JPS61219627A - Manufacture of laminated body - Google Patents

Abstract

PURPOSE:To efficiently manufacture a laminated body, which consists of fiber layer and thermoplastic resin layer and has water permeability or air permeability by a method wherein through holes are formed by the pressure difference produced by suction. CONSTITUTION:Resin layer 2 is supplied at nearly the same speed as the peripheral speed of a rotating cylinder 11 onto the surface of the cylinder 11 of a roll 10 for forming through holes in order to closely contact with the surface of the cylinder 11. When the resin layer 2 reaches a through hole forming range, to which a suction hood 15 is open, through the rotation of the cylinder 11, the resin layer 2 is pulled in through holes 12 due to the difference of pressures applied on both the sides of the resin layer 2 at the portion, which faces to the through hole 12, of the resin layer 2 and further developed and elongated until the bursting of the resin layer occurs at the bottom of a recess developed by the pulling on of the resin layer in the through hole 12, resulting in forming a through hole 8 in the resin layer. The pitch of through holes 8 and the diameter of the hole 8 formed on the resin layer 2 are determined in due consideration of the quantity of water flow or air flow in the environment, in which a laminated body 9 is used. The resin layer, in which the through hole 8 is formed, is successively pinched together with fiber layer 1 between the roll 10 for forming through holes and a pressure roll 20 in order to be manufactured into the laminated body 9.

Description

[Detailed Description of the Invention] The present invention relates to a method for efficiently producing a water-permeable or air-permeable laminate comprising a fiber layer and a thermoplastic resin layer and used as a rug, for example. .

Lost my grasp! Artificial lawns are laid on balconies, terraces, gardens, etc. by laminating a fiber layer imitating grass on top of a flat resin layer made from thermoplastic resin. However, water that accumulates on its surface does not drain easily.

If you walk on it, it has the drawback of getting wet and staining your shoes.

In order to eliminate such conventional drawbacks, the present invention provides a laminate in which through holes are continuously formed in the resin layer in the same process before or after adhesion with the fiber layer. This is a manufacturing method.

A through-hole for forming a through-hole is provided in the resin layer portion before or after adhesion to the hand fiber layer for transferring to the resin layer, and the through-hole is located in the through-hole formation range and moves together with the resin layer. The bottom of the through hole is connected to the intake mechanism on the peripheral surface of the cylinder or belt, and the through hole is formed by the differential pressure caused by the intake air.

Furthermore, the resin layer for forming through holes must be heated and softened, and for this reason, a measure is taken to use a sheet sent out from a continuous sheet manufacturing device that is still in a softened state and still has thermal energy as the resin layer.

Furthermore, a method is also taken in which a large number of protrusions or protrusions are provided on one surface of the resin layer before the formation of the pores, and the perforations are formed in the non-protrusions or non-protrusions.

Anal run An example of the operation of the present invention will be explained with reference to FIG.

The resin layer 2 in a softened state is continuously passed through the hole forming roll 1.
0. A large number of through-holes 12 for forming through-holes are bored in the cylinder 11 in which the through-hole forming roll 10 rotates. The through hole 12 located in the through hole forming range is connected to the vacuum pump via the suction hood 15, so that
The resin layer 2 on the upper part of the cylinder 11 in the through-hole forming range is
It is drawn into the through hole 12 due to the differential pressure at the through hole 12 portion, and finally ruptures to form the through hole 8.

A laminate 9 can be obtained by attaching the resin layer 2 to the back side of the fiber layer before or after forming holes in the resin layer 2.

Further, if the resin layer 2 is a softened sheet sent out from a continuous sheet manufacturing device, there is no need for reheating.

Furthermore, as shown in FIG. 2, by providing a large number of protrusions or protrusions on one surface of the resin layer 2 and forming through holes in the non-protrusions or non-protrusions, the holes are formed when the through holes 8 are formed. Even if a protruding portion is formed on the peripheral edge, the laminate 9
When the hole is installed, this protruding portion will not block the hole.

Su J1 sacrifice An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 is a schematic vertical sectional view of an apparatus for manufacturing a laminate according to the present invention, as an example.

The fiber layer 1 is a woven fabric, a non-woven fabric, a knitted fabric, a carpet, or an artificial lawn material, and the back side is made of a thermoplastic resin and has a backing material or heating material that thermally bonds to the resin layer 2 when heated and compressed. In some cases, an adhesive activated by the method may be applied in advance. The backing material made of thermoplastic resin and the film made of adhesive do not necessarily have to have air permeability.

The resin layer 2 is a sheet-shaped thermoplastic resin, and is supplied in a softened state. The resin layer 2 contains a filler and an extender in addition to a thermoplastic resin, and a material having a relatively small elongation at break when heated is suitable for the present invention.

The thickness of the resin layer 2 is generally 0.5 to 5+m+.

Furthermore, if a sheet in a softened state that still has thermal energy sent out from a continuous sheet manufacturing device such as an extruder or a calendar is used as the resin layer 2, there is no need for reheating.
Moreover, it is suitable for the present invention because it is uniformly heated and softened to the inside.

The through hole forming roll 10 has a cylindrical cylinder 11,
A large number of through holes 12 are bored in the cylinder 11. The cylinder 11 has a structure in which it is rotated by an external drive device (not shown) while being in airtight contact with the outer peripheral flange of a fixed disk (not shown) attached to both ends thereof.

A hollow shaft 14 is attached to the center of the fixed disks on both sides in the form of a skewer, one end of which is closed, and the other end connected to the suction port side of the vacuum pump. Several outer cylinders 16 having spring seats are fixed to the outer peripheries of the inner portions of both fixed disks of the hollow shaft 14, and an exhaust pipe 17 is loosely and airtightly fitted into the hollow shaft 14 and the outer cylinders 16. The suction hood 15 is located inside the cylinder 11, and is a box-like body with a sector-shaped cross section that opens in correspondence with the through-hole formation range of the cylinder 11. An exhaust pipe 17 is fixedly connected to the bottom of the suction hood 15, and the suction hood 15 is connected to the bottom of the suction hood 15. The end surface of the opening of the hood 15 is constantly pressed against the inner peripheral surface of the cylinder 11 by the force of a coil spring 18 attached to the outer periphery of the exhaust pipe 17. The air sucked from the through hole 12 in this way is transferred to the suction hood 15, the exhaust pipe 17, and the hollow shaft 1.
4 and is effectively introduced into the suction port of the vacuum pump.

On the surface of the cylinder 11 of the roll 10 for forming holes.

The resin layer 2 is supplied at approximately the same speed as the circumferential rotational speed of the cylinder 11 and brought into close contact with the surface of the cylinder 11.

As the cylinder 11 rotates, the resin layer 2 reaches the open hole forming range of the suction hood 15, and the pressure difference between the two sides of the resin layer 2 causes the through hole 1 to close at the 1 through hole 12 portion.
2 and further expanded, the bottom part finally ruptures and a through hole 8 is formed.

What are the pitch and diameter of the through holes 8 formed in the resin layer 2?

It is determined by taking into consideration the amount of water flow or ventilation in the environment in which the laminate 9, which will be described later, is used. Note that the diameter of the through-hole 12 of the cylinder 11 is preferably set to 2 to 5 times the diameter of the required through-hole 8, but as the thickness of the resin layer 2 increases, the value needs to be increased.

The resin layer 2 in which the holes 8 have been formed is then pressed together with the fiber layer 1 between the hole-forming roll 10 and the pressure roll 20 to produce the laminate 9.

In the example of FIG. 1, the aim layer l is laminated on the resin layer 2 in which the through holes 8 are formed, but it is also possible to form the through holes 8 in the resin layer 2 after laminating both layers. . in this case,
Even if a continuous film made of a thermoplastic resin such as a backing layer or an adhesive is formed on the back surface of the fiber layer 1 to which it is attached, the fiber layer 1 and the resin layer 2 may A heat softening treatment is performed before lamination, and the heat softened resin layer 2 and fiber layer l are pasted together via a film, and then through holes are formed using the cylinder 11 of the through hole forming roll 10 using the method described above. edge,
Through-holes 8 penetrating the resin layer 2 and the film can be formed by the differential pressure. Further, even in the case of a bonded body in which the fiber layer l and the resin layer 2 are bonded in advance in separate steps, the through holes 8 may be formed by the hole forming roll 10 after the resin layer 2 is heated and softened. is possible.

Further, as shown in FIG. 2, the resin M2 in a softened state is compressed by a forming roll 30 in which a large number of grooves or depressions 31 are carved, and a pressure roll 35, so that one side 4 of the resin layer 2 has protrusions or protrusions. After forming the protrusions 3, the cylinder 11' of the hole forming roll 10', which is provided with the recesses 19 and through holes 12 corresponding to the protrusions or protrusions 3, makes the non-protrusions or non-protrusions transparent. Holes 8 can also be formed. Note that when the exhaust hole 13 is provided at the bottom of the recess 19, the protrusions or protrusions 3 of the resin layer 2 are brought into instantaneous contact with the cylinder 11' surface.

The example shown in FIG. 3 is a device similar to the cylindrical hole-forming roll 1°, in which the hole-forming belt 41 is attached to the cylinder 1.
It is provided with a through hole and a recess similar to the 1, 1 Bi, and is continuously moved in the direction of the arrow by a 5 drive pulley 42. A vacuum box 44 is provided via a net-like belt 43 that is in contact with a portion of the lower surface of the through-hole forming belt 41 and moves together with it.

When the softened resin layer 2 supplied onto the through-hole forming belt 41 reaches the vacuum box 44, it is drawn into the through-hole to form the through-hole 8, and then the fiber layer 1 is adhered and laminated. A body 9 is obtained.

In the present invention, when a through hole is punched in the resin layer portion of a laminate consisting of a fiber layer and a resin layer, the layers are integrated almost at the same time (before or after the punch is punched), so it can be carried out in the same process. This saves man-hours.

Also,! Using a softened sheet sent out from a continuous sheet manufacturing device as the M fat layer eliminates the need for reheating and saves energy, and the softened sheet is heated evenly to the inside, which is advantageous for adhesion and hole formation. .

Furthermore, by providing protrusions or protrusions on the resin layer, when the laminate is laid on the ground, etc., the through holes will be separated from the ground, etc., so that the holes will be blocked by the protruding parts of the edges around the through holes, or It will not be reduced.

The laminate produced by the method of the present invention has good water permeability, such as rugs laid outdoors and overlays for floors with underfloor heating.
Used for rugs that require breathability.

[Brief explanation of drawings]

1 and 2 are schematic vertical sectional views each showing an example of an apparatus for carrying out the method according to the present invention. FIG. 3 is a schematic side view of an apparatus showing another embodiment. 1...Fiber layer 2...Resin layer 3...Convex stripes or convexities 8...Through holes 9...Laminated body
11,1 Bi...Cylinder 12...Through hole
30... Forming roll 41... Belt

Claims (4)

[Claims] (1) In a method for manufacturing a laminate in which a thermoplastic resin layer in a softened state is adhered to the back side of a fiber layer by pressing, the resin is applied to the resin layer portion before or after adhering to the fiber layer. A through-hole is provided for forming a through-hole that contacts the layer and moves together with the layer, and the bottom of the through-hole located in the through-hole forming range is connected to the intake mechanism on the circumferential surface of the cylinder or belt. A method for producing a laminate, the method comprising forming holes. (2) The method for manufacturing a laminate according to claim 1, wherein the thermoplastic resin layer in a softened state is a sheet delivered from a continuous sheet manufacturing device. (3) After forming a large number of protrusions or protrusions on one surface of the resin layer using a forming roll, through-holes are formed in the non-protrusions or non-protrusions by differential pressure, as claimed in claim 1. Or the method for manufacturing a laminate according to item 2. (4) The method for producing a laminate according to claim 1, 2, or 3, wherein the fiber layer is a woven fabric, a nonwoven fabric, a knitted fabric, a carpet, or an artificial lawn material.