JPS60135235A - Preparation of skinless foam sheet - Google Patents

Abstract

PURPOSE:To form a skinless foam sheet having various surface configuration and different in feeling, by providing a foam layer between base materials and, thereafter, mechanically tearing the part of said foam layer. CONSTITUTION:A composite body consisting of a base material 1, a base material 2 and a foam layer 3 is torn to form a skinless foam sheet A consisting of the base material 1 and a foam layer 4, and a skinless foam sheet B consisting of the base material 2 and a form layer 5. In each skinless foam sheet, the cell size of the foam layer 3 is controlled by appropriately selecting the composition of the foam layer 3 of the composite body or a foaming heating condition and, further, a tearing condition is controlled to enable the preparation of a sheet having various surface configurations. For example, when tearing is performed at a hightemp. directly after the foam layer 3 was formed, a sheet having a configuration, such that a fiber is embedded in the sheet, is obtained because a cell wall is cut in an extended state. In addition, when the foam 3 layer has a large cell, touch-feeling similar to artificial turf is developed and, when a small cell, back skin like finish can be performed.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a sheet whose surface is made of a skinless vinyl chloride resin foam.

PVC resin foam is used as artificial leather and wall covering materials because of its excellent texture, strength, and weather resistance, and because it is relatively easy and inexpensive to manufacture.

Used for flooring, etc. Improvements in printing and embossing techniques have made it possible to produce products that look extremely similar to natural products.

4+ to Gowa! 1-Lips are treated as a single treat Kaoru Tennagi J-#, #1. "It has excellent water and ventilation blocking properties. However, these excellent properties may be undesirable depending on the application. For example, leather applications require a moderate amount of breathability. However, preventing mold growth through breathability is also an important issue for wall covering materials.

To achieve this kind of breathability, for example, open cells can be intentionally created, but when molding into a sheet, the surface skin formed during foam formation and the subsequent cooling process is It has the disadvantage that it impedes breathability, making it impossible to achieve satisfactory results.

As a result of intensive studies to eliminate these drawbacks, the inventor of the present invention found that by providing a foam layer between the base materials and then mechanically tearing the foam layer, a material with various surface shapes and textures can be created. We have discovered that different skinless sheets can be manufactured and have completed the present invention.

That is, the present invention provides a foam layer 6 between the base material 1 and the base material 2.
The present invention provides a method for producing a skinless vinyl chloride/I/xm sheet, which is characterized by tearing the foam layer 3 of a composite provided with a skinless vinyl chloride/I/xm sheet.

Hereinafter, the present invention will be explained with reference to the drawings.

FIG. 1 is a cross-sectional view of a composite body in which a foam layer 3 is provided between a base material 1 and a profiteer 2. FIG.

The base material 1 and the base material 2 are not limited in any way as long as they can be bonded to a vinyl chloride resin, and may be, for example, cotton cloth, woven fabric of synthetic fibers, or non-woven fabric.

Flame retardant paper etc. can be used.

These are appropriately selected depending on the intended use.

The base material 1 and the base material 2 may be of the same type or different types.

The foam layer 3 is a layer made of a vinyl chloride resin foam, and a vinyl chloride paste resin foam is preferable.

The method for manufacturing the composite is as follows: (After the foam layer is formed into a sheet, a base material is laminated on both sides of the foam layer simultaneously or one side separately. (2) The base material is laminated on both sides of the unfoamed layer sheet. (3) After laminating a base material on one side of the unfoamed layer sheet, heating to form a foam layer, and further laminating the base material on one side. (4) This can be carried out by various methods, such as coating a base material with a paste resin sol composition and then laminating a low base material to form a gel, or gelling and then laminating a low base material.

Since the bonding strength between the base material and the foam layer in the composite is torn by the foam layer, it is not necessary to increase the bonding strength more than necessary.

After forming the composite, tearing separates the base material and the foam layer 3.
It must be done in the foam monolayer 3, rather than in between. Examples of tearing methods include mechanically slicing with a knife or making cuts and then pulling the torn sheet in a different direction. Note that tearing may be performed on the same manufacturing line immediately after forming the composite, or may be performed anew after forming the composite.

FIG. 2 shows a cross-sectional view of the composite when it is torn into sheets. Base material 1. The composite consisting of the substrate 2 and the foam layer 3 is torn to produce a skinless foam sheet A consisting of the substrate 1 and the foam J'Fj 4 and a skinless foam sheet consisting of the substrate 2 and the foam layer 5. Sheet B is formed.

The skinless foam sheet can be produced by controlling the cell size of the foam layer 3 and controlling the tearing conditions by appropriately selecting the composition of the foam m6 of the composite and the foaming heating conditions. Accordingly, sheets with various surface shapes can be manufactured.

For example, if the foam layer 3 is torn at a high temperature immediately after it is formed, the cell walls will extend and be cut, resulting in a shape that looks like fibers are embedded in the sheet.

In addition, if the foam layer 5 has large cells, it can give a texture similar to artificial grass, and if the cells are small, it can give a buckskin-like finish.

As explained above, according to the method of the present invention, by not forming a skin layer, it is possible to produce foam sheets with a wide variety of surface shapes that have not been seen before, and at the same time, foam sheets with the same shape can be produced. can be obtained with twice the production amount, and has extremely high economic efficiency.

The present invention will be explained below using examples.

Example 1 FIG. 6 shows an example of a manufacturing apparatus implemented by the present inventor.

After unrolling the base material 1 from the unrolling machine 6 and extruding the foam composition forming the foam layer 3 onto the upper surface of the base material 1 from the coke 8, the base material 2 unrolled from the unrolling machine 7 is Roll 9 forms an unfoamed composite. After the composite is passed through a heating foaming device 13 to form a foam layer 3, it is passed through a cooling roll 10, then torn by the foam layer 3, and squeezed by scrapers 11 and 12. The cooling roll 10 can be slid in the flow direction to adjust the temperature when tearing the foam. Also, although cutting device 14 is not necessary in all cases, it is useful in creating extremely smooth surfaces.

Using the above apparatus, the foam composition shown in Table 1(a) was prepared and coated on flame-retardant paper as a base material to a thickness of 0.4 mm, and the same flame-retardant paper as the base material was coated on the other side. was used to form an unfoamed composite. After foaming the composite in a heated foaming device at 210° C., a cooling roll is provided at a position 2771 from the exit, and after cooling, the foam layer is immediately torn in the vertical direction without using a cutting device, and the foam layer is torn in the vertical direction, Each sheet was rolled up to obtain two relatively smooth skinless foam sheets with a cover skin-like surface at the same time.

Example 2 A foam composition shown in Table 1(b) was prepared, and the same operations as in Example 1 were performed. When a cooling roll was set 1 m from the outlet of the heating and foaming device without passing water through it, and tearing was performed without using a cutting device, two foam sheets with a long-pile artificial turf-like surface were formed. Obtained.

Table 1 Rice 1) Polymerization degree 850, manufactured by Toyo Soda Kogyo Co., Ltd. -*-2) ADOA foaming agent (Vinihole AO-3, manufactured by Hyoso Kasei Co., Ltd.) Rice 3) Stabilizer for foaming, manufactured by Adeka Argus Co., Ltd.
FL-30)

[Brief explanation of drawings]

FIG. 1 is a schematic sectional view of the foam sheet composite before tearing, and FIG. 2 is a schematic sectional view after tearing. FIG. 3 is an explanatory diagram showing an example of a manufacturing apparatus for implementing the present invention. 1.2...Base material 44.5...Foam layer 47...Extruder 9, 10... - Rolls 11, 12... Winding machine 13... Heat foaming device 14...
...... Cutting device patent applicant: Toyo Soda Kogyo Co., Ltd. Figure 1, Figure 2 14

Claims (1)

[Claims] A method for producing a skinless vinyl chloride resin foam sheet, which comprises tearing a foam layer 3 of a composite body in which a foam N3 is provided between a base material 1 and a base material 2.