JPH05269846A - Method for manufacturing synthetic resin laminate and synthetic resin laminate - Google Patents

Abstract

(57) [Abstract] [Purpose] A synthetic resin foam that has an excellent appearance and surface function by embossing a decorative pattern and anti-slip on the synthetic resin foam without reducing the production line speed. A method for producing a laminated body made of synthetic resin and a laminated body made of synthetic resin are provided. [Structure] A synthetic resin sheet 12 is extrusion-laminated on a synthetic resin foam 11. The laminated laminate 14 is passed through the punching device 15 to make a large number of through holes in the synthetic resin sheet layer 14 that do not penetrate the synthetic resin foam 11. The perforated laminated laminate is passed through an embossing device.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a synthetic resin laminate obtained by subjecting a synthetic resin foam to embossing such as a decorative pattern and anti-slip, and a synthetic resin laminate. ..

[0002]

2. Description of the Related Art Foams made of synthetic resin such as foams made of olefinic resin have uniform fine cells, are lightweight, have excellent heat insulating properties, are excellent in cushioning properties, and have various excellent properties such as withstanding load capacity. It is an excellent material because of its characteristics. And
Such synthetic resin foams are used as high-value-added products by laminating synthetic resin films or sheets to enhance the decorativeness of the front surface and to prevent the back surface from slipping.

As described above, for laminating a synthetic resin film or sheet on a synthetic resin foam, for example, the synthetic resin film or sheet is superposed on the synthetic resin foam, and thermal lamination and embossing are performed. Or a synthetic resin film or sheet is once extrusion-coated or heat-laminated on the surface of the synthetic resin foam, and then the synthetic resin film or sheet is heated and embossed.

[0004]

By the way, during the embossing process, the surface of the synthetic resin foam is liable to be broken by heating and pressurization, and especially when it is rapidly heated at a high temperature, it is more easily broken. When air bubbles build up between the synthetic resin film or sheet and swelling occurs, or when continuous embossing is performed, earthworm-like air pockets occur, which significantly impairs the appearance and performance of the product. , The value of the product will be diminished.

Therefore, in an actual laminated production line, the heating capacity is reduced by reducing the heat capacity to reduce the conveying speed of the synthetic resin foam, that is, by decreasing the production speed, the synthetic resin foam is produced. The occurrence of the bubble breaking phenomenon on the surface was suppressed.

In particular, a synthetic resin foam having a higher expansion ratio is more likely to be broken during embossing, and the production speed must be significantly reduced, or sufficient fusion bonding strength cannot be obtained. For example, in the case of an olefin resin crosslinked foam, if the expansion ratio is 30 times or more, it is impossible to completely prevent the foam from breaking even if the production speed is reduced and the heating is suppressed. There is a problem that it is not possible to manufacture a synthetic resin laminate having a sufficient function.

The present invention solves the problems of the conventional methods as described above, without lowering the production line speed,
A synthetic resin foam is provided with a decorative pattern, embossing such as anti-slip, and a method for producing a synthetic resin laminate having an excellent appearance and excellent surface function, and a synthetic resin laminate. is there.

[0008]

The method for producing a synthetic resin laminate of the present invention is a method of laminating a synthetic resin film or sheet on the surface of a synthetic resin foam, and synthesizing from the synthetic resin film or sheet surface. In this method, a large number of holes that do not penetrate the resin foam are formed, and then the laminated surface of the synthetic resin film or sheet is embossed.

In the synthetic resin laminate of the present invention, a synthetic resin film or sheet is laminated on the surface of the synthetic resin foam, and a large number of synthetic resin films or sheets do not penetrate through the synthetic resin foam. A hole is provided, and the laminated surface of the synthetic resin film or sheet is embossed.

In the present invention, the synthetic resin foam is made of a material such as polyethylene, polypropylene, an ethylene-vinyl acetate copolymer, an ethylene-propylene copolymer olefin resin, or a soft polyvinyl chloride. A resin foam may be used. In particular, an olefin resin foam is preferably used. In the present invention,
As the synthetic resin film or sheet, for example,
Polyvinyl chloride, polyethylene, ethylene-vinyl acetate copolymer (EVA), polymethylmethacrylate (PM
A soft resin film or sheet made of a thermoplastic resin such as MA) or an olefin elastomer (TPO) is preferably used.

In the present invention, after the synthetic resin film or sheet is laminated on the synthetic resin foam, a large number of through holes which do not penetrate the synthetic resin foam are formed. The diameter of the through hole is preferably 0.1 to 1.0 mm, particularly preferably 0.3 to 0.8 mm, but is not particularly limited to this range. The distance between the through holes is preferably, for example, 5 to 10 mm, but is not particularly limited to this range. The through holes are preferably arranged in, for example, a staggered pattern or a grid pattern, but are not particularly limited to this array.

A synthetic resin film or sheet is laminated on a synthetic resin foam, and the synthetic resin film or sheet is passed through a punching device equipped with a needle roll or the like to penetrate through the synthetic resin film or sheet, The resin foam may be provided with holes that reach a certain depth but do not penetrate.

In the present invention, as a method for laminating a synthetic resin film or sheet on a synthetic resin foam, a method of extrusion laminating a synthetic resin film or sheet on a synthetic resin foam, or a synthetic resin foam is used. A method of stacking synthetic resin films or sheets, thermocompression-bonding and heat-laminating, and the like are appropriately selected.

In the present invention, as an embossing method, for example, a synthetic resin film or sheet is laminated on the surface of a synthetic resin foam, and at the same time as or after the lamination, these are embossed with an embossing roll or the like. A method of embossing the surface of the synthetic resin film or sheet under heat and pressure by passing through the processing device is appropriately selected.

In the present invention, as a form of embossing to the synthetic resin laminate by embossing, for example, a decorative pattern such as a geometric pattern or a patterned pattern formed on the front surface or a back surface is formed. Examples thereof include slip prevention such as a large number of convex portions in a grid-like array and a large number of disk-shaped convex portions in a staggered arrangement.

In the method of the present invention, an adhesive such as a heat-sensitive adhesive may be interposed between the synthetic resin foam and the synthetic resin film or sheet in the laminating step, if necessary.

Examples of the synthetic resin laminate obtained by the present invention include bath mats and outdoor rugs whose surface is decorated with a decorative pattern and whose back surface is non-slip.

[0018]

According to the method of manufacturing a synthetic resin laminate of the present invention, a large number of through holes are provided in a laminate of a synthetic resin film or sheet before embossing and a synthetic resin foam, and then a synthetic resin film. Alternatively, since the laminated surface of the sheet is embossed, even if the surface of the synthetic resin foam is ruptured by heating and pressurization at this time, the bubbles generated by the rupture of bubbles cause the synthetic resin film or sheet to pass through. Since it is discharged to the outside through the holes, bulging does not occur, and when embossing is continuously performed, earthworm-like air pockets do not occur, and the appearance and performance are not significantly impaired. In addition, without damaging the production line speed, the synthetic resin foam is subjected to embossing such as decorative patterns and anti-slip to produce a synthetic resin laminate with excellent appearance and surface function. You can

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The method of the present invention will be described below with reference to the accompanying drawings. FIG. 1 is an explanatory view showing a first half step of an embodiment of the invention, and FIG. 2 is an explanatory view showing a second half step thereof.

In FIG. 1, numeral 11 is a synthetic resin foam as a raw material. Reference numeral 12 is a synthetic resin sheet as an original fabric. A synthetic resin sheet 12 formed by extrusion molding is laminated on a synthetic resin foam 11 for lamination 2.
After passing through the main roll 131, the two rolls 13 for cooling
2 is passed to form a laminated laminate 14 in which the synthetic resin sheet layer 142 is laminated on the synthetic resin foam layer 141.

The laminated laminate 14 that has passed through the two cooling rolls 13 is then passed through a punching device 15 including a needle roll 151 and a backup roll 152, so that the synthetic resin sheet layer 142 is passed through. A synthetic resin foam layer 1 which is opened and communicates with the through hole.
41 is provided with a hole that reaches a certain depth from the front surface but does not penetrate to the back surface.
Create ´ and wind it once.

In this perforated laminated laminate 14 ', a synthetic resin sheet layer 142 having a through hole so that the through hole communicates with the hole is formed on the synthetic resin foam layer 141 having a hole. It has a laminated structure.

Next, as shown in FIG. 2, the laminated laminate 14 ′ with holes is unwound, and the surface of the synthetic resin sheet layer 142 with holes is heated by the heater 16. Then, this perforated laminated laminate 14 '
In the embossing device 17 consisting of an embossing roll 171 having an uneven embossing pattern on its outer peripheral surface and a backup roll 172, with the surface of the synthetic resin sheet layer 142 having a through hole facing the embossing roll 171. Pass it as directed.

At this time, even if the surface of the perforated synthetic resin foam layer 142 is ruptured by heating and pressurization, the synthetic resin sheet in which the bubbles generated by the rupture are perforated. Since it is released to the outside through the through hole of the layer 142, there is no occurrence of swelling or earthworm-like air pockets during continuous embossing, which does not impair the appearance and performance. ..

Then, as shown in FIG. 3, the synthetic resin foam layer 141 is provided with an uneven pattern, and the synthetic resin sheet layer 142 is fixed on the uneven pattern along the uneven pattern. An embossed synthetic resin laminate is obtained. This is appropriately wound into a large roll by a winder and used for secondary processing.

Example As the synthetic resin foam 11 of the original fabric, a cross-linked polyethylene foam having a thickness of 8 mm and an expansion ratio of 40 was used.
A PMMA sheet having a thickness of 100 μm was used as the raw synthetic resin sheet 12, and the perforation device 15 was used to form a synthetic resin sheet layer 142 with an interval of through holes of 5 mm.
And the holes are arranged in a zigzag pattern such that one through hole is provided in the middle between the through holes, and a through hole having a hole diameter of 0.7 mm is opened, and the through holes are made of synthetic resin. Foam layer 141
According to the process described with reference to FIGS. 1 and 2, except that a hole reaching a depth of about 2 mm is formed in the
As shown in FIG. 3, an embossed bath mat for slipping having a large number of staggered protrusions on the back surface was obtained.

The obtained bath mat has a zigzag-shaped convex portion on one surface and is embossed for slip prevention, and bulges are generated during the embossing and earthworm-like air traps are formed. There was no appearance, the appearance was good, and a sharp embossed pattern was formed, and the coating layer was firmly laminated.

[0028]

EFFECTS OF THE INVENTION Since the method for producing a synthetic resin laminate of the present invention is constructed as described above, swelling or earthworm-like air pockets are generated, and the appearance and performance are remarkably improved. Synthetic resin laminate with excellent appearance and excellent surface function by giving decorative patterns and embossing such as non-slip to the synthetic resin foam without hindering and reducing the production line speed. Can be manufactured.

[0029]

[Brief description of drawings]

FIG. 1 is an explanatory view showing a first half of an embodiment of the present invention.

FIG. 2 is an explanatory view showing the latter half of the steps of one embodiment of the present invention.

FIG. 3 is a cross-sectional view showing a synthetic resin laminate of the present invention.

[Explanation of symbols]

 11,241 Synthetic resin foam 12,21 Synthetic resin sheet 14 Laminate laminated product 15 Punching device 131 Two rolls for lamination 132 Two rolls for cooling 141 Synthetic resin foam layer 142 Synthetic resin sheet layer 151 Holes Drilling roll 171 Embossing roll 2 holes

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Internal reference number FI Technical display location B29L 9:00 4F

Claims (2)

[Claims] 1. A synthetic resin film or sheet is laminated on the surface of a synthetic resin foam, and a large number of holes not penetrating the synthetic resin foam are bored from the surface of the synthetic resin film or sheet, and then synthesized. A method for producing a synthetic resin laminate, which comprises embossing a laminated surface of a resin film or sheet. 2. A synthetic resin film or sheet is laminated on the surface of a synthetic resin foam, and a large number of holes that do not penetrate through the synthetic resin foam are bored from the surface of the synthetic resin film or sheet. A synthetic resin laminate obtained by embossing the laminated surface of a resin film or sheet.