100 g / m ² .

On the other hand, the laminated film layer 3 to be laminated on the base paper 2 includes the laminated film layer 3
When the present process paper 1 is peeled off from the flexible urethane foam to be foamed on after the completion of the foaming process, the peeling is easy via the laminate film layer 3 and the urethane foam may remain on the process paper. It is essential to use polypropylene having good releasability from the flexible urethane foam so that the laminate film layer 3 does not peel off and remain on the urethane foam surface. This polypropylene has a high Vicat softening point,
Polypropylene having a high melting point, a large difference from the heat generation temperature of foaming of the soft urethane, and good releasability is preferable, for example, polypropylene having a Piccat softening point of 139 ° C to 155 ° C. Examples of such a polypropylene include "FW163 (trade name)" Chisso Corporation (Vicat softening point 145 ° C) and "FW363A (trade name)" Sumitomo Chemical Co., Ltd. (Vicat softening point 148 ° C). , "LR510 (trade name)" Showa Denko KK (Vicat softening point 139 ° C), "LR510
710-3 (trade name) "Showa Denko KK (Vicat softening point 14
5 ° C), “F3990 (trade name)” Chisso Corporation (Vicat softening point 151 ° C), “LA221 (trade name)” Mitsui Petrochemical Industries, Ltd. (Vicat softening point 150 ° C), “FL25E (trade name) ) "Mitsubishi Yuka Co., Ltd. (Vicat softening point 145 ℃)," FL
25T (trade name) "Mitsubishi Yuka Co., Ltd. (Vicat softening point 146
C) can be used, and these can be used alone or in combination of two or more.

As a method of laminating the laminate film layer 3 on the base paper 2, in consideration of adhesion to the base paper, suitability for processing, and economic efficiency, the extrusion lamination method is used at an extrusion temperature of 270 to 340 ° C. It is preferably extruded, and its thickness is preferably 15 to 50 μm in consideration of the adhesive strength to the base paper and economy. In this case, the surface of the cooling roll used for extrusion lamination is semi-mirror finished.
Alternatively, it is preferable to use a mirror-finished one from the viewpoint of surface smoothness that gives a synergistic effect to the releasability.

At the time of lamination, the lip opening of the T-die used for extruding the molten resin is adjusted so that the central portion becomes thicker in the width direction of the process paper, that is, both ends of the process paper. By adjusting the lip gap so that the film thickness is slightly smaller than that of the central portion, it is possible to prevent meandering of the paper when the paper is fed during the foaming process.

On the other hand, FIG. 2 is a partially enlarged sectional view of a second embodiment of the process paper for producing urethane foam of the present invention.

In FIG. 2, reference numeral 11 indicates a process paper (hereinafter simply referred to as “process paper”) for producing a flexible urethane foam of the present invention as a whole, and the process paper 11 is basically a base paper. It is composed of an unstretched polypropylene (CPP) film layer 13 adhered to a paper 12 via a laminate layer 14.

Here, kraft paper or the like can be used as the base paper 12 in consideration of strength and economy, and its thickness can be calculated in terms of basis weight in consideration of strength and economy. It is preferred to be 50 to 100 g / m ² .

Examples of the unstretched polypropylene (CPP) film layer 13 include “E ₂ , Q, R type” manufactured by Tosero Chemical Co., Ltd., “P1011” Toyobo Co., Ltd.
"CPR-1, CPR-II" manufactured by Ruitsu Co., Ltd. and the like can be used, and the film thickness is preferably 20 to 30 μm in consideration of the occurrence of wrinkles. By using this unstretched polypropylene (CPP) film layer 13, the releasability from the flexible urethane foam is good, and therefore, from the flexible urethane foam to be foamed on the CPP film layer 13, after the foaming step, When the present process paper 11 is peeled off, the peeling becomes easy via the CPP film layer 13, and the urethane foam does not remain on the process paper, or conversely, the CPP film layer 13 peels off on the urethane foam surface. It does not survive.

When the unstretched polypropylene (CPP) film layer 13 is adhered to the base paper 12 via the laminate layer 14, the laminate layer 14 is made of polyethylene or the like in consideration of workability and economy. It is preferable to use a polyolefin-based synthetic resin such as polypropylene, EVA, EEA, and the like. As the bonding method, the extrusion strength is extruded at 200 to 340 ° C., and the thickness is set to 15 μm. It is preferable from the viewpoint of economy.

[0024]

【Example】

(Example 1) Kraft paper (basis weight 75 g / m ² ) as base paper
Is used as a polypropylene on the upper surface thereof, "FW163" (trade name, manufactured by Chisso Corp.) (Vicat softening point temperature: 145 ° C), and a mat roll as a cooling roll at the time of extrusion lamination using an extrusion lamination method. The product A of the present invention was obtained by extrusion at 320 ° C. and extrusion lamination to a thickness of 20 μm.

(Example 2) Kraft paper (basis weight: 75 g / m ² ) was used as a base paper, and “FW363A” (trade name) manufactured by Sumitomo Chemical Co., Ltd. Temperature 148 ° C.) by using an extrusion lamination method, extruding at 320 ° C. using a mat roll as a cooling roll at the time of extrusion lamination, and performing extrusion lamination so as to have a thickness of 20 μm, thereby obtaining a product B of the present invention. .

(Comparative Example 1) Kraft paper (basis weight: 75 g / m ² ) was used as a base paper, and polypropylene was formed on the upper surface of the kraft paper, and “MFW2971” manufactured by Mitsui Petrochemical Industries, Ltd. was used.
(Product name) (Vicat softening point temperature 120 ° C) is extruded at 320 ° C using a mat roll as a cooling roll at the time of extrusion lamination using an extrusion lamination method, and is extruded to a thickness of 20 µm. Thus, Comparative Product 1 was obtained.

(Comparative Example 2) Kraft paper (basis weight: 75 g / m ² ) was used as the base paper, and polypropylene was formed on the upper surface of the kraft paper, and “MFW2971” manufactured by Mitsui Petrochemical Industries, Ltd. was used.
A resin obtained by mixing (trade name) (Vicat softening point temperature 120 ° C.) and “FW263” (trade name) manufactured by Chisso Corporation (trade name) (Vicat softening point temperature 145 ° C.) at a weight ratio of 1: 1 is extruded by a lamination method. Using a mat roll as a cooling roll during extrusion lamination.
A comparative product 2 was obtained by extruding at 20 ° C. and extruding lamination to a thickness of 20 μm.

(Comparative Example 3) Kraft paper (basis weight: 75 g / m ² ) was used as a base paper, and polypropylene “LA221” (trade name) manufactured by Mitsui Petrochemical Industries, Ltd. (The point temperature of 150 ° C.) was extruded at 320 ° C. by using an extruded lamination method using a mat roll as a cooling roll at the time of the extruded lamination, and extruded so as to have a thickness of 20 μm, thereby obtaining Comparative Product 3. .

(Comparative Test 1) A test of the releasability from a flexible urethane foam was performed using the process papers produced in Examples 1 and 2 and Comparative Examples 1 to 3 above. The results are shown in Table 1 below. As is apparent from these results, the product of the present invention using a polypropylene having a higher Vicat softening point (having a Vicat softening point in the range of 139 to 155 ° C.) than using a polypropylene having a lower Vicat softening point is used. It can be seen that the better the releasability from the flexible urethane foam.

[0030]

[Table 1]

(Comparative Test 2) A comparative test was performed on the case where the conventional CPP film was used and the case where the product of the present invention was used, on the occurrence of wrinkles, breaks, and tears when used in the process of manufacturing a flexible urethane foam. Carried out. The results are shown in Table 2 below. As is evident from the results, wrinkles, breaks, and tears were remarkably reduced when the product of the present invention was used as compared with the case where the conventional CPP film was used.

[0032]

[Table 2]

[0033]

According to the process paper for producing a flexible urethane foam of the present invention constituted as described above, (1) When the homopolymer type polypropylene is laminated on the base paper, the homopolymer Since the type of polypropylene has good releasability from flexible urethane foam, it can be easily peeled off through homopolymer type polypropylene, and even when peeled after urethane foam production, process paper etc. remains attached to the urethane foam (2) In the case where a CPP film is adhered on a base paper via a polyolefin, this CPP film is
Since it has good releasability from flexible urethane foam, it can be easily peeled through this CPP film. Even when peeled after urethane foam production, process paper etc. do not adhere to and remain on the urethane foam. (3) Laminate polypropylene to the width direction on the base paper, or paste the CPP film on the base paper to the width direction via polyolefin. Because it is a worn configuration, even when laying on the foaming machine, there is a certain amount of stiffness, so that it does not break, bend, warp, meander etc.
(4) In addition, since the above-described configuration has strength even when peeled from the urethane foam block,
The invention is an extremely excellent invention that has many excellent effects, such as no breakage, tearing, and tearing, and does not remain on the urethane foam side, so that the yield can be improved.

[Brief description of the drawings]

FIG. 1 is a partially enlarged sectional view showing a first embodiment of a process paper for producing a flexible urethane foam of the present invention.

FIG. 2 is a partially enlarged sectional view showing a second embodiment of the process paper for producing a flexible urethane foam of the present invention.

FIG. 3 is a schematic top view showing steps of a conventional urethane foam.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Urethane foam manufacturing process paper 2 ... Base paper 3 ... Laminated film layer 11 ... Urethane foam manufacturing process paper 12 ... Base paper 13 ... Unstretched polypropylene (CPP) film layer 14 ... Laminating layer 100 ... Bottom 101 102 ... wall 103 ... mold 104 ... conveyor belt 105 ... support

────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁷ identification code FI B29L 9:00 (58) Field surveyed (Int.Cl. ⁷ , DB name) B32B 1/00-35/00 B29C 39/00 -39/44

Claims (3)

(57) [Claims] (1) Base paper and poly laminated on the base paper
Soft composed of propylene laminate film layer
Urethane foam manufacturing process paper, The polypropylene laminate film layer, in the width direction
It is formed so that the thickness becomes larger toward the center, Soft poly on the polypropylene laminate film layer
Urethane foam generated by foaming urethane resin
Form paper to a polypropylene laminate
Characterized in that it can be peeled off via a film layer
Process paper for manufacturing flexible urethane foam. Wherein said polypropylene is its Vicat softening point of polypropylene 139 ° C. to 155 ° C. according
Item 4. A process paper for producing a flexible urethane foam according to Item 1 . 3. A laminate comprising a base paper, a polyolefin-based synthetic resin laminate film layer laminated on the base paper, and an unstretched polypropylene (CPP) film layer laminated on the synthetic resin laminate film layer. A process paper for producing a flexible urethane foam, wherein the process paper is configured to be releasable from urethane foam generated by foaming a flexible polyurethane resin on the unstretched polypropylene film layer via the unstretched polypropylene film layer.