KR100721023B1 - Method for fabricating sheet-type resin-foamed product - Google Patents

Abstract

The present invention is to arrange a base sheet to foam a foamable water support material (for example, polyurethane resin) mixed with a functional material (for example, carbonized powder containing clay powder, ocher powder, ceramic powder, jade powder, etc.) to form a resin foam layer In the case of forming, it is possible to ensure the air permeability of the functional material contained in the resin foam layer by performing the through-hole forming operation for the base sheet while preventing the overflow foam layer is formed on the base sheet A method for producing a sheet-shaped resin molded article.

According to a preferred embodiment, when the foamable water support material containing the functional material is foamed with respect to the base sheet of the breathable tissue (eg, fiber, nonwoven fabric, etc.) to form a resin foam layer, the outer surface or the inner surface of the base sheet is formed. By adhering the overflow foam prevention sheet by the non-breathable synthetic resin film to prevent the overflow foam layer from forming during the foaming of the support material, a plurality of needles are punched to the depth through the base sheet to the resin foam layer. By forming a through hole to ensure breathability for the functional material contained in the resin foam layer.

When the hole is formed by the needle punching, the overflow antifoam sheet adhered to the outer surface of the base sheet is removed, whereas the overflow antifoam sheet adhered to the inner surface of the base sheet has holes formed by the needle punching. do.

Description

METHOD FOR FABRICATING SHEET-TYPE RESIN-FOAMED PRODUCT}

1 is a view for explaining the manufacturing process of the sheet-shaped resin molded article is disposed in the base sheet according to a conventional example;

2 is a view for explaining the manufacturing process of the sheet-shaped resin molded article is disposed in the base sheet according to another conventional example;

3A is a view for explaining a method for producing a sheet-shaped resin molding according to the first embodiment of the present invention;

3B is a view for explaining a method for producing a sheet-shaped resin molded article according to the first embodiment of the present invention shown in FIG. 3A;

4A is a view for explaining a method for producing a sheet-shaped resin molding according to a second embodiment of the present invention;

4B is a view for explaining a method for producing a sheet-shaped resin molded article according to a modification of the second embodiment of the present invention shown in FIG. 4A.

* Explanation of symbols for main parts of drawings *

10,20: sheet-shaped resin molding, 12,22: base sheet,

14,24: resin foam layer, 16: overflow foam layer,

30: sheet-shaped resin molding, 32: base sheet,

34: overflow foam sheet, 36: resin foam layer,

38: needle punching machine, 38a: through hole forming needle,

40: sheet-shaped resin molding, 42, 44: first, second base sheet,

46: resin foam layer, 48: overflow foam prevention layer,

50: needle punching machine, 50a: through hole forming needle.

The present invention relates to a method for producing a sheet-shaped resin molded article, more specifically, a foamable support material (especially, a polycarbonate containing a charcoal powder, ocher powder, ceramic powder, jade powder, etc.) is added. The urethane resin) is foamed into a sheet shape, and the present invention relates to a method for producing a sheet-shaped resin molded article suitable for use in various applications (for example, building materials, interior finishing materials, vehicle interior materials, bedding materials, shoemaking members, and the like).

At present, various techniques for obtaining a resin molded article of a required form by mixing and foaming a functional material with a foamable water support material (especially a polyurethane resin) tend to be proposed. Functional materials mixed with the foamable water support material to obtain such resin moldings are typically charcoal powders including charcoal powders for the purpose of humidity control, antimicrobial / deodorizing function, far infrared radiation function and / or anion release function or loess powder. , Ceramic powder, jade powder and the like.

The resin molded product obtained by foaming the foamable water support material mixed with the above functional material is foamed in a state in which one side or both sides, for example, a fiber sheet, a nonwoven sheet, a leather sheet, a rubber sheet, etc. are arranged as a base sheet depending on the application. Is made, or foaming is made without placing any base sheet.

Here, in the case of foaming a foamable water support material mixed with a functional material without applying any base sheet, the functional material contained in the resin molded product obtained by the foaming exhibits a proper function, but the base on one side or both sides. In the case of foaming in the state of seating, foaming process overflows to the outside depending on the structure of the base sheet, and the multifunctional material contained in the resin molding functions properly. Will not exert.

That is, FIG. 1 is a view for explaining the manufacturing process of the sheet-shaped resin molding in which the base sheet according to the conventional example is disposed.

Referring to the drawings, a sheet-like resin composition 10 is prepared for foaming a foamable water support material mixed with a functional material (eg, charcoal powder, ocher powder, ceramic powder, jade powder, etc.) to produce a shoe sole as a shoemaking member. In order to obtain, if the resin foam layer 14 is foamed in the state where the base sheet 12 of the perforated breathable tissue, such as a weaving fiber or a nonwoven fabric, is disposed on one side thereof, the support fee is reduced by the pressure at the time of foaming. The overflow foam layer 16 is unnecessarily formed by passing through the sex muscle tissue of the base sheet 12.

For this reason, the overflow foam layer 16 needs to be additionally removed later, and even if the overflow foam layer 16 is removed from the base sheet 12 by the subsequent work, The tissue of the sheet 12 is filled by the water support fee, so that the humidity control function, the antibacterial / deodorizing function, the far infrared radiation function and / or the anion emission function for obtaining by the functional material are not sufficiently exhibited.

2 is a view for explaining the manufacturing process of the sheet-shaped resin molding in which the base sheet is disposed according to another conventional example.

Referring to the drawings, for example, leather or rubber sheets or synthetic resin sheets on at least one side for producing a sheet-shaped resin molding 20 suitable for manufacturing leather products such as bags, handbags, or automobile interior materials or bedding. When foaming a support material mixed with a multifunctional material in a state in which the base sheet 22 of the non-breathable tissue is disposed, the support material does not pass through the base sheet 22 so that an overflow foaming layer is not formed. Since the base sheet 22 is a non-breathable tissue, the base sheet includes a humidity control function, an antibacterial / deodorant function, a far-infrared radiation function, and / or anion emission function for obtaining from a functional material mixed with the water support material and foamed. It is blocked by 22, and the proper function cannot be exhibited.

Accordingly, the present invention has been made in view of the above-described prior art, and a multi-functional material (for example, carbonized powder containing clay powder, loess powder, ceramic powder, jade powder, etc.) is mixed with a foamable water support material to one side or It is an object of the present invention to provide a method of manufacturing a sheet-shaped resin molding for effectively exerting a given function of a multifunctional material while preventing the overflow foam layer from being formed when the base sheet is foamed in a state in which both sides of the base sheet are disposed.

In order to achieve the above object, according to a first preferred embodiment of the present invention, any one or a mixture of carbonized powder, ocher powder, ceramic powder, and jade powder containing charcoal powder is used as a functional material. In the manufacturing method of the sheet-shaped resin molding to foam the base sheet to form a resin foam layer, by adhering the overflow foam prevention sheet to the base sheet so that the overflow foam layer is not formed when the water support material is foamed And forming a plurality of through holes by needle punching through the base sheet to the resin foam layer so as to obtain air permeability for the functional material contained in the resin foam layer. This is provided.

Preferably, the overflow foam preventing sheet is applied to a non-breathable synthetic resin film.

The overflow foam prevention sheet is disposed on any one of the outer surface and the inner surface of the base sheet, the overflow foam prevention sheet adhered to the outer surface of the base sheet is removed and the through hole forming process by the needle punching is performed On the other hand, the overflow foam prevention sheet is attached to the inner surface of the base sheet is formed through the hole by the needle punching.

The basesheet of the breathable tissue includes fibers and nonwovens.

According to a second preferred embodiment of the present invention, a carbonaceous powder containing a charcoal powder, ocher powder, ceramic powder, jade powder any one or a mixture of foaming support material containing a functional material to the base sheet by foaming the resin A method for producing a sheet-like resin molded article for forming a foam layer, wherein the base sheet is in the form of a non-breathable tissue, and the resin foam layer is foamed to the non-breathable base sheet, and then the needle is punched from the base sheet. Provided is a method for producing a sheet-shaped resin molded article which forms a plurality of through holes to a depth reaching the resin foam layer to obtain the porosity of the functional material contained in the resin foam layer.

Preferably, the non-breathable base sheet includes a leather sheet, a rubber sheet, a synthetic resin sheet.

According to a third preferred embodiment of the present invention, the resin is formed by foaming a foamable support material containing any one or a mixture of carbonized powder, ocher powder, ceramic powder, and jade powder containing charcoal powder as a functional material on a base sheet. In the method for producing a sheet-like resin molding to form a foam layer, wherein the base sheet is formed by first and second base sheets which are one of a breathable structure and a non-breathable structure are spaced apart from each other, and the first and second A resin foam layer containing the functional material is foamed between the base sheets, and a plurality of holes are formed by needle punching to the depth of the first and second base sheets to the resin foam layer to form the functional material. Provided is a method for producing a sheet-shaped resin molded article to obtain breathability for the present invention.

Preferably, if any one or both of the first and second base sheet is a breathable tissue, by adhering the overflow foam prevention sheet by the non-breathable synthetic resin film to either one of the outer surface and the inner surface of the base sheet of the breathable tissue At the time of forming the resin foam layer, the water support material does not form an overflow foam layer on the breathable base sheet.

Basesheets of the breathable tissue include fibers and nonwovens.

According to the present invention, the overflow foaming prevention sheet adhered to the outer surface of the breathable base sheet is removed and then the hole forming by the needle punching is performed, whereas the overflow foaming prevention adhered to the inner surface of the breathable base sheet A plurality of through holes are formed by the needle punching of the sheet so that air permeability for the functional material contained in the resin foam layer is obtained.

The non-breathable base sheet includes a leather sheet, a rubber sheet, and a synthetic resin sheet.

Hereinafter, with reference to the accompanying drawings, the present invention will be described in detail.

3A is a view illustrating a method of manufacturing a sheet-shaped resin molding according to the first embodiment of the present invention, and FIG. 3B is a method of manufacturing a sheet-shaped resin molding according to the first embodiment of the present invention shown in FIG. 3A. It is a figure explaining.

First, referring to FIG. 3A, the sheet-shaped resin molded article 30 according to the first embodiment has a base sheet 32 disposed on one side thereof, and the base sheet 32 is formed of the corresponding resin molded article 30. Depending on the field of application, it is optionally envisaged that the form has a perforated tissue such as fibers or non-woven fabrics, and the form of a non-breathable tissue such as a leather sheet or a rubber sheet or a synthetic resin sheet.

In addition, according to the present invention, if the base sheet 32 is a fiber of the breathable tissue or a nonwoven fabric is assumed, the base sheet 32 passes through the tissue of the base sheet 32 so that the overflow foam ?? The overflow foaming prevention sheet 34 for sticking to prevent it from forming is adhered, and the overflow foaming prevention sheet 34 is preferably a non-breathable synthetic resin film.

Therefore, in the state where the overflow foam prevention sheet 34 is adhered to one side of the base sheet 32, the other side of the base sheet 32 is a functional material (eg, carbonized powder, loess powder, ceramic represented by charcoal powder) The resin foam layer 36 is formed on the other side of the base sheet 32 by foaming the foamable water support material mixed with powder, jade powder or any one thereof, and the foaming material is foamed at the foaming pressure. Also, the overflow foaming prevention sheet 34 does not form the overflow foaming layer.

When the resin foam layer 36 is formed on the other side of the base sheet 32 by the foaming process, the overflow foam preventing sheet 34 is removed from the base sheet 32.

After the overflow foaming prevention sheet 34 is removed from the base sheet 32, a plurality of holes are regularly or irregularly formed on the bottom of the base sheet 32, considering that the breathable tissue of the base sheet 32 is blocked by the support fee. A through hole forming process is performed by a needle punching machine 38 of an automatic control method or a manual operation method in which the forming needle 38a is disposed.

According to the hole forming process, when the needle punching machine 38 is lowered on the base sheet 32 from which the overflow foam preventing sheet 34 is removed, the resin foam layer 36 is removed from the base sheet 32. The plurality of through-hole forming needles (38a) to form a plurality of through holes to a depth up to, so that the plurality of through holes formed in the base sheet 32 to the functional material contained in the resin foam layer (36) The air permeability is guaranteed, so that the humidity control function, the antibacterial / deodorant function, the far-infrared radiation function and / or the anion emission function as its inherent functions can be satisfactorily exhibited.

3B is a modified example of the first embodiment described with reference to FIG. 3A. The sheet-shaped resin molding 30 illustrated in FIG. 3A adheres to the overflow foam preventing sheet 34 on the base sheet 32. However, in the resin molding 30 shown in FIG. 3B, the overflow foam preventing sheet 34 is disposed on the surface on which the resin foam layer 36 of the base sheet 32 is formed.

Therefore, when the foaming support material mixed with a functional material is foamed on the overflow foam preventing sheet 34 adhered to the base sheet 32 to form the resin foam layer 36, the overflow foaming prevention The sheet 34 prevents overflow foaming of the support material, but the overflow foam prevention sheet 34 blocks the unique function of the multifunctional material mixed in the support material.

In view of such a point, even in the case of the resin molding 30 shown in FIG. 3B, the needle punching machine 38 described with reference to FIG. 3A passes through the overflow foam preventing sheet 34 from the base sheet 32. A plurality of through holes are formed to a depth reaching the resin foam layer 36, so that even in the case of the resin molding 30 shown in FIG. 3B, the breathability of the functional material contained in the resin foam layer 36 is improved. As a result, the humidity control function, the antibacterial / deodorizing function, the far infrared radiation function and / or the anion emitting function can be satisfactorily exhibited.

Meanwhile, in FIGS. 3A and 3B, the overflow foam preventing sheet 34 is applied to prevent the overflow foam layer from being formed when the base sheet 32 has a perforated tissue. When 32) is a non-breathable form of, for example, a leather sheet, a rubber sheet or a synthetic resin sheet, the overflow foam preventing sheet 34 may be excluded.

Here, when the base sheet 32 is in the form of a non-breathable structure, the desired moisture control function, antibacterial / deodorant by the functional material contained in the resin foam layer 36 formed on one side of the base sheet 32 In view of the limited function, far-infrared radiation function and / or negative ion emission function, when the resin foam layer 36 is formed on the non-breathable base sheet 32, the needle punching machine 38 is used as a follow-up operation. By forming a plurality of through holes in the non-breathable base sheet 32, the air permeability of the functional material contained in the resin foam layer 36 is ensured, thereby exhibiting a unique function.

4A is a view for explaining a method of manufacturing a sheet-shaped resin molding according to the second embodiment of the present invention, and FIG. 4B is a sheet-shaped resin molding according to a modification of the second embodiment of the present invention shown in FIG. 4A. It is a figure explaining a method.

3A and 3B, the first embodiment of the present invention is related to the resin molding 30 when the base sheet 32 is disposed on one side of the resin foam layer 35. In the resin molding 40 according to the second embodiment and its modification shown in FIGS. 4A and 4B, a resin foam layer 46 is formed between the first and second base sheets 42 and 44.

Such resin molding 40 has a structure suitable for manufacturing bags, such as handbags, or mattresses for beds / leisure, for example.

That is, referring to FIG. 4A, in the sheet-shaped resin molding 40, first and second base sheets 42 and 44 are disposed on both sides thereof, and between the first and second base sheets 42 and 44. A resin foam layer 46 containing a functional material is formed.

Here, the first and second base sheets 42 and 44 are determined according to the application field of the corresponding sheet-shaped resin molding 40, and the sheet-shaped resin molding 40 is, for example, a handbag or the like. Assuming that the first base sheet 42 is non-breathable and waterproof, the case is applied to the manufacture of the outer skin of the bag of the bag, for example, flexible synthetic resin or natural leather or artificial leather is applied while the second base sheet (44) may be applied to the fibers of the sex muscle tissue or non-woven fabrics to obtain the unique function of the functional material contained in the resin foam layer 46 while being located on the inner surface of the bag.

Therefore, assuming that case, an overflow foam of support fee is applied on the second base sheet 44 while the non-breathable first base sheet 42 and the breathable base sheet 44 are maintained at mutually necessary intervals. Overflow foam prevention sheet 48 to prevent the adhesion.

In this state, the resin foam layer 46 is formed by foaming a foamable support material mixed with the functional material between the first and second base sheets 42 and 44, and as the subsequent operation, the first The overflow foam prevention sheet 48 adhered to the two base sheets 44 is removed.

Then, the needle punching machine 50 is lowered on the second base sheet 44 and passed through the second base sheet 44 by the plurality of through hole needles 50a formed on the bottom surface of the resin foam layer ( A large number of through holes are formed to the depth of 45).

The sheet-shaped resin molding 40 formed by the above process is suitable for the outer structure of bags, for example, since the first base sheet 42 is waterproof and breathable, and the second base sheet 44 is Since a plurality of through-holes are formed on the inner surface and communicated with the resin foam layer 45, the humidity control function, the antibacterial / deodorizing function, the far infrared radiation function and / or by the multifunctional material contained in the resin foam layer 46 are formed. Anion release function is effectively exhibited.

According to the modification shown in FIG. 4A, the overflow base sheet 48 applied to the second base sheet 44 is the same as the second base sheet 44 as described in FIG. 3B. Is placed on the inner surface of the.

In this case, after the resin foam layer 46 is formed between the first and second base sheets 42 and 44, a plurality of through hole forming needles 50a provided on the bottom surface of the needle punching machine 50 are provided. A plurality of through holes having a depth reaching the resin foam layer 46 through the second base sheet 42 and the overflow foam prevention sheet 48 is formed and contained in the resin foam layer 46. The desired function by the functional material can be satisfactorily exhibited.

On the other hand, in the case of the sheet-shaped resin molded article 40 described in Figs. 4A and 4B, the first and second base sheets 42 and 44 may be applied to ones of breathable structures such as fibers or nonwoven fabrics, for example.

In this case, the overflow foaming prevention sheet is removed after the resin foaming layer 46 is formed between the first and second base sheets 42 and 44 in the state of adhering the overflow foaming prevention sheet to the outside. And through the hole forming operation by the needle punching machine (50).

On the other hand, in the state where the overflow foam preventing sheet is positioned inside the first and second base sheets 42 and 44, the resin foam layer 46 is formed and then the hole is formed by the needle punching machine 50. The forming work can be done.

In addition, the first and second base sheets 42 and 44 form a resin foam layer 46 containing the multi-functional material therebetween in a state in which a material of non-breathable tissue is applied, and either side 42; 44) or forming a plurality of through holes by the needle punching machine 50 on both sides of the base sheets 42 and 44 to secure air permeability to the functional material contained in the resin foam layer 46, Humidity control function, antibacterial / deodorizing function, far infrared radiation function and / or anion release function is effectively exhibited.

On the other hand, the present invention is not limited to the above examples and various changes and modifications can be made within the scope not departing from the technical gist and gist of the invention, of course,

In other words, in the above, the case where the resin foam layer containing the multifunctional material is formed on the base sheet of the breathable or non-breathable tissue is formed, but after the base sheet is adhered to one side or the other side of the resin foam layer, the through-hole operation is performed. Alternatively, the base sheet on which the through operation has been performed in advance may be attached to one side or the other side of the resin foam layer.

As described above, according to the manufacturing method of the sheet-shaped resin molding according to the present invention, when the breathable base sheet is disposed on one side or both sides and the resin foam layer is formed on the base sheet, the outer surface and the inner surface of the base sheet overflow. Since the resin foam layer is formed by adhering the prevention sheet, the overflow foam layer is prevented from being formed through the tissue of the base sheet when the water support material is foamed.

In addition, since the resin foaming layer is formed, through the hole forming operation by nipple punching is performed on the base sheet, the functional material contained in the resin foaming layer (eg, carbonized powder, loess powder, ceramic powder including charcoal powder). Air permeability, jade powder, etc.), so that the humidity control function, antibacterial / deodorant function, far-infrared radiation function and / or anion emission function by the functional material can be effectively achieved.

Claims (9)

A sheet-like resin molded product which forms a resin foam layer by foaming a foamable support material containing any one or a mixture of carbonized powder, loess powder, ceramic powder, and jade powder containing charcoal powder as a functional material on a base sheet. In the manufacturing method, By adhering the overflow foam preventing sheet to the base sheet so that the overflow foam layer is not formed when the water support material is foamed, A sheet-shaped resin molded article characterized in that a plurality of through holes are formed by needle punching through the base sheet to the depth of the resin foam layer to obtain breathability for the functional material contained in the resin foam layer. Manufacturing method. The method of claim 1, wherein the overflow foam preventing sheet is a non-breathable synthetic resin film, The overflow foam sheet is disposed on any one of the outer surface and the inner surface of the base sheet, The overflow foam prevention sheet adhered to the outer surface of the base sheet is removed, and then a hole forming process by needle punching is performed. The overflow foam preventing sheet is attached to the inner surface of the base sheet is a method of producing a sheet-shaped resin molding, characterized in that the through-hole is formed by the needle punching. The method according to claim 1, wherein the base sheet of the breathable tissue includes a fiber and a nonwoven fabric. A sheet-like resin molded product which forms a resin foam layer by foaming a foamable support material containing any one or a mixture of carbonized powder, loess powder, ceramic powder, and jade powder containing charcoal powder as a functional material on a base sheet. In the manufacturing method, The basesheet is in the form of non-breathable tissue. After the resin foam layer is foamed to the non-breathable base sheet, a plurality of through holes are formed at a depth from the base sheet to the resin foam layer by needle punching, thereby providing the porosity of the functional material contained in the resin foam layer. A method for producing a sheet-shaped resin molded article, which is obtained. The method of claim 4, wherein the non-breathable base sheet includes a leather sheet, a rubber sheet, and a synthetic resin sheet. A sheet-like resin molded product which forms a resin foam layer by foaming a foamable support material containing any one or a mixture of carbonized powder, loess powder, ceramic powder, and jade powder containing charcoal powder as a functional material on a base sheet. In the manufacturing method, The base sheet is formed by mutually spaced apart the first and the first base sheet which is any one of the breathable tissue and non-breathable tissue, Between the first and second base sheet, the resin foam layer containing the functional material is foamed, And a plurality of through holes formed by needle punching with respect to the first and second base sheets to the resin foam layer to obtain air permeability for the functional material. 7. The method of claim 6, wherein if either or both of the first and second base sheets are breathable tissues, the overflow foam prevention sheet is formed by adhering the non-breathable synthetic resin film to either one of an outer surface and an inner surface of the base sheet of the breathable tissues. To prevent the water support material from forming an overflow foam layer on the breathable base sheet when the resin foam layer is formed. The base sheet of the breathable tissue manufacturing method of the sheet-like resin molding, characterized in that the fiber and non-woven fabric. The through-foaming prevention sheet adhered to the outer surface of the breathable base sheet is removed, and then through hole formation is performed by the needle punching. The overflow foam prevention sheet adhered to the inner surface of the breathable base sheet is a sheet-shaped resin, characterized in that a plurality of through-holes are formed by the needle punching to obtain breathability for the functional material contained in the resin foam layer Method of Making Molded Products. The method of claim 7, wherein the non-breathable base sheet includes a leather sheet, a rubber sheet, and a synthetic resin sheet.

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