JPS61199926A - Manufacture of laminated body - Google Patents

Abstract

PURPOSE:To continuously produce a laminated body, the peel strength of which is high and the partial scattering of peel force of which is scarce, by a method wherein thermoplastic resin sheet, which is in softened state by melting, is polymerized with fiber layer under the sucking action through the fiber layer side and the pinching between a pressure roll and a sticking roll. CONSTITUTION:Firstly, material for fiber layer 1 is continuously supplied onto the outer peripheral surface 13 of a rotating sticking roll 10. Secondly, thermoplastic resin sheet 2, which is molten in an extruder 3 and extruded through a die 4, is continuously supplied onto the fiber layer 1 in order to polymerize the sheet 2 and the layer 1 with each other. When the resultant polymerized sheet is moved peripherally together with a cylinder 11 so as to arrive the predetermined region, within which the suction holes 12 on the outer peripheral surface 13 are effectively used for evacuation, the sheet 2 is pressed onto the top surface of the fiber layer 1 through the fiber layer 1 by means of the differential pressure developed by evacuation, resulting in penetrating resin into the space formed between fibers. The polymerized sheet is pinched between the pressed by the sticking roll 10 and the pressure roll 2 in order to obtain a laminated body 5, which rotates together with the cylinder 11 and, after that, is transferred to the peripheral surface of a cooling cylinder 21 in order to be cooled down.

Description

DETAILED DESCRIPTION OF THE INVENTION This invention relates to a method for producing a laminate by adhering a thermoplastic resin sheet, or a thermoplastic resin sheet and a backing layer, to a fiber layer.

A method of laminating a fiber layer and a softened thermoplastic resin sheet by pressing them between a pair of rolls is conventionally well known. However, in such conventional methods,
A load is only momentarily applied between the two, and when the fiber layer has a low apparent density, is rough, or has large irregularities, the adhesion between the two may become insufficient.

The purpose of the present invention is to eliminate the above-mentioned conventional drawbacks and to provide a method for producing a laminate as described at the beginning for firmly adhering a fiber layer and a thermoplastic resin sheet. It is to provide.

In the first invention of this application, a number of suction holes are bored through the circumferential surface of a rotating cylinder, and
In addition, a fibrous layer is continuously supplied to the cylinder circumferential surface using an adhesive roll configured so that air on the cylinder outer circumferential surface located within a predetermined area is discharged to the outside through suction holes. A thermoplastic resin sheet in a melted and softened state is polymerized into a fiber layer on the circumferential surface of the cylinder, and then the thermoplastic resin sheet is attached to the fiber layer by air intake from the fiber layer side and pressure by a pressure roll. This is a method for manufacturing a laminate.

A second invention of this application is that in the above invention, a thermoplastic resin sheet in a melted and softened state is polymerized into a fiber layer on the cylinder peripheral surface located within a predetermined area, and then a fiber layer is polymerized from the fiber layer side. When the two are joined by the action of air intake, the free surface of the thermoplastic resin sheet and the backing layer are also polymerized,
This is a method for manufacturing a laminate in which a thermoplastic resin sheet and a backing layer are attached to a fiber layer by pressure using a pressure roll.

11■ A method for manufacturing a laminate according to the present invention will be explained based on the drawings.

FIG. 1 is a diagram showing an example of an apparatus implementing the first invention.

The cylinder 11 of the pasting roll IO has a large number of suction holes 12 perforated on its outer peripheral surface 13.
1 while in airtight contact with the outer peripheral flange of a fixed disk (not shown) attached to both ends of the external drive device! A hollow shaft 14 is attached in the center of the fixed disk on both sides in the form of a skewer, one end of which is closed, and the other end is connected to a vacuum pump. Connected to the suction port side of the Several outer cylinders 15 having spring seats are fixed to the outer periphery of the inner portions of both fixed disks of the hollow shaft 14, and an exhaust pipe 16 is loosely and airtightly fitted between the hollow shaft 14 and the outer cylinder 15. The suction hood 18 is located inside the cylinder 11 and has a box-like shape with a fan-shaped cross section that opens corresponding to a predetermined area for intake of air on the outer circumferential surface 13 of the cylinder 11. The exhaust pipe 16 is fixed to the bottom of the suction hood 18. It is connected. The opening end surface of the suction hood 18 is constantly pressed against the inner circumferential surface 19 of the cylinder 11 by the force of a coil spring 17 mounted on the outer periphery of the exhaust pipe 16. The air sucked in from the suction hole 12 of the cylinder 11 located within a predetermined area is transferred to the suction hood 18, the exhaust pipe 16, the hollow shaft 1
4 and is effectively introduced into the suction port of the vacuum pump.

The fiber layer 1 material unraveled from the reel 23 is continuously supplied to the cylinder outer peripheral surface 13 of the rotating adhesive roll 10 through an expander (not shown) or a heater 24 as required. On the other hand, the thermoplastic resin sheet 2 melted in the extruder 3 and extruded through the die 4 is continuously supplied onto the fiber layer 1 at approximately the same speed as the circumferential rotational speed of the cylinder 11, and both are polymerized. When this superposed sheet rotates together with the cylinder 11 and reaches a predetermined area where the suction holes 12 in the cylinder outer circumferential surface 13 are effectively sucked.

The thermoplastic resin sheet 2, which is still in a softened state, is pressed against the upper surface of the fiber layer 1 by the differential pressure caused by the intake air through the fiber layer 1, and further penetrates into the spaces between the fibers of the fiber layer 1. The polymerized sheet is then pressed between the adhesive roll 10 and the pressure roll 20 which is pressed against the adhesive roll 10 with a constant force, and is intertwined to obtain the laminate 5. This stacked body 5 rotates together with the cylinder 11, passes through a predetermined area where the suction holes 12 are effectively sucked, and then the cooling roll 2
1 and cooled. If the cooling is insufficient, further cooling is performed using another cooling roll 22 or other cooling means. The laminate 5 adhered in this manner is wound up and sent to the next process. Of course, the material may be directly supplied to a molding device such as a thermoforming machine without going through the cooling process described above.

FIG. 2 is a diagram showing an example of a device implementing the second invention,
The configuration of the device is almost the same as the first invention. In the first invention, the thermoplastic resin sheet 2 is melted and is still in a softened state on the circumferential surface of the cylinder 11 located within a predetermined area.
After polymerizing the fiber layer 1, if necessary, the backing layer 6 whose joint surface is heated with a heater 25 is placed on the pressure roll 2.
The resin is supplied onto the circumferential surface of the thermoplastic resin sheet 2 as the roll 20 rotates, and is continuously polymerized onto the free surface side of the thermoplastic resin sheet 2.

Immediately after that, polymerized fiber layer 1 and thermoplastic resin sheet 2
The backing layer 6 is compressed and integrated between the adhesive roll IO and the pressure roll 20 to obtain a three-layer second laminate 7.

The fiber layer 1 material used in this invention is a woven fabric, a nonwoven fabric, a knitted fabric, a felt, a carpet, etc. made of natural fibers or synthetic fibers alone or in a blend. The thermoplastic resin sheet 2 material is polyethylene, polypropylene, soft vinyl chloride resin, thermoplastic elastomer, etc.
．． It is extruded to a thickness of 0.05 to 2.0 mm. The backing layer 6 may be a foamed sheet made of polyethylene, polypropylene, polyurethane, etc., with a foaming ratio of 10 to 50 times and a thickness of 1 to 20++n, a foamed resin layer of a sheet, felt, etc.
Carpets etc. are used. Note that an adhesive layer is provided in advance on the side surfaces of the fiber layer 1 and the backing layer 6 that overlap with the thermoplastic resin sheet 2.・If it can be heat-sealed or intertwined with 2, an adhesive layer is not required.6 In either case, the fiber layer l
Furthermore, if the backing layer 6 is heated with a heater 24, 25 before polymerization, the peel strength will be increased.

The diameter and spacing of the suction holes 12 bored on the circumferential surface of the cylinder 11 are determined as appropriate depending on the thickness and roughness of the fiber layer, but generally the diameter is 0.5 to 2.0+a and the spacing is 5 to 20 as. be.

The distance on the circumferential surface of the cylinder 11 from the point where the thermoplastic resin sheet 2 polymerizes with the fiber layer 1 to the point where it contacts the pressure roll 20 or the pressure roll 20 via the backing layer 6 is 50 to 100 cm. degree or 3 to 1
It is preferable to set the movement distance after 0 seconds have elapsed. The clamping pressure of the pressure roll 20 against the pasting roll IO is 0.5 to 10 kg/a
It is m.

A PP/polyester blend needle-punched carpet with a basis weight of 250 g/rrr is used as the fiber layer 1, and a low-density polyethylene homopolymer (melt flow index 20
) is extruded from the die 4 of the extruder 3 to a thickness of 0.15 as and at a resin temperature of 180 to 200°C.The two are polymerized on the pasting roll 10, and the thermoplastic resin sheet 2 is passed through the fiber layer 1 into the cylinder 11. It was adsorbed onto the outer circumferential surface 13 side, and further pressed with a pressure roll 20 at a linear pressure of 0.5 kg/cm to obtain a laminate. As described above, the peel strength between the carpet and the polyethylene sheet of the laminate produced according to the present invention was such that the carpet structure was destroyed and the two were so strongly adhered that it was impossible to measure the peel strength.

In addition, a buckskin-like knit fabric made of 100% 6.6 nylon yarn with a basis weight of 250 g/- is used as the fiber layer 1, and a low-density polyethylene homopolymer (melt flow index 10) from die 4 of extruder 3 to a thickness of 0
．． 15 mm at a resin temperature of 200 to 220° C., both are polymerized on an adhesive roll 1O, the thermoplastic resin sheet 2 is adsorbed to the outer peripheral surface 13 side of the cylinder 11 through the fiber layer 1, and a thick layer is added as a backing layer 6. A 15 times expanded polyethylene foam sheet with a length of 3 m is supplied onto the circumferential surface of the pressure roll 20 as the roll 20 rotates, and is continuously polymerized on the free surface side of the thermoplastic resin sheet 2. The three members were crimped together at a linear pressure of 1.0 kg1c+s to obtain a laminate. The peel strength between the nylon woven fabric and the polyethylene sheet of the laminate made according to the second invention is 6k.
g/3 ao width, and the peel strength of a laminate made with the same material and the same lamination conditions using a conventional pasting roll without suction mechanism was 4 kg/3 am wide. Furthermore, the local variation in peeling force in the former case was smaller than that in the latter case.

The laminate of the present invention is used as a vehicle interior material, construction material, etc. after being cut as is or after being thermoformed.

As explained above, the method for producing a laminate of the present invention uses a pasting roll in which air on the circumferential surface of a cylinder located within a predetermined area is discharged to the outside through a suction hole, Since the fiber layer and the thermoplastic resin sheet are integrated on the cylinder circumferential surface by the suction action and the pressure by the pressure roll, the thermoplastic resin sheet penetrates into the fiber layer and has a high peel strength between the two. , it is possible to continuously produce a laminate with little local variation in peel force. This is especially effective when the fiber layer is rough or uneven.

A three-layer laminate consisting of a fiber layer, a thermoplastic resin sheet and a backing layer can also be produced in a similar apparatus, in which case the backing layer in particular has holes or cutouts.

Even if the unevenness is non-uniform due to different expansion ratios, it does not affect the peel strength of the fiber layer and the thermoplastic resin sheet, and the three can be bonded between two rolls.

[Brief explanation of the drawing]

1 and 2 are partial cross-sectional views showing an example of an apparatus for carrying out the present invention.

Claims (2)

[Claims] (1) Adhesion in which a number of suction holes penetrating the cylinder are drilled on the circumferential surface of a rotating cylinder, and air on the outer circumferential surface of the cylinder located within a predetermined area is exhausted to the outside through the suction holes. The fiber layer is continuously supplied to the cylinder circumferential surface by a roll, and the thermoplastic resin sheet in a melted and softened state is polymerized into the fiber layer on the cylinder circumferential surface in the predetermined area, and then an air intake action from the fiber layer side is applied. A method for producing a laminate, comprising adhering a thermoplastic resin sheet to a fiber layer by applying pressure using a pressure roll. (2) Adhesion in which the circumferential surface of a rotating cylinder has a number of suction holes penetrating through the cylinder, and the air on the outer circumferential surface of the cylinder located within a predetermined area is exhausted to the outside through the suction holes. The fiber layer is continuously supplied to the circumferential surface of the cylinder by a roll, and on the circumferential surface of the cylinder in the predetermined area,
The thermoplastic resin sheet in a molten and softened state is polymerized into a fiber layer, and then the thermoplastic resin sheet and the backing layer are formed into the fiber layer by an air intake action from the fiber layer side and a pressure roll using a compression roll through the backing layer. A method for manufacturing a laminate, characterized by adhering.