JPS58972B2 - Method for manufacturing composite sheet - Google Patents

Description

[Detailed description of the invention] The present invention relates to a method for manufacturing a three-component composite sheet.

More specifically, it relates to a method for producing a composite sheet that is a three-component multilayer body that can be made bulky without generating any foaming gas, and that can be cut into fibers to make bulky fibers. It is something.

Although the objects of the present invention are numerous, the main ones are as follows.

(1) The purpose of the present invention is to provide a material that is bulky without generating any foaming gas and is useful as a cushioning agent, a heat insulating material, a reinforcing agent, etc.

(2) By cutting, the purpose is to obtain a composite that can be used as fibers, tapes, ribbons, small pieces, or blocks, and that can be made bulky by heating.

Such composites are useful as, for example, field-processed mats, futons, mattresses, quilting stuffing, stuffed animal stuffing, stuffing for protecting articles, various heat insulating materials, reinforcing agents for door sliding doors, and the like.

(3) The idea of intermittently discharging the intermediate component of a three-component polymer, stretching it in the longitudinal direction, and mechanically pulling out each component is already known in JP-A-52-137027. When discharging polymer in the form of threads or ribbons, it is extremely difficult to discharge it intermittently at fine pitches.

In other words, due to the phenomenon of tailing, it is industrially impossible to make fine cuts.

The present invention not only creates a product that can be partially separated by A "continuous ejection" without such intermittent ejection, but also B "self-separates" and C "width direction". The objective is to obtain a sheet-like material that shrinks by 15% or more in the form of a sheet, and D, which exhibits sufficient bulk.

(4) In the case of conventional heat-foamed foams, once foaming begins, that part acts as a heat insulator, making it difficult for the inside to foam.

Another object of the present invention is to create a composite sheet suitable for creating a three-dimensional multilayer composite structure that can be bulky from 1 meter to 10 meters in height.

(5) Another object of the present invention is to easily provide a composite sheet that can sufficiently exhibit strength characteristics in a specific direction by forming the composite sheet into a honeycomb-like structure.

(6) Another purpose is to achieve effective industrial use of the three-component discharge method.

The present invention was obtained as a result of various studies aimed at achieving the above object, and the gist thereof is as follows.

That is, (1) at least three components, A and B components that have sheet-forming ability, have different shrinkage characteristics, and can adhere to each other, and C component that can be peeled off from A and/or B components, are The B component with a high ratio is small (both have two layers, the A and B components together form three or more layers, and the C component has A,
A method for producing a composite sheet, comprising discharging components B intermittently at the same time in the width direction, and then stretching them in the width direction.

Hereinafter, the present invention will be described in detail with reference to the drawings.

FIG. 1 is an example of a three-component composite sheet.

In other words, such a sheet can be made three-dimensional by using a multilayer laminated film.

Moreover, it consists of a film 1 with no or poor shrinkability or spontaneous extensibility made of component A, a highly shrinkable film 2 made of component B, and an adhesive layer 3 made of component C.

This becomes the basis for understanding the three-component discharge method, that is, one-shot molding.

The order of the layers is 2.3.1.3.2.3.1.
It is 3.2.

When this material is heated or the like to shrink the layer 2 made of the shrinkage component B, the cross section becomes as shown in FIG. 2.

In other words, it becomes bulky.

In FIGS. 1 and 2, the upper and lower portions of the adhesive layer 3 are depicted as being slightly spaced apart, but in reality, they are glued and snugly pressed together.

It is drawn with a slight pause for clarity.

Therefore, in reality, the thickness shown in FIG. 1 is relatively small.

If the number of layers is further increased as shown in Fig. 3, it becomes even bulkier as shown in Fig. 4 (this can be said to be a honeycomb structure with horizontal striations). The number of layers increases from 2 to bulky, but there are many drawbacks, and as a solution to these problems, the present invention has a particularly small number of layers (
It is necessary that there are two B layers in both cases, and that the number of A and B layers is three or more.

When used in a honeycomb shape with horizontal striations, the number is preferably 5 or more.

The shrinkage of component B is preferably 15% or more, particularly preferably 20 to 25% or more.

If it is less than 15%, the desired bulkiness cannot be obtained.

Such a sheet has the following features and effects. (a) Unlike bimetallic composites, the bulk can be obtained only by bending the A component, so it is possible to make bulky objects even if the B component is thin and the A component is quite thick.

(When the entire surface is bonded together, it is difficult to bend because the bending is A and B.

) (b) Bulky products can be produced without generating heated foaming gas.

It can be made bulky just by heating.

(c) A cylindrical hole is formed in the bulky part.

Because thermal fluid (hot air or hot liquid) can pass through these holes, heat can pass through to the inside no matter how bulky it is.
It is possible to eliminate the problem of bulkiness (bulk) and defects.

B) It can be cut into fibers or ribbons, and the cut material can be bulked up by heat treatment, so it can be made into threads to make windy knitted fabrics and non-woven fabrics.

In addition to these, it has an extremely large number of uses and markets, including bulky stuffing, rugs, mats, cushioning agents, insulation materials for heat and cold insulation, and soundproofing agents.

(e) It can also be used as a drainage material in civil engineering work by taking advantage of its breathability and water permeability.

It can also be used to insulate and prevent water leaks under tin roofs by combining heat and cold insulation properties, as well as to remove leakage water.

(f) The two components after bulking are both in a state of tension,
It has the property of being extremely hard to bend in the direction perpendicular to the waveform.

It also shows strong resistance to compression in the thickness direction.

Therefore, it is extremely useful as a lightweight reinforcing material.

If the A layer is one layer and the B layer is one layer, the bulkiness is poor, the cushioning properties deteriorate in a short period of time, it is easy to bend, and there is no firmness.

Although it has drawbacks such as not being able to exhibit significant bulkiness, these have all been resolved.

Methods for applying adhesive to such films include hand coating, roll coating, printed coating, and spray coating.

Furthermore, an adhesive film method may also be used.

The temperature is below the temperature at which contraction occurs. If it is caused by water or chemical solution contraction, there is no need to worry about this.

Flame retardants, colorants, lubricants, stabilizers, plasticizers, weathering agents, etc. can be added to such materials.

In addition, color effects, optical effects, heat insulation effects, and electrical effects can be imparted to the non-shrinkable component by metallizing or ion pre-tentering.

The present inventors have discovered an innovative configuration and means for such a composite, which will be described below.

That is, this is a method and structure for producing a composite sheet using a one-shot method, that is, a three-component simultaneous and continuous discharge method.

FIG. 5 shows an example of such a new configuration, in which a non-shrinkable layer 4 made of component A (less shrinkable than component B),
A layer 5 having release properties made of component 7B and having adhesive properties with component A, and a release layer 6 made of component C (this layer is continuous in the longitudinal direction but discontinuous in the width direction). There is.

Component C has weak adhesive strength with component A and/or B, and has a weak adhesive strength with component A-
Component B can be partially peeled off.

Such components are preferably polymeric substances that are solid at room temperature, but in principle they may also be liquids or gaseous fluids.

), and in FIG. 7, they are laminated in the order of BCACB (partially BCAB or BACB).

These sheets are significantly different from the above-mentioned sheets in the following points.

That is, there is no adhesive layer consisting of component C, but instead
The mutual adhesive properties of and B are used.

Furthermore, since A and B have adhesive properties, a removable component is selected as the intermediate component to partially prevent this.

As a preferable combination of components, for example, when polyethylene terephthalate is used as component A, and component A is copolymerized with isophthalic acid (this will cause high shrinkage by appropriate stretching) as component B, A and B will be well-formed when melted and discharged. Glue.

(AB combinations such as nylon and polypropylene are inappropriate and cannot be used) In this case, as the C component, polyamide, polyolefin (polyethylene, polypropylene, etc.), polyalkylene oxide, polystyrene, polyurethane, etc. are used.

Polyorganosiloxane It can be a liquid such as various oils or a grease, and it can also be a liquid with a mold release effect.In addition, if it tends to be adhesive or you want to choose from the same type of ingredients, you can use something like silicone. It can also be used by blending or copolymerizing a large amount.

For other polymers other than polyester, shrinkage of 15% or more, non-shrinkage, and release components can be selected as appropriate.
In particular, it is recommended to utilize copolymer components and similar polymers.

(Since it is easier to select the peeling components, you can mainly choose components A and B.

) Also, rubber may be selected as at least one component to achieve an elastic effect.

Further, from the viewpoint of dyeability, polymers of the same type are preferable.

The thickness of each layer is not limited to what is shown in the drawings, and can be freely determined depending on the desired characteristics, manufacturing method, etc.

However, it is extremely noteworthy that as long as the shrinkage force of the shrinkage component is strong enough, the thickness of the less shrinkable component may be ten times or more greater.

In general, the thinner the peeling component is, the less unnecessary components are required, so it is preferable.

However, it is different when utilizing the properties of this component itself other than exfoliation.

FIG. 5 shows the image before being stretched at least in the width direction.
Although it may be considered as the latter, a space may be created on both sides due to the stretching behavior of the peeling component that is an intervening component, but this does not in any way detract from or limit the structure of the present invention. .

FIG. 6 shows an example of an apparatus for discharging the composite sheet according to the present invention all at once.
There are various well-known methods such as the inflation method, so there is no need to stick to the one shown in the figure.

Rather, the figure shows that not only T-stretching and elongation in the longitudinal direction, but also stretching in the width direction Y for shrinkage of 15% or more is necessary.

That is, the sheet-like material 9 discharged from the discharge die (nozzle) 7 passes through a cooling roll 8, is held by a clip tenter, and is stretched by, for example, 2 to 4.5 times.

The K-' cross section can be viewed as a cross section as shown in FIG.

It is also possible to have multiple layers according to the example of FIG.

Further, as shown in FIG. 4, it is particularly preferable that there is no bonding portion with the B component layer at the same position on both sides of the A component layer.

FIG. 7 is a sectional view of the discharge dia in FIG. 6 viewed from the width direction.

As can be seen from FIG. 7, each component is introduced into the discharge die in a layered manner, combined with other components, and further squeezed and discharged in a layered manner.

The slit holes that supply the C component are divided in places, so
Three components can be discharged in the form shown in FIG.

FIG. 8 shows a partial schematic cross-sectional example for clearly explaining the arrangement of components A, B, and C and changes that may occur due to peeling.

(a) Due to the contraction of H, A and C slacken and swell.

(b) As B contracts, C also contracts, causing A to sag and expand.

(c) Due to the contraction of B, A becomes sagging and expands, and C becomes A and B.
and floating independently.

A when C is liquid. It adheres to both sides of B, and air enters the others.

(d) Due to the contraction of B, there is no place for A and C to go, and the contraction component B is pushed up in a prickly manner.

(e) When the support of AtC gets in the way and the contractile force of B is not sufficient to inflate.

(f) B is a preferable example because it easily shrinks.

A. C is making magic together.

One B layer may be omitted, but the swelling will be weaker.

This type is suitable for creating a honeycomb structure with horizontal striations, and is extremely suitable for making bulky yarns and sheets.

This is unique to the present invention. etc.

It should be noted that heating often causes wrinkles in the layers, but this does not prevent the effectiveness of the present invention.

Next, examples according to the present invention will be shown.

Example 1 A copolymer of 10 mo1% isophthalic acid (when added in the form of dimethyl terephthalate and copolymerized) to polyethylene terephthalate was used as the high shrinkage component B, and polyethylene terephthalate was used as the low shrinkage component A, and the former was used as the upper and lower layers. , the latter is used as an intermediate layer, and polyethylene is used as a release intervening component C, and each component is arranged in the form of a film (A:B:C≒5:5:0.5) as shown in Figure 5.
It was extruded from a °C nozzle die and immediately quenched on the surface of a roll applying cold water.

This thing is approximately 3.1 times larger in the longitudinal direction, and then approximately 3 times larger in the width direction.
．． It was stretched 3 times at about 90 to 100°C to obtain a sheet with a thickness of about 160 microns.

Cut each of these pieces into small notebook-sized pieces and long thin fibers with a width of approximately 1 mm (cut by inserting a cutter in the width direction)
However, when placed in hot air at approximately 110°C, the film lost 15%
It shrunk in the width direction, exhibited bulkiness of 2 to 4 mm, and had a honeycomb structure with horizontal striations.

The fibers became ladder-like bulky fibers and shrunk by more than 15%.

[Brief explanation of drawings]

1 and 3 are schematic cross-sectional views of a three-component composite sheet according to the present invention. FIGS. 2 and 4 are schematic cross-sectional views when the sheets shown in FIGS. 1 and 3 exhibit bulkiness. FIG. 5 is a perspective view of another three-component composite sheet according to the present invention. FIG. 6 is a perspective view showing an example of an apparatus suitable for manufacturing the sheet according to the present invention. FIG. 7 is a partial cross-sectional view of FIG. 6. FIG. 8 is a schematic partial cross-sectional view showing various ways of increasing the bulk of the sheet according to the present invention.

Claims (1)

[Scope of Claims] 1 At least three components having sheet-forming ability, having different shrinkage characteristics, and mutually adhesive AtB component, and C component capable of being peeled off from A and/or B component are shrinkable. There are at least two layers of B component with high A. A composite in which the B component forms three or more layers in total, and the C component is continuously and simultaneously discharged so that it is intermittently interposed between the A and B components in the width direction, and then stretched in the width direction. Method of manufacturing sheets.