JPS5842315B2 - Method for manufacturing synthetic resin sheet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a novel method for producing a synthetic resin sheet, and more specifically, the present invention relates to a method for producing a novel synthetic resin sheet, and more specifically, a method for producing a sheet-like product using a composite made of a thermoplastic synthetic resin that does not contain or contains a blowing agent. The present invention relates to a method of manufacturing an unprecedented synthetic resin sheet by heating this and fusing each assembly, or fusing and foaming the composite.

Conventional methods for manufacturing synthetic resin sheets generally involve applying a calendar method,
Doctor knife coating method, reverse roll coater method,
A synthetic resin layer is formed by an appropriate means such as a lamination method,
There have been methods of applying a printed pattern using a printing method such as gravure printing, applying a squeezed pattern using an embossing roll, or applying both a printed pattern and a squeezed pattern.

However, with these methods, it has not been possible to obtain a synthetic resin sheet having the unique appearance of leather, such as knitted or woven leather straps.

Therefore, in order to manufacture a synthetic resin sheet that has an appearance similar to knitted or woven leather straps, a laminated sheet in which synthetic resin is laminated on the surface of a base material is cut into string shapes and then knitted or woven. method was tried.

However, the synthetic resin sheet obtained by this method does not have a smooth surface like the sheet obtained by knitting or weaving leather straps, and the knitted or woven part swells unnaturally, giving the surface a rough feel. It was far from knitted or woven leather straps.

In addition, when knitting or weaving leather straps or knitting or weaving a string-like material of a laminated sheet with a synthetic resin layer laminated to the base material, the cut portion may fray when it is cut and processed. It is difficult to process, and has disadvantages such as the fact that it takes time and effort to process.

A first object of the present invention is to provide a method for manufacturing a synthetic resin sheet that has a smooth feel and appearance similar to knitted or woven leather straps.

The second object of the present invention is to eliminate disadvantages in cutting processing such as knitted or woven leather straps,
To provide a method for manufacturing a synthetic resin sheet that has an appearance very similar to that of knitted or woven leather straps and is easy to cut.

That is, the method for producing a synthetic resin sheet of the present invention involves knitting a string-like object made of a thermoplastic synthetic resin or weaving it with another string-like object to form a sheet-like object, which is then heated to make it thermoplastic. A first invention in which string-like objects made of resin are fused together, and a sheet-like object is formed by knitting string-like objects made of thermoplastic synthetic resin containing a foaming agent or by weaving them with another string-like object. The second aspect of the present invention is to heat and foam the material, and to fuse the string-like materials to each other.

The thermoplastic synthetic resin used in the present invention to form the string-like material made of thermoplastic synthetic resin is generally a synthetic resin sheet such as vinyl chloride resin, vinyl chloride-vinyl acetate copolymer resin, acrylic resin, polyurethane resin, etc. Any thermoplastic synthetic resin used to form a material can be used.

These resins contain commonly used plasticizers, stabilizers,
Fillers and other additives can also be blended.

String-like objects made of thermoplastic synthetic resin include those in which a layer of the thermoplastic synthetic resin described above is formed around the entire outer periphery of thread or string, and paper: the above-mentioned thermoplastic resin on the surface of a base material such as knitted or woven fabric or non-woven fabric. Thinly cut laminated sheets with layers of
A sheet made of the above-mentioned thermoplastic synthetic resin cut into thin pieces, a sheet formed from the above-mentioned thermoplastic synthetic resin into a thread or string shape by extrusion molding, etc. can be used.

Of course, string-like objects made of these thermoplastic synthetic resins can be used alone, but string-like objects made of a plurality of thermoplastic synthetic resins can also be used as a twisted string.

In this case, if the strings made of each thermoplastic synthetic resin are made in different colors, the twisted strings will be mottled with multiple colors. The synthetic resin sheet has a unique appearance and is excellent in design.

In addition, as a string-like object made of thermoplastic synthetic resin, there are thick parts and thin parts (thick parts with a large amount of thermoplastic synthetic resin and thin parts with a small amount of thermoplastic resin). It is also possible to use one with a

When such a string-like material made of thermoplastic synthetic resin is used, it is possible to obtain a synthetic resin sheet that expresses an uneven pattern other than the unevenness caused by knitting or weaving.

Furthermore, when knitting or weaving, a pattern can be created by appropriately combining thick and thin parts.

In order to form thick parts and thin parts in a string-like material made of thermoplastic synthetic resin, when extrusion molding is used, the diameter of the extrusion port of the extruder can be made thicker or thinner as appropriate. can be obtained by adjusting the extrusion port.

In addition, when paper cutting is performed to obtain a laminated sheet in which a thermoplastic synthetic resin is laminated on the base material or a sheet made of thermoplastic synthetic resin, the thickness of the laminated sheet or thermoplastic synthetic resin sheet may be changed as appropriate. .

The simplest method for changing the thickness is to emboss a laminated sheet or a thermoplastic synthetic resin sheet with an embossing roll that has irregularities.

In addition, the string-like material made of thermoplastic synthetic resin may be partially colored in advance by printing or the like.

A string-like object made of partially colored thermoplastic synthetic resin is
This is advantageous when forming a woven pattern or the like.

Of course, partial coloring can also be combined with a string-like object made of thermoplastic synthetic resin having a thick part and a thin part.

In addition to the strings made of thermoplastic synthetic resin, those made of foamed thermoplastic synthetic resin can also be used.

When weaving a string-like material made of thermoplastic synthetic resin,
It may be knitted with threads or strings made from commonly used synthetic fibers or natural fibers, or it may be knitted with ribbon-like tapes made of these threads, tapes made from finely cut nonwoven fabrics, etc. .

Of course, it is also possible to weave strings made of thermoplastic synthetic resin.

Furthermore, a string-like material made of thermoplastic synthetic resin can be woven into a coarse woven or knitted fabric.

It is also possible to weave a string-like material made of a thermoplastic synthetic resin and a string-like material made of a thermoplastic synthetic resin containing a foaming agent.

When knitting a string-like object obtained by shredding a thermoplastic synthetic resin sheet, or when forming a sheet-like object by weaving these string-like objects together, there is a problem of shape retention during heat fusing. Therefore, it is preferable to laminate it on a commonly used base material such as paper, woven fabric, non-woven fabric, etc. and heat-seal it.

In this case, there is no problem simply placing the sheet-like material on these base materials because the base material and the sheet-like material will be integrated during heat-sealing, but it is also possible to laminate them using adhesive in advance. good.

Furthermore, sheet-like materials can be made by weaving string-like materials obtained by shredding thermoplastic synthetic resin sheets, such as knitting methods that create patterns such as lace knitting, or weaving methods that create patterns such as jacquard weaving. You can also create one.

The string-like object made of thermoplastic synthetic resin containing a blowing agent used in the second invention is basically the same as the one used in the string-like object made of thermoplastic synthetic resin used in the first invention. It can be obtained in the same manner by incorporating a foaming agent into the plastic synthetic resin.

As the string-like material made of a thermoplastic synthetic resin containing a foaming agent, it is also possible to use a material having partially different degrees of foaming.

A string-like object made of thermoplastic synthetic resin containing a blowing agent with different degrees of foaming can be divided into a thick part and a thin part (a thick part where a large amount of thermoplastic synthetic resin containing a blowing agent is present and a thick part with a foaming agent). Thin parts containing only a small amount of thermoplastic synthetic resin, or string-like objects made of thermoplastic synthetic resin containing a foaming agent, may not foam partially or the degree of foaming will be small. There are some that have been processed in this way.

As a treatment method for preventing partial foaming of a string-like object made of a thermoplastic synthetic resin containing a blowing agent, the first method is to treat a string-like object made of a thermoplastic synthetic resin containing a blowing agent, as described in Japanese Patent Publication No. 43-28636. A method of partially applying an inhibitor to a string-like material made of synthetic resin, and a second method described in JP-A No. 4843468
As seen in the above publication, a reactive plasticizer is blended into a thermoplastic synthetic resin containing a blowing agent, thereby forming a string-like object, and the reactive plasticizer is partially added to this string-like object. The method of applying a catalyst for polymerization, and the third
As seen in Japanese Patent No. 299, there is a method of partially applying a paint that penetrates a string-like material made of thermoplastic synthetic resin containing a foaming agent and hardens by heating prior to the decomposition of the foaming agent, and As seen in Publication No. 52-54764, a photosensitizer is blended with a thermoplastic synthetic resin containing a foaming agent together with a polymer or monomer that hardens upon irradiation with external rays, thereby forming a string-like object. , a method of partially applying a paint containing a ray shielding agent and/or a ray absorbing agent to this string-like object and irradiating it with rays of rays, or a method of applying a foaming agent as seen in JP-A No. 52-68267. The thermoplastic synthetic resin contained is blended with polymers and monomers that harden when exposed to external radiation, forming a string-like object, and a paint containing a photosensitizer is partially applied to this string-like object. There are methods such as irradiation with external radiation.

In addition, the thermoplastic synthetic resin layer of a sheet of thermoplastic synthetic resin that does not contain a blowing agent or a laminated sheet in which thermoplastic synthetic resin that does not contain a blowing agent is laminated as a base material is used. It is also possible to fill only the concave portions of the unevenness with a thermoplastic synthetic resin containing a foaming agent, and then cut the resin into thin pieces to form a string-like material.

As a method for weaving a string-like object made of a thermoplastic synthetic resin containing these blowing agents, the method for weaving a string-like object made of a thermoplastic synthetic resin according to the first aspect of the invention can be employed as is.

In addition, when forming a sheet-like material by weaving a string-like material made of a thermoplastic synthetic resin containing a foaming agent, the weft and warp may have different foaming ratios, or the weft may have a plurality of wefts with different foaming ratios. In addition to using a braided material, a plurality of string-like materials having different expansion ratios may be used as warp threads.

A sheet-like material obtained by knitting a braided material made of a thermoplastic synthetic resin or woven with another braided material is heated to fuse the string-like material made of a thermoplastic synthetic resin to each other. Another method is to knit a string-like material made of a thermoplastic synthetic resin containing a foaming agent, or to heat and foam a sheet-like material obtained by weaving it with another braided material, and to form a string-like material. Basically, the same method can be used to fuse objects together.

That is, this is carried out by passing these sheet-like materials through a heated ozone heater using a hot air circulation type or an infrared lamp heater.

At this time, the sheet-like material can also be embossed using an embossing roll.

As the embossing roll, a roll with a smooth surface, a roll with a pattern engraved on the surface, etc. can be used.

When a roll with a smooth surface is used, the fusion of string-like objects made of thermoplastic synthetic resin or assemblies made of thermoplastic synthetic resin containing a foaming agent can be made stronger, and the surface can be made smoother. Therefore, it is preferable.

When a pattern-engraved roll is used, it is possible to further strengthen the fusion of the assembled material and to form an uneven pattern on the surface of the sheet-like material.

When using a pattern engraving roll, the printing ink is applied only to the convex parts of the roll, and the printing ink is applied only to the concave parts of the roll in so-called valley-dyed embossing, which transfers the printing ink at the same time as embossing. It is also possible to perform so-called head stain embossing in which printing ink is transferred simultaneously with embossing.

In the case of a sheet-like product obtained by knitting a composite made of a thermoplastic synthetic resin containing a foaming agent or by weaving it with another composite, before foaming and fusing by heating. , it is also possible to emboss it and give it an uneven pattern.

In this case, after foaming, the uneven pattern swells up and a rounded pattern appears.

In addition, a string-like material made of a thermoplastic synthetic resin containing a blowing agent (including a reactive plasticizer, a polymer or monomer that is hardened by a chemical ray, or a photosensitizer if necessary) may be knitted or separated. A printed pattern is applied to the surface of the sheet-like material obtained by weaving it with a string-like material using a paint that does not foam the thermoplastic synthetic resin containing a foaming agent or that reduces the degree of foaming. This can also be foamed.

The method for producing a synthetic resin sheet of the present invention involves heating a sheet-like material made by knitting a string-like material made of thermoplastic synthetic resin or weaving it with other string-like materials, and fusing each braided material, or foaming. When a thermoplastic synthetic resin containing a thermoplastic agent is used, foaming and fusing is performed, so the resulting synthetic resin sheet is simply a composite made of thermoplastic synthetic resin knitted or woven with other composites. To produce a synthetic resin sheet having a smooth feel and appearance as if it were knitted or woven with a leather strap, without causing the knitted or woven part to swell unnaturally and make the surface rough.

Furthermore, since the composites of the synthetic resin sheet obtained by the present invention are fused together, the cut portions do not fray even when cut, and processing such as sewing is easy. It can be applied to a wide range of fields.

Furthermore, in the present invention, string-like objects made of thermoplastic synthetic resin having partially thick parts and thin parts, or braided objects made of thermoplastic synthetic resin partially containing blowing agents with different degrees of foaming, etc. If you use a special braided material and knit or weave it so that a pattern is formed in the thick part or a pattern is formed in the highly foamed part, it can be seen in leather crafts. It is possible to obtain a synthetic resin sheet having such irregularities as shown in FIG.

When using a composite made of thermoplastic synthetic resin containing a foaming agent, the unevenness seen in leather crafts may be partially unfoamed or partially foamed after knitting or weaving. It can also be obtained by applying a paint that reduces the degree of foaming in a pattern, heating and foaming it, and fusing it together.

Furthermore, by applying pressure with an embossing roll during heat fusing, the thermoplastic synthetic resin spreads through the gaps between the knitted or woven sheets to the back surface of the sheets, so each assembly is bonded more firmly. However, it does not fray at all when cut, and even if the string-like material is partially damaged, it will not fray at all.
It is possible to produce a synthetic resin sheet that does not fray in chains unlike conventional knitted or woven fabrics.

Example A vinyl chloride resin composition A having the following formulation was laminated on a base fabric at a constant thickness of about 40097 yl to form a sheet, and the following vinyl chloride composition B was further laminated on the surface of this sheet. Then, a leather-like print was applied using gravure printing to produce a laminated sheet.

Vinyl chloride 1 Plasticizer Stabilizer Foaming agent Pigment 00 parts by weight 1 80 〃 3 〃 3 〃 5 〃 00 parts by weight 70 〃 3 〃 10 // The obtained laminated sheet has a width of 5 m11! Cut into string-like pieces,
This was woven into a warp yarn and a hemp thread as a weft yarn to obtain a sheet-like product.

The obtained sheet-like material is heated and foamed at about 200°C and pressed with a roll with a smooth surface to fuse the vinyl chloride resin composition of each assembly, and to pass the vinyl chloride resin through the gaps between the sheet-like materials. A part of the composition was exposed on the back side and fused to the hemp thread to obtain a synthetic resin sheet.

The obtained synthetic resin sheet had a smooth surface and an appearance with leather straps woven into it, did not fray when cut, and was easily sewn into bags and the like.

Claims (1)

[Scope of Claims] 1. A sheet-like product made by knitting a string-like material made of a thermoplastic synthetic resin or weaving it with another braided material,
A method for producing a synthetic resin sheet, which comprises heating the sheet and fusing string-like objects made of thermoplastic synthetic resin to each other. 2. The method for producing a synthetic resin sheet according to claim 1, wherein the assembled material made of a thermoplastic synthetic resin has a thermoplastic synthetic resin layer formed around the entire outer periphery of threads or strings. 3. The foamed sheet according to claim 1, wherein the string-like material made of thermoplastic synthetic resin is obtained by cutting a laminated sheet formed by laminating a thermoplastic synthetic resin layer on the surface of a base material into string-like or thread-like shapes. manufacturing method. 4. The method for producing a synthetic resin sheet according to claim 1, wherein the composite made of thermoplastic synthetic resin is obtained by cutting a thermoplastic synthetic resin sheet into a string or thread shape. 5. The method for producing a synthetic resin sheet according to claim 1, wherein the string-like material made of a thermoplastic synthetic resin is formed by molding the thermoplastic synthetic resin into a string-like or filament-like shape by extrusion molding or the like. . 6 Claims 1 to 5, in which the string-like object made of thermoplastic synthetic resin has a thick part and a thin part.
A method for producing a synthetic resin sheet according to any one of the items. 7. A sheet-like material is formed by knitting a string-like material made of a thermoplastic synthetic resin containing a foaming agent or by weaving it with another braided material, and this is heated and foamed,
A method for producing a synthetic resin sheet, characterized by fusing string-like materials to each other. 8. The synthetic resin according to claim 7, wherein the string-like object is made of a thermoplastic synthetic resin containing a blowing agent, and a thermoplastic synthetic resin layer containing a blowing agent is formed around the entire outer periphery of the thread or string. Method of manufacturing sheets. 9. Claim No. 9 in which the assembled product made of thermoplastic synthetic resin is obtained by cutting a foamable sheet-like product into strings or threads on which a thermoplastic synthetic resin layer containing a foaming agent is formed on the surface of the base material. 7. The method for producing a synthetic resin sheet according to item 7. 10. The synthetic resin sheet according to claim 7, wherein the string-like material made of a thermoplastic synthetic resin containing a blowing agent is obtained by cutting a thermoplastic synthetic resin sheet containing a blowing agent into a string or thread shape. Production method. 11. Claim 7, wherein the string-like object made of a thermoplastic synthetic resin containing a blowing agent is formed by molding a thermoplastic synthetic resin containing a blowing agent into a string or thread shape by extrusion molding or other means. A method for manufacturing a synthetic resin sheet. 12. According to any one of claims 7 to 11, the string-like material made of a thermoplastic synthetic resin containing a foaming agent does not foam or has a portion with a small foaming degree. A method for manufacturing a synthetic resin sheet.