JPS6021548B2 - Manufacturing method of laminated sheet - Google Patents

Description

[Detailed Description of the Invention] - The present invention provides a method for attaching a thermoplastic synthetic resin foam layer and a porous covering material used for walls, ceilings, floors, etc. of automobiles and buildings, especially automobile trunk mats and door linings. The present invention relates to a method for manufacturing a laminated sheet.

Conventionally, a method for manufacturing this type of laminated sheet is explained based on FIG. 1. A thermoplastic synthetic resin paste such as polyvinyl chloride (PVC) paste 3A is applied onto a machine pattern 1 using a doctor knife 2. The PVC paste 3A is heated and gelled and foamed in a heating furnace 4 to form a foamed layer 3 and a skin layer 3', an adhesive 6 is applied to the surface of the foamed layer 3 by a doctor knife 5, and a line drawing roll is applied. A porous facing material such as a non-woven fabric 8 is fed out through 7, 7A and 7B, and the non-woven fabric 8 is adhered to the surface of the foam layer 3 by a polymerization roll 9 via an adhesive 6.

The adhesive 6 is dried through the drying oven 10, and the roll 11
The template paper 1 is peeled off, wound onto a roll 12, and then cut into a predetermined size using a cutter 13. In this way, a laminated sheet is obtained in which the PVC foam layer 3 and the nonwoven fabric 8 are bonded together via the adhesive 6 as shown in FIG. According to the above-mentioned method, an adhesive is required, and accordingly, it is necessary to dry the adhesive in a drying oven.

Further, even if an adhesive is used, the adhesive strength between the foam layer and the facing material is not large. The present invention does not use an adhesive, so there is no need for a drying process using a drying oven, and the bond between the foam layer and the covering material is
The purpose of this invention is to provide a method for manufacturing a laminated sheet with high adhesive strength, and the main idea is to use plastisol instead of paste resin.

The present invention will be explained in detail based on FIG. 3 and subsequent figures. Process 1
In this step, plastisol 23A to which a foaming agent has been added is applied onto a release base such as release paper 21 by a reverse roll coater 22.

If you use a reverse roll coater, plastisol 23A
It is applied thickly onto the release paper. Of course, other coating devices other than the reverse roll coater, such as a doctor coater or a flow coater, may also be used. Blastisol used in the present invention is
A paste resin made by kneading a thermoplastic synthetic resin such as PVC, polystyrene, polymethacrylate, styrene-butadiene resin, acrylonitrile-styrene-butadiene resin with a plasticizer, and suspending it only in the plasticizer. For example, a blowing agent is added to the plastisol.

For example, a formulation example of PVC plastisol to which a blowing agent has been added is as follows. PVC paste
10 parts by weight Plasticizer (dioctyl phthalate) 70 Blowing agent (azodicarbonamide) 3
~5 Stabilizers 2 to 3 Pigments 0 to 1 In step 2, plastisol 23A coated on the rock pattern paper 20 in step 1 is heated in a heating furnace 2.
Heat at step 4 to semi-gel.

Thus, as shown in FIG. 4, a skin layer 23 is formed on the release paper 21 side.
A semi-gelled plastisol layer 23B is obtained. When using PVC plastisol with the above formulation, the heating temperature is approximately 180 oo. In step 3, plastisol 26A to which a coating agent has been added is applied onto the semi-gelled layer 238 of plastisol 23A in step 2.

To apply plastisol 26A, use doctor knife 2
5. Reverse. Well-known coating equipment such as a roll coater or a flow coater is used. In step 4, the nonwoven fabric 28 is fed out from the feeding rolls 27, 27A, 27B,
The nonwoven fabric 28 is pressed onto the plastisol coating layer 26A by a pressure roll 29.

At this time, since the fourth semi-gelled layer 23B does not exhibit fluidity, it does not undergo fluid deformation even by the pressing force of the pressing roll 29.
Furthermore, since the plastisol coating layer 26A has fluidity,
A transparent layer 26B is formed on the adhesive surface of the nonwoven fabric 28 with a slight penetration as shown in FIG. Other breathable upholstery materials such as chute felt, fabric, tricot, etc. may be used in place of the nonwoven fabric 28. The laminated structure shown in FIG. 5 is then heated in a heating furnace 30, and the semi-gelled layer 23B of the plastisol 23A and the plastisol coating layer 26A are completely gelled and foamed to form a foamed layer 23. After that, the template paper 21 is peeled off with a roll 31. The laminate is wound onto a roll 32, and cut into a predetermined size by a cutter 33, thereby obtaining a screen layer sheet having a cross-sectional structure as shown in FIG. In the laminated sheet shown in FIG. 6, the foam layer 23 slightly digs into the adhesive surface of the nonwoven fabric 28 at a biting part 28'.
, the foam layer 23 and the nonwoven fabric 28 are strongly bonded together without using an adhesive. In the present invention, as described above, the plastisol applied to the mold release base material is heated to become a semi-gel, so even if a pressing force is applied when polymerizing an air-permeable surface material, the semi-gelled layer has no fluidity. Since the breathable facing material is polymerized on the low-viscosity plastisol coating layer, the plastisol coating layer digs into the breathable covering material, resulting in a product with high interlayer adhesion strength even without the use of adhesives. is obtained.

In addition, even if the facing material is polymerized on the plastisol coating layer and then heated to form a foaming gel, the decomposition gas of the blowing agent can easily pass through the facing material because the facing material has air permeability. He is also easy-going.

[Brief explanation of the drawing]

FIG. 1 is a conventional process diagram, FIG. 2 is a side sectional view of a conventional laminated sheet, FIG. 3 is a process diagram of an embodiment of the present invention, and FIG. 4 is a side sectional view after completion of step 2. FIG. 5 is a side sectional view after the completion of step 4, and FIG. 6 is a side sectional view of the laminated sheet of the present invention. In the figure, 21... Release paper, 23... Foaming layer, 23A... Plastisol, 23B... Plastisol semi-gelled layer, 25A... Foaming agent added. Plastisol, 28...Nonwoven fabric, 29...
・Press roll. 1st neighbor 2nd figure 3rd figure 4th figure 5th figure 6th figure

Claims (1)

[Claims] 1. Step 1 of applying plastisol with or without a blowing agent to a mold release substrate. Step 2 of heating the coating layer of Step 1 to make it semi-gel. Step 3 of applying plastisol to which a foaming agent has been added on the semi-gelled coating layer in Step 2. Step 4 of polymerizing the breathable facing material on the coating layer of Step 3 and then pressing it with a pressure roll. Step 5 of heating the polymer of Step 4 to gel and foam the plastisol layer. Step 6 of removing the mold release base material and cutting it into predetermined dimensions. A method for manufacturing a laminated sheet consisting of the above steps 1, 2, 3, 4, 5, and 6.