JPS632775B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a laminate material having foam-like protrusions on the surface, such as for use in socks for infants, the back side of the belt part of skirts and pants, and mats for entrances and baths. It is used in areas where anti-slip properties are required, such as the back side, the shoulder strap of shoulder bags, and the handle covers of automobiles.

[Prior art and its problems] Laminated materials in which a synthetic resin foam layer is provided on the surface of a base material and protrusions with a structure in which bubbles are destroyed are formed on the surface of the resin layer are disclosed in, for example, Japanese Utility Model Application Publication No. 53-137203, It is described in Japanese Patent Application Laid-open No. 54-146864 and Japanese Utility Model Publication No. 36-235.

The protrusions described in Japanese Utility Model Application Publication No. 53-137203 are made by layering wallpaper fabric on the synthetic resin foam layer provided on the covering fabric base fabric, heating it, and transferring the melted material of the skin of the covering fabric to the wallpaper fabric. A suede-like synthetic resin foam layer is formed by adhering the wallpaper fabric and the base fabric, and then peeling the molten material onto the surface of the wallpaper fabric in the form of threads.

These protrusions are not formed when bubbles burst, but when the foam layer is torn. Moreover, the surface of the torn foam layer has a microporous structure, and the remaining thread-like parts has a suede look. Therefore, the protrusions are string-like, flexible, and short in height.

Moreover, the manufacturing method is as described above, and can only be applied to sheet-like products.

The protrusions described in JP-A-54-146864 are produced by processing a synthetic resin containing a foaming agent into a sheet, laminating a backing material at the same time, and then heating and foaming the laminate. Alternatively, the sheet may be treated with a solvent to provide a large number of rupture marks of foamed cells on the surface of the sheet, or furthermore, an uneven pattern may be added to the top surface thereof.

These protrusions break the bubbles by reheating the surface that has solidified without breaking the bubbles, but the surface of the sheet is once solidified and then the bubbles are broken, as shown in the attached drawing. The tips of the protrusions are flat so that In addition, the layer is completely foamed except for the surface.

As mentioned above, the manufacturing method also requires many steps such as a lamination step, a heating foaming step, and a foam breaking step using ignition or a solvent.

The protrusions described in Japanese Utility Model Publication No. 36-235 are produced by foaming a liquid containing a foaming agent on the surface of the rubber glove base 1 by heating to form a hollow sphere, and cutting and polishing the upper half of the hollow sphere. The suction cup 3 has a hemispherical concave surface.

As you can see from the lack of the word protrusion here, the glove has countless hemispherical recesses formed on its surface, and the ones formed between the hemispherical recesses are more like partitions than protrusions, and their tips are not sharp either. .

As described above, all the protrusions described in the above-mentioned publications are formed after solidification, and therefore the protrusions are low in height and do not have sharp tips.

For this reason, the anti-slip effect is not sufficient.
Particularly when there is liquid such as water or oil on the surface of the object, a layer of liquid is formed between the laminated material and the object, so that no anti-slip effect can be expected.

[Object of the present invention] The present invention provides a laminated material having a sharp tip and a sufficient height to provide an anti-slip effect even when wet with water, etc., and a method for manufacturing the same. It provides:

[Configuration of the present invention] The configuration of the present invention taken to achieve the above object is as follows.

Regarding the invention of a laminated material having foam-like protrusions on the surface, a resin liquid containing small bubbles is in a sol state on the surface of a resin layer provided on the surface of a permeable base material formed into a desired shape. It has countless bubble-shaped protrusions formed by the bubble-broken process and countless holes formed surrounded by the bubble-broken protrusions, and the bubble-broken protrusions have elasticity and extend toward the tip. Moreover, the height of the hole is not uniform, and the size of the hole is not uniform, and the bottom of the hole sometimes reaches the surface of the base material and sometimes does not. It's a mixture.

Regarding the invention of a method for manufacturing a laminated material having bubble-like protrusions on the surface, a rubber or synthetic resin liquid containing a large amount of small bubbles is attached to the surface of a permeable base material formed into a desired shape, Next, while a part of the liquid phase is infiltrated into the base material, the small bubbles are broken in a sol state to form a bubble-like protrusion with a sharp tip and a hole surrounded by the bubble-broken protrusion and having different sizes. and then heated and molded.

The base material has permeability, and examples include paper, cotton, synthetic fibers, nonwoven fabrics such as cotton, woven fabrics, knitted fabrics, and sheets having these on the surface.

The base material is usually formed into a sheet shape, but it can be formed into a sock shape or any other desired shape as required. Examples of means for providing the resin layer on the base material include a method of immersing the base material in a resin liquid, a method of applying a resin liquid to the base material, and the like.

Examples of the resin include natural resins such as natural rubber, and synthetic resins such as vinyl chloride resin, vinyl acetate resin, and polyurethane resin.

To break the bubbles, the base material with the bubbles attached is placed under reduced pressure, the air pressure of 4 m/sec or more is applied, the bubbles are expanded and broken by rapidly heating at 100°C to 200°C, Examples include a method of applying vibration or impact to a base material to which air bubbles are attached.

[Example] The present invention will be described in more detail based on an example shown in the drawings.

Fig. 1 is a plan view of a laminated material formed into a sheet with some of the foam-like protrusions omitted; Fig. 2 is a partially enlarged cross-sectional view showing a state in which resin liquid has adhered to the base material;
The figure is an enlarged sectional view taken along the line XX in FIG.

A sheet-like base material 1 made of a knitted fabric with good moisture absorption such as cotton, synthetic fiber, or cotton is made of latex, plastisol,
Organosol or solution with a particle size of 0.2
A resin layer 2 is provided on the surface of the base material 1 by immersing it in a foamed resin solution containing a large number of small bubbles of about 2 mm to adhere the resin solution. The surface of this resin layer 2 is surrounded by numerous elastic and sharp-pointed foam-like protrusions 3 that are formed when the resin liquid is in a sol state. Numerous holes 9 and 10 are formed over the entire surface of the resin layer 2 in a honeycomb or mesh shape.

The sharp bubble-rupturing protrusions 3 are formed by dipping the base material 1 in a resin liquid to adhere the resin liquid, then pulling it up to break the bubbles in a sol state, and then heat-treating. , resin liquid tends to break foam easily.
A viscosity of about 500CP or less is preferred. Further, it is preferable to apply the resin liquid slightly thinly so that the base material 1 can be easily bent.

Numerous holes are formed in the resin layer 2 surrounded by bubble-shaped protrusions 3. The bubbles in the resin liquid have different sizes, and when the large bubbles 7 break, a crater-shaped hole 9 is formed in the broken part that reaches the base material 1, and the small bubbles 8 break. When this happens, the broken bubbles form a crater-shaped hole 1 that does not reach the base material 1.
0 is formed (see FIGS. 2 and 3).

In addition, since the foam-breaking protrusions 3 are successively broken in the sol state, the base material 1 is affected by the cohesive force of the broken liquid phase.
The starting point is wide, becoming narrower and more pointed towards the tip.

Although the mechanism by which the bubble-like projections 3 are formed is not necessarily clear, it is thought to be as follows. That is, a part of the liquid phase (diluent, plasticizer) containing the diluent of the resin liquid permeates into the base material 1, so the liquid phase of the resin decreases, making it easier to break foam, and the viscosity and yield value also decrease. Rise. After the bubbles are broken, the resin liquid whose viscosity and yield value have increased will form a continuous protuberance along the contour of the bubbles due to cohesive force, and the diluent will be vaporized and released by heating. It is thought that it is formed by heat treatment under a contracted state.

In this way, the resin liquid after the foam breaks has a higher viscosity in balance with the decrease in the liquid phase, and at the same time, the yield value also increases, resulting in poor fluidity, so that the foam-like protrusion 3 becomes difficult to collapse and forms an acute angle. It becomes a protrusion.

In addition, in order to increase the protrusion of the foam-breaking protrusions 3, an appropriate amount of coarse resin or other coarse particles 4 should be added to the raw material to an extent that does not cause sudden sedimentation when the resin is in a foamed state. is desirable.

That is, when the resin liquid to which the coarse particles 4 have been added is attached to the base material 1, the adsorption force and cohesive force of the liquid to the coarse particles 4 work simultaneously, resulting in tall and sharp protrusions due to the additive effect. Foam-like projections 3 can be formed.

An example of the resin composition and an example of the manufacturing method for manufacturing the laminate according to the present invention are shown below.

Vinyl chloride paste resin (HX-M: Sumitomo Chemical) 80 parts Vinyl chloride paste resin (SX-D: Sumitomo Chemical) 20 parts DBP (Kyowa Hakko) 50 parts DOP (Sekisui Chemical) 100 parts Stabilizer (KP-270A: Kyodo Chemicals: 4 parts foam stabilizer (SH-1250: Toray Silicone) 12 parts diluent (Diobase: Etsuso) 70 parts and foam the resulting paste (viscosity 300CP) with a stirrer.

Immersing the cotton knitted base material 1 in the resin solution,
After the resin solution has sufficiently adhered to the base material 1, it is lifted out of the resin solution and placed in a sealed vacuum container, and the pressure is reduced to 400 mm/Hg with a vacuum pump to burst the bubbles.
After that, heat it at 180℃ for 20 minutes to ensure good ventilation.
In addition, a laminated material having sharp foam-like projections on the surface thereof is obtained.

[Effect of the invention] The present invention has the following effects.

(a) The resin layer provided on the surface of the base material has bubble-shaped protrusions with sharp tips and holes of different sizes surrounded by the bubble-shaped protrusions that are formed over the entire surface. Therefore, since the foam-broken projections are formed in a honeycomb or net shape on the surface of the resin layer, they can perform an anti-slip function even against external forces from different directions.

(b) Since the tips of the bubble-rupturing protrusions are sharp, even if the object is wet with water or oil, the protrusions will pierce through the film of water or oil, and the water or oil, etc. that is expelled will be removed from the base. Since it permeates through materials, there is no intervening film of water or oil, and the protrusions can directly adhere to objects. Therefore, there is no slippage due to films of water, oil, etc., and a sufficient anti-slip function can be achieved.

(c) Although the bubbles are small in the broken bubble part, the bottom of the hole does not reach the base material, so it has a suction cup shape, and by interacting with the sharpness of the protrusion, a sufficient anti-slip effect can be expected.

(d) On the surface of the resin layer, holes of different sizes surrounded by foam-like protrusions are formed over the entire surface, so the resin portion is reduced by the holes, and the hole portions are bent. It becomes a relief part for the resin during the process. Therefore, it is extremely flexible and has no resistance to bending.

(e) The base material can be used as socks, tape, rugs for motorcycles and scooters, steering wheel covers for cars, etc.
By forming the anti-slip member on the inner surface of the heel of a shoe in various shapes, it can be used for items that require anti-slip properties.

In addition, some holes have their bottoms reaching the surface of the base material, so if a breathable base material is used, the laminate as a whole will have breathability, so breathable socks, etc. are required. It is suitable for those who want to

(f) Since a permeable material is used for the base material, part of the liquid phase containing the diluent of the resin liquid permeates into the base material, reducing the resin liquid phase and making it easier for bubbles to break. After the bubbles break, the viscosity increases, and due to the cohesive force of the resin liquid, a bubble-like protrusion with a sharp tip and a relatively high height and thick base forms along the contour of the bubble. can. Therefore, it has sufficient strength against wear.

[Brief explanation of the drawing]

Fig. 1 is a plan view of a laminated material formed into a sheet with some of the foam-like protrusions omitted; Fig. 2 is a partially enlarged cross-sectional view showing a state in which resin liquid has adhered to the base material;
The figure is an enlarged sectional view taken along the line XX in FIG. DESCRIPTION OF SYMBOLS 1...Base material, 2...Resin layer, 3...Bubble-shaped protrusion.

Claims (1)

[Claims] 1. Formed on the surface of a resin layer provided on the surface of a permeable base material formed into a desired shape, when a resin liquid containing small bubbles breaks when in a sol state. The foam-like projections have elasticity and become sharper toward the tip. Moreover, the height of the holes is not uniform, and the size of the holes is not uniform, and the bottoms of some holes reach the surface of the base material and others do not. A laminated material with characteristic bubble-like protrusions on the surface. 2. A resin liquid containing a large amount of small air bubbles is attached to the surface of a permeable base material formed into a desired shape, and then a part of the liquid phase is allowed to penetrate into the base material while the small air bubbles are turned into a sol. to form a foam-like protrusion with a sharp tip and a hole of different size surrounded by the foam-like protrusion, and then heat-formed to form a foam-like protrusion on the surface. A method for producing a laminated material having protrusions.