KR20230119294A - Manufacturing method of non-sewing composite sheet with embedded three-dimensional molded article - Google Patents

Abstract

The present invention comprises the steps of preparing a nonwoven fabric sheet 20 having a certain thickness; After filling each molding space of the first mold 11 with a certain amount of the solid thermoplastic synthetic resin 30, one side of the nonwoven fabric sheet 20 is placed on the upper side, or one side of the nonwoven fabric sheet 20 Placing a certain amount of solid thermoplastic synthetic resin 30 on each of the other surface portions of the non-woven fabric sheet 20 corresponding to the respective positions of the molding spaces of the first mold 11 after being placed in the first mold 11; By heating the first and second molds 11 and 15 in a molded state, the molten solid thermoplastic synthetic resin 30 is integrated with the nonwoven fabric sheet 20, thereby forming the nonwoven fabric sheet 20 and the solid thermoplastic synthetic resin 30, respectively. Manufacturing step of the first outer sheet (1) to form the shape of each molding space of the first mold (11); Placing one surface of the second outer sheet 40 having a certain thickness in the first mold 11; Placing one surface of the first outer sheet 1 on the other surface of the second outer sheet 50 with the first molding part positioned to correspond to each molding space of the first mold 11; The first and second molds 11 and 15 are heated in a molded state to form the one surface of the second outer sheet 50 into the shape of the molding space of the first mold 11 while forming the first outer shell in which the first molding part is formed. Manufacturing a composite sheet in which one surface of the sheet 1 is integrated with the other surface of the second outer sheet 50; provides a method for manufacturing a non-sewn composite sheet having a three-dimensional molding embedded therein.

Description

Manufacturing method of non-sewing composite sheet with embedded three-dimensional molded article}

The present invention relates to a method for manufacturing a non-sewn composite sheet having a three-dimensional molding embedded therein, and more specifically, it is possible to perfectly reproduce the three-dimensional shape no matter what shape the molding space of the mold is made in, and stable for a long time. It relates to a method for manufacturing a composite sheet that can be guaranteed to be used and can express a specific part in a three-dimensional shape by reproducing the shape of a molding having a built-in outer skin having various textures without sewing.

Sporting goods such as shoes and bags, as well as clothing such as clothes, are provided with three-dimensional moldings as a means for indicating the origin of the product or highlighting design elements for differentiation from other products. These products, which are conventionally prepared with moldings, were manufactured by placing a substrate in a mold in which a molding surface of an arbitrary shape is formed, and then injecting molten resin into the molded mold.

However, this method has a problem of being damaged or separated from the substrate by external force or washing in that the three-dimensional molded article is directly exposed to the outside from the surface of the substrate. In addition, it was impossible to use this method itself when the molding itself is composed of a plurality of divided structures, or when the thickness varies for each part, especially when the thickness is very thin.

As an alternative to this, a PU casting method for producing a molded article using a liquid synthetic resin is proposed. This method has the advantage of not being limited by the specific shape or thickness of the molded product in that the synthetic resin is melted and the molding space of the mold is overfilled, and then unnecessary parts of the filled resin are removed as a scraper to produce the molded product. It is widely used in industry.

However, PU casting is not a method of manufacturing a base material and a molded article in one piece, but a technology for manufacturing the molded article itself. When a molded article is produced through this method, pressurization and heating are performed while placing a base material such as a fabric on the upper part of the molded article. In terms of integration, the manufactured molding is exposed to the outside as it is. By the way, if the molding is made of a configuration that is directly exposed to the outside in this way, the problems of the prior art described above may be expressed in much the same way.

That is, when various types of external forces act on the molded article exposed on the surface of the substrate, the molded article itself may be damaged or a portion of the molded article with weak bonding force may be separated from the substrate. In addition, it is difficult to expect various textures or ductility due to the physical properties of synthetic resins, and it is impossible to apply designs of various colors to the surface due to the characteristics of moldings made of three-dimensional shapes.

Along with PU casting, there is a no-saw method among technologies that are widely used in manufacturing shoe uppers. This technology has the advantage of being able to couple decorative objects having various shapes to the surface of a base material without going through a complicated manual process of sewing, but it is almost impossible to manufacture decorative objects having different shapes or heights for each part. In addition, it has the disadvantage of the PU casting method in that the decoration itself is exposed to the outside, so it is time to develop an alternative technology.

Republic of Korea Patent Publication No. 2009-0046450 Republic of Korea Patent No. 0390025 Republic of Korea Patent No. 1361659

The present invention has been proposed to solve the problems of the prior art, and the object of the present invention is to freely express various three-dimensional shapes, as well as to add designs of arbitrary colors to the surface of three-dimensional shapes, and to provide various shapes desired by consumers. It is to provide a non-sewn composite sheet that can secure stable durability for a long time while satisfying the needs.

In order to achieve this object, the present invention comprises the steps of preparing a first mold 11 formed with a molding space having a different depth; Preparing a non-woven fabric sheet 20 having a certain thickness; After filling each molding space of the first mold 11 with a certain amount of the solid thermoplastic synthetic resin 30, one side of the nonwoven fabric sheet 20 is placed on the upper side, or one side of the nonwoven fabric sheet 20 Placing a certain amount of solid thermoplastic synthetic resin 30 on each of the other surface portions of the non-woven fabric sheet 20 corresponding to the respective positions of the molding spaces of the first mold 11 after being placed in the first mold 11; Molding the second mold 15 to the upper part of the first mold 11; By heating the first and second molds 11 and 15 in a molded state, the molten solid thermoplastic synthetic resin 30 is integrated with the nonwoven fabric sheet 20, thereby forming the nonwoven fabric sheet 20 and the solid thermoplastic synthetic resin 30, respectively. Manufacturing step of the first outer sheet (1) to form the shape of each molding space of the first mold (11); Opening the second mold 15 to separate the first outer sheet 1 on which the first molding part is formed from the first mold 11; Placing one surface of the second outer sheet 40 having a certain thickness in the first mold 11; Placing one surface of the first outer sheet 1 on the other surface of the second outer sheet 50 with the first molding part positioned to correspond to each molding space of the first mold 11; Molding the second mold 15 to the upper part of the first mold 11; The first and second molds 11 and 15 are heated in a molded state to form the one surface of the second outer sheet 50 into the shape of the molding space of the first mold 11 while forming the first outer shell in which the first molding part is formed. A step of manufacturing a composite sheet in which one surface of the sheet 1 is integrated with the other surface of the second outer sheet 50;

Another technical feature of the present invention is to prepare a first mold 11 formed with a molding space having a different depth; Preparing a non-woven fabric sheet 20 and a second outer sheet 40 having a predetermined thickness; Placing one surface of the second outer sheet 40 in the first mold 11; A certain amount of solid thermoplastic synthetic resin 30 is placed on each of the other surface portions of the second outer sheet 40 corresponding to the respective positions of the molding space of the first mold 11, and then one side of the nonwoven fabric sheet 20 is placed on the upper portion thereof. Place the other side of the non-woven fabric sheet 20, or place the other side of the non-woven fabric sheet 20 on the other side of the second outer sheet 40, and then place the other side of the non-woven fabric sheet 20 corresponding to each position of the molding space of the first mold 11 positioning a certain amount of a solid thermoplastic synthetic resin (30) on each site; Molding the second mold 15 to the upper part of the first mold 11; By heating the first and second molds 11 and 15 in a combined state, the molten solid thermoplastic synthetic resin 30 is integrated with the nonwoven fabric sheet 20 and the second outer sheet 40, respectively, while the second outer sheet ( 40), manufacturing a composite sheet for molding each of the nonwoven fabric sheet 20 and the solid thermoplastic synthetic resin 30 into the shape of each molding space of the first mold 11;

The thermoplastic synthetic resin 30 may contain a foaming agent.

When the composite sheet is manufactured, an endothelial sheet 50 having a predetermined thickness is prepared, and then the endothelial sheet 50 is placed in a state in which one surface portion of the endothelial sheet 50 faces the other surface portion of the composite sheet (1). ), place the second mold 15 on the upper part of the first mold 11, and then heat the first and second molds 11 and 15 to remove one surface of the endothelial sheet 50. A step of integrating with the other side of the composite sheet may be added.

The non-woven fabric sheet 20 may be impregnated or coated with polyurethane.

The melting point of the nonwoven fabric sheet 20 may be higher than the melting point of the thermoplastic synthetic resin 20 .

The melting point of the second outer sheet 40 may be higher than the melting point of the thermoplastic synthetic resin 20 .

The second outer sheet 40 is made of a non-permeable film and integrally coupled to one surface of the nonwoven fabric sheet 20, and the one surface is placed in the first mold 11, and the solid thermoplastic synthetic resin (30) may be located in a certain amount on each of the other surface portions of the non-woven fabric sheet 20 corresponding to the respective positions of the molding space of the first mold 11.

The present invention proposes a method in which a nonwoven fabric sheet and a solid thermoplastic synthetic resin are combined, and the molten thermoplastic synthetic resin permeates into the nonwoven fabric sheet to form an integral structure with the nonwoven fabric sheet and is molded into the molding space of the mold. Even if it is made of a shape, it is possible to perfectly reproduce the three-dimensional shape.

In addition, the present invention finishes the surface of the combination of the nonwoven fabric sheet and the thermoplastic synthetic resin produced in the shape of the molding space of the mold as an outer sheet without sewing work, so that the three-dimensional shape of the molding part is projected through the outer sheet while the molding part itself Since it can be protected from the external environment by using it, it can guarantee stable use for a long time.

In addition, the present invention is a product of various shapes according to consumer preference in that the outer sheet having various colors or textures or the outer sheet having a design having various colors or shapes can be combined with a combination of a nonwoven fabric sheet and a thermoplastic synthetic resin. Not only is it possible to supply, but it is also possible to express the three-dimensional shape projected through the outer sheet more prominently, which can enhance the competitiveness of the product.

In addition, the present invention can sufficiently satisfy the convenience or functionality required by consumers in various products in that a separate endothelial sheet made of various materials can be added or air permeability can be imparted to a specific area.

1a to 1g are schematic manufacturing steps of a composite sheet as an example according to the present invention.
2a to 2c are schematic steps that can be added during the manufacture of a composite sheet according to the present invention.
3a to 3e are schematic manufacturing steps of a composite sheet as another example according to the present invention, respectively.
4a and 4b are schematic manufacturing steps of a composite sheet as another example according to the present invention, respectively.
5a to 5d are schematic manufacturing steps of a composite sheet as another example according to the present invention, respectively.

Looking at the preferred embodiment according to the present invention in detail with reference to the accompanying drawings, as follows, in detailing the embodiment of the present invention, there is no direct relationship with the technical features of the present invention, or A detailed description will be omitted for matters that are obvious to those skilled in the art.

The present invention relates to a method for manufacturing a non-sewn composite sheet having a three-dimensional molding embedded therein, and the specific steps for manufacturing the composite sheet are as follows with reference to the accompanying drawings.

First, a first mold 11 is prepared. In the first mold 11, as shown in FIG. 1A, molding spaces 121 and 123 having different depths may be formed. Although an example of a configuration in which molding spaces communicate with each other is disclosed in the drawing, otherwise, the molding spaces may be formed of a plurality of spaces spaced apart from each other as a non-communicating structure.

Reference numeral 13 denotes a pressure end that does not form a molding space on the molding surface of the first mold, and is a part not involved in molding of the thermoplastic synthetic resin to be described later. In this way, if at least one pressing end 13 is provided on the molding surface, it may be used to form a portion that functions as a ventilation part in the final product, which will be described later.

Next, a nonwoven fabric sheet 20 having a certain thickness is prepared. A non-woven fabric is an artificial fabric produced by using heat and synthetic resin, and since the fibers constituting the non-woven fabric are treated to be entangled with each other, durability is weak but breathable. The present invention is characterized in that a non-woven fabric sheet is used as a base sheet in a composite sheet in order to utilize the air permeability of the non-woven fabric.

The thickness of the prepared nonwoven fabric sheet 20 may be variously changed, and the thickness may be variously changed according to the depth of the molding spaces 121 and 123 formed in the first mold 11. That is, when the depth of the molding space is deep, it is preferable to use a relatively thick nonwoven fabric sheet.

At this time, the present invention does not exclude the case where polyurethane is impregnated or applied to the nonwoven fabric sheet 20. In this case, durability such as strength or resilience of the non-woven fabric sheet 20 may be improved, and physical bonding between the non-woven fabric sheet and the thermoplastic synthetic resin may be further enhanced during a molding process to be described later.

When the nonwoven fabric sheet 20 is prepared, the nonwoven fabric sheet 20 and the thermoplastic synthetic resin 30 are placed in the first mold 10, respectively. At this time, the thermoplastic synthetic resin 30 is preferably made of solid particles. Each of the nonwoven fabric sheet 20 and the thermoplastic synthetic resin 30 may be positioned in the first mold 10 in one of the following ways.

Among them, in the first (hereinafter, the first embodiment), as shown in FIG. 1B, a certain amount of thermoplastic synthetic resin 30 is filled in each molding space of the first mold 11, and then one side of the nonwoven fabric sheet 20 is placed on the upper part. It is to settle the area. The amount of thermoplastic synthetic resin filled in each molding space is to be determined in consideration of the depth of each molding space formed in the mold and the thickness of the nonwoven fabric.

In the second (hereinafter referred to as the second embodiment), as shown in FIG. 3A, one surface portion of the nonwoven fabric sheet 20 is placed in the first mold 11, and then the first mold 11 corresponds to each position of the molding space. A certain amount of the solid thermoplastic synthetic resin 30 is placed on each of the other surface portions of the nonwoven fabric sheet 20.

The third (hereinafter referred to as the third embodiment) is a combination of the above methods, and as shown in FIG. 4a, a part of the thermoplastic synthetic resin 30 with the nonwoven fabric sheet 20 interposed therebetween is in each molding space of the first mold 11 , and the remaining part of the thermoplastic synthetic resin 30 is positioned on each of the other surface portions of the nonwoven fabric sheet 20 corresponding to the respective positions of the molding space of the first mold 11.

In the drawing, an example of using a thermoplastic synthetic resin 30 made of a pellet is disclosed, but in the present invention, the thermoplastic synthetic resin 30 is made of any one of various solid materials such as a sheet widely used in the related industry, or a hot melt. It does not exclude the case where it is made, of course, and also does not exclude the case where a material that is linearly molded or 3d printed in the shape of the molding space of the mold is used for convenience of work.

On the other hand, the present invention does not exclude the case where the thermoplastic synthetic resin 30 contains a foaming agent. In this way, if the thermoplastic synthetic resin 30 contains a foaming agent, the foaming action of the foaming agent during the heating process, which will be described later, can induce the molten thermoplastic synthetic resin to adhere to the inner surface of the molding space of the first mold, and the product itself due to the bubbles generated. It is possible to make it much lighter.

As a first embodiment, when the nonwoven fabric sheet 20 and the solid thermoplastic synthetic resin 30 are positioned in the first mold 11, as shown in FIG. ) is combined to pressurize the nonwoven fabric sheet 20 and the solid thermoplastic synthetic resin 30 and then heat it. The heating of the mold is sufficient if the solid thermoplastic synthetic resin 30 is melted and molded into the shape of the molding space.

When the first and second molds 11 and 15 are heated in a combined state, the solid thermoplastic synthetic resin 30 melts and pressurizes the nonwoven fabric sheet 20 and at the same time permeates into it. Accordingly, the thermoplastic synthetic resin 30 is molded into the shape of each molding space of the first mold 11 while being integrated with the nonwoven fabric sheet 20 .

In the case of injecting molten resin into the molding space in a state where a substrate such as fabric is placed in a conventional mold, the molten resin does not completely fill the molding space, resulting in defects. Even if a certain amount of molten resin is filled into the molding space, air bubbles are generated in the area in contact with the molding surface of the mold during the curing process of the resin, resulting in poor surface conditions of the product.

In addition, since fabrics such as non-woven fabrics have a limited thickness, it has been impossible to manufacture products having various three-dimensional shapes using only the conventional non-woven fabric itself. , The mixture of the non-woven fabric sheet and the resin completely fills the molding space and at the same time fundamentally prevents these various phenomena in which the surface condition of the product is poor.

Meanwhile, in heating the mold after molding, high frequency may be additionally applied to the mold. In this case, while the solid thermoplastic synthetic resin 30 melts more quickly, a part of it permeates into the nonwoven fabric sheet 20 and can be molded into the shape of the molding space of the mold.

When the nonwoven fabric sheet 20 and the thermoplastic synthetic resin 30 are integrated and molded into the shape of the molding space of the first mold 11, the second mold 15 is opened to form the thermoplastic synthetic resin 30 after a cooling step for a certain period of time. And the non-woven fabric sheet 20 is integrated with the first outer sheet (1) is separated from the first mold (11). 1d shows an example of the first outer sheet 1 manufactured through this process.

As shown in the figure, the first outer sheet 1 is formed with first molding parts 321 and 323 formed in the shape of the molding spaces 121 and 123 of the first mold 11. In the first molding parts 321 and 323, the upper part of the melted thermoplastic synthetic resin 30 is molded into the shape of the molding space 121 and 123, and the lower part of the first molding parts 321 and 323 The rest of the thermoplastic synthetic resin 30 is a part naturally permeated into the inner space of the nonwoven fabric sheet 20 (lower side of the dotted line) and molded. Reference numeral 23 is a portion formed by the pressing end 13 of the first mold 11 in the nonwoven fabric sheet 20.

In the second embodiment as well, when the first and second molds 11 and 15 are combined and heated as shown in FIG. 3B, the nonwoven fabric sheet 20 and the thermoplastic synthetic resin 30 are integrated with each other, and the first mold 11 It is molded into the shape of the molding spaces 121 and 123, and the first outer sheet 1' as shown in Fig. 3c is produced.

In this case, in the upper portion of the first molding parts 321 and 323 in the first outer sheet 1', a part of the molten thermoplastic synthetic resin 30 permeates into the inner space of the nonwoven fabric sheet 20 (upper side of the dotted line). It is molded into the shape of the molding spaces 121 and 123 while lifting, and the lower part is a part where the rest of the thermoplastic synthetic resin 30 is molded. Unlike the case described above, the upper portions of the first molding parts 321 and 323 are made of a composite structure of the nonwoven fabric sheet 20 and the thermoplastic synthetic resin 30 .

Even in the case of the third embodiment, when heating the first and second molds 11 and 15 in a combined state as shown in FIG. 4B, the nonwoven fabric sheet 20 and the thermoplastic synthetic resin 30 are integrated with each other and the first mold 10 ) It is molded into the shape of the molding space (121, 123). In this case, although not shown, in the first outer sheet to be manufactured, the central part of the first molded part is integrated with the molten thermoplastic synthetic resin permeating into the inner space of the nonwoven fabric sheet, and the upper and lower parts respectively contain the thermoplastic synthetic resin. It is sufficiently predictable that it can be molded into the shape of 1 and 2 molds (mixed structure of FIGS. 1D and 3C, respectively).

On the other hand, in the present invention, in placing the nonwoven fabric sheet 20 and the thermoplastic synthetic resin 20 together in the first mold 11, the nonwoven fabric sheet 20 having a melting point higher than the melting point of the thermoplastic synthetic resin 20 is used suggest that In this case, it is obvious that the breathable properties of the nonwoven fabric itself can be fully utilized during the above-described process of heating the mold.

When the first outer sheet 1 is manufactured in the first embodiment, as shown in FIG. 1E, one surface of the second outer sheet 40 having a certain thickness is placed in the first mold 11. The second outer sheet 40 is a part constituting the outer surface of the final product, and may be made of any one of various types of materials such as artificial leather as well as natural leather.

At this time, the present invention does not exclude the case where a non-permeable thin film or film layer is formed on the surface exposed to the outside when the second outer sheet 40 is made of breathable fabric, and the second outer sheet 40 itself A case made of a non-air permeable thin film is not excluded.

In addition, the second outer sheet 40 is preferably made of a material having a higher melting point than the thermoplastic synthetic resin 30 . This is to prevent a phenomenon in which one surface of the second outer sheet 40 placed in contact with the molding surface of the first mold 11 is damaged by heat when the mold is heated to melt the thermoplastic synthetic resin 30. am.

When one surface of the second outer sheet 40 is placed in the first mold 11, as shown in the drawing, the first molding parts 321 and 323 in the first outer sheet 1 form the first mold 11 One side of the first outer sheet 1 is placed on the other side of the second outer sheet 50 in a state in which it is positioned to correspond to each of the molding spaces 121 and 123.

Typically, when a thermoplastic synthetic resin is filled in the molding space of a mold and then subjected to melting and cooling steps, a product molded in the shape of the molding space of the mold is made while shrinking at a certain rate due to the characteristics of the material. Therefore, even if the molded product itself is placed in the molding space of the same mold, a dimensional difference of a certain interval occurs between the molding space and the product.

However, the present invention does not go through the melting and cooling steps in a state in which only the thermoplastic synthetic resin is filled in the molding space of the mold, but melts and In terms of the cooling step, even if the first outer sheet is located in the molding space of the same mold, the first molding part formed on the first outer sheet accurately corresponds to the molding space of the mold without a difference in size.

At this time, the present invention does not exclude the case where a design of an arbitrary shape or color is formed on one surface of the second outer sheet 40. The design formed on one surface of the second outer sheet 40 is preferably formed at a position corresponding to the first molding parts 321 and 323 of the first outer sheet 1.

Next, as shown in FIG. 1F, the second mold 15 is molded on the upper side of the first mold 11 and then heated. When the first and second molds 11 and 15 are heated in a combined state, the second outer sheet 50 facing the first mold 11 is molded into the shape of the molding spaces 121 and 123, and the first mold 11 While the thermoplastic synthetic resin constituting the first molded parts 321 and 323 of the outer sheet 1 is melted, it is integrated with and combined with the other surface of the second outer sheet 40.

When the second mold 15 is opened after a cooling step for a certain period of time, a composite sheet 2 as disclosed in FIG. 1G can be obtained. As shown in the drawing, the composite sheet 2 has a structure in which the first molding parts 321 and 323 are protected by the second outer sheet 40, and the second outer sheet 40 exposed to the outside is It is characterized in that the three-dimensional shape of the molding parts 321 and 323 is reproduced as it is.

In this case, the first molding unit reflects its three-dimensional characteristics by projecting it onto the second outer sheet 40, but itself can be safely protected inside the composite sheet 2. When a product such as a shoe upper or a bag is made using the composite sheet 2, unlike the prior art, it has high durability even when various external forces act on it and can ensure stable use for a long time.

Meanwhile, an example of a composite sheet 2' that can be manufactured according to the second embodiment is disclosed in FIG. 3D. This composite sheet 2' goes through the same steps as those in Figs. 1e and 1f, respectively, in much the same way as in the first embodiment. In the first outer sheet 1' formed, the upper portions of the first molding parts 321 and 323 are integrated with the other surface portion of the second outer sheet 40.

That is, when the mold is heated, a portion of the thermoplastic synthetic resin impregnated in the upper portions of the first molding parts 321 and 323 is melted, and the melted thermoplastic synthetic resin flows into the inside through the other surface of the second outer sheet 40. While permeating, the first outer sheet 1' and the second outer sheet 40 are integrated. If necessary, an adhesive means such as a separate hot melt may be mediated between the first outer sheet 1' and the second outer sheet 40.

Although the third embodiment is not specifically shown, since the third embodiment has a configuration similar to that of the first embodiment as shown in FIGS. It can be fully predicted that it will be integrated with the second outer sheet 40 similarly to the case of the first embodiment.

At this time, the present invention does not exclude the case where an endothelial sheet is further added to the manufactured composite sheet when the composite sheet is manufactured. As a case where an endothelial sheet is added according to the present invention, the first embodiment will be described.

When the composite sheet 2 is manufactured according to the heat forming step of FIG. 1F, as shown in FIG. 2), the endothelial sheet 50 is placed on the other side of the first outer sheet 1 in the composite sheet 2 while facing the other side.

The inner sheet 50 is a part forming the inner surface of the final product, and its material may be made of the same material as the second outer sheet 40. However, if a product such as a shoe upper or clothing is made using the composite sheet, the endothelial sheet 50 is preferably made of a material such as fabric because it is a part in contact with the user's body in the final product.

When the endothelial sheet 50 is placed, as shown in FIG. 2B, a second mold 15 is molded on the upper side of the first mold 11, and then the first and second molds 11 and 15 are heated. When the mold is heated, a part of the thermoplastic synthetic resin permeated into the inside of the second outer sheet 40 constituting the composite sheet 2 melts and permeates into the inside through one surface of the inner sheet 50, and thus the second outer sheet 40 is melted. The outer sheet 40 and the inner sheet 50 are integrated.

When the second mold 15 is opened through the heat forming step and the cooling step, a composite sheet 3 having a configuration different from that of the aforementioned composite sheet 2 is manufactured as shown in FIG. 2C. This composite sheet 3 is similar to the composite sheet 2 disclosed in FIG. 1G in that the three-dimensional first molded parts 231 and 233 are made of a composite structure of a nonwoven fabric sheet and a thermoplastic synthetic resin and are exposed to the outside, There is a difference in that the endothelial sheet 50 is additionally coupled. For more tight coupling, an adhesive means may be interposed between the second outer sheet 40 and the inner sheet 50 .

3E shows an example of a composite sheet 3' manufactured according to the second embodiment when an endothelial sheet 50 is added according to the present invention. In the composite sheet 3', a part of the thermoplastic synthetic resin constituting the first molded parts 231 and 233 is melted and penetrated into the inner sheet 50 to be integrated. Unlike the first embodiment, this embodiment is characterized in that the first molded parts 231 and 233 are completely protected by the second outer sheet 40 and the inner sheet 50, respectively.

When the endothelial sheet 50 is added according to the present invention, an example of a composite sheet that can be manufactured according to the third embodiment is not disclosed, but if a large amount of thermoplastic synthetic resin is located on the lower part of the nonwoven fabric sheet It will have a configuration close to that of FIG. 2c, and on the other hand, it can be sufficiently predicted that it will have a configuration close to that of FIG.

Meanwhile, in the composite sheet 2 disclosed in FIG. 1G, reference numerals 23 and 43 denote parts formed by the pressing end 13 of the first mold 11, and these are the nonwoven fabric sheet 20 and the second outer sheet. The corresponding part of (40) is a part molded into the shape of the pressing end (13). If the second outer sheet 40 is made of a breathable material such as fabric, portions 23 and 43 are breathable.

Therefore, when the composite sheet 2 as shown in FIG. 1G is manufactured, the outer portion of the reference numeral 421 is cut and removed from the first molding parts 421 and 423, or the reference numeral 421 and 423 In a state where the outer portion of 421 is cut and removed and at the same time the portions 23 and 43 are removed, the same operation as in FIGS. 2A to 2B may be performed by adding a breathable endothelial sheet 50.

In this case, in the former, in which the work is performed in a state in which the outer portion of reference numeral 421 is removed, all of the areas 53, 23, and 43 in the composite sheet 3 disclosed in FIG. 2c have air permeability, and In the latter case, in which the outer part and the parts 23 and 43 are all removed, only the part 53 in the composite sheet 3 has air permeability. of the final product can be produced.

The present invention also proposes a method for manufacturing a composite sheet as follows, in which some steps are configured differently from the above method in manufacturing a composite sheet having a three-dimensional molded article embedded therein. In this embodiment, the same parts as the previous embodiment will be omitted.

First, as shown in FIG. 5A, a first mold 11 having forming spaces 121 and 123 having different depths is prepared. The prepared first mold 11 may have a structure similar to that of the first mold 11 of the above-described embodiment disclosed in FIG. 1A.

Next, each of the nonwoven fabric sheet 20 and the second outer sheet 40 having a predetermined thickness is prepared. Each of the nonwoven fabric sheet 20 and the second outer cover sheet 40 may have the same configuration as the nonwoven fabric sheet described in the foregoing embodiment.

When the nonwoven fabric sheet 20 and the second outer sheet 40 are prepared, one surface of the second outer sheet 40 is placed in the first mold 11, and then the nonwoven fabric sheet 20 and the solid thermoplastic synthetic resin 30 are placed. ) Place a certain amount on the other side of the second outer sheet 40. The thermoplastic synthetic resin 30 may be made substantially the same as the material of the above-described embodiment.

At this time, the thermoplastic synthetic resin 30 may be located on either side of the lower part or upper part of the nonwoven fabric sheet 20, or both sides of the nonwoven fabric sheet 20. That is, it may be positioned in the same configuration as each of FIGS. 1B, 3A, and 4A of the above-described embodiment.

5A is an example of a configuration similar to that of FIG. 3A among these configurations. When one surface of the second outer sheet 40 is placed in the first mold 11, one surface of the nonwoven fabric sheet 20 is moved to the second outer sheet. (40) In a state where it is placed on the other side, a certain amount of the solid thermoplastic synthetic resin 30 is placed on each of the other side of the nonwoven fabric sheet 20 corresponding to each position of the molding space of the first mold 11. Shown.

At this time, in the present invention, the second outer sheet 40 is made of a film structure of a thin film, and the other side of the second outer sheet 40 having such a thin film structure is an integrated structure on one side of the nonwoven fabric sheet 20. It does not exclude cases consisting of In this case, the second outer sheet 40 is preferably made of a non-permeable material.

Although not clearly disclosed in the drawings, when the second outer sheet 40 and the nonwoven fabric sheet 20 have an integrated structure, a state in which one surface of the second outer sheet 40 is placed in the first mold 11 It is preferable that a certain amount of the solid thermoplastic synthetic resin 30 be located on each of the other surface portions of the nonwoven fabric sheet 20 corresponding to the respective positions of the molding space of the first mold 11 (see FIG. 5a).

When the second outer sheet 40, the nonwoven fabric sheet 20, and the thermoplastic synthetic resin 30 are respectively positioned in the first mold 11, the second mold 15 is located on the upper part of the first mold 11 as shown in FIG. 5B. ) is compounded and heated. When the first and second molds 11 and 15 are heated in a combined state, the solid thermoplastic synthetic resin 30 gradually melts and permeates into the non-woven fabric sheet 20, forming the second outer sheet 40 and the non-woven fabric sheet. (20), each of the thermoplastic synthetic resin 30 is molded in the shape of the molding space of the first mold (11).

When the second mold 15 is opened after the heating and cooling steps have elapsed, a composite sheet as shown in FIG. 5C is made. In the composite sheet, in the molding parts 321 and 323, some of the thermoplastic synthetic resin 30 permeates into the non-woven fabric sheet 20 and is integrated with the non-woven fabric sheet 20, and the molding parts 321 and 323 are built-in It is finished and protected by the second outer sheet 40.

Unlike the case of FIG. 5A, when the thermoplastic synthetic resin 30 is located on the lower, upper, or both sides of the nonwoven fabric sheet 20, the second outer sheet 40 in FIGS. 1B and 4B of the above-described embodiment, respectively. ) If the operation proceeds in a manner of combining and heating the second mold 15 through the medium, it will be possible to obtain a composite sheet having a configuration similar to that of the composite sheet 2 of the above-described embodiment.

As described in the foregoing embodiment, the second outer sheet 40 is preferably made of a material whose melting point is higher than that of the thermoplastic synthetic resin 20 . In particular, when the second outer sheet 40 is made of a thin film, if the melting point of the second outer sheet 40 is not higher than the melting point of the thermoplastic synthetic resin 20, the second outer sheet 40 in the heating process of the mold This is because the other surface of the melt may damage its physical properties or gloss.

In addition, much the same as the case of the second outer sheet 40 of the above-described embodiment, in this embodiment, a design consisting of an arbitrary shape or color may be formed on one surface of the second outer sheet 40, such Of course, it is preferable that the design is formed in a position corresponding to the molding spaces 121 and 123 of the first mold 11.

Even in this embodiment, the case of manufacturing a composite sheet having a different configuration in which the endothelial sheet 50 is further added as shown in FIG. 5D is not excluded. The added endothelial sheet 50 may be coupled to the other side of the nonwoven fabric sheet 20 in the composite sheet, and the endothelial sheet 50 may be made of the same material as in the above-described embodiment.

On the other hand, in this embodiment, when the second outer sheet 40 has a film structure of a thin film and is manufactured as a composite sheet as shown in FIG. 5C in a state in which it has an integrated configuration with the nonwoven fabric sheet 20, 323) is cut or the parts 23 and 43 molded by the molding parts 321 and 323 and the pressing end 13 of the first mold 11 are cut, and then only the cut parts are drawn. As shown in 5d, it may be combined with the endothelial sheet 50 to manufacture a product.

The operation of cutting a specific part of the composite sheet and combining it with the endothelial sheet 50 can be performed through a conventional hot melt or adhesive treatment. Of course it can be done.

In the above, the description has been limited to the preferred embodiments of the present invention, but this is only an example, and the present invention is not limited thereto and can be modified and implemented in various ways, and furthermore, separate technical features are provided based on the disclosed technical idea. It will be obvious that it can be added and implemented.

11, 15: first and second molds 121, 123: molding space
20: non-woven fabric sheet 30: thermoplastic synthetic resin
40: first outer sheet 50: inner sheet

Claims (8)

preparing a first mold 11 in which molding spaces having different depths are formed;
Preparing a non-woven fabric sheet 20 having a certain thickness;
After filling each molding space of the first mold 11 with a certain amount of the solid thermoplastic synthetic resin 30, one side of the nonwoven fabric sheet 20 is placed on the upper side, or one side of the nonwoven fabric sheet 20 Placing a certain amount of solid thermoplastic synthetic resin 30 on each of the other surface portions of the non-woven fabric sheet 20 corresponding to the respective positions of the molding spaces of the first mold 11 after being placed in the first mold 11;
Molding the second mold 15 to the upper part of the first mold 11;
By heating the first and second molds 11 and 15 in a molded state, the molten solid thermoplastic synthetic resin 30 is integrated with the nonwoven fabric sheet 20, thereby forming the nonwoven fabric sheet 20 and the solid thermoplastic synthetic resin 30, respectively. Manufacturing step of the first outer sheet (1) to form the shape of each molding space of the first mold (11);
Opening the second mold 15 to separate the first outer sheet 1 on which the first molding part is formed from the first mold 11;
Placing one surface of the second outer sheet 40 having a certain thickness in the first mold 11;
Placing one surface of the first outer sheet 1 on the other surface of the second outer sheet 50 with the first molding part positioned to correspond to each molding space of the first mold 11;
Molding the second mold 15 to the upper part of the first mold 11;
The first and second molds 11 and 15 are heated in a molded state to form the one surface of the second outer sheet 50 into the shape of the molding space of the first mold 11 while forming the first outer shell in which the first molding part is formed. Manufacturing a composite sheet in which one surface of the sheet 1 is integrated with the other surface of the second outer sheet 50;
Method for producing a non-sewn composite sheet containing a three-dimensional molded article comprising: preparing a first mold 11 in which molding spaces having different depths are formed;
Preparing a non-woven fabric sheet 20 and a second outer sheet 40 having a predetermined thickness;
Placing one surface of the second outer sheet 40 in the first mold 11;
A certain amount of solid thermoplastic synthetic resin 30 is placed on each of the other surface portions of the second outer sheet 40 corresponding to the respective positions of the molding space of the first mold 11, and then one side of the nonwoven fabric sheet 20 is placed on the upper portion thereof. Place the other side of the non-woven fabric sheet 20, or place the other side of the non-woven fabric sheet 20 on the other side of the second outer sheet 40, and then place the other side of the non-woven fabric sheet 20 corresponding to each position of the molding space of the first mold 11 positioning a certain amount of a solid thermoplastic synthetic resin (30) on each site;
Molding the second mold 15 to the upper part of the first mold 11;
By heating the first and second molds 11 and 15 in a combined state, the molten solid thermoplastic synthetic resin 30 is integrated with the nonwoven fabric sheet 20 and the second outer sheet 40, respectively, while the second outer sheet ( 40), manufacturing a composite sheet for molding each of the nonwoven fabric sheet 20 and the solid thermoplastic synthetic resin 30 into the shape of each molding space of the first mold 11;
Method for producing a non-sewn composite sheet containing a three-dimensional molded article comprising: According to any one of claims 1 or 2,
The thermoplastic synthetic resin 30 is characterized in that the foaming agent is contained, a method for producing a non-sewn composite sheet with a built-in molding of a three-dimensional shape. According to any one of claims 1 or 2,
When the composite sheet is manufactured, an endothelial sheet 50 having a predetermined thickness is prepared, and then the endothelial sheet 50 is placed in a state in which one surface of the endothelial sheet 50 faces the other surface of the composite sheet (1). ), place the second mold 15 on the upper side of the first mold 11, and then heat the first and second molds 11 and 15 to remove one surface of the endothelial sheet 50. Step of integrating with the other side of the composite sheet; Method for manufacturing a non-sewn composite sheet with a built-in three-dimensional molding, characterized in that the addition. According to any one of claims 1 or 2,
Method for producing a non-sewn composite sheet having a three-dimensional molding, characterized in that the non-woven fabric sheet 20 is impregnated or coated with polyurethane. According to any one of claims 1 or 2,
The melting point of the non-woven fabric sheet 20 is higher than the melting point of the thermoplastic synthetic resin 20, characterized in that the manufacturing method of the non-sewn composite sheet with a built-in three-dimensional molding. According to any one of claims 1 or 2,
The melting point of the second outer sheet (40) is higher than the melting point of the thermoplastic synthetic resin (20). According to claim 2,
The second outer sheet 40 is made of a non-permeable film, and the other surface is integrally coupled to one surface of the nonwoven fabric sheet 20, and the one surface is placed in the first mold 11, and the solid phase The thermoplastic synthetic resin 30 is a non-seamless composite with a built-in three-dimensional molding, characterized in that a certain amount is located on each of the other surface portions of the nonwoven fabric sheet 20 corresponding to each position of the molding space of the first mold 11 Sheet manufacturing method.

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