JPS6052950B2 - Method for manufacturing laminate - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to polymer waterproof lining treatments for fabrics, nonwovens, and the like.

Conventionally, resin lining treatments for the purpose of imparting waterproof properties to these materials and improving surface properties have included coating or impregnation with a polymer solution, and lamination of a polymer film onto the base material using adhesives, heat pressing, or other means. However, when coating porous substrates such as cloth and nonwoven fabrics using these methods, the solution penetrates into the substrate greatly, and an excessive coating amount is required to obtain a uniform lining film. This not only significantly impairs the texture and air permeability of the base material, but also requires drying equipment and solvent recovery equipment to dry unnecessary solvents, resulting in high production costs. There were safety issues such as fire prevention, as well as problems such as the tendency for solvents to remain in the product. A method has also been proposed in which a thermoplastic elastomer is coated on a silicone release paper or the like, dried, formed into a film, and then laminated to the base material. However, the same problems as mentioned above are unavoidable, and the cost is low because the release paper is expensive. It will be expensive. Another option is to melt-extrude coat the base material with a thermoplastic elastomer, but if you extrude coat a single layer of elastomer, it is difficult to make the layer thinner, so the texture and breathability of the base material will be affected. Problems with physical properties of the product, such as sagging, and high resin weight (coating amount per unit fabric) increase manufacturing costs. In addition, for single-layer extrusion coating, the film thickness is 20
The limit is approximately μ, but when coating thinly, the amount of heat held by the molten resin becomes smaller, and as it is instantly cooled by contact between the cooling roll and the pressure roll, strong adhesion is achieved with less penetration into the base material. Hateful. Further, thermoplastic elastomers have problems such as being prone to blocking on metal cooling rolls, which significantly impairs workability. The present invention
Coating a laminated molten film of at least two layers of a thermoplastic elastomer and a resin that has releasability to the elastomer by a coextrusion coating method on a base material such as cloth, nonwoven fabric, or paper, and then peeling off the resin. As a result, a thermoplastic elastomer lining film is obtained.

The coextrusion coating method is a type in which the resin extruded from two or more extruders passes through a resin confluence part called a combining adapter or black box, and then the laminated resin is extruded from a T die, or two or more extruders. Multi-manifold type extruders, in which the resin extruded from the T-die is laminated inside the T-die and extruded, and multi-slot type extruders, in which the resin is laminated outside the die. The molten film is pressed and solidified onto the base material using a pressure roll, but by using the coextrusion method, the retention and take-up properties of the molten film are improved, and thin-layer elastomer coating, which is impossible with a single layer, is possible. It becomes possible. At this time, the resin layer is peeled off after coating is completed, and in order to obtain an elastomer lining film on the base, the interlayer strength between the elastomer and the resin must be such that it can be easily peeled off. Coating with a laminated molten film of two or more layers in this way allows the elastomer layer to be made extremely thin because the molten film can be held by the resin layer, which was previously impossible with a single layer. Thin layer coating of about 1 to 20 μm, which was previously thought to be possible, is now possible.

Furthermore, since the heat of the molten resin is accumulated in all layers, even if one layer, that is, the elastomer layer, is made sufficiently thin, the amount of heat in the entire molten film is large, and when it is pressed onto the base material by the cooling roll and pressure roll. , the penetration into the base material due to the anchoring effect is large, and excellent adhesion can be obtained. Furthermore, since the elastomer film is covered with a resin layer during coating, blocking due to contact with the cooling roll can be prevented, and workability is greatly improved. The thermoplastic elastomer that can be used in the present invention includes, for example, 2
NC functional polyols, glycols and diisocyanates
Thermoplastic, polyurethane resin, manufactured by reacting at a ratio of O/0H = 0.95 to 1.1, consisting of a polyester block copolymerization of a crystalline hard segment polyester and an amorphous soft segment Polie. Stell elastomer, 1-2 polybutadiene, styrene-butadiene block copolymer resin (SBS)
, styrene-isoprene block copolymer resin (SIS)
However, polyurethane and polyester elastomers are preferred in consideration of the surface physical properties of the coating film and the ease of peeling from polyolefin.

As the resin layer, for example, polyolefin can be used, such as high pressure polyethylene (LDPE), medium and low pressure polyethylene (MDPE, HDPE), polypropylene, polymethylpentene, polybutene, polystyrene,
Polyvinyl chloride and their copolymer resins.

Although the above-mentioned coextrusion coating apparatus is used for the production of the present invention, a combining adapter system or a multi-manifold system that can easily form a thin layer is particularly effective.

The elastomer lining film produced in this way can have a minimum thickness of approximately 1 μm, and the elastomer layer thickness can be controlled as desired within the range of a total thickness of 15 to 20 μm or more.

Furthermore, at this time, the surface of the base material may be treated with a polyurethane-based, isocyanate-based, polyamide-based, rubber-based, etc. adhesive or anchor agent in order to further increase the adhesion to the base material. The amount of application should be kept within a range that does not impair the texture and breathability of the product. The elastomer lining film obtained by the method of the present invention can be made into a thin layer as described above, and is characterized by less impregnation into the base material. The air permeability, texture, etc. of the elastomer layer can be easily maintained, but in order to further improve the air permeability, texture, appearance, etc., all or part of the elastomer layer may be subjected to foaming treatment.

Foaming treatment uses organic blowing agents such as azodicarbonamide, azoisobutyronitrile, dinitropentamethylenetetramine, valatoluenesulfonyl hydrazide, 4,4'' oxyheath benzenesulfonyl hydrazide, sodium bicarbonate, ammonium carbonate, ammonium bicarbonate, etc. This can be done by adding an inorganic blowing agent, etc. to the raw elastomer, but it can be done by primary foaming at the same time as extrusion, extrusion at a temperature lower than the blowing agent decomposition temperature, heat treatment after coating, or by using water, solvent, etc. Although secondary foaming is possible by washing away the foaming agent, secondary foaming is superior because the foamed bubbles are not directional and the bubbles are more uniform. Unlike lining methods that are already known, the present invention uses a coextrusion coating method, so it is easy to coat a thin layer, and it not only has excellent physical properties such as breathability and texture. Since it is basically a solvent-free process, there is no concern about residual solvent in the product.
Drying equipment and solvent costs can be reduced.

In addition, it does not use expensive release paper such as silicone release paper, but instead uses inexpensive resin such as polyolefin, and the resin after release can be recycled and reused, resulting in low manufacturing and material costs. becomes. The present invention will be explained below with reference to Examples. <Example 1> A polyester nonwoven fabric was used as the base material 1, and a thermoplastic polyurethane elastomer (Baraprene 22S, manufactured by Nippon Polyurethane Co., Ltd.) 2 and a melt index were coated on this base material 1 by the method shown in the explanatory diagram of FIG. 16 polypropylene (manufactured by Mitsubishi Yuka Co., Ltd., Noblen FL-25F') 3
Laminate.

Elastomer 2 and resin 3 are each extruder 4,4"
After being extruded at a resin temperature of 0°C and laminated in die 5,
It is applied onto the base material 1 and crimped between a cooling roll 6 and a pressure roll 7. After this, the polypropylene film 3 was peeled off.

At this time, the polyurethane layer 2 could have a thickness of 10μ, and the polypropylene layer 3 had a thickness of 35μ. <Example 2> The method shown in Fig. 1 was carried out using a polyester-cotton blend fabric as the base material 1, a thermoplastic polyester elastomer (manufactured by Toyobo Co., Ltd., Belprene P-70B) as the elastomer 2, and polypropylene as the resin 3. The elastomer 2 was laminated on the base material 1 by the following steps.

The thickness of the elastomer layer 2 was 5μ, and the thickness of the polypropylene layer was 40μ.

[Brief explanation of drawings]

The drawings show an embodiment of the present invention, and FIG. 1 is an explanatory diagram thereof. 1... Base material, 2... Elastomer, 3
...Resin with releasability to elastomer, 4,
4″...Extruder, 5...Die, 6...
...Cooling roll, 7...Crimping roll.

Claims (1)

[Claims] 1. Melt extrusion coating a thermoplastic elastomer and a resin that has release properties on this elastomer on a porous substrate such as cloth or nonwoven fabric using a coextrusion method, and then peeling off the resin. A method for manufacturing a laminate, characterized by: 2. The method according to item 1 above, wherein the resin is a polyolefin. 3. The method according to item 1 or 2 above, wherein the thermoplastic elastomer contains a blowing agent.