U.S. patent application number 11/149280 was filed with the patent office on 2005-10-13 for method and device for producing laminated composite.
This patent application is currently assigned to SEKISUI Chemical Co., Ltd.. Invention is credited to Hirata, Masanori, Ishiyama, Masafumi, Matsuzaka, Katsuo, Okabe, Masashi, Tsujimoto, Michitaka, Yamaguchi, Koji.
Application Number | 20050224174 11/149280 |
Document ID | / |
Family ID | 27346590 |
Filed Date | 2005-10-13 |
United States Patent
Application |
20050224174 |
Kind Code |
A1 |
Tsujimoto, Michitaka ; et
al. |
October 13, 2005 |
Method and device for producing laminated composite
Abstract
A polyolefin resin drawn sheet 4 is laminated on at least one
face of a sheet-form core material 6 having a density of 30 to 300
kgf/m.sup.3. At this time, a sheet or film 5 made of a bonding
synthetic resin or rubber having a flow starting temperature lower
than the thermal deformation temperature of the core material 6 and
the melting point of the drawn sheet 4 is interposed between the
core material 6 and the drawn sheet 4. The resultant stack product
is heated to not less than the flow starting temperature of the
synthetic resin or the rubber and not more than the thermal
deformation temperature of the core material 6 and the melting
point of the drawn sheet 4. At the same time of or after the
heating, the stack product is pressed to apply a compression strain
of 0.01 to 10% to the core material 6.
Inventors: |
Tsujimoto, Michitaka;
(Kyoto, JP) ; Matsuzaka, Katsuo; (Kyoto, JP)
; Yamaguchi, Koji; (Kyoto, JP) ; Okabe,
Masashi; (Kyoto, JP) ; Hirata, Masanori;
(Osaka, JP) ; Ishiyama, Masafumi; (Kyoto,
JP) |
Correspondence
Address: |
RADER FISHMAN & GRAUER PLLC
LION BUILDING
1233 20TH STREET N.W., SUITE 501
WASHINGTON
DC
20036
US
|
Assignee: |
SEKISUI Chemical Co., Ltd.
|
Family ID: |
27346590 |
Appl. No.: |
11/149280 |
Filed: |
June 10, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11149280 |
Jun 10, 2005 |
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10343380 |
Jan 31, 2003 |
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10343380 |
Jan 31, 2003 |
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PCT/JP02/04008 |
Apr 23, 2002 |
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Current U.S.
Class: |
156/324 |
Current CPC
Class: |
B32B 27/08 20130101;
B32B 2038/0028 20130101; B32B 2037/148 20130101; Y10T 156/1712
20150115; B32B 5/18 20130101; B32B 2307/516 20130101; B32B 37/08
20130101; B32B 2307/306 20130101; B32B 37/04 20130101; B32B 38/0036
20130101; B32B 2471/04 20130101; B32B 2307/748 20130101; B32B
2037/243 20130101; B32B 37/1207 20130101; B32B 2305/022 20130101;
B32B 38/1816 20130101; B32B 27/32 20130101 |
Class at
Publication: |
156/324 |
International
Class: |
B65H 001/08; B65C
009/25; C09J 005/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 23, 2001 |
JP |
2001-124770 |
Jun 5, 2001 |
JP |
2001-169785 |
Mar 1, 2002 |
JP |
2002-55953 |
Claims
1.-8. (canceled)
9. A device for producing a laminated composite by laminating a
longitudinal sheet and a lateral sheet on at least one face of a
core material, comprising: core supplying means for supplying the
core material in a longitudinal direction; longitudinal sheet
supplying means for supplying the longitudinal sheet for a face
material in the longitudinal direction onto at least one face of
the core material; lateral sheet supplying means for supplying the
lateral sheet for the face material in a lateral direction onto the
upper or lower face of the longitudinal sheet; and sheet
thermocompression-bonding means for pressing the longitudinal sheet
and the lateral sheet stacked in an orthogonal form against the
core material under heating.
10. A method for producing a laminated composite by laminating a
longitudinal sheet and a lateral sheet on at least one face of a
core material, comprising: a core supplying step of supplying the
core material in a longitudinal direction, a longitudinal sheet
supplying step of supplying the longitudinal sheet for a face
material in the longitudinal direction onto at least one face of
the core material; a lateral sheet supplying step of supplying the
lateral sheet for the face material in a lateral direction onto the
upper or lower face of the longitudinal sheet; and a sheet
thermocompression-bonding step of pressing the longitudinal sheet
and the lateral sheet stacked in an orthogonal form against the
core material under heating.
11. The device for producing a laminated composite according to
claim 9, wherein at a position where the longitudinal sheet starts
to contact a heating roll of the sheet thermocompression-bonding
means the lateral sheet supplying means supplies a cut piece of the
lateral sheet between the heating roll and the longitudinal
sheet.
12. The method for producing a laminated composite according to
claim 10, further comprising: a lateral sheet supplying step of
supplying a cut piece of the lateral sheet between a heating roll
and the longitudinal sheet at a position where the longitudinal
sheet starts to contact the heating roll during the sheet
thermocompression-bonding step.
13. The device for producing a laminated composite according to
claim 9 or 11, wherein the longitudinal sheet supplying means is
means for supplying upper side longitudinal sheets and lower side
longitudinal sheets to be arranged alternatively in the lateral
direction, and the lateral sheet supplying means is means for
supplying plural lateral sheets successively between the upper side
longitudinal sheets and the lower side longitudinal sheets so as to
be arranged in parallel.
14. The method for producing a laminated composite according to
claim 10 or 12, wherein the longitudinal sheet supplying step is a
step of supplying upper side longitudinal sheets and lower side
longitudinal sheets to be arranged alternatively in the lateral
direction, and the lateral sheet supplying step is a step of
supplying plural lateral sheets successively between the upper side
longitudinal sheets and the lower side longitudinal sheets so as to
be arranged in parallel.
15. The device for producing a laminated composite according to
claim 9, 11 or 13, wherein the lateral sheet supplying means
includes an attracting roll set at a position where the
longitudinal sheet starts to contact the heating roll of the sheet
thermocompression-bonding means, and single sheet supplying means
for supplying cut pieces of the lateral sheet one by one to the
attracting roll.
16. The method for producing a laminated composite according to
claim 10, 12 or 14, wherein the lateral sheet supplying step
includes a single sheet supplying step of supplying cut pieces of
the lateral sheet one by one to an attracting roll set at a
position where the longitudinal sheet starts to contact the heating
roll during the sheet thermocompression-bonding step.
17. A device producing a laminated composite by laminating a
longitudinal sheet and a lateral sheet on at least one face of a
core material, comprising: core material supplying means for
supplying the core material in a longitudinal direction;
longitudinal sheet supplying means for supplying the longitudinal
sheet for a face material, in the longitudinal direction, onto at
least one face of the core material; first
thermocompression-bonding means for pressing the longitudinal sheet
and the core material under heating to form an intermediate
lamination; first cutting means for cutting the intermediate
lamination; carrying means for carrying cut pieces of the
intermediate lamination in a direction having a given angle to the
longitudinal direction; lateral sheet supplying means for supplying
the lateral sheet for the face material, in the carriage direction,
onto the upper face or the lower face of the cut pieces; second
thermocompression-bonding means for pressing the cut pieces of the
intermediate lamination and the lateral sheet, which are stacked,
under heating to form a final lamination; and second cutting means
for cutting the final lamination.
18. A method for producing a laminated composite by laminating a
longitudinal sheet and a lateral sheet on at least one face of a
core material, comprising: a core material supplying step of
supplying the core material in a longitudinal direction; a
longitudinal sheet supplying step of supplying the longitudinal
sheet for a face material, in the longitudinal direction, onto at
least one face of the core material; a first
thermocompression-bonding step of pressing the longitudinal sheet
and the core material under heating to form an intermediate
lamination; a first cutting step of cutting the intermediate
lamination; a carrying step of carrying cut pieces of the
intermediate lamination in a direction having a given angle to the
longitudinal direction; a lateral sheet supplying step of supplying
the lateral sheet for the face material, in the carriage direction,
onto the upper face or the lower face of the cut pieces; a second
thermocompression-bonding step of stacking and pressing the cut
pieces of the intermediate lamination and the lateral sheet under
heating to form a final lamination; and a second cutting step of
cutting the final lamination.
19. A device for producing a laminated composite by laminating a
longitudinal sheet and a lateral sheet on at least one face of a
core material, comprising: core material supplying means for
supplying the core material in a longitudinal direction;
longitudinal sheet supplying means for supplying the longitudinal
sheet for a face material, in the longitudinal direction, onto at
least one face of the core material; first
thermocompression-bonding means for pressing the longitudinal sheet
and the core material under heating to form an intermediate
lamination; first cutting means for cutting the intermediate
lamination; carrying means for rotating cut pieces of the
intermediate lamination at an angle of 90.degree. to carry the cut
pieces in the longitudinal direction; lateral sheet supplying means
for supplying the lateral sheet for the face material, in the
longitudinal direction, onto the upper face or the lower face of
the cut pieces; second thermocompression-bonding means for pressing
the cut pieces of the intermediate lamination and the lateral
sheet, which are stacked, under heating to form a final lamination;
and second cutting means for cutting the final lamination.
20. A method for producing a laminated composite by laminating a
longitudinal sheet and a lateral sheet on at least one face of a
core material, comprising: a core material supplying step of
supplying the core material in a longitudinal direction; a
longitudinal sheet supplying step of supplying the longitudinal
sheet for a face material, in the longitudinal direction, onto at
least one face of the core material; a first
thermocompression-bonding step of pressing the longitudinal sheet
and the core material under heating to form an intermediate
lamination; a first cutting step of cutting the intermediate
lamination; a carrying step of rotating cut pieces of the
intermediate lamination at an angle of 90.degree. to carry the cut
pieces in the longitudinal direction; a lateral sheet supplying
step of supplying the lateral sheet for the face material, in the
longitudinal direction, onto the upper face or the lower face of
the cut pieces; a second thermocompression-bonding step of stacking
and pressing the cut pieces of the intermediate lamination and the
lateral sheet under heating to form a final lamination; and a
second cutting step of cutting the final lamination.
Description
TECHNICAL FIELD
[0001] The present invention relates to a method and a device for
producing a laminated composite which is used as a civil
engineering and construction material, a construction material
including a tatami mat core material, a material for vehicles and
so on, and has a high rigidity, and more specifically to a device
and a method for producing a laminated composite which is suitable,
for example, when a polyolefin resin drawn sheet is laminated on at
least one face of a sheet-form core material having a density of 30
to 300 kg/m.sup.3, or when a longitudinal sheet and a lateral sheet
are laminated on at least one face of a core material.
[0002] Throughout the present specification, longitudinal and
lateral directions are defined on the basis of the direction of a
core material. The term "longitudinal" means the length direction
of a core material, and the term "lateral" means the width
direction of the core material. A longitudinal sheet means a sheet
supplied in the length direction of a core material, and a lateral
sheet means a sheet supplied in the width direction of the core
material.
BACKGROUND ART
[0003] For a civil engineering and construction material, a
construction material including a tatami mat core material, a
material for vehicles, and the like, the so-called sandwich
structure in which a plastic foamed body is used as a light core
material and high-strength face materials are laminated on both
surfaces thereof, has been actively developed as a material instead
of a woody board which has been conventionally used. For example,
Japanese Unexamined Patent Publication No. 6-134913 (1994)
describes a laminated product wherein a polypropylene foamed body
sheet is sandwiched between glass fiber reinforced polypropylene
type resin layers, and also describes, as a method for producing
the same, a method of heating a glass fiber reinforced
polypropylene layer to not less than the melting point thereof to
be made into a melting state, stacking this with a surface of a
foamed body sheet, adhering them to each other to melt the surface
of the foamed body sheet with heat which the polypropylene layer
has, thereby melting and adhering the two to each other, and
subsequently cooling and solidifying the two so as to be integrated
with each other.
[0004] The present inventors advanced the development of a sandwich
structure as described above. As a result, the inventors suggested
a composite lamination wherein a reinforcing face material made of
a polyolefin resin drawn sheet drawn up 10 times or more is
laminated on a polyolefin resin foamed body sheet (an example of a
sheet-form core material having a density of 30 to 300 kg/M.sup.3)
(Japanese Patent Application No. 2001-13553). This composite
lamination has the following advantages as compared with the
product described in Japanese Unexamined Patent Publication No.
6-134913 (1994):
[0005] Since no glass fiber is used, the lamination is friendly to
working environment and friendly to use environment;
[0006] Since the material thereof is made only of the polyolefin
resin, the lamination can be re-melted or re-worked and can be
recycled; and
[0007] The composite lamination deforms plastically in a certain
bending strain area, and the shape thereof is kept.
[0008] However, if the reinforcing face material is heated to the
melting point thereof or higher in order to attempt the production
of this composite lamination by the method described in Japanese
Unexamined Patent Publication No. 6-134913 (1994), the drawn
orientation of the molecules is lost since the reinforcing face
material is made of the polyolefin resin drawn sheet. As a result,
desired flexural-rigidity and linear expansion property cannot be
obtained.
[0009] The laminating described above is usually controlled by
laminating-pressure. However, the compression property of the
foamed body varies dependently on laminating-temperature;
therefore, it is necessary to change the laminating-pressure
dependently on the temperature. Furthermore, a problem that the
thickness of manufactured product is scattered arises.
[0010] In recent years, in the field of house design, attention has
been paid to the so-called barrier-free housing, wherein no step is
present between a Japanese-style room and a Western-style room, as
housing of a compromise type between Japanese and Western styles.
However, conventional tatami mats (thick tatami mats) used in
Japanese-style rooms have a thickness of approximately 55 mm;
therefore, in order to remove a step between a Japanese-style room
and a Western-style room using flooring materials for western-style
rooms, the main current thickness of which is from approximately 5
to 20 mm, it is necessary to take measures in construction work,
for example, lower the ground-beam sleeper of the Japanese-style
room or increase the bulk of a floor bed of the Western room. Thus,
a problem that construction work becomes much complicated is
involved.
[0011] In order to cope with the above-mentioned problem, in recent
years thin tatami mats having a thickness of approximately 7 to 25
mm have been commercially available instead of the conventional
thick tatami mats. The thin tatami mats have advantages that
application thereof is easy and exchange between a Japanese-style
room and a Western-style room can easily be performed.
[0012] The performance required for the tatami mat material for
thin tatami mats is that the material has flexural-rigidity even if
the material is thin, and the linear expansion coefficient thereof
is as small as possible. Specifically, as described in the
specification of Japanese Patent Application No.13-33990 (2001), a
tatami mat core material made of a laminated composite satisfying
the above-mentioned requirements can be produced by laminating a
sheet, for a face material, made of a polyolefin resin drawn sheet
having a linear expansion coefficient of 5.times.10.sup.-5
(1/.degree. C.) or less on at least one face of a core material
made of a polyolefin foamed body sheet in which cells extend in a
spindle form in the thickness direction.
[0013] In order to exhibit the performance of the above-mentioned
laminated composite at maximum, it is preferred to cross sheets for
a face material which laminate on a surface of a core material (C)
in the longitudinal direction and in the lateral direction, as
illustrated in FIG. 4. This is because the face material is
composed of longitudinal sheets (S1) and lateral sheets (S2) in an
orthogonal form in this way, whereby anisotropy in the longitudinal
direction and the lateral direction is cancelled.
[0014] In order to laminate sheets for a face material, in a
longitudinally and laterally orthogonal-form, beforehand on a core
material, it has been necessary in the conventional art to set
longitudinal sheets and lateral sheets in an orthogonal form on a
surface of the core material and then thermally melt and adhere
them with a press or bond them with an adhesive agent. In this
method, however, the operation for producing the lamination is
intermittent; therefore, the speed of the production is small and a
large amount of scrap material is generated and production
efficiency is low, thereby resulting in high costs.
[0015] In light of the problems in the conventional art, an object
of the present invention is to provide a method for producing a
composite lamination using no inorganic fiber such as glass fiber
without damaging the performance of a polyolefin resin drawn sheet
and with a high thickness precision.
[0016] In light of the problems in the conventional art, another
object of the present invention is to provide a device and a method
which make it possible to continuously perform an operation for
laminating sheets, for a face material, in a longitudinally and
laterally orthogonal form on a core material and to produce a
tatami core material made of a laminated composite with a high
production efficiency.
DISCLOSURE OF THE INVENTION
[0017] The invention of claim 1 is a method for producing a
laminated composite by laminating a polyolefin resin drawn sheet on
at least one face of a sheet-form core material having a density of
30 to 300 kg/m.sup.3, including:
[0018] interposing, between the core material and the drawn sheet,
a bonding synthetic resin or rubber having a flow starting
temperature lower than the thermal deformation temperature of the
core material and the melting point of the drawn sheet; heating the
synthetic resin or the rubber to not less than the flow starting
temperature and not more than the thermal deformation temperature
of the core material and the melting point of the drawn sheet
before or after the three materials are stacked into a stack
product; and pressing the stack product to apply a compression
strain of 0.01 to 10% to the core material at the same time of or
after the heating.
[0019] The invention of claim 2 is a method for producing a
laminated composite by laminating a polyolefin resin drawn sheet on
at least one face of a sheet-form core material having a density of
30 to 300 kg/m.sup.3, including:
[0020] interposing, between the core material and the drawn sheet,
a sheet or a film made of a bonding synthetic resin or rubber
having a flow starting temperature lower than the thermal
deformation temperature of the core material and the melting point
of the drawn sheet; heating the resultant stack product to not less
than the flow starting temperature of the synthetic resin or the
rubber and not more than the thermal deformation temperature of the
core material and the melting point of the drawn sheet; and
pressing the stack product to apply a compression strain of 0.01 to
10% to the core material at the same time of or after the
heating.
[0021] The invention of claim 3 is a method for producing a
laminated composite by laminating a polyolefin resin drawn sheet on
at least one face of a sheet-form core material having a density of
30 to 300 kg/m.sup.3, including:
[0022] coating or impregnating a face to be bonded of the core
material and/or the drawn sheet with a bonding synthetic resin or
rubber having a flow starting temperature lower than the thermal
deformation temperature of the core material and the melting point
of the drawn-sheet; heating the synthetic resin or the rubber to
not less than the flow starting temperature thereof and not more
than the thermal deformation temperature of the core material and
the melting point of the drawn sheet before or after the core
material and the drawn sheet are stacked into a stack product; and
pressing the stack product to apply a compression strain of 0.01 to
10% to the core material at the same time of or after the
heating.
[0023] The invention of claim 4 is a method for producing a
laminated composite by laminating a polyolefin resin drawn sheet on
at least one face of a sheet-form core material having a density of
30 to 300 kg/m.sup.3, including:
[0024] coating or impregnating a face to be bonded of the core
material and/or the drawn sheet with a bonding synthetic resin or
rubber having a flow starting temperature lower than the thermal
deformation temperature of the core material and the melting point
of the drawn sheet; stacking the core material and the drawn sheet
into a stack product so as to contact each other in the coated face
or impregnated face; heating the resultant stack product to not
less than the flow starting temperature of the synthetic resin or
the rubber and not more than the thermal deformation temperature of
the core material and the melting point of the drawn sheet; and
pressing the stack product to apply a compression strain of 0.01 to
10% to the core material at the same time of or after the
heating.
[0025] The invention of claim 5 is the method for producing a
laminated composite according to any of claims 1 to 4, wherein when
the shrinkage starting temperature of the drawn sheet at the time
of the heating is lower than the heating temperature at the time of
the laminating, the laminating is performed while a tension of 0.1
to 3 kgf/1 cm-width is applied to the sheet in the orientation
direction of the sheet.
[0026] The invention of claim 6 is the method for producing a
laminated composite according to any of claims 1 to 5, wherein the
draw magnification of the sheet is from 5 to 40 times.
[0027] The invention of claim 7 is the method for producing a
laminated composite according to any of claims 1 to 6, wherein the
core material is a resin foamed body in which the average of aspect
ratios (Dz/Dxy) of cells is from 1.1 to 4.0.
[0028] The invention of claim 8 is the method for producing a
laminated composite according to any of claims 1 to 7, wherein as
the polyolefin resin drawn sheet, there is used a drawn sheet
having a face to be bonded being at least locally heated and melted
at a temperature higher than the melting point of the resin by
10.degree. C. or more or being roughened.
[0029] The invention of claim 9 is a device for producing a
laminated composite by laminating a longitudinal sheet and a
lateral sheet on at least one face of a core material, including: a
core supplying means for supplying the core material in a
longitudinal direction; a longitudinal sheet supplying means for
supplying the longitudinal sheet for a face material in the
longitudinal direction onto at least one face of the core material;
a lateral sheet supplying means for supplying the lateral sheet for
the face material in a lateral direction onto the upper or lower
face of the longitudinal sheet; and a sheet
thermocompression-bonding means for pressing the longitudinal sheet
and the lateral sheet stacked in an orthogonal form against the
core material under heating.
[0030] The invention of claim 10 is a method for producing a
laminated composite by laminating a longitudinal sheet and a
lateral sheet on at least one face of a core material, including: a
core supplying step of supplying the core material in a
longitudinal direction, a longitudinal sheet supplying step of
supplying the longitudinal sheet for a face material in the
longitudinal direction onto at least one face of the core material;
a lateral sheet supplying step of supplying the lateral sheet for
the face material in a lateral direction onto the upper or lower
face of the longitudinal sheet; and a sheet
thermocompression-bonding step of pressing the longitudinal sheet
and the lateral sheet stacked in an orthogonal form against the
core material under heating.
[0031] The invention of claim 11 is the device for producing a
laminated composite according to claim 9, wherein at a position
where the longitudinal sheet starts to contact a heating roll of
the sheet thermocompression-bonding means the lateral sheet
supplying means supplies a cut piece of the lateral sheet between
the heating roll and the longitudinal sheet.
[0032] The invention of claim 12 is the method for producing a
laminated composite according to claim 10, further including: a
lateral sheet supplying step of supplying a cut piece of the
lateral sheet between a heating roll and the longitudinal sheet at
a position where the longitudinal sheet starts to contact the
heating roll during the sheet thermocompression-bonding step.
[0033] The invention of claim 13 is the device for producing a
laminated composite according to claim 9 or 11, wherein the
longitudinal sheet supplying means is a means for supplying upper
side longitudinal sheets and lower side longitudinal sheets to be
arranged alternatively in the lateral direction, and the lateral
sheet supplying means is a means for supplying plural lateral
sheets successively between the upper side longitudinal sheets and
the lower side longitudinal sheets so as to be arranged in
parallel.
[0034] The invention of claim 14 is the method for producing a
laminated composite according to claim 10 or 12, wherein the
longitudinal sheet supplying step is a step of supplying upper side
longitudinal sheets and lower side longitudinal sheets to be
arranged alternatively in the lateral direction, and the lateral
sheet supplying step is a step of supplying plural lateral sheets
successively between the upper side longitudinal sheets and the
lower side longitudinal sheets so as to be arranged in
parallel.
[0035] The invention of claim 15 is the device for producing a
laminated composite according to claim 9, 11 or 13, wherein the
lateral sheet supplying means includes an attracting roll set at a
position where the longitudinal sheet starts to contact the heating
roll of the sheet thermocompression-bonding means, and single sheet
supplying means for supplying cut pieces of the lateral sheet one
by one to the attracting roll.
[0036] The invention of claim 16 is the method for producing a
laminated composite according to claim 10, 12 or 14, wherein the
lateral sheet supplying step includes a single sheet supplying step
of supplying cut pieces of the lateral sheet one by one to an
attracting roll set at a position where the longitudinal sheet
starts to contact the heating roll during the sheet
thermocompression-bonding step.
[0037] The invention of claim 17 is a device producing a laminated
composite by laminating a longitudinal sheet and a lateral sheet on
at least one face of a core material, including: a core material
supplying means for supplying the core material in a longitudinal
direction; a longitudinal sheet supplying means for supplying the
longitudinal sheet for a face material, in the longitudinal
direction, onto at least one face of the core material; a first
thermocompression-bonding means for pressing the longitudinal sheet
and the core material under heating to form an intermediate
lamination; a first cutting means for cutting the intermediate
lamination; a carrying means for carrying cut pieces of the
intermediate lamination in a direction having a given angle to the
longitudinal direction; a lateral sheet supplying means for
supplying the lateral sheet for the face material, in the carriage
direction, onto the upper face or the lower face of the cut pieces;
a second thermocompression-bonding means for pressing the cut
pieces of the intermediate lamination and the lateral sheet, which
are stacked, under heating to form a final lamination; and a second
cutting means for cutting the final lamination.
[0038] The invention of claim 18 is a method for producing a
laminated composite by laminating a longitudinal sheet and a
lateral sheet on at least one face of a core material, including: a
core material supplying step of supplying the core material in a
longitudinal direction; a longitudinal sheet supplying step of
supplying the longitudinal sheet for a face material, in the
longitudinal direction, onto at least one face of the core
material; a first thermocompression-bonding step of pressing the
longitudinal sheet and the core material under heating to form an
intermediate lamination; a first cutting step of cutting the
intermediate lamination; a carrying step of carrying cut pieces of
the intermediate lamination in a direction having a given angle to
the longitudinal direction; a lateral sheet supplying step of
supplying the lateral sheet for the face material, in the carriage
direction, onto the upper face or the lower face of the cut pieces;
a second thermocompression-bonding step of stacking and pressing
the cut pieces of the intermediate lamination and the lateral sheet
under heating to form a final lamination; and a second cutting step
of cutting the final lamination.
[0039] The invention of claim 19 is a device for producing a
laminated composite by laminating a longitudinal sheet and a
lateral sheet on at least one face of a core material, including: a
core material supplying means for supplying the core material in a
longitudinal direction; a longitudinal sheet supplying means for
supplying the longitudinal sheet for a face material, in the
longitudinal direction, onto at least one face of the core
material; a first thermocompression-bonding means for pressing the
longitudinal sheet and the core material under heating to form an
intermediate lamination; a first cutting means for cutting the
intermediate lamination; a carrying means for rotating cut pieces
of the intermediate lamination at an angle of 900 to carry the cut
pieces in the longitudinal direction; a lateral sheet supplying
means for supplying the lateral sheet for the face material, in the
longitudinal direction, onto the upper face or the lower face of
the cut pieces; a second thermocompression-bonding means for
pressing the cut pieces of the intermediate lamination and the
lateral sheet, which are stacked, under heating to form a final
lamination; and a second cutting means for cutting the final
lamination.
[0040] The invention of claim 20 is a method for producing a
laminated composite by laminating a longitudinal sheet and a
lateral sheet on at least one face of a core material, including: a
core material supplying step of supplying the core material in a
longitudinal direction; a longitudinal sheet supplying step of
supplying the longitudinal sheet for a face material, in the
longitudinal direction., onto at least one face of the core
material; a first thermocompression-bonding step of pressing the
longitudinal sheet and the core material under heating to form an
intermediate lamination; a first cutting step of cutting the
intermediate lamination; a carrying step of rotating cut pieces of
the intermediate lamination at an angle of 900 to carry the cut
pieces in the longitudinal direction; a lateral sheet supplying
step of supplying the lateral sheet for the face material, in the
longitudinal direction, onto the upper face or the lower face of
the cut pieces; a second thermocompression-bonding step of stacking
and pressing the cut pieces of the intermediate lamination and the
lateral sheet under heating to form a final lamination; and a
second cutting step of cutting the final lamination.
[0041] The inventions of claims 1 to 8 are carried out as the
following embodiments.
[0042] First, the sheet-form core material having a density of 30
to 300 kg/m.sup.3, which constitutes the composite lamination
according to the present invention, will be described.
[0043] The sheet-form core material having a density of 30 to 300
kg/.sup.3 is made of, for example, a foamed body obtained by
expanding a resin sheet, a hollow body such as plastic corrugated
cardboard, or a honeycomb structure.
[0044] The reason why the density is from 30 to 300 kg/m.sup.3 is
that: if the density is over 300kg/m.sup.3, the effect of making
the laminated composite light is small; and if the density is less
than 30 kg/m.sup.3, required strength cannot be obtained.
[0045] In general, the thickness of the sheet-form core material is
set to 1 to 40 mm. If the thickness is over 40 mm, mechanical
properties of the composite lamination lower unfavorably. If the
thickness is less than 1 mm, the occupation ratio of the laminated
polyolefin sheet becomes large and it cannot be expected to make
the laminated composite light. The thickness of the core material
is preferably from 3 to 20 mm.
[0046] The material used in the formation of the core material is
thermoplastic resin, thermosetting resin, paper, metal, or the
like.
[0047] Examples of the thermoplastic resin include polyolefin
resin, polystyrene resin, ABS resin, vinyl chloride resin, vinyl
chloride copolymer, vinylidene chloride resin, polyamide resin,
polycarbonate resin, polyethylene terephthalate resin, polyimide
resin, and polyurethane resin. These may be used alone or in
combination of two or more thereof.
[0048] Examples of the thermosetting resin include urethane resin,
unsaturated polyester resin, epoxy resin, phenol resin, melamine
resin, urea resin, diallylphthalate resin, and xylene resin.
[0049] The material which makes the honeycomb may be paper or metal
such as aluminum besides thermoplastic resin or thermosetting
resin.
[0050] Among the above-mentioned materials, thermoplastic resin is
more preferred as the material of the core material. The core
material made of thermoplastic resin is advantageous for recycle
since it can be reworked by being remelted. Particularly preferred
is a core material made of polyolefin resin. When polyolefin resin
is also used as the material of a reinforcing sheet, recycle can be
easily attained.
[0051] As the core material having a density of 30 to 300
kg/m.sup.3, a foamed body made of polyolefin resin is most
preferred; therefore, the present invention will be described in
detail, giving a polyolefin resin foamed body as an example.
[0052] The kind of polyolefin resin is not particularly limited if
it is made of a homopolymer of a monomer, or a copolymer. For
example, the following can be preferably used: polyethylenes such
as low density polyethylene, high density polyethylene, and linear
low density polyethylene; polypropylenes such as propylene
homopolymer, propylene random polymer, and propylene block polymer;
polybutene; and copolymers made mainly of ethylene, such as
ethylene-propylene copolymer, ethylene-propylene-diene terpolymer,
ethylene-butene copolymer, ethylene-vinyl acetate copolymer, and
ethylene-acrylate copolymer. Polyethylene and polypropylene are
particularly preferably used. These polyolefin resins may be used
alone or in combination of two or more thereof.
[0053] The above-mentioned polyolefin resin may be a polyolefin
resin composition in which to polyolefin resin is added less than
30% by weight of a resin different therefrom is added. The kind of
the different resin is not particularly limited, and examples
thereof include polystyrene and styrene type elastomers. These
different resins may be used alone or in combination of two or more
thereof.
[0054] If the amount of the different resin added to polyolefin
resin is 30% by weight or more, superior properties that polyolefin
resin has, such as lightness, chemical resistance, flexibility, and
elasticity, maybe damaged. It maybe difficult to ensure melting
viscosity necessary when the composition foams.
[0055] Furthermore, the above-mentioned polyolefin resin may be a
polyolefin resin composition to which a modifying monomer is added.
The kind of the modifying monomer is not particularly limited, and
examples thereof include dioxime compounds, bismaleimide compounds,
divinylbenzene, allyl-based polyfunctional monomers, (meth)acrylic
polyfunctional monomers, and quinine compounds. These
modifying-monomers may be used alone or in combination of two or
more thereof.
[0056] In general, polyolefin resin has a low elasticity modulus.
When the resin is made up to a foamed body, the foamed body has a
low compression elasticity modulus, and is weak for the core
material of a laminated composite. Therefore, the resin has a
problem that the expansion ratio thereof cannot be raised to a
necessary value. However, this problem can be solved by orienting
the shape of foams in the foamed body into a spindle shape along
the thickness direction. Specifically, the average value of the
aspect ratios (Dz/Dxy) of cells (foams) is from 1.1 to 4.0,
preferably from 1.3 to 2.5.
[0057] FIG. 1(a) is a perspective view illustrating a foamed body
sheet as a sheet-form core material, and FIG. 1(b) is an enlarged
view of an A portion in FIG. 1(a). The average value of the aspect
ratios (Dz/Dxy) means the number (arithmetic) average of the ratios
between the maximum diameters in given directions of cells (204)
inside a foamed body sheet (201), and can be measured by a method
described below.
[0058] Method of Measuring the Average Value of the Aspect Ratios
(Dz/Dxy):
[0059] An enlarged photograph is taken of an arbitrary section
(201a) parallel to the sheet thickness direction (called the z
direction) of the foamed body sheet (201) with 10 magnifications.
Approximately 50 or more cells (204) selected at random, the
decided-direction maximum diameters thereof are measured in two
directions described below. The number (arithmetic) average of the
respective aspect ratios (Dz/Dxy) is calculated.
[0060] Dz: the maximum diameter parallel to the Z direction of the
cells (204) in the foamed body sheet (201), and
[0061] Dxy: the maximum diameter parallel to the plane direction
(called the xy direction) perpendicular to the z direction of the
cells (204) in the foamed body sheet (201) (for example, the sheet
width direction or the sheet length direction).
[0062] By setting the average value of the aspect ratios (Dz/Dxy)
to 1.1 to 4.0 (preferably, 1.3 to 2.5), the cells (204) in the
foamed body sheet (201) become spindle-shaped cells (204) having a
long axis along the thickness direction of the foamed body sheet
(201). Accordingly, in the case that the foamed body sheet (201)
receives compressive force in the thickness direction, the
compressive force is applied to the spindle-shaped cells (204)
along the long axis thereof. Therefore, the foamed body sheet (201)
can exhibit a high compressive strength (compressive elasticity
module) in the thickness direction.
[0063] If the average value of the aspect ratios (Dz/Dxy) is less
than 1.1, the shape of the cells (204) becomes spherical so that
the effect of improving the compressive strength (compressive
elasticity module) resulting from the spindle-shaped cells (204)
cannot be sufficiently obtained. Therefore, the flexural-rigidity
of the composite lamination, which is a target of the present
invention, gets small. Contrarily, if the average value of the
aspect ratios (Dz/Dxy) is more than 4.0, the foaming resin receives
a considerable quantity of extension strain only in the z direction
so that the control of foaming becomes difficult. As a result, a
homogeneous foamed body sheet is not easily produced.
[0064] The density of the foamed body sheet is preferably from 30
to 300 kg/m.sup.3. If the density exceeds 300 kg/m.sup.3, the
weight of the target composite lamination gets large and the cost
thereof becomes high. Thus, the practicability thereof
deteriorates. Contrarily, if the density of the foamed body sheet
is less than 30 kg/m.sup.3, the thickness of the cell walls gets
small so that the compressive force (compressive elasticity
modulus) becomes insufficient.
[0065] Method of Measuring the Density:
[0066] A sample is cut out from the foamed body sheet with a
cutter, and then the weight of the sample is measured.
[0067] Next, the volume thereof is measured with a buoyancy gauge,
and the density is calculated on the basis of the weight/the
volume.
[0068] The method for producing a foamed body sheet having
spindle-shaped cells as described above is not particularly
limited. From the standpoint of recycle ability and productivity,
the following method can be preferably used.
[0069] In general, a foamed body made of a polyolefin resin
composition is roughly classified into a foamed body obtained by a
chemically foaming method and a foamed body obtained by a physical
foaming method. In the present invention, any one of the two foamed
bodies may be used. Preferably, the foamed body obtained by a
chemically foaming method, which is easy in foaming operation
thereof, is used.
[0070] The foamed body sheet by a chemically foaming method can be
produced by dispersing a thermolysis type chemically foaming agent,
which generates decomposition gas by heating, in the polyolefin
resin composition beforehand, shaping the same composition once
into a sheet-form foaming original fiber, and subsequently heating
the fiber to cause the polyolefin resin composition to foam by gas
generated from the foaming agent.
[0071] The kind of the thermolysis type chemically foaming agent is
not particularly limited. For example, the following is preferably
used: azodicarbonic amide (ADCA), benzenesulfonylhydrazide,
dinitrosopentamethylenetetramine, toluenesulfonylhydrazide,
4,4-oxybis(benzenesulfonylhydrazide) or the like. Among these
compounds, ADCA is more preferred. These thermolysis type
chemically foaming agents may be used alone or in combination of
two or more thereof.
[0072] The foamed body sheet by a physical foaming method can be
produced by dissolving a physically foaming agent once in the
polyolefin resin composition under a high pressure, and causing the
polyolefin resin composition to foam by gas generated when the
temperature of the same composition is returned to ambient
temperature.
[0073] The kind of the physically foaming agent is not particularly
limited. For example, water, carbon dioxide, nitrogen, an organic
solvent or the like is preferably used. These physically foaming
agents may be used alone or in combination of two or more
thereof.
[0074] Specific methods for producing the foamed body sheet are as
follows. To 100 parts by weight of a modified polyolefin resin
component obtained by melting and kneading the polyolefin resin as
a main component, the above-mentioned modifying monomer, and the
different resin are added 2 to 20 parts by weight of the
above-mentioned thermolysis type chemically foaming agent, and then
the respective components are dispersed. The composition is once
shaped into a sheet-form to produce a foaming sheet. Thereafter,
this foaming sheet is heated to a temperature not less than the
decomposition temperature of the thermolysis type chemically
foaming agent so as to cause the sheet to foam. By adopting this
method, a desired foamed body sheet can be formed.
[0075] By modifying the polyolefin resin with the modifying
monomer, the shaped foaming sheet can foam under normal pressure
although the sheet has a low crosslinking degree. The crosslinking
degree referred to herein means a gel fraction. The term "the
crosslinking degree is low" means that the gel fraction is 25% or
less by weight. The gel fraction can be obtained as a percentage of
the dry weight of a non-dissolved fraction (a gel fraction) after a
sample is dissolved in hot xylene of 120.degree. C. temperature for
24 hours in the initial weight of the sample.
[0076] The above-mentioned foaming sheet has a lower crosslinking
degree (gel fraction) as compared with crosslink sheets crosslinked
by electron rays or crosslink sheets crosslinked by a thermolysis
type chemically crosslinking agent. Moreover, the above-mentioned
foaming sheet foams under normal pressure by heating. Therefore,
cells in the foamed body get larger and have a larger wall than
cells in the foamed body obtained from the crosslink sheet.
Consequently, the above-mentioned foamed body sheet is superior in
mechanical properties such as compressive force and buckling
resistance.
[0077] Since the foamed body sheet has a small crosslinking degree,
the sheet can be remelted by being heated. Thus, the sheet is rich
in recycle ability. This makes it possible to use the material of
the sheet again or apply the material to some other purpose.
[0078] The method for shaping the foaming sheet is not particularly
limited, and may be any one of shaping methods which are generally
performed to shape plastic, such as extrusion, press forming, blow
molding, calendaring forming and injection molding. Particularly
preferred is an extrusion method of shaping a polyolefin resin
composition extruded from, for example, a screw extruder directly
into a sheet-form since the method is superior in productivity.
This method makes it possible to obtain a continuous foaming sheet
having a constant width.
[0079] The method of producing a foamed body sheet by the
chemically foaming method from the foaming sheet is usually
performed within the temperature range from a temperature not less
than the decomposition temperature of the thermolysis type
chemically foaming agent to a temperature less than the thermal
decomposition temperature of the polyolefin resin.
[0080] The above-mentioned foaming is preferably performed using a
continuous system foaming machine. The method of performing the
foaming using a continuous system foaming machine is not
particularly limited. Examples thereof include a method using a
pulling-in type foaming machine, which causes the foaming sheet to
foam continuously while the foaming sheet is pulled in at the side
of an outlet of a heating furnace, a belt type foaming machine, a
vertical type or horizontal type foaming furnace, or a hot-wind
thermostat; and a method of causing foaming in a hot bath such as
an oil bath, a metal bath or a salt bath.
[0081] The method of setting the average value of the aspect ratios
(Dz/Dxy) of the thus-obtained foamed body sheet to 1.1 to 4.0 is
not particularly limited. Preferred is, for example, a method of
laminating, on at least one face of the foaming sheet which has not
yet foamed, a face material having such a strength that the foaming
strength in the plane direction (the xy direction) of the foaming
sheet, when it foams, can be suppressed.
[0082] By laminating the above-mentioned face material on at least
one face of the foaming sheet which has not yet foamed, foaming in
the two-dimensional direction (the xy direction) in the plane of
the foaming sheet is suppressed when the sheet foams. As a result,
foaming can be caused only in the thickness direction (the z
direction). The cells inside the resultant foamed body sheet become
spindle-shaped cells having a long axis oriented in the thickness
direction.
[0083] The kind of the face material is not particularly limited if
it can resist temperatures not less than the foaming temperature of
the foaming sheet, that is, temperatures not less than the melting
point of the polyolefin resin and temperatures not less than the
decomposition temperature of the thermolysis type chemically
foaming agent. For example, the following is preferably used:
paper, cloth, wood, iron, nonferrous metal, woven fabric or
nonwoven fabric made of organic fiber or inorganic fiber,
cheesecloth, glass fiber, carbon fiber, or a polyolefin resin drawn
sheet, which will be described later. The foamed body sheet may be
obtained by using a sheet having releasing ability, such as a
Teflon sheet, as the face material, causing the foaming sheet to
foam in the thickness direction and subsequently stripping the
releasing sheet.
[0084] However, when the face material made of a material other
than the polyolefin resin is used, the use amount thereof is
preferably made as small as possible from the viewpoint of recycle
ability.
[0085] Among the above-mentioned face materials, nonwoven cloth or
cheesecloth is more preferably used, which is superior in anchor
effect when the polyolefin resin drawn sheet is laminated and
hardly produces a bad effect on the human body or environment.
[0086] The following will describe the polyolefin resin drawn sheet
(referred to as the drawn sheet hereinafter) used in the present
invention.
[0087] The kind of the polyolefin resin used for the production of
the drawn sheet is not particularly limited. Examples thereof
include polyethylenes such as low density polyethylene, high
density polyethylene, and linear low density polyethylene; and
polypropylenes such as propylene homopolymer, propylene random
polymer, and propylene block polymer. In particular, polyethylene
having a high theoretical elasticity modulus is more preferably
used in light of the elasticity modulus thereof after it is drawn.
High density polyethylene having a high crystallinity is most
preferably used. These polyolefin resins may be used alone or in
combination of two or more thereof.
[0088] The weight average molecular weight of the polyolefin resin
for producing the drawn sheet is not particularly limited, and is
preferably from 100000 to 500000. If the weight average molecular
weight of the polyolefin resin is less than 100000, the polyolefin
resin itself gets brittle so that the drawing ability may be
damaged. Contrarily, if the weight average molecular weight of the
polyolefin resin exceeds 500000, the drawing ability deteriorates
so that the drawn sheet may not be easily shaped or drawing with a
high ratio may not be easily performed.
[0089] The method of measuring the weight average molecular weight
is generally the so-called gel permeation chromatography
(high-temperature GPC), wherein the polyolefin resin is dissolved
in a heated organic solvent such as o-dichlorobenzene, the solution
is poured into a column, and then the elution time thereof is
measured. The above-mentioned weight average molecular weight is
also a value measured by the high-temperature GPC using
o-dichlorobenzene as the organic solvent.
[0090] The melt flow rate (MFR) of the polyolefin resin for
producing the drawn sheet is not particularly limited, and is
preferably from 0.1 to 20 g/10 minutes. If the MFR of the
polyolefin resin is less than 0.1 g/10 minutes or exceeds 20 g/10
minutes, drawing with a high ratio may become difficult. The MFR is
measured according to JIS K-7210 Flow Test of Thermoplastic.
[0091] As the polyolefin resin for producing the drawn sheet, there
is particularly preferably used a high density polyethylene having
a weight average molecular weight of 100000 to 500000 and an MFR of
0.1 to 20 g/10 minutes.
[0092] If necessary, it is allowable to add, to the inside of the
drawn sheet, a crosslinking auxiliary, a radical
photopolymerization initiator, or the like besides the polyolefin
resin, which is a main component, as far as the attainment of the
objects of the present invention are not be disturbed.
[0093] Examples of the crosslinking auxiliary include
polyfunctional monomers such as triallyl cyanurate,
trimethylolpropane triacrylate and diallylphthalate. Examples of
the radical photopolymerization initiator include benzophenone,
thioxanthone and acetophenone. These crosslinking auxiliaries or
the radical photopolymerization initiators may be used alone or in
combination of two or more thereof.
[0094] The added amount of the crosslinking auxiliary or the
radical photopolymerization is not particularly limited.
Preferably, the added amount of the crosslinking auxiliary or the
radical photopolymerization is from 1 to 2 parts by weight per 100
parts by weight of the polyolefin resin. If the added amount of the
crosslinking auxiliary or the radical photopolymerization thereof
is less than 1 part by weight per 100 parts by weight of the
polyolefin resin, the crosslinking of the polyolefin resin or the
radical photopolymerization may not advance promptly. Contrarily,
if the added amount of the crosslinking auxiliary or the radical
photopolymerization exceeds 2 parts by weight per 100 parts by
weight of the polyolefin resin, drawing with a high ratio may
become difficult.
[0095] The method of forming the drawn sheet is not particularly
limited. For example, a non-drawn sheet (drawing original fabric)
is first formed by following: melting and kneading a polyolefin
resin composition comprising the polyolefin resin as a main
component, and the crosslinking auxiliary and the radical
photopolymerization, which are optionally added, with an extruder
or the like so as to be made plastic; extruding the melted product
into a sheet-form through a T die; and cooling the extruded
product.
[0096] The thickness of the non-drawn sheet is not particularly
limited, and is preferably from 0.5 to 10 mm. If the thickness of
the non-drawn sheet is less than 0.5 mm, a drawn sheet obtained by
subjecting the non-drawn sheet to drawing treatment becomes tooth
in so that the strength thereof becomes in sufficient. Thus, the
handling performance thereof may be damaged. Contrarily, if the
thickness of the non-drawn sheet exceeds 10 mm, drawing treatment
may become difficult.
[0097] Next, the non-drawn sheet is subjected to drawing treatment
to produce a drawn sheet.
[0098] It is advisable that the draw magnification when the drawing
treatment is performed is set in such a manner that the tensile
elasticity of the drawn sheet will be 5 GPa or more. The draw
magnification is preferably from 5 to 40 times, more preferably
from 10 to 40 times, and still more preferably from 20 to 40 times.
If the drawn ratio is less than 5 times, the tensile elasticity of
the drawn sheet lowers regardless of the kind of the polyolefin
resin or the average linear expansion coefficient thereof, which
will be described later, gets small. As a result, a desired
flexural-rigidity or dimensional stability is not obtained in a
target laminated composite. Contrarily, if the drawn ratio is more
than 40 times, it may be difficult to control the drawing.
[0099] The width of the drawn sheet may be basically arbitrary.
However, if the width is too small, it is necessary to arrange many
sheets when a plane is formed. Thus, the process becomes
complicated and productivity deteriorates. Accordingly, the width
of the drawn sheet is preferably 10 mm or more, more preferably 50
mm or more, and still more preferably 100 mm or more.
[0100] The drawing temperature when the drawing treatment is
performed is not particularly limited, and is preferably from 85 to
120.degree. C. If the drawing temperature is less than 85.degree.
C., the drawn sheet is easily whitened and drawing with a high
ratio may become difficult. Contrarily, if the drawing temperature
exceeds 120.degree. C., the non-drawn sheet is easily cut or
drawing with a high ratio may become difficult.
[0101] The drawing method is not particularly limited, and may be a
conventional monoaxially drawing method. A roll drawing method is
particularly preferred.
[0102] The roll drawing method is a method of sandwiching the
non-drawn sheet between two pairs of drawing rolls, the speed of
the pairs being different, and then pulling the non-drawn sheet
while being heated. The sheet can be molecule-oriented only in a
monoaxially drawing direction. In this case, the speed ratio
between the two pairs becomes equal to the drawn ratio.
[0103] In the case that the thickness of the non-drawn sheet is
relatively large, it may be difficult that smooth drawing is
performed only by the roll drawing method. In such a case, rolling
treatment may be performed before the roll drawing.
[0104] The rolling treatment is performed by inserting, between a
pair of reduction rolls which rotate in opposite directions, the
non-drawn sheet having a thickness larger than the gap between the
reduction rolls to reduce the thickness of the non-drawn sheet and
extent the sheet in the long direction. Since the non-drawn sheet
subjected to the rolling treatment is beforehand oriented in the
monoaxial direction, the sheet is smoothly drawn in the monoaxial
direction by roll drawing in the next step.
[0105] In the drawing step, in order to make the drawing
temperature within a preferred range (85 to 120.degree. C.), it is
advisable to adjust appropriately the pre-heating temperature of
the non-drawn sheet, the temperature of the drawing roll, the
temperature of atmosphere, and the like.
[0106] In order to improve the heat resistance of the thus-obtained
drawn sheet or the heat resistance or the creep resistance of a
composite lamination to be finally obtained, crosslinking treatment
may be performed.
[0107] The kind of the crosslinking treatment is not particularly
limited. For example, the treatment can be performed by electron
beam radiation or ultraviolet ray radiation.
[0108] The quantity of the electron beam radiation in the case that
the crosslinking treatment is performed by the electron beam
radiation may be appropriately set, considering the composition or
the thickness of the drawn sheet, or the like. The quantity is not
particularly limited, and is generally from 1 to 20 Mrad, more
preferably from 3 to 10 Mrad. In the case of the crosslinking
treatment by electron beam radiation, the crosslinking can be
smoothly preformed by adding the crosslinking auxiliary to the
inside of the drawn sheet beforehand.
[0109] The quantity of the ultraviolet ray radiation in the case
that the crosslinking treatment is performed by ultraviolet ray
radiation may be appropriately set, considering the composition or
the thickness of the drawn sheet, or the like. The quantity is not
particularly limited, and is generally from 50 to 800 mW/cm2, more
preferably from 100 to 500 mW/cm.sup.2. In the case of the
crosslinking treatment by ultraviolet ray radiation, the
crosslinking can be smoothly preformed by adding the radical
photopolymerization initiator or the crosslinking auxiliary to the
inside of the drawn sheet beforehand.
[0110] The degree of the crosslinking of the drawn sheet is not
particularly limited, and the above-mentioned gel fraction is
preferably from approximately 50 to 90% by weight.
[0111] Since the drawn sheet is a sheet drawn 5 times or more, the
degree of thermal stretch and shrinkage to temperature change
becomes small. Therefore, by laminating this drawn sheet on the
foamed body sheet, the drawn sheet suppresses thermal stretch and
shrinkage of the foamed body sheet so that dimensional stability
against temperature can be kept in the target composite
lamination.
[0112] One of the numerical values for indicating the degree of the
thermal stretch and shrinkage is an average linear expansion
coefficient.
[0113] The drawn sheet used in the present invention is a sheet
having an average linear expansion coefficient of 5 x
10.sup.-5/.degree. C. or less, preferably
3.times.10.sup.-5/.degree. C. or less, and still more preferably
from -2.times.10.sup.-5 to 2.times.10.sup.-5/.degree. C.
[0114] The average linear expansion coefficient is an index
indicating the rate of expansion of the dimension of an object on
basis of temperature. There is a method in which the dimension of
an object whose temperature is rising is accurately measured in
sequence by TMA (mechanical analysis) in order to measure the
average linear expansion coefficient. However, the dimensions of
the drawn sheet at 5.degree. C. and 80.degree. C. are measured and
the average linear expansion coefficient can be calculated from the
difference therebetween.
[0115] In general, the average linear expansion coefficient of an
object made of the polyolefin resin is larger than
5.times.10.sup.-5/.degree. C. However, by subjecting the resin to
drawing treatment, a drawn sheet having an average linear expansion
coefficient of 5.times.10.sup.-5/.degr- ee. C. or less can be
obtained. As the drawn ratio of this drawn sheet is made larger,
the average linear expansion coefficient thereof is lower.
[0116] About the foamed body sheet, the average linear expansion
coefficient of the polyolefin resin sheet, which makes by itself up
to the sheet, is from approximately 5.times.10.sup.-5 to
15.times.10.sup.-5/.degree. C. Thus, the foamed body sheet has a
problem that a dimensional change based on thermal shrinkage is
large. However, by lamination, on at least one face thereof, the
above-mentioned drawn sheet having an average linear expansion
coefficient of 5.times.10.sup.-5/.degree. C. or less, a laminated
composite which has a small average linear expansion coefficient
and does not cause any dimensional change based on thermal
shrinkage easily can be obtained.
[0117] Since the drawn ratio of the above-mentioned drawn sheet is
made large to set the average linear expansion coefficient thereof
to 5.times.10.sup.-5/.degree. C. or less, the tensile strength
(tensile elasticity) in the drawing direction also becomes large.
Thus, the flexural-strength (bend elastic constant) of the
composite lamination wherein the above-mentioned drawn sheet is
laminated on at least one face of the above-mentioned foamed body
sheet is drastically improved. Thus, a synergetic effect is
generated.
[0118] In the invention of claim 1, the heating of the bonding
synthetic resin or rubber may be performed before or after this is
interposed between the core material and the drawn sheet. For
example, only the synthetic resin or the rubber is heated and
melted with an extruder or the like without heating the core
material nor the drawn sheet, and this is interposed between the
core material and the drawn sheet. Thereafter, this stack product
may be pressed to adhere the layers therein to each other. In the
invention of claim 2, before heating and laminating the core
material and the drawn sheet, the sheet or the film made of the
bonding synthetic resin or rubber, preferably the synthetic resin
film, is interposed between the core material and the drawn
sheet.
[0119] If the synthetic resin film is used, the lamination of the
core material/the synthetic resin film/the drawn sheet can easily
be obtained. The method of interposing the sheet or the film made
of the synthetic resin or the rubber between the core material and
the drawn sheet is not particularly limited, and may be according
to a batch system or a continuous system.
[0120] The inventions of claims 3 and 4, before heating and
pressing the core material and the drawn sheet, the bonding face(s)
of the core material and/or the drawn sheet is/are beforehand
coated or impregnated with the bonding synthetic resin or rubber.
In the case of claim 3, the heating of the synthetic resin or the
rubber may be performed before stacking them.
[0121] By this coating or impregnating treatment, the heating and
pressing of the core material and the drawn sheet can be performed
at a lower pressure for a short time.
[0122] The method of coating the core material with the synthetic
resin or the rubber is not particularly limited, and may be a
generally-used method. Examples thereof include a method of using a
screw extruder or the like to heat the synthetic resin or the
rubber to a temperature not less than the flow starting temperature
thereof so as to be melted, and subsequently roll-coating the core
material with the resultant melted product or lining the core
material with the resultant product by means of a crosshead die;
and a method of compression-bonding a film or a sheet made of the
synthetic resin or the rubber to the core material while heating
the film or the sheet at a temperature not less than the flow
starting temperature thereof and a temperature not more than the
thermal deformation temperature thereof.
[0123] The thermal deformation temperature referred to herein means
a temperature measured by the method described in ASTM D648 (method
of applying a given load to a sample, and obtaining a temperature
showing a given change when temperature is raised at a constant
rate). The flow starting temperature means, in the case of
crystalline resin, the melting point thereof, and means, in the
case of non-crystalline resin, the glass transition temperature
thereof.
[0124] The method of impregnating the core material with the
synthetic resin or the rubber is not particularly limited. As
described above, when the core material is formed, a face material
such as nonwoven fabric or cheesecloth is used in many cases. A
film or a sheet made of the synthetic fiber or the rubber is
beforehand compression-bonded to this plate-material while the film
or the sheet is heated at a temperature not less than the flow
starting temperature thereof. This face material is then
compression-bonded to the core material while this face material is
heated at a temperature not less than the flow starting temperature
of the synthetic resin or the rubber and not more than the thermal
deformation temperature of the core material. In this way, the core
material with the face material impregnated homogeneously with the
synthetic resin or the rubber can be obtained. As described above,
a film or a sheet made of the synthetic resin or the rubber may be
thermocompression-bonded to the face material of the core material
with the face material.
[0125] The method of impregnating the drawn sheet with the
synthetic resin or the rubber is not particularly limited. For
example, by laminating a face material, such as nonwoven fabric or
cheesecloth, having a large anchor effect, and then
compression-bonding a film or sheet made of the synthetic resin or
the rubber to the drawn sheet while heating the film or the sheet
at a temperature not less than the flow starting temperature
thereof, the drawn sheet with the face material impregnated
homogenously with the synthetic resin or the rubber can be
obtained. It is also allowable to thermocompression-bond a film or
a sheet made of the synthetic resin or the rubber to the face
material beforehand, as described above, and thermocompression-bond
this face material to the drawn sheet.
[0126] By using the face material having a large anchor effect in
this way, it is easy to be impregnated with the synthetic resin or
the rubber. As a result, the bonding strength with the polyolefin
resin drawn sheet can be made high.
[0127] In the invention of claim 8, as the polyolefin resin drawn
sheet, there is used a drawn sheet whose face to be bonded is at
least locally heated and melted at a temperature higher than the
melting point of the resin by 10.degree. C. or more or is
roughened.
[0128] Since the polyolefin resin drawn sheet has a highly-oriented
fibrous structure, its surface layer is subjected to melting
treatment in such a manner that the fibrous structure is cancelled
in the surface layer without damaging the strength of the drawn
sheet, in order to improve the bonding property of the synthetic
resin or the rubber, which will be described later.
[0129] In order to melt the surface layer of at least one face of
the polyolefin resin drawn sheet, for example, the drawn sheet is
passed between a first roll having a surface temperature being kept
at a temperature higher than the melting point of the polyolefin
resin of the drawn sheet by +10.degree. C. or higher and a second
roll whose surface temperature is kept at a temperature lower than
the melting point of the polyolefin resin while the drawn sheet is
brought into contact with the rolls. The melting of the surface
layer means melting of only the surface layer of the drawn sheet.
Considering the maintenance of mechanical strength, the surface
layer portion is preferably a portion of 1 to 10% of the total
thickness. By the melting of the surface layer, the fibrous
structure in the surface layer is cancelled.
[0130] The melting treatment is subjected to at least one face of
the drawn sheet. In the drawn sheet wherein only one face thereof
is melted, the melted face exhibits a good bonding property to the
synthetic resin or the rubber. In the drawn sheet wherein two faces
thereof are melted, both the faces exhibit a heightened bonding
property or melting/bonding property to the synthetic resin or the
rubber.
[0131] The surface temperature of the first roll is set to a
temperature higher than the melting point of the polyolefin resin
of the drawn sheet by 10.degree. C. or more. This temperature is
preferably is selected from the range of 10.degree. C. higher than
the melting point to 100.degree. C. higher than the melting point,
more preferably the range of 30.degree. C. higher than the melting
point to 60.degree. C. higher than the melting point. In the case
of temperatures less than a temperature 10.degree. C. higher than
the melting point, the fibrous structure in the surface layer is
not sufficiently cancelled by the melting treatment. Thus, effects
of improving the bonding property and melting property cannot be
sufficiently obtained. In the case of temperature of 100.degree. C.
or more higher than the melting point, it is feared that the
polyolefin resin drawn sheet is melted and bonded to the first
roll.
[0132] As described above, the surface temperature of the second
roll is set to a temperature not more than the melting point of the
polyolefin resin, and is preferably controlled in the range of
0.degree. C. to the melting point of the polyolefin resin, more
preferably in the range of 50.degree. C. to 100.degree. C. If the
surface temperature of the second roll is more than the melting
point of the polyolefin resin, the cooling effect based on the
second roll is insufficient. Thus, it is feared that physical
properties of the polyolefin resin drawn sheet drop. If the surface
temperature of the second roll is lower than 0.degree. C., water
content condensates and adheres onto the roll so that proper roll
processing may become difficult.
[0133] The melting point of the polyolefin resin is measured by
thermal analysis such as differential scanning calorimeter (DSC),
and means the maximum value of endothermic peaks which follow
crystal melting.
[0134] The polyolefin resin drawn sheet may be a sheet whose face
to be bonded is roughened. By the roughening, the bonding property
to the synthetic resin or the rubber is improved and the
above-mentioned coating or impregnation is easily attained. The
method of the roughening is not particularly limited, and examples
thereof include embossing means such as sandblasting.
[0135] The degree of fine irregularities formed by roughening the
surface of the drawn sheet, which is represented as central line
average roughness (Ra) according to JIS B 0601, is preferably 0.5
.mu.m or more. If the Ra is less than 0.5 .mu.m, the roughening
effect may not be sufficiently obtained.
[0136] Another method of reforming the surface is a method of
performing corona treatment to cause the surface to have polarity
and bonding property.
[0137] By melting or roughening the polyolefin resin drawn sheet as
described above, a large number of the drawn sheets can be
laminated through the synthetic resin or the rubber.
[0138] Examples of the bonding synthetic resin or rubber used in
the present invention include thermoplastic resins, thermoplastic
elastomers and rubbery polymers having a flow starting temperature
lower than the thermal deformation temperature of the core material
and the melting point of the polyolefin resin constituting the
drawn sheet. By using the synthetic resin or the rubber having such
a characteristic, only the synthetic resin or the rubber can be
caused to start flowing at a temperature at which the bore material
does not deform thermally and the drawn sheet does not melt.
Without damaging performances such as flexural-rigidity and
dimensional stability, a good bonding strength can be obtained.
When a lower value between the thermal deformation temperature of
the core material and the melting point of the polyolefin resin
constituting the drawn sheet is represented by Tm.sub.lower.degree.
C., the flow starting temperature of the synthetic resin or the
rubber is preferably (Tm.sub.lower-5).degree. C. or less, more
preferably (Tm.sub.lower-10).degree. C. or less.
[0139] The kind of the synthetic resin or the rubber used in the
present invention is not particularly limited if it satisfies the
above-mentioned requirements. Examples thereof include compounds
described below.
[0140] Polyolefin Resins
[0141] Polyethylene (PE): very low density polyethylene (VLDP), low
density polyethylene (LDPE), linear low density polyethylene
(LLDPE), middle density polyethylene (MDPE), and high density
polyethylene (HDPE),
[0142] Polypropylene (PP): homo type polypropylene, random type
polypropylene, and block type polypropylene,
[0143] Polybutene,
[0144] Ethylene-vinyl acetate (EVA),
[0145] Ionomer: metal salts of ethylene-(meth)acrylic acid
copolymer
[0146] Ethylene-(meth)acrylic copolymer: ethylene-acrylic acid
[0147] copolymer (EAA), ethylene-ethyl acrylate copolymer (EEA),
ethylene-methacrylic acid copolymer (EMAA), and ethylene-methyl
methacrylate copolymer (EMMA),
[0148] Modified polyolefin: maleic acid modified polyethylene,
maleic acid modified polypropylene, silane modified polyethylene
and silane modified polypropylene, and
[0149] Chlorinated polyethylene.
[0150] Other Resins
[0151] Bonding polyester resins, and
[0152] Polystyrene.
[0153] Thermosplastic Elastomers
[0154] Styrene-based elastomer:
polystyrene-polybutadiene-polystyrene (SBS),
polystyrene-polyisoprene-polystyrene (SIS),
polystyrene-poly(ethylene-butylene)-polystyrene (SEBS), and
polystyrene-poly(ethylene-propylene)-polystyrene,
[0155] Vinyl chloride based elastomer,
[0156] Polyolefin based elastomer: ethylene-propylene rubber (EPR),
and ethylene-propylene-diene terpolymer (EPDM), and
[0157] Thermoplastic polyurethane.
[0158] Rubbery Polymers
[0159] Natural rubber (NR), isoprene rubber (IR), styrene rubber
(SBR), nitrile rubber (NBR), chloroprene rubber (CR), butadiene
rubber (BR), butyl rubber (IIR), chlorosulfonated polyethylene, and
polyisobutylene (PIB).
[0160] Among these examples, polyolefin based resin, polyolefin
based elastomer or styrene based elastomer is preferably used as a
compound having a good bonding property to the core material and
the drawn sheet made of the polyolefin resin. In particular,
polyolefin base resin is more preferably used.
[0161] Polyolefin based elastomer or styrene based elastomer is
preferably used as a compound having a good bonding property to the
core material and the drawn sheet made of a resin other than the
polyolefin resin. In particular, polyolefin based elastomer is more
preferably used.
[0162] The thickness of the sheet or the film made of the synthetic
resin or the rubber used in the invention of claim 2 and the
thickness of the coating layer of the synthetic resin or the rubber
used in the inventions of claims 3 and 4 are appropriately decided,
considering bonding property thereof. Usually, the thickness is
from approximately 5 .mu.m to 2 mm. If the thickness is less than 5
.mu.m, the bonding property deteriorates. If the thickness exceeds
2 mm, the bending and shear strength drop.
[0163] In the invention of claim 1, the synthetic resin or the
rubber is heated, or the lamination of the core material/the
synthetic resin or the rubber/the drawn sheet is heated. In the
invention of claim 2, the lamination of the core material/the sheet
or the film made of the synthetic resin or the rubber/the drawn
sheet is heated. In the invention of claim 3, the core material
and/or the drawn sheet coated or impregnated with the synthetic
resin or the rubber is/are heated, or the lamination thereof is
heated. In the invention of claim 4, the lamination of the core
material coated or impregnated with the synthetic resin or the
rubber and/or the drawn sheet is heated.
[0164] In all of the inventions, the heating temperature is not
less than the flow starting temperature of the synthetic resin or
the rubber and not more than the thermal deformation temperature of
the core material and the melting point of the drawn sheet. If the
heating temperature is less than the flow starting temperature of
the synthetic resin or the rubber, the melting of the synthetic
resin or the rubber does not advance so that sufficient bonding
force cannot be obtained. If the heating temperature is more the
thermal deformation temperature of the core material or the melting
point of the drawn sheet, the resin constituting the core material
or the drawn sheet melts so that desired mechanical properties
cannot be kept.
[0165] The kind of heating means is not particularly limited, and
examples thereof include hot-window heating, infrared ray heating,
electron beam heating, and contact heating using a heater.
[0166] At the same time of or after the heating, in the invention
of claim 1 the stack product of the core material/the synthetic
resin or the rubber/the drawn sheet is pressed. In the invention of
claim 2, the stack product of the core material/the sheet or the
film made of the synthetic resin or the rubber/the drawn sheet is
pressed. In the inventions of claims 3 and 4, the stack product of
the core material coated or impregnated with the synthetic resin or
the rubber and/or the drawn sheet is pressed.
[0167] In all of the inventions, loaded pressure is a value such
that a compressive strain of 0.01 to 10% is applied to the core
material.
[0168] As an example, FIG. 2 shows a stress-strain (S-S) curve from
a compression test of a foamed body sheet made of the polyolefin
resin used in the present invention. When the temperature changes,
the compressive yield changes. Therefore, it is necessary to change
applied pressure dependently on heating situation. However, the
present inventors have found out that even when the temperature
changes, the compressive elasticity area of the foamed body sheet
hardly changes. Thus, in the present invention, the pressure is not
controlled but displacement in the range of the compressive
elasticity area is changed, thereby performing the above-mentioned
compression. According to this method, even if the heating
temperature or the thickness of the foamed body sheet changes, a
laminated composite having a good thickness precision can be
obtained.
[0169] If the compressive strain is less than 0.01%, sufficient
bonding force cannot be obtained. If it exceeds 10%, it exceeds the
yield point of the foamed body sheet so that the compressive
strength of the foamed body sheet drops or the thickness thereof
does not recover.
[0170] A more specific range of the compressive strain is from 0.01
to 10% about the foamed body sheet of thermoplastic resin and
thermosetting resin, and is from 0.01 to 5% about a hollow body or
a honeycomb structure of thermoplastic resin and thermosetting
resin. Since the hollow body or the honeycomb structure has a lower
yield point than the foamed body sheet, it is preferred to make the
upper limit relatively small.
[0171] The method of controlling the displacement (thickness) is
not particularly limited. Examples of the method as a batch system
include a pressing manner in which stroke is controlled. Examples
thereof as a continuous system include a method of passing the
stack product through rolls whose gas is regulated.
[0172] By performing the pressing at the same time of or after the
heating in this way, the bonding synthetic resin or rubber causes
the foamed body sheet and the drawn sheet to bond to each other.
The pressing time is not particularly limited, and preferably from
0.01 second to 10 minutes. If the pressing time is less than 0.01
second, sufficient bonding force cannot be obtained. If it exceeds
10 minutes, productivity deteriorates unfavorably.
[0173] The heating operation and the pressing operation may be
separately performed, or simultaneously performed. For example, in
the pressing manner using a contact heater according to a batch
system, or the like, the stack production can be pressed while it
is heated from both faces thereof.
[0174] The lamination heated and pressed as described above is
cooled so that the synthesis resin or the rubber is solidified to
produce a composite lamination. The cooling method is not
particularly limited. In the cooling step, it is preferred to press
the lamination within the range of a compressive strain of 0.01 to
10%.
[0175] In the case that the shrinkage starting temperature of the
drawn sheet when it is heated is lower than the heating temperature
when it is laminated, shrinkage is caused so that the form of the
sheet deforms. Therefore, beautiful arrangement is difficult. For
this reason, it is preferred to perform the lamination while a
tension of 0.1 to 3 kgf/1 cm-width in the direction along which the
sheet is oriented is applied to the sheet. This tension varies
dependently on the material thereof or the drawn ratio, and
application of a tension of 0.1 to 3 kgf l cm-width makes the
laminating possible. If the tension is less than 0.1 kgf/1
cm-width, the tension is weak so that the shrinkage cannot be
suppressed. On the other hand, if the tension exceeds 3 kgf/1
cm-width, the tension is too strong so that the holding force of
the heated drawn sheet is not kept. Thus, the sheet is unfavorably
cut.
[0176] The shrinkage starting temperature of the sheet, which is
described above, was measured by a method described below.
[0177] First, the drawn sheet was cut into squares with sides 100
mm long, and the longitudinal and lateral sizes thereof were
measured. Next, the sheets were set in ovens whose temperatures
were set to various temperatures for 40 seconds. The sheets were
taken out and then the sizes of the sheets were measured. The
values of (the size after the heating/the initial size).times.100
(%) were calculated. A temperature at which this became smaller
than 99% was set as the shrinkage starting temperature.
[0178] The shrinkage starting temperature varies dependently on
difference in material, or the drawn ratio thereof. However, in the
case of polyolefin type materials, the shrinkage starting
temperature becomes higher as the drawn ratio is made higher and
the shrinkage starting temperature becomes lower as the drawn ratio
is made lower.
[0179] Relationship between the shrinkage starting temperature and
the heating temperature at the time of the laminating is as
follows:
[0180] (the flow starting temperature of the synthetic resin or the
rubber for bonding the core material and the drawn sheet to each
other)
[0181] <(the heating temperature at the time of the
laminating)
[0182] <(the shrinkage starting temperature of the drawn
sheet)
[0183] <(the thermal deformation temperature of the core
material or the melting temperature of the drawn sheet)
[0184] However, dependently on the kind of the sheet, the following
case may be caused:
[0185] (the flow starting temperature of the synthetic resin or the
rubber for bonding the core material and the drawn sheet to each
other)
[0186] <(the shrinkage starting temperature of the drawn
sheet)
[0187] <(the heating temperature at the time of the
laminating)
[0188] <(the thermal deformation temperature of the core
material or the melting temperature of the drawn sheet)
[0189] In this case, in order to control the shrinking sheet, it is
necessary to apply the above-mentioned tension. When the tension is
weak, the sheet looses up by shrinkage so that the laminating
thereof is not easily performed. When the tension is too strong,
the sheet is cut. The tension applied to the sheet is preferably
from 0.1 to 3 kgf/1 cm-width.
[0190] In the invention of claim 1, the following steps are
performed: the steps of interposing, between the core material and
the drawn sheet, a bonding synthetic resin or rubber having a flow
starting temperature lower than the thermal deformation temperature
of the core material and the melting point of the drawn sheet,
heating the synthetic resin or the rubber to not less than the flow
starting temperature and not more than the thermal deformation
temperature of the core material and the melting point of the drawn
sheet before or after the three materials are stacked into a stack
product, and pressing the stack product to apply a compression
strain of 0.01 to 10% to the core material at the same time of or
after the heating. In the invention of claim 2, the following steps
are performed: the steps of interposing, between the core material
and the drawn sheet, a sheet or a film made of a bonding synthetic
resin or rubber having a flow starting temperature lower than the
thermal deformation temperature of the core material and the
melting point of the drawn sheet, heating the resultant stack
product to not less than the flow starting temperature of the
synthetic resin or the rubber and not more than the thermal
deformation temperature of the core material and the melting point
of the drawn sheet, and pressing the stack product to apply a
compression strain of 0.01 to 10% to the core material at the same
time of or after the heating. Therefore, without deforming or
melting the resin constituting the core material and the drawn
sheet, only the bonding synthetic resin or rubber can be melted and
the core material and the drawn sheet can be laminated on each
other without damaging their physical properties.
[0191] In the inventions of claims 3 and 4, a face to be bonded of
the core material and/or the drawn sheet is coated or impregnated
with a bonding synthetic resin or rubber before heating and
pressing the core material and the drawn sheet. Therefore, the
synthetic resin or the rubber can be homogeneously caused to
penetrate into the body to be bonded (the core material and/or the
drawn sheet). Thus, even if the pressing is performed for a short
time, a sufficient bonding force can be obtained.
[0192] In the invention of claim 5, the laminating is performed
while a tension of 0.1 to 3 kgf/1 cm-width is applied to the sheet
in the orientation direction of the sheet, whereby the laminating
can easily be performed even under conditions that the drawn sheet
shrinks easily.
[0193] In the invention of claim 6, the draw magnification of the
sheet is from 5 to 40 times, whereby a laminated composite having a
necessary rigidity can be realized.
[0194] In the invention of claim 7, the core material is a resin
foamed body in which the average of aspect ratios (Dz/Dxy) of cells
is from 1.1 to 4.0, whereby a light and highly-rigid laminated
composite can be obtained.
[0195] In the invention of claim 8, as the drawn sheet, there is
used a drawn sheet whose face to be bonded is at least locally
heated and melted at a temperature higher than the melting point of
the resin by 10.degree. C. or more or is roughened. Therefore, the
bonding synthetic resin or rubber is liable to be compatible with
the drawn sheet and they are easily bonded to each other by anchor
effect.
[0196] According to the inventions of claims 1 and 2, without
deforming or melting the polyolefin resin constituting the core
material and the drawn sheet, only the bonding synthetic resin or
rubber can be melted and the core material and the drawn sheet can
be laminated on each other without damaging their physical
properties.
[0197] According to the inventions of claims 3 and 4, the synthetic
resin or the rubber can be homogeneously caused to penetrate into
the body to be bonded. Thus, even if the pressing is performed for
a short time, a sufficient bonding force can be obtained.
[0198] According to the invention of claim 5, the laminating can
easily be performed.
[0199] According to the invention of claim 6, a stable laminated
composite can be obtained.
[0200] According to the invention of claim 7, a light and
highly-rigid laminated composite can be obtained.
[0201] According to the invention of claim 8, the bonding synthetic
resin or rubber is liable to be compatible with the drawn sheet and
they are easily bonded to each other by anchor effect.
[0202] The inventions of claims 9 to 20 are carried out as
embodiments described below.
[0203] It is sufficient that the core material has rigidity, and it
is in general preferred that the core material is a board having a
certain measure of thickness, for example, a thickness of 1 mm or
more.
[0204] Examples of the core material board include the
following:
[0205] Boards made of a thermoplastic resin such as polyethylene
resin, polyethylene copolymer resin, ethylene-vinyl acetate
copolymer resin, polypropylene resin, ABS resin, vinyl chloride
resin, vinyl chloride copolymer, vinylidene chloride resin,
polyamide resin, polycarbonate resin, polyethylene terephthalate
resin, polyimide resin, or polyurethane resin. These thermoplastic
resins may be used alone or in a blend form. Of course, the board
may be made light by foaming treatment or the like.
[0206] The core material board may be a board made of both plastic
corrugated cardboard or plastic honeycomb and a face material.
[0207] Boards made of a thermosetting resin such as urethane resin,
unsaturated polyester resin, epoxy resin, phenol resin, melamine
resin, urea resin, diallylphthalate resin, or xylene resin.
[0208] Woody fiber boards, wherein woody fibers are hardened with
an adhesive agent or the like, such as insulation boards (A-class
insulations, tatami-boards, and seizing boards), MDF (middle fiber
plates), and HDF (hard fiber boards); woody chip boards, wherein
woody chips are hardened with an adhesive agent, such as particle
boards; plywood (that is, material obtained by laminating plural
veneer sheets on each other perpendicularly), and veneer sheet
laminated material (that is, material obtained by plural veneer
sheets in parallel); longitudinally spliced material (that is,
material wherein sweeping boards are longitudinally spliced with
finger joints; assembly material (that is, material wherein
sweeping boards are laminated on each other); and woody board
products.
[0209] It is allowable to use boards wherein the above-mentioned
plate material as a face material is sandwiched between paper
honeycombs or metal honeycombs.
[0210] Iron sheets such as melted zinc steel sheets, zinc aluminum
alloy steel sheets, and stainless steel sheets. Nonferrous metal
sheets made of aluminum, titanium, copper or the like.
[0211] In order to improve the bonding property of the core
material to a sheet for face material, which is laminated on this
core material, it is naturally allowable to deposit an adhesive
layer on the core material or the face material sheet beforehand,
or apply an adhesive agent thereto.
[0212] A two-layer type, wherein the core material and the face
material are melted and bonded by heating, is basically used.
Dependently on use, however, an adhesive layer may be interposed
between the core material and the face material.
[0213] Examples of the method for depositing the adhesive layer
include a method of inserting a film, which will be the adhesive
layer, between the core material and the face material sheet,
supplying them between rolls at the same time, and heating and
pressing them; a method of coating, at the time of supplying the
core material and the face material sheet between rolls, at least
one thereof with an adhesive agent by means of a roll coater, a gun
or the like, thereby forming the adhesive layer; and a method of
forming the adhesive layer on at least one of the core material and
the face material sheet beforehand, and heating and pressing them
at the time of being passed between rolls, thereby laminating
them.
[0214] Examples of the film which makes up to the adhesive layer
include films made of linear low density polyethylene resin, middle
density polyethylene resin, very low density polyethylene resin,
ethylene-vinyl acetate copolymer resin, high density polyethylene
resin, polypropylene resin, ionomer resin, EMAA resin, or
polyacrylonitrile resin.
[0215] Examples of the adhesive agent include vinyl acetate resin
emulsion adhesive agents, acrylic emulsion adhesive agents, vinyl
acetate copolymer emulsion adhesive agents, polyvinyl alcohol
adhesive agents, vinyl acetate resin mastic adhesive agents, dope
cements, monomer cements, vinyl chloride resin adhesive agents,
ethylene-vinyl acetate copolymer hot melt adhesive agents,
polyamide type hot melt adhesive agents, polyester type hot melt
adhesive agents, thermoplastic rubber type adhesive agents,
urethane hot melt adhesive agents, chloroprene rubber type adhesive
agents, synthetic rubber type adhesive agents, natural rubber type
adhesive agents, urea resin adhesive agents, melamine resin
adhesive agents, phenol resin adhesive agents, epoxy resin adhesive
agents, and polyurethane type adhesive agents.
[0216] It is sufficient that the face material sheet is a material
flexible along the curvature of rolls in order to embrace the
rolls. A sheet having a small thickness, for example, a sheet
having a thickness of 1 mm or less is preferred. Examples of such a
sheet include sheets described below.
[0217] Sheets which are caused to have anisotropy in mechanical
properties (such as tensile strength and linear expansion
coefficient) by drawing, orientation or the like and made of a
thermoplastic resin such as polyethylene resin, polypropylene
resin, polyester resin, ABS resin, polycarbonate resin, vinyl
chloride resin, acryl-modified vinyl chloride resin, modified
polyproplyeneoxide resin, polycarbonate/ABS resin, modified
polyphenylene ether resin, acrylic resin, or acryl-styrol resin;
glass cloth such as a surface mat obtained by making glass fiber
into a paper form, material obtained by weaving glass robbing (a
binder for bonding glass short fibers to each other may be
contained in the surface mat. Examples of the binder include
thermoplastic resin, such as polyvinyl alcohol resin, saturated
polyester resin, and acrylic resins, and thermosetting resins such
as epoxy resin and unsaturated polyester resin): prepreg sheets,
wherein long fibrous materials are hardened with a resin binder
(examples of the long fiber include glass fiber, carbon fiber,
polyester resin, acrylic fiber, nylon fiber, carbon fiber and
aramide fiber); stampable sheets, which are composite materials
wherein thermosetting resin and a glass long fiber mat are combined
with each other (polypropylene is frequently used as the
thermoplastic resin); cheesecloth, woven fabric or nonwoven fabric,
and needle punch (cheesecloth, woven fabric or nonwoven fabric, and
needle punch are made mainly of synthetic resin fiber of polyester,
nylon or the like. Woven fabric may be ordinary cloth made of
natural fiber or synthetic fiber. Examples of organic fiber
constituting woven fabric or nonwoven fabric include polyester
fiber, cotton, acrylic fiber, nylon fiber, carbon fiber and aramide
fiber); paper or metal sheets (an iron sheet or nonferrous metal
sheets made of aluminum, titanium, copper or the like. Examples of
the iron sheet include a melt zinc steel sheet, a melt zinc
aluminum alloy steel sheet, and a stainless steel sheet. As such a
metal sheet, a rolled thin sheet having a thickness of 0.01 to 2 mm
is particularly preferably used. These metals may be arbitrarily
plated, or coated with organic paint, in organic paint or the like,
or coated with an adhesive agent; and liquid crystal polymers
(macromolecules exhibiting a liquid crystal structure, and examples
thereof include liotropic liquid crystal polymers of
entirely-aromatic polyamides, a typical example of which is Kevlar,
thermotropic liquid crystals of entirely aromatic polyesters,
typical examples of which are Zaider and Vectra).
[0218] Among the above-mentioned face materials, particularly
desired are materials having anisotropy in mechanical properties
along the MD direction and the TD direction. Specific examples
thereof include prepreg sheets wherein a drawn or oriented sheet of
a thermoplastic resin or a long fibrous material thereof is
hardened into a sheet-form with a resin binder.
[0219] The inventions of claims 17 to 20 are carried out, in
particular, as embodiments described below.
[0220] About the supplied longitudinal sheets or lateral sheets,
they may be used alone or a plurality of them may be arranged in
parallel. An adhesive layer may be supplied together with the
longitudinal sheet.
[0221] The temperature of the longitudinal sheet supplied to the
core material surface is raised by heating and pressing, so that
the sheet is melted and bonded/laminated on the core material.
Examples of the heating and pressing means include a heating roll,
a heating roll with a belt, and a hot-press. In the case that a
heating roll and a heating roll with a belt are used, the core
material and the longitudinal sheet are continuously carried. In
the case that a hot-press is used, the core material and the
longitudinal sheet are intermittently carried. Before the heating
and pressing means (step), an auxiliary heating means (step) based
on radiant heating, hot-window heating, a plane-heater or the like
is set.
[0222] The intermediate lamination made of the longitudinal sheet
and the core material is cut into a constant-size with a cutting
means. Examples of the cutting means include a circular saw, a chip
saw, a metal saw, a pushing-down type cutter, and a hot wire.
[0223] The intermediate lamination is pushed out with the core
material supplying means, so as to be carried. At this time, the
carriage may be supported with a driving roll, or assisted with a
driving belt. In either case, the carriage up to the end of the
cutting of the intermediate lamination is performed in the
longitudinal direction.
[0224] After the compression-bonding by heating and pressing, the
intermediate lamination is preferably cooled to not more than the
melting point of the longitudinal sheet by a cooling means (step).
Examples of the cooling means include a cooling roll, natural
cooling, and air-cooling.
[0225] In the inventions of claims 17 and 18, the constant-size cut
pieces of the intermediate lamination made of the longitudinal
sheet and the core material is carried in a direction having a
given angle to the advancing direction (longitudinal direction),
and the lateral sheet is supplied and thermocompression-bonded in
the same manner as the longitudinal sheet while the cut pieces of
the intermediate lamination move in the carriage direction. The
given angle is, for example, 90.degree., but may be any angle other
than 90.degree.. Examples of the means for carrying the cut pieces
of the intermediate lamination include a member of pushing out the
pieces with a cylinder or the like, and a member of holding up the
cut pieces with an attracting pad or supporting the cut pieces on a
turntable to deliver the pieces to the next carrying line, and
carrying the pieces with a roll, a belt or the like.
[0226] In the inventions of claims 19 and 20, the constant-size cut
pieces of the intermediate lamination made of the longitudinal
sheet and the core material are rotated by 90.degree. and further
carried in the advancing direction (longitudinal direction), and
the lateral sheet is supplied and thermocompression-bonded in the
same manner as the longitudinal sheet while the cut pieces move in
the longitudinal direction. Examples of the means for rotating the
cut pieces of the intermediate lamination by 90.degree. to the
carriage direction while the carriage direction of the cut pieces
is kept as it is include a member of using a turntable or a member
of holding up the cut pieces with an attracting pad and rotating
the pieces.
[0227] The device for producing a laminated composite of claim 9
includes a core supplying means for supplying the core material in
the longitudinal direction, a longitudinal sheet supplying means
for supplying a longitudinal sheet for a face material in the
longitudinal direction onto at least one face of the core material,
a lateral sheet supplying means for supplying the lateral sheet for
the face material in the lateral direction onto the upper or lower
face of the longitudinal sheet, and a sheet
thermocompression-bonding means for pressing the longitudinal sheet
and the lateral sheet stacked in an orthogonal form against the
core material under heating. Therefore, the longitudinal sheet and
the lateral sheet can be continuously laminated, into an orthogonal
form, on the core material.
[0228] The method for producing a laminated composite of claim 10
includes a core supplying step of supplying the core material in
the longitudinal direction, a longitudinal sheet supplying step of
supplying the longitudinal sheet for a face material in the
longitudinal direction onto at least one face of the core material,
a lateral sheet supplying step of supplying the lateral sheet for
the face material in the lateral direction onto the upper or lower
face of the longitudinal sheet, and a sheet
thermocompression-bonding step of pressing the longitudinal sheet
and the lateral sheet stacked in an orthogonal form against the
core material under heating. Therefore, the longitudinal sheet and
the lateral sheet can be continuously laminated, into an orthogonal
form, on the core material.
[0229] In the device for producing a laminated composite of claim
11, at a position where the longitudinal sheet starts to contact a
heating roll of the sheet thermocompression-bonding, the lateral
sheet is supplied between the heating roll and the longitudinal
sheet by the lateral sheet supplying means. Therefore, the
operation of laminating the sheets for the face material in a
longitudinal and laterally orthogonal form on the core can be
performed with a high efficiency.
[0230] The method for producing a laminated composite of claim 12
further includes a lateral sheet supplying step of supplying a cut
piece of the lateral sheet between a heating roll and the
longitudinal sheet at a position where the longitudinal sheet
starts to contact the heating roll during the sheet
thermocompression-bonding step. Therefore, the operation of
laminating the sheets for the face material in a longitudinally and
laterally orthogonal form on the core can be performed with a high
efficiency.
[0231] In the device for producing a laminated composite of claim
13, the longitudinal sheet supplying means is a means for supplying
upper side longitudinal sheets and lower side longitudinal sheets
to be arranged alternatively in the lateral direction, and the
lateral sheet supplying means is a means for supplying plural
lateral sheets successively between the upper side longitudinal
sheets and the lower side longitudinal sheets so as to be arranged
in parallel. Therefore, the longitudinal sheet and the lateral
sheet can be alternately woven. As a result, a laminated composite
having such physical properties that reinforcing strengths in the
longitudinal direction and the lateral direction are uniform can be
obtained.
[0232] In the method for producing a laminated composite of claim
14, the longitudinal sheet supplying step is a step of supplying
upper side longitudinal sheets and lower side longitudinal sheets
to be arranged alternatively in the lateral direction, and the
lateral sheet supplying step is a step of supplying plural lateral
sheets successively between the upper side longitudinal sheets and
the lower side longitudinal sheets so as to be arranged in
parallel. Therefore, the longitudinal sheet and the lateral sheet
can be alternately woven. As a result, a laminated composite having
such physical properties that reinforcing strengths in the
longitudinal direction and the lateral direction are uniform can be
obtained.
[0233] In the device for producing a laminated composite of claim
15, the lateral sheet supplying means includes an attracting roll
set at a position where the longitudinal sheet starts to contact
the heating roll of the sheet thermocompression-bonding means, and
a single sheet supplying means for supplying cut pieces of the
lateral sheet one by one to the attracting roll. Therefore, the
longitudinal sheet and the lateral sheet can be continuously
adhered, in an orthogonal form, on the surface of the core
material.
[0234] In the method for producing a laminated composite of claim
16, the lateral sheet supplying step includes a single sheet
supplying step of supplying cut pieces of the lateral sheet one by
one to an attracting roll set at a position where the longitudinal
sheet starts to contact the heating roll during the sheet
thermocompression-bonding step. Therefore, the longitudinal sheet
and the lateral sheet can be continuously adhered, in an orthogonal
form, on the surface of the core material.
[0235] The device for producing a laminated composite of claim 17
includes a core material supplying means for supplying the core
material in the longitudinal direction, a longitudinal sheet
supplying means for supplying the longitudinal sheet for a face
material, in the longitudinal direction, onto at least one face of
the core material, a first thermocompression-bonding means for
pressing the longitudinal sheet and the core material under heating
to form an intermediate lamination, a first cutting means for
cutting the intermediate lamination, a carrying means for carrying
cut pieces of the intermediate lamination in a direction having a
given angle to the longitudinal direction, a lateral sheet
supplying means for supplying the lateral sheet for the face
material, in the carriage direction, onto the upper face or the
lower face of the cut pieces, a second thermocompression-bonding
means for pressing the cut pieces of the intermediate lamination
and the lateral sheet, which are stacked, under heating to form a
final lamination, and a second cutting means for cutting the final
lamination. Therefore, the longitudinal sheet and the lateral sheet
can be continuously laminated, in an orthogonal form, on the core
material. Moreover, the lateral sheet can be supplied in a
longitudinal state in the same manner as the longitudinal
sheet.
[0236] The method for producing a laminated composite of claim 18
includes a core material supplying step of supplying the core
material in a longitudinal direction, a longitudinal sheet
supplying step of supplying the longitudinal sheet for a face
material, in the longitudinal direction, onto at least one face of
the core material, a first thermocompression-bonding step of
pressing the longitudinal sheet and the core material under heating
to form an intermediate lamination, a first cutting step of cutting
the intermediate lamination, a carrying step of carrying cut pieces
of the intermediate lamination in a direction having a given angle
to the longitudinal direction, a lateral sheet supplying step of
supplying the lateral sheet for the face material, in the carriage
direction, onto the upper face or the lower face of the cut pieces,
a second thermocompression-bonding step of stacking and pressing
the cut pieces of the intermediate lamination and the lateral sheet
under heating to form a final lamination, and a second cutting step
of cutting the final lamination. Therefore, the longitudinal sheet
and the lateral sheet can be continuously laminated, in an
orthogonal form, on the core material. Moreover, the lateral sheet
can be supplied in a longitudinal state in the same manner as the
longitudinal sheet.
[0237] The device for producing a laminated composite of claim 19
includes a core material supplying means for supplying the core
material in the longitudinal direction, a longitudinal sheet
supplying means for supplying the longitudinal sheet for a face
material, in the longitudinal direction, onto at least one face of
the core material, a first thermocompression-bonding means for
pressing the longitudinal sheet and the core material under heating
to form an intermediate lamination, a first cutting means for
cutting the intermediate lamination, a carrying means for rotating
cut pieces of the intermediate lamination at an angle of 90.degree.
to carry the cut pieces in the longitudinal direction, a lateral
sheet supplying means for supplying the lateral sheet for the face
material, in the longitudinal direction, onto the upper face or the
lower face of the cut pieces, a second thermocompression-bonding
means for pressing the cut pieces of the intermediate lamination
and the lateral sheet, which are stacked, under heating to form a
final lamination, and a second cutting means for cutting the final
lamination. Therefore, the longitudinal sheet and the lateral sheet
can be continuously laminated, in an orthogonal form, on the core
material. Moreover, the lateral sheet can be supplied in a
longitudinal state in the same manner as the longitudinal
sheet.
[0238] The method for producing a laminated composite of claim 20
includes a core material supplying step of supplying the core
material in the longitudinal direction, a longitudinal sheet
supplying step of supplying the longitudinal sheet for a face
material, in the longitudinal direction, onto at least one face of
the core material, a first thermocompression-bonding step of
pressing the longitudinal sheet and the core material under heating
to form an intermediate lamination, a first cutting step of cutting
the intermediate lamination, a carrying step of rotating cut pieces
of the intermediate lamination at an angle of 90.degree. to carry
the cut pieces in the longitudinal direction, a lateral sheet
supplying step of supplying the lateral sheet for the face
material, in the longitudinal direction, onto the upper face or the
lower face of the cut pieces, a second thermocompression-bonding
step of stacking and pressing the cut pieces of the intermediate
lamination and the lateral sheet under heating to form a final
lamination, and a second cutting step of cutting the final
lamination. Therefore, the longitudinal sheet and the lateral sheet
can be continuously laminated, in an orthogonal form, on the core
material. Moreover, the lateral sheet can be supplied in a
longitudinal state in the same manner as the longitudinal
sheet.
[0239] According to the laminated composite and the production
device of claims 9 to 20, the operation of laminating the sheet for
the face material in the longitudinally and laterally orthogonal
form on the core material can be continuously performed and the
laminated composite can be produced with a high productive
efficiency. Accordingly, the laminated composite which has a high
flexural-elasticity if the thickness is small and which has a small
linear expansion coefficient and no anisotropy can be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0240] FIG. 1(a) is a schematic perspective view of spindle-shaped
cells, and FIG. 1(b) is an enlarged schematic view of a part of a
section in parallel to the z direction in FIG. 1(a);
[0241] FIG. 2 is a graph showing a stress-strain (S-S) curve from a
compressive test for a foamed body sheet made of a polyolefin
resin;
[0242] FIG. 3 is a perspective view illustrating a stack product in
Example 2;
[0243] FIG. 4 is a perspective view illustrating a laminated
composite wherein a face material in a longitudinally and laterally
orthogonal state is laminated on a core material;
[0244] FIG. 5 is a perspective view illustrating a device for
producing a laminated composite of Example 9;
[0245] FIGS. 6(a), 6(b), 6(c) and 6(d) are side views each
illustrating a supplying roll;
[0246] FIG. 7(a) is a perspective view illustrating a sheet
meandering correcting device, FIG. 7(b) is a front view of a
tension adjusting function, and FIGS. 7(c) and 7(d) are plan views
illustrating an arrangement of a plurality of narrow sheets
constituting a longitudinal sheet;
[0247] FIGS. 8(a) and 8(b) are perspective views illustrating a
lateral sheet supplying means, FIG. 8(c) is a side view
illustrating the lateral sheet supplying means, and FIG. 8(d) is a
side view illustrating a servo motor;
[0248] FIG. 9(a) is a front view illustrating a heating roll, FIG.
9(b) is a side view illustrating the heating roll and a stand, and
FIGS. 9(c), 9(d) and 9(e) are side views illustrating a driving
device of the heating roll;
[0249] FIGS. 10(a) and 10(b) are side views illustrating a
modification of a device for producing a laminated composite of
Example 9;
[0250] FIG. 11(a) is a side view illustrating an example of a
device for producing a laminated composite of Example 10, and FIG.
11(b) illustrates an example wherein a non-melting sheet is
supplied onto the surface thereof;
[0251] FIG. 12(a) is a side view illustrating another modification
of the device for producing a laminated composite of Example 10,
and FIG. 12(b) illustrates an example wherein a non-melting sheet
is supplied onto the surface thereof;
[0252] FIG. 13(a) is a side view illustrating a still another
modification of the device for producing a laminated composite of
Example 10, and FIG. 13(b) illustrates an example wherein a
non-melting sheet or a melting sheet is supplied on to the surface
thereof;
[0253] FIG. 14 is a side view illustrating one embodiment for
making a surface functional;
[0254] FIG. 15(a) is a side view illustrating a device for
producing a laminated composite of Example 11, and FIGS. 15(b) and
15(c) are plan views illustrating a lateral sheet supplying
means;
[0255] FIGS. 16(a) and 16(d) are side views illustrating a
mechanism for delivering cut pieces of a lateral sheet, and FIGS.
16(b) and 16(c) are plan views illustrating the mechanism for
delivering cut pieces of a lateral sheet;
[0256] FIG. 17(a) is a side view illustrating a device for
producing a laminated composite of Example 12, FIG. 17(b) is a
perspective view of a main part of the device, and FIG. 17(c) is a
perspective view illustrating a laminated composite produced in
this device;
[0257] FIG. 18(a) is a side view illustrating a device for
producing a laminated composite of Example 13, and FIG. 18(b) is a
front view of the device;
[0258] FIG. 19(a) is a side view illustrating a cassette in which
cut pieces of a lateral sheet are stored, FIG. 19(b) is a side view
illustrating a means for supplying cut pieces of the lateral sheet,
FIG. 19(c) is a side view illustrating a servo motor, FIG. 19(d) is
a front view illustrating a suction roll, FIG. 19(e) is a side view
illustrating a mechanism for delivering cut pieces of the lateral
sheet, and FIG. 19(f) is a front view illustrating a mechanism for
continuously supplying lateral sheets;
[0259] FIG. 20 is a perspective view illustrating an arrangement of
a plurality of narrow sheets constituting a longitudinal sheet;
[0260] FIG. 21 is a perspective view illustrating a device for
producing a laminated composite of Example 14; and
[0261] FIG. 22 is a perspective view illustrating a device for
producing a laminated composite of Example 15.
BEST MODES FOR CARRYING OUT THE INVENTION
[0262] The present invention will be more specifically described by
way of Examples.
[0263] i) Preparation of Sheet-Form Core Material with Face
Materials (Foamed Body Sheet with Face Materials)
[0264] (1) Preparation of Modified Polyolefin Resin
[0265] As a modifying screw extruder, BT 40 two-axis screw extruder
(manufactured by Research Laboratory of Plastics Technology Co.,
Ltd.), the axes being rotated in the same direction, was used. This
has 2 self-wiping screws. The L/D thereof is 35, and the D thereof
is 39 mm. Its cylinder barrel is composed of 1.sup.st to 6.sup.th
barrels from the upper stream of the extruder to the lower stream
thereof. Its die is a strand die having three holes. A vacuum vent
is installed in the 4.sup.th barrel in order to recollect volatile
components.
[0266] Operation conditions are as follows.
[0267] Cylinder barrel set temperature: 1.sup.st barrel;
180.degree. C.
[0268] 2.sup.nd to 6.sup.th barrels; 220.degree. C. die;
220.degree. C.
[0269] Screw rotation number: 150 rpm
[0270] First, a polyolefin resin was charged into a modifying screw
extruder having the above-mentioned structure from its rear end
hopper. From the third barrel, a mixture of a modifying monomer and
an organic peroxide was put into the extruder, and these were
melted and mixed to yield a modified resin. At this time, volatile
components generated in the extruder were subjected to vacuum
drawing from the vacuum vent.
[0271] The polyolefin resin was a polypropylene random copolymer
(EX6 manufactured by Japan Polychem Corp., MFR; 1.8, density; 0.9
g/cm.sup.3), and the supply amount thereof was set to 10 kg/h. The
modifying monomer was divinylbenzene, and the supply amount thereof
was set to 0.5 part by weight per 100 parts by weight of the
polyolefin resin. The organic peroxide was
2,5-dimethyl-2,5-di(t-butylperoxide)hexyne-3, and the supply amount
thereof was set to 0.1 part by weight per 100 parts by weight of
the polyolefin resin.
[0272] The modified resin yielded by melting and mixing the
polyolefin resin, the modifying monomer and the organic peroxide
was jetted out from the strand die, cooled with water, and cut with
a pelletizer to obtain pellets made of the modified resin.
[0273] (2) Preparation of Foaming Resin Composition
[0274] A screw extruder for kneading a foaming agent was a two-axis
screw extruder, TEX-44 model (manufactured by Nippon Steel Corp.),
the axes being rotated in the same direction. This has 2
self-wiping screws. The L/D thereof is 45.5, and the D thereof is
47 mm. Its cylinder barrel is composed of 1.sup.st to 12.sup.th
barrels from the upper stream of the extruder to the lower stream
thereof. Its forming die is a strand die having 7 holes.
Temperature-setting divisions are as follows.
[0275] The 1.sup.st barrel was constantly cooled.
[0276] 2.sup.nd zone; the 2.sup.th to the 4.sup.th barrels
[0277] 2.sup.nd zone; the 5.sup.th to the 8.sup.th barrels
[0278] 3.sup.rd zone; the 9.sup.th to the 12.sup.th barrels
[0279] 4.sup.th zone; the die and an adaptor section
[0280] A side feeder is installed to the sixth barrel to supply a
foaming agent, and a vacuum vent is installed in the eleventh
barrel in order to recollect volatile components. Operation
conditions were as follows.
[0281] Cylinder barrel set temperature: 1.sup.st zone; 150.degree.
C.
[0282] 2.sup.nd zone; 170.degree. C.
[0283] 3.sup.rd zone; 180.degree. C.
[0284] 4.sup.th zone; 160.degree. C.
[0285] Screw rotation number: 40 rpm
[0286] The modified resin obtained as described above and a homo
type polypropylene (FY4 manufactured by Japan Polychem Corp., MFR;
5.0, density; 0.9 g/cm.sup.3) were supplied, in respective supply
amounts of 10 kg/h, to the screw extruder for kneading the foaming
agent. The foaming agent was supplied from the side feeder to the
extruder. The foaming agent was azodicarbonamide (ADCA), and the
supply amount thereof was set to 1.0 kg/h. A foaming resin
composition was obtained by kneading the modified resin and the
foaming agent in this way.
[0287] (3) Preparation of Foaming Sheet
[0288] This foaming resin composition was extruded from a T die, to
obtain a polyolefin resin foaming sheet having a width of 350 mm
and a thickness of 0.5 mm.
[0289] (4) Preparation of Foaming Sheet with Face Material
[0290] In Examples 1 to 6 and Comparative Examples 2 to 3,
polyethylene terephthalate nonwoven fabrics (Spunbond Ecoole 630
1A, manufactured by Toyobo Co., Ltd., grammage; 30 g/m.sup.2) as
face materials were laminated on both faces of the above-mentioned
polyolefin resin foaming sheet. A press-forming machine was used to
perform press-forming at a temperature of 180.degree. C., to obtain
a foaming sheet with the face material.
[0291] In Comparative Example 1, Teflon sheets were laminated on
both faces of the above-mentioned foaming sheet, and a hand press
machine was used to perform diluting at 180.degree. C. to obtain a
foaming sheet with the face material.
[0292] (5) Foaming
[0293] From the resultant foaming sheet with the face material, the
peripheral portion thereof was removed to obtain a sample of 300 mm
square. This sample was heated in an oven at 230.degree. C. for
approximately 5 minutes, to cause the foaming sheet to foam. In
this way, a polyolefin resin foamed body sheet having a thickness
of 8 mm was obtained.
[0294] In Comparative Example 1, the resin was cooled and
solidified after the foaming. Thereafter, the laminated Teflon
sheets were stripped to obtain a foamed body sheet having a surface
made of the polyolefin resin.
[0295] (6) Impregnation with Synthetic Resin
[0296] In Examples 2, 3 and 5, a synthetic resin film of 60 .mu.m
thickness, which will be described later, was stacked on the face
materials of the foamed body sheet with the face material, obtained
in the previous step (5), and then the hand press machine heated to
120.degree. C. was used to apply a load to the stack product in
such a manner that a compressive strain of 0.4 mm (5%) would be
applied to the foamed body sheet, and the stack product was heated
for 1 minute to obtain a synthetic resin impregnated foamed body
sheet.
[0297] (7) Evaluation of Synthetic Resin Impregnated Foamed Body
Sheet
[0298] The resultant polyolefin resin foamed body sheet was
evaluated about items described below.
[0299] Foaming Magnification:
[0300] The face materials were scratched off from the laminated
composite with a cutter, and subsequently the apparent density
thereof was measured according to JIS K-6767 Polyethylene Foam
Test. The reciprocal number thereof was defined as the foaming
magnification.
[0301] Cell Shape (Average Aspect Ratio):
[0302] The laminated composite sheet was cut along the thickness
direction (the z direction). While the center of the section
thereof was observed with an optical microscope, an enlarged
photograph thereof was taken with 15 magnifications. Dz and Dxy of
all of the photographed cells were measured with a vernier
micrometer. Dz/Dxy of each of the cells was then calculated. The
number average of the values Dz/Dxy of the cells in the number of
100 was calculated and defined as the average aspect ratio. In the
measurement, however, the cells having a Dz (actual diameter) of
0.05 mm or less and the cells having a Dz of 10 mm or more were
excluded.
[0303] Melting Point
[0304] In the step (2), a polyolefin resin composition containing
no foaming agent (ADCA) was prepared. A differential scanning
calorimeter (DSC) was used to read out the peak temperature of
this. The melting point thereof was 148.degree. C.
[0305] ii) Preparation of Synthetic Resin Film Laminated Drawn
Sheet
[0306] (1) Preparation of Extruded Sheet
[0307] One part by weight of benzophenone (a photopolymerization
initiator) was blended per 100 parts by weight of high density
polyethylene (trade name: HY540, manufactured by Mitsubishi
Chemical Corp., MFR=1.0, melting point; 133.degree. C., weight
average molecular weight; 300000). The blend product was melted and
kneaded in a 30-mm biaxial extruder at a resin temperature of
200.degree. C., and then extruded into a sheet-form through a T
die. The resultant product was cooled with a cooling roll to obtain
a non-drawn sheet having a thickness of 1.0 mm and a width of 200
mm.
[0308] (2) Rolling and Crosslinking
[0309] A 6-inch roll (manufactured by Kodaira Seisakusyo Co., Ltd.)
having surface temperature set to 100.degree. C. was used to roll
this non-drawn sheet up to a draw magnification of 9 times.
Thereafter, the resultant rolled sheet was sent out by rolls having
a sending-out rate of 2 m/minute, passed through a heating furnace
having atmosphere temperature set to 85.degree. C., pulled and
taken by rolls having a pulling rate of 6 m/minute so as to be
rolled up to a draw magnification of 3 times and wound out. Next, a
high-pressure mercury lamp was illuminated onto both faces of the
resultant sheet for 5 seconds so that the sheet was crosslinked. At
last, the resultant sheet was subjected to relieving treatment at
130.degree. C. under non-tension for 1 minute.
[0310] The drawn sheet obtained by way of the above-mentioned
operations had a width of 100 mm and a thickness of 0.20 mm and was
transparent. The total draw magnification of this sheet was 27
times, and the linear expansion coefficient thereof was
-1.5.times.10.sup.-5 The melting point [the peak temperature in a
DSC (differential scanning calorimeter)] of this drawn sheet was
135.degree. C.
[0311] (3) Local Melting
[0312] In Examples 3, 4 and 5, the polyolefin resin drawn sheet
obtained as described above was passed between a first roll which
was rotated at a rotation speed of 3 m/minute and had a surface
temperature of 180.degree. C. and a second roll which was rotated
at the same speed and had a surface temperature of 50.degree. C. in
such a manner that the pressure was 100 kg/cm.sup.2, so as to be
continuously compressed. As a result, the face of the drawn sheet
which was in contact with the first roll was melted. Next, by
treating the opposite face of the drawn sheet in the same manner as
described above, a drawn sheet having both faces melted was
obtained.
[0313] (4) Synthetic Resin Film Laminated Drawn Sheet
[0314] In Examples 3, 4 and 5, the first roll having surface
temperature set to 160.degree. C. and the second roll having
surface temperature set to50.degree. C. were rotated at respective
rotation speeds of 3 m/minute. A synthetic resin film having a
thickness of 60 .mu.m, which will be described later, was stacked
on the drawn sheet obtained in the previous step (3), and this
stack product was passed between in such a manner that the
synthetic resin film made in contact with the first roll and the
pressure was 100 kg/cm.sup.2, so as to perform laminating
continuously. In this way, a synthetic resin film laminated drawn
sheet was obtained.
[0315] (5) Evaluation of Drawn Sheet
[0316] The linear expansion coefficient and the tensile elasticity
of the drawn sheet were measured by the following methods.
[0317] Linear Expansion Coefficient:
[0318] Index lines having an interval of approximately 150 mm were
written on the sample, and subsequently the sample was allowed to
stand still in a thermostat set to 5.degree. C. for 1 hour. The
distances between the index lines was measured at 5.degree. C.
Next, the sample was allowed to stand still in the thermostat set
to 80.degree. C. for 1 hour. Thereafter, the distance between the
index lines was measured in the same way. This operation was
repeated 3 times. The distance between the index lines at 5.degree.
C. and 80.degree. C. was measured in the second and third
operations, and the average thereof was obtained. From the
following equation, the linear expansion coefficient was
calculated:
Linear expansion coefficient (1/.degree. C.)=(distance between the
index lines at 80.degree. C.-distance between the index lines at
5.degree. C.)/{(distance between the index lines at 5.degree.
C.).times.(80-5)}.
[0319] Tensile Elasticity:
[0320] The tensile elasticity was measured according to the tension
test of JIS K 7113.
[0321] Preparation of Synthetic Resin Film
[0322] A low density polyethylene (LC 600A manufactured by
Mitsubishi Chemical Corp., MFR; 7, melting point; 107.degree. C.)
was melted and kneaded at a resin temperature of 180.degree. C. in
a biaxial extruder, extruded into a sheet-from through a T die, and
cooled by a cooling roll, to obtain a synthetic resin film having a
thickness of 60 .mu.m and a width of 100 mm.
[0323] iii) Production of Laminated Composite
[0324] (1) Stacking of Sheets or Films
[0325] As illustrated in FIG. 3, in Example 2, the respective
material sheets or films were stacked on each other to obtain a
stack product of the drawn sheet (203)/the synthetic resin film
(202)/the synthetic resin impregnated foamed body sheet (201)/the
synthetic resin film (202)/the drawn sheet (203).
[0326] In Examples 1, 3 to 5, and Comparative Examples 1 and 2, the
material sheets or films were stacked on each other as described
below. The plurality of drawn sheets corresponding to the upper and
the lower faces of a laminated composite were arranged in such a
manner that the drawn direction thereof would be plane-symmetrical
with respect to the foamed body sheet.
EXAMPLE 1
Drawn Sheet/Two Synthetic Resin Films/Foamed Body Sheet/Two
Synthetic Resin Films/Drawn Sheet
EXAMPLE 2
Drawn Sheet/Synthetic Resin Film/Synthetic Resin Impregnated Foamed
Body Sheet/Synthetic Resin Film/Drawn Sheet
EXAMPLE 3
Synthetic Resin Film Laminated Drawn Sheet/Synthetic Resin
Film/Foamed Body Sheet/Synthetic Resin Film/Synthetic Resin Film
Laminated Drawn Sheet
EXAMPLE 4
Synthetic Resin Film Laminated Drawn Sheet/Synthetic Resin
Impregnated Foamed Body Sheet/Synthetic Resin Film Laminated Drawn
Sheet
EXAMPLE 5
Synthetic Resin Film Laminated Drawn Sheet (0.degree.)/Synthetic
Resin Film Laminated Drawn Sheet (90.degree.)/Synthetic Resin
Impregnated Foamed Body Sheet/Synthetic Resin Film Laminated Drawn
Sheet (90.degree.)/Synthetic Resin Film Laminated Drawn Sheet
(0.degree.)
COMPARATIVE EXAMPLE 1
Drawn Sheet After Heated to 160.degree. C., which will be Described
Later/Foamed Body Sheet with no Face Material/Drawn Sheet after
Heated to 160.degree. C.
COMPARATIVE EXAMPLE 2
Drawn Sheet/Two Synthetic Resin Films/Foamed Body Sheet/Two
Synthetic Resin Films/Drawn Sheet
[0327] (2) Heating, Pressing and Cooling
[0328] In Examples 1 to 5, each of the above-mentioned stack
products was heated to 120.degree. C. (and 110.degree. C. in
Example 1) from its upper and lower sides, using a hand press
machine. The product was pressed in such a manner that a
compressive strain of 0.4 mm (5%) was applied to the foamed body
sheet, so as to perform press-forming for 2 minutes. Thereafter,
the stack product was pressed by water-cooling press in such a
manner that a compressive strain of 5% would be generated in the
same way.
[0329] In Example 6, among the drawn sheets used in Example 1, the
sheet rolled 9 times in the drawing step was used. At the time of
laminating by press, both ends of the drawn sheet were clipped and
a tension of 0.5 kgf/cm was applied thereto in the sheet oriented
direction. In this state, heating and laminating were carried out.
Except this, the same manner as in Example 1 was carried out. As a
result, a good laminated composite was obtained.
[0330] In Example 7, instead of the polyolefin resin foamed body
sheet described in Example 1, an acrylic foamed body (Rohacell
manufactured by Rohm Co., Ltd. foaming magnification; 20 times,
thermal deformation temperature; 130.degree. C.) was used, and as a
synthetic resin film used for adhesion, an SEBS film CS-S
manufactured by Sekisui Film Co., Ltd. was used. The structure of
the stack product and the heating temperature were set to the same
in Example 1.
[0331] In Example 8, instead of the polyolefin resin foamed body
sheet described in Example 1, a thermoplastic resin plastic hollow
body (Sunply manufactured by Sumika Plastech Co., Ltd. thickness; 7
mm) was used, and as a synthetic resin film used for adhesion, a
VLDPE film SE605M manufactured by Tamapoly Co., Ltd. was used. The
structure of the stack product and the heating temperature were set
to the same in Example 1.
[0332] In Comparative Example 1, the drawn sheets were fixed with
clips, and allowed to stand still in an oven heated to 160.degree.
C. for 2 minutes. The drawn sheets were wholly shrunk and a part
thereof was melted. This drawn sheet was taken out from the oven,
and the above-mentioned foamed body sheet with no face material was
immediately sandwiched between the drawn sheets. A hand press
machine was used to heat the stack product from its upper and lower
sides at 50.degree. C., and a pressure was applied thereto in such
a manner that a compressive strain of 5% would be generated in the
foamed body sheet with no face material. The stack product was
allowed to stand still for 2 minutes to obtain a laminated
composite. The surfaces of this laminated product, in which
numerous irregularities were generated, were not smooth.
[0333] In Comparative Example 2, the thickness control as described
above was changed to a pressure controlling manner. At a pressure
of 0.8 MPa and temperatures of 110.degree. C. and 120.degree. C.,
heating/pressing and cooling/pressing were performed in the same
way as described above, to obtain a laminated product.
[0334] In Comparative Example 3, at the time of heating and
laminating, the laminating was performed without applying any
tension in Example 8. As a result, the sheet was shrunk, and the
surfaces of this laminated composite, in which numerous
irregularities were generated, were not smooth.
[0335] (3) Evaluation of Laminated Composites
[0336] The resultant laminated composites were evaluated about the
following items.
[0337] Thickness
[0338] A vernier micrometer was used to measure the thickness of
the laminated composites.
[0339] Bending Strength and Bend Plastic Constant:
[0340] The bend plastic constant and the bending strength were
measured at a test speed of 10 mm/minute on the basis of JIS K7203.
The samples having directivity were measured along their drawn
direction.
[0341] Linear Expansion Coefficient
[0342] The linear expansion coefficient was obtained in the same
way as described above. The samples having directivity were
measured along their drawn direction.
[0343] The structures and the evaluation results of Examples and
Comparative Examples are collectively shown in Table 1.
1 Example 1 Example 2 Example 3 Example 4 Foamed Foaming
magnification Times 10 10 10 10 body sheet Aspect ratio 2 2 2 2
Melting point .degree. C. 148 148 148 149 Thickness mm 8 8 8 8
Drawn sheet Melting point .degree. C. 135 135 135 135 Direction
Monoaxial Monoaxial Monoaxial Monoaxial Thickness .mu.m 300 300 300
300 Number of the laminated Number 1 1 1 1 sheet(s) on the single
side Shrinkage starting .degree. C. 125 125 125 125 temperature
Local melting Not observed Not Observed Observed observed Linear
expansion coefficient *10-5 -1.5 -1.5 -1.5 -1.5 Tensile elasticity
Gpa 24 24 24 24 Synthetic Melting point .degree. C. 105 105 105 105
resin Thickness .mu.m 120 60 60 Penetration into the foamed .mu.m
60 60 body Lamination to drawn sheet .mu.m 60 60 Pressing Heating
temperature .degree. C. 110 120 120 120 120 process Manner
Thickness Thickness Thickness Thickness Thickness control control
control control control Compressive ratio of the % 5 5 5 5 5 foamed
body Pressure Mpa Tension to the sheet kgf/1 cm 0 0 0 0 Laminated
Thickness mm 8.6 8.6 8.6 8.6 8.6 composite Bending strength Mpa 8.0
9.0 11.0 11.0 13.0 Bend elastic constant Gpa 1.2 1.3 1.4 1.4 1.5
Linear expansion coefficient .times.10-5/.degree. C. -1 -1.1 -1.2
-1.2 -1.3 Example 5 Example 6 Example 7 Example 8 Foamed Foaming
magnification Times 10 10 .sup. 20 .sup. 20 body sheet Aspect ratio
2 2 .sup. 0.9 .sup. 0.9 Melting point .degree. C. 148 148 (130)
(75) Thickness mm 8 8 .sup. 8 .sup. 8 Drawn sheet Melting point
.degree. C. 135 135 .sup. 135 .sup. 135 Direction Orthogonal
Monoaxial Monoaxial Thickness .mu.m 300 300 300 Number of the
laminated Number 2 1 1 sheet(s) on the single side Shrinkage
starting .degree. C. 125 105 125 temperature Local melting Observed
Not Not observed observed Linear expansion coefficient *10-5 -1.5
0.5 -1.5 Tensile elasticity Gpa 24 8 24 Synthetic Melting point
.degree. C. 105 105 (-) (-) resin Thickness .mu.m 120 .sup. 120
.sup. 120 Penetration into the foamed .mu.m 60 body Lamination to
drawn sheet .mu.m 60 Pressing Heating temperature .degree. C. 120
120 .sup. 120 .sup. 70 process Manner Thickness Thickness Thickness
Thickness control control control control Compressive ratio of the
% 5 .sup. 5 .sup. 5 foamed body Pressure Mpa Tension to the sheet
kgf/1 cm 0 0.5 .sup. 0 .sup. 0 Laminated Thickness mm 8.6 8.6 .sup.
8.6 .sup. 7.6 composite Bending strength Mpa 13.0 9.5 .sup. 9.5
.sup. 11.0 Bend elastic constant Gpa 1.5 0.8 .sup. 1.4 .sup. 2.0
Linear expansion coefficient .times.10-5/.degree. C. -1.3 -1.1
.sup. -1.1 .sup. -1.2 Comparative Comparative Comparative Example 1
Example 2 Example 3 Foamed Foaming magnification Times 10 10 10
body sheet Aspect ratio 2 2 2 Melting point .degree. C. 148 148 148
Thickness mm 8 8 8 Drawn sheet Melting point .degree. C. 135 135
135 Direction Monoaxial Monoaxial Monoaxial Thickness .mu.m 300 300
300 Number of the laminated Number 1 1 1 sheet(s) on the single
side Shrinkage starting .degree. C. 125 125 105 temperature Local
melting Not observed Not observed Not observed Linear expansion
coefficient *10-5 -1.5 -1.5 0.5 Tensile elasticity Gpa 24 24 8
Synthetic Melting point .degree. C. Not observed 105 105 resin
Thickness .mu.m 120 120 Penetration into the foamed .mu.m body
Lamination to drawn sheet .mu.m Pressing Heating temperature
.degree. C. 160 110 120 120 process Manner Thickness Pressure
Pressure Thickness control control control control Compressive
ratio of the % 5 8 15 foamed body Pressure Mpa 0.8 0.8 Tension to
the sheet kgf/1 cm 0 0 0 0 Laminated Thickness mm 8.7 8.5 8 8.7
composite Bending strength Mpa 3.0 8.3 6.5 3.1 Bend elastic
constant Gpa 0.7 1.3 1.2 0.6 Linear expansion coefficient
.times.10-5/.degree. C. 4 -1 -1 4.5
[0344] As is evident from Table 1, in the laminated composites of
Examples 1 to 8, the drawn sheets are not shrunk and the foamed
bodies do not buckle. They have larger bending strengths and bend
elastic constants as compared with that of Comparative Example 1,
and are high-strength laminated composites. Moreover, they have
small linear expansion coefficients so as to be good in dimensional
stability.
[0345] In Examples 1 to 8, the pressing quantity is controlled by
the compressive strain quantity of the foamed body sheets;
therefore, even if the heating temperature changes, laminated
composites having a uniform thickness can be produced as compared
with Comparative Example 2, wherein pressure control is
performed.
[0346] Next, Examples will be given hereinafter in order to
describe the present invention of claims 9 to 20 in more detail.
The present invention are not limited to only these Examples.
EXAMPLE 9
[0347] As a core material, a polypropylene foamed body having a
foaming magnification of 10 times, a thickness of 10 mm and a width
of 1200 mm was used. As a sheet for a face material, a polyethylene
drawn sheet having a thickness of 0.2 mm and a width of 1000 mm was
used. As an adhesive layer, a very low density polyethylene film
(manufactured by Tamapoly Co., Ltd.) having a thickness 60 .mu.m
was previously laminated on one face of the sheet for the face
material.
[0348] As illustrated in FIG. 5, a device for producing a laminated
composite of this Example (the production device of claim 9)
includes a core material supplying means for supplying a core
material (C) in the longitudinal direction, a longitudinal sheet
supplying means for supplying a longitudinal sheet (S1) for a face
material, in the longitudinal direction, on at least one face of
the core material (C), a lateral sheet supplying means for
supplying a lateral sheet (S2) for the face material, in the
lateral direction, on the upper or lower face of the longitudinal
sheet (S1), and a sheet thermocompression-bonding means for
pressing the longitudinal sheet (S1) and the lateral sheet (S2),
which are stacked in an orthogonal form, onto the core material (C)
under heating.
[0349] The method for producing a laminated composite of this
Example (the production method of claim 10) includes a core
material supplying step of supplying a core material (C) in the
longitudinal direction, a longitudinal sheet supplying step of
supplying a longitudinal sheet (S1) for a face material, in the
longitudinal direction, on at least one face of the core material
(C), a lateral sheet supplying step of supplying a lateral sheet
(S2) for the face material, in the lateral direction, on the upper
or lower face of the longitudinal sheet (S1), and a sheet
thermocompression-bonding step of pressing the longitudinal sheet
(S1) and the lateral sheet (S2), which are stacked in an orthogonal
form, onto the core material (C) under heating.
[0350] The core supplying means for supplying the core material (C)
in the longitudinal direction has a pair of upper and lower
supplying rolls (1) having a diameter of 200 mm, and a plurality of
feed rollers (19) arranged at the lower stream of the lower
supplying roll (1). As illustrated in FIG. 6(a), the pair of the
upper and lower supplying rolls (1) are driven through a belt (14)
by a driving device (6). The core material (C) sandwiched between
these supplying rolls (1) is fed onto the feed roll (19) at a line
speed of 1 m/minute.
[0351] The supplying rolls (1) may be rubber rolls, metal rolls or
resin rolls. As illustrated in FIG. 6(b), the lower roll (15) is
lifted or lowered by a lifting device (7) such as an oil pressure
cylinder or an air cylinder, and the core material (C) may be
closely interposed between the supplying rollers (1).
[0352] Examples of the core material supplying means other than the
supplying rolls include a device for feeding the core material (C)
by belts or caterpillars (8), between which the core material (C)
is interposed, as illustrated in FIG. 6(c); and a device for
feeding the core material (C) by a roll (9) wherein only its upper
face makes in contact with the core material (C) as illustrated in
FIG. 6(d). The core material supplying means may be a means having
capability of feeding the core material at a constant speed. In
these figures, the reference numeral (14) denotes a belt.
[0353] The longitudinal sheet supplying means for pulling out the
longitudinal sheet, in the longitudinal direction, onto the upper
face of the core material has a reel (2) on which the longitudinal
sheet (S1) is wound, and a press roll (5) for pressing the
longitudinal sheet (S1) pulled out from the reel (2) to the surface
of the core material (C) along this against the core material
(C).
[0354] As illustrated in FIG. 7(a), at the lower stream of the reel
(2), a sheet meandering correcting device is provided for sensing a
deviation in the width direction between the core material (C) and
the longitudinal sheet (S1) with a position sensor (10) to correct
the center of the longitudinal sheet (S1) to the center of the core
material. The sheet meandering correcting device includes a width
direction moving device, as illustrated in FIG. 7(b), in order to
correct the width direction deviation when it is sensed. This
moving device has, for example, a rail (11) arranged in the width
direction, the reel (2) which can move thereon, and a cylinder (12)
for moving this in the width direction.
[0355] In order that the longitudinal sheet (S1) may not loosen,
there is provided a tension adjusting function of braking the
rotation of the reel (2) by pad brakes (13) between which the axis
of the reel (2) is interposed and giving a constant tension to the
longitudinal sheet (SI).
[0356] In order that the longitudinal sheet made of a plurality of
narrow sheets (S3) can be laminated on the core material (C), the
narrow sheets (S3) may be arranged in parallel (FIG. 7(c)) or in a
staggered form (FIG. 7(d)).
[0357] When the state of supplying the longitudinal sheet becomes
stable, the lateral sheet (S2) for a face material is supplied in a
direction perpendicular to the core material feed direction, that
is, the lateral direction by the lateral sheet supplying means.
[0358] As illustrated in FIG. 8(a), the lateral sheet supplying
means has a reel (21) on which the lateral sheet (S2) is wound, and
a driving device (22) for driving the reel (21) to send the lateral
sheet (S2) in the lateral direction.
[0359] The lateral sheet supplying means also includes a reel (24)
arranged in the feed direction of the core material (C), the reel
(21) which can move thereon, and a cylinder (23) for moving this in
the feed direction of the core material (C) at a speed equal to
this. When the lateral sheet (S2) is sent out by the width of the
core material (C), the lateral sheet (S2) is cut by a cutter (25)
and the resultant cut piece (36) is adhered to the surface of the
core material (C). Thereafter, the reel (21) is returned to the
original position so as to send out another lateral sheet again.
This operation is repeated.
[0360] The lateral sheet supplying means also has a tension
adjusting function based on pad brakes (28) in the same manner as
the longitudinal sheet supplying means.
[0361] As illustrated in FIG. 8(b), in another example of the
lateral sheet supplying means, the lateral sheet (S2) is sent out
by the width of the core material (C), so that the lateral sheet
(S2) is cut by a cutter (33). The cut piece (36) is attracted on an
attracting pad (34), carried onto the surface of the core material
by a cylinder (35), and laminated on the core material.
[0362] As illustrated in FIG. 8(c), in still another example, the
lateral sheet (S2) is previously cut into a length equal to the
width of the core material (C). A great number of the cut pieces
(36) are stacked inside a cassette (41), and one of the cut pieces
(36) is attracted on an attracting pad (43) at the tip of a
carriage device (42), rotated by 180.degree., carried and laminated
onto the surface of the core material (C). This operation is
repeated. For the 180.degree.-rotation, a servo motor (44)
illustrated in FIG. 8(d) is used.
[0363] As illustrated in FIG. 5, the sheet
thermocompression-bonding means presses the longitudinal sheet (S1)
and the lateral sheet (S2) stacked in an orthogonal form on the
core material (C) under heating.
[0364] In the state that the longitudinal sheet (S1) and the
lateral sheet (S2) are laminated on the surface of the core
material (C), these are fed to a pair of upper and lower heating
rolls (4) having a diameter of 300 mm and a clearance of 10 mm. At
a temperature of 120.degree. C. and a line speed of 1 m/minute, the
longitudinal sheet (S1) and the lateral sheet (S2) are pressed on
the core material (C) under heating by the heating rolls (4) at a
line speed of 1 m/minute, and further they are fed by the driving
of the rolls.
[0365] As illustrated in FIG. 9(a), the pair of the upper and lower
heating rolls (4) is rotated and driven by a driving device (51),
and oil or water as a hot medium is circulated inside a temperature
adjustor (52) provided with an electric heater. The heating rolls
(4) are rubber rolls, resin rolls or metal rolls, and only the
surface thereof may be coated with rubber or resin.
[0366] The core material (C) and the sheets for the face material
may be interposed between the two heating rolls (4) under pressure,
or may be interposed between one heating roll (4) and a flat stand
(17) and under pressure, as illustrated in FIG. 9(b).
[0367] As illustrated in FIG. 9(c), the driving device (51) for the
heating rolls (4) is made to rotate the heating rolls (4) through a
belt (14). As illustrated in FIG. 9(d), the lower heating roll (4)
is made to be lifted and lowered by a hydraulic cylinder (53). As
illustrated in FIG. 9(e), a cotter (54) is attached to the lower
heating roll. (4) so that the clearance between the rolls can be
adjusted.
[0368] In FIG. 10(a), a pair of upper and lower lateral sheets (S2)
is sent out onto the upper and lower faces of the core material
(C), as described above. Next, the longitudinal sheet (S1) is
supplied along the periphery of the pair of the upper and lower
heating rolls (4). Thereafter, the longitudinal sheet (S1) and the
lateral sheets (S2) may be melted and bonded to the core material
(C), under heating and pressing, by the heating rolls (4). As
illustrated in FIG. 10(b), the longitudinal sheet (S1) is first
supplied along the periphery of the pair of the upper and lower
heating rolls (4), and next a pair of upper and lower lateral
sheets (S2) is sent out onto the upper and lower faces of the core
material (C), as described above. Thereafter, the longitudinal
sheet (S1) and the lateral sheets (S2) can be melted and bonded to
the core material (C), under pressing and heating, by another pair
of upper and lower heating rolls (18).
[0369] The longitudinal sheet (S1) and the lateral sheets (S2) may
be laminated on at least one face of the core material (C). If a
cooling roll, an air cooling or the like is necessary after the
melting and bonding, it is set up just after the heating rolls.
[0370] This process allows continuous production of laminated
composites wherein the face material in a longitudinal and
laterally orthogonal state, which has a width of 1000 mm, is
laminated on the core material having a thickness of 10 mm and a
width of 1200 mm, illustrated in FIG. 4.
EXAMPLE 10
[0371] As illustrated in each of FIGS. 11, 12 and 13, a device for
producing a laminated composite of this Example (another embodiment
of the production device of claim 9) includes a core material
supplying means for supplying a core material (C) in the
longitudinal direction, a longitudinal sheet supplying means for
supplying a longitudinal sheet (S1) for a face material in the
longitudinal direction onto at least one face of the core material
(C), a lateral sheet supplying means for supplying a lateral sheet
(S2) for the face material in the lateral direction onto the upper
or lower face of the longitudinal sheet (S1), and a sheet
thermocompression-bonding means for pressing the longitudinal sheet
(S1) and the lateral sheet (S2), stacked in an orthogonal form,
against the core material under heating.
[0372] The method for producing a laminated composite of this
Example (another embodiment of the production method of claim 10)
includes a core material supplying step of supplying a core
material (C) in the longitudinal direction, a longitudinal sheet
supplying step of supplying a longitudinal sheet (S1) for a face
material in the longitudinal direction onto at least one face of
the core material (C), a lateral sheet supplying step of supplying
a lateral sheet (S2) for the face material in the lateral direction
onto the upper or lower face of the longitudinal sheet (S1), and a
sheet thermocompression-bonding step of pressing the longitudinal
sheet (S1) and the lateral sheet (S2), stacked in an orthogonal
form, against the core material under heating.
[0373] Hereinafter, points different from Example 9 will be
described. To the same reference numerals as in Example 9 are
attached the same reference numerals, and description thereof will
not be repeated.
[0374] A device (a method) for producing a laminated composite of
Example 10 further includes a sheet cooling means (step) after the
sheet thermocompression-bonding means (step).
[0375] In a device for producing a laminated composite illustrated
in FIGS. 11(a) and 11(b), its sheet cooling means has a plurality
of pairs (three pairs in FIGS. 11(a) and 11(b)) of upper and lower
cooling rolls (16). Cooling water is supplied into the cooling
rolls (16). The core material (C) and the sheets (S1) and (S2) for
the face material are interposed between the pairs of the upper and
lower cooling rolls (16) under pressure. The respective cooling
rolls (16) are rotated by the movement of the core material (C) and
the sheets (S1) and (S2) for the face material. The cooling rolls
(16) are rubber rolls, resin rolls, metal rolls or the like, and
may be metal rolls having surfaces coated with rubber or resin.
[0376] In a device for producing a laminated composite illustrated
in FIGS. 12(a) and 12(b), as the sheet thermocompression-bonding
means, a pair of upper and lower heating presses (26) is used
instead of the heating rolls (4), and a sheet cooling means has a
pair of upper and lower cooling presses (27) having a size equal to
that of the heating presses (26). Inside the heating presses (26),
heaters are set up. Cooling water is supplied into the cooling
presses (27). The core material (C) and the face material sheets
(S1) and (S2) are carried in the state that the sheets (S1) and
(S2) are laminated in an orthogonal form, and first heated and
pressed by the pair of the heating presses (26). Thereafter, they
are cooled by the pair of the cooling presses (27). The feed of the
core material (C) and the face material sheets (S1) and (S2) is
intermittently performed at a pitch of the width of the presses
(26) and (27). A gap corresponding to one of the pitches is set
between the heating presses (26) and the cooling rolls (27). This
makes continuous production of laminated products possible. Of
course, the method of heating the heating presses (26) may be one
other than the heater and the method of cooling the cooling presses
(27) may be some other method.
[0377] In a production method for a laminated composite illustrated
in FIGS. 13(a) and 13(b), as the sheet thermocompression-bonding
means, a pair of upper and lower heating presses (4) is used, and
further a pair of upper and lower cooling presses (29) having a
size equal to that of the heating rolls (4) is used as a sheet
cooling means. The upper rolls (4) and (29) are connected to each
other and the lower rolls (4) and (29) are connected to each other
by means of endless belts (30), respectively. The core material (C)
and the face material sheets (S1) and (S2) are sandwiched between
the pair of the upper rolls (4) and between the pair of the lower
rolls (29) and pressed by the upper rolls and the lower rolls,
respectively, thorough belts. Portions of the upper and lower belts
(30) contacting the lateral sheet (S2) are pressed against the
sheet (S2) by plural pressing rolls (31) (three rolls in FIGS.
13(a) and 13(b)), respectively. As the material of the belts, glass
fiber or aramide fiber into which Teflon is incorporated is usually
used. The belts (30) may be metal belts made of stainless steel or
the like. The core material (C) and the face material sheets (S1)
and (S2) are carried in the state that the face material sheets
(S1) and (S2) are laminated on each other in an orthogonal form,
and then put between the belts (30) and pressed by the belts (30),
so as to be sent out. At this time, the starting ends of the belts
(30) are heated and pressed by the heating rolls (4) and the
terminal ends of the belts are cooled by the cooling rolls (29).
This makes continuous production of laminated products
possible.
[0378] The three production devices of FIGS. 11, 12 and 13 are
appropriately selected dependently on subsequent processing. That
is, in the case of laminating a surface layer (specifically,
nonwoven fabric, a resin film, a rubber sheet, a flame resistant
material, a weather resistant material or the like) which is not
melted at the time of the laminating on the topmost layer of the
laminated composite in the subsequent processing in order to give
functions (decoration, bonding property, releasing ability, sliding
stop, flame resistance, weather resistance and so on) to the
surface, it is advisable to use the device in the roll manner
illustrated in FIGS. 11(a) and 11(b) or the device in the belt
manner illustrated in FIGS. 13(a) and 13(b), and further supply a
non-melting sheet (S4) for forming the surface layer by means of
the heating rolls (4) or the belt (30) as illustrated in FIGS.
11(b) and 13(b). As illustrated in FIG. 12(b), by setting up
heating rolls (4) for supplying the non-melting sheet separately
before the heating press (26), the non-melting surface layer can be
formed even if the device in the press manner illustrated in FIG.
12(a) is used.
[0379] Among the above-mentioned face material sheets, the sheet
having a higher melting point than that of the face material sheet
used as the surface material can be appropriately used as the
non-melting sheet. Examples thereof include a resin sheet, a paper
sheet, a metal sheet, a ceramic sheet, nonwoven fabric, and woven
fabric.
[0380] Examples of the required function and the material for the
function are as follows:
[0381] Decoration . . . a sheet into which pigment is filled, a
printed sheet, dyeing, or printed nonwoven fabric or woven
fabric
[0382] Bonding . . . a sheet subjected to corona treatment, or a
sheet containing a material having a polar group
[0383] Releasing ability . . . a sheet having a low frictional
coefficient, a sheet painted or coated in order to lower its
frictional coefficient or a plated sheet.
[0384] Sliding stop . . . a sheet having a high frictional
coefficient, a sheet in which irregularities are made, or nonwoven
fabric or woven fabric in which resin or rubber is scattered
[0385] Flame resistance . . . a sheet containing a flame retardant,
a sheet made of nonflammable material (metal, ceramic or the like),
or a sheet painted or plated with nonflammable or flame resistant
material
[0386] Weather resistance . . . a sheet containing an UV absorber,
or a sheet for reflecting light
[0387] In the case of laminating a surface layer newly on the
topmost layer, the surface layer may be deposited across an
adhesive layer thereon. The adhesive layer is not limited and may
be as follows: simultaneous lamination of an HM film, coating with
an adhesive agent by means of a roll coater, spot-coating with an
adhesive agent, use of a face material sheet on which an adhesive
layer is beforehand laminated, or the like.
[0388] In the case of exhibiting decoration, bonding property,
releasing ability, flame resistance or weather resistance by a
melting sheet, the belt system illustrated in FIGS. 13(a) and 13(b)
is selected. In FIG. 13(b), the non-melting sheet (S4) is replaced
by the melting sheet. In this way, the belt (30) keeps releasing
ability in heating and melting, and cooling. Thus, the melting
sheet can be used. Among the above-mentioned materials of the face
material sheet, the material which can be melted and has a lower
melting point than the surface material can be used as the melting
sheet.
[0389] Examples of the required function and the material for the
function are as follows:
[0390] Decoration . . . a sheet into which pigment is filled
[0391] Bonding . . . an HM film, a sheet subjected to corona
treatment, or a sheet containing a material having a polar
group
[0392] Releasing ability . . . a sheet having a low frictional
coefficient
[0393] Sliding stop . . . a sheet having a high frictional
coefficient
[0394] Flame resistance . . . a sheet containing a flame
retardant
[0395] Weather resistance . . . a sheet containing an UV
absorber
[0396] In order to exhibit decoration, bonding property, releasing
ability, flame resistance, weather resistance or the like by a
melting resin having a low viscosity, a liquid paint or the like, a
pair of upper and lower roll coaters (37) may be separately
disposed as illustrated in FIG. 14. Each of the roll coaters (37)
is composed of a paint tank (38), a trans flow roller (39) and a
composition roller (40). While the core material (C) and the face
material sheet (S1) and (S2) are put between the composition
rollers (40) and pressed by the rollers (40), a given paint can be
applied to the lateral sheet (S2).
[0397] Examples of the required function and the material for the
function are as follows:
[0398] Decoration . . . a melting resin into which pigment is
filled, or a liquid paint
[0399] Bonding . . . an HM melting resin, or a melting resin
containing a material having a polar group
[0400] Releasing ability . . . a melting resin having a low
frictional coefficient
[0401] Sliding stop . . . a melting resin having a high frictional
coefficient
[0402] Flame resistance . . . a melting resin containing a flame
retardant
[0403] Weather resistance . . . a melting resin containing an UV
absorber
EXAMPLE 11
[0404] As a core material, a polypropylene foamed body having a
foaming magnification of 10 times, a thickness of 10 mm and a width
of 1200 mm was used. As a sheet for a face material, a polyethylene
drawn sheet having a thickness of 0.2 mm and a width of 1000 mm and
a polyethylene drawn sheet having a thickness of 0.2 mm and a width
of 500 mm were used. As an adhesive layer, a very low density
polyethylene film (manufactured by Tamapoly Co., Ltd.) having a
thickness 60 .mu.m was beforehand laminated on a single face of the
face material sheet.
[0405] As illustrated in FIGS. 15(a) to 15(c), the device for
producing a laminated composite of this Example (the production
device of claim 11) has a core material supplying means for
supplying a core material (C) in the longitudinal direction, a
longitudinal sheet supplying means for supplying a longitudinal
sheet (S1) for a face material, in the longitudinal direction, on
at least one face of the core material (C), a lateral sheet
supplying means for supplying a lateral sheet (S2) for the face
material, in the lateral direction, on the upper face of the
longitudinal sheet (S1), and a sheet thermocompression-bonding
means for pressing the longitudinal sheet (S1) and the lateral
sheet (S2), which are stacked in an orthogonal form, onto the core
material (C) under heating, wherein at a position (73) where the
longitudinal sheet (S1) starts to contact a heating roll (4) of the
sheet thermocompression-bondi- ng means the lateral sheet supplying
means supplies a cut piece (108) of the lateral sheet (S2) between
the heating roll (4) and the longitudinal sheet (S1).
[0406] The method for producing a laminated composite of this
Example (the production method of claim 12) includes a core
material supplying step of supplying a core material (C) in the
longitudinal direction, a longitudinal sheet supplying step of
supplying a longitudinal sheet (S1) for a face material, in the
longitudinal direction, on at least one face of the core material
(C), a lateral sheet supplying step of supplying a lateral sheet
(S2) for the face material, in the lateral direction, on the upper
face of the longitudinal sheet (S1), a sheet
thermocompression-bonding step of pressing the longitudinal sheet
(S1) and the lateral sheet (S2), which are stacked in an orthogonal
form, onto the core material (C) under heating, and a lateral sheet
supplying step of supplying a cut piece (108) of the lateral sheet
between a heating roll (4) and the longitudinal sheet (S1) at a
position where the longitudinal sheet (S1) starts to contact the
heating roll (4) during the sheet thermocompression-bonding
step.
[0407] As illustrated in FIG. 15(a), the core material (C) is first
sent out at a line speed of 1 m/minute by a pair of upper and lower
supplying rolls (1) of the same core material supplying as in
Example 9, and then put between heating rolls (4) having a diameter
of 300 mm and a clearance of 10 mm and pressed by the rolls
(4).
[0408] A pair of upper and lower longitudinal sheet supplying means
is each made of a reel (2) on which the longitudinal sheet (S1)
having a width of 500 mm is wound, and is arranged at the lower
stream of the heating rolls (4) in the core material feed
direction. The longitudinal sheet (S1) is carried along the
periphery of the heating rolls (4) and heated by the same rolls.
Moreover, the longitudinal sheet (S1) together with the core
material (C) is put between the core material (C) and a contact
portion (72) of the rolls (4), and pressed by them. By the feeding
capability of the heating rolls (4), the longitudinal sheet (S1) is
sent out in the core material feed direction and laminated on the
core material (C).
[0409] In the same manner as in Example 9, the longitudinal sheet
supplying means has a tension adjustor based on pad brakes, and a
sheet meandering correcting device based on a position sensor.
[0410] When the above-mentioned supply state becomes stable, the
lateral sheet (S2) made of a polyethylene drawn sheet cut into a
piece having a width of 500 mm and a length of 1000 mm is supplied,
from a lateral sheet supplying device (3), in a direction
perpendicular to the core material feed direction and between the
heating rolls (4) and the longitudinal sheet (S1) at a position
(73) where the longitudinal sheet (S1) starts to contact the
heating rolls (4).
[0411] As illustrated in FIGS. 15(b) and (c), the lateral sheet
supplying means is composed of a lateral rail (81), a longitudinal
rail (82) arranged perpendicularly to this, laterally moving chucks
(83) and (84) and longitudinal moving chucks (85) and (86) for
grasping the lateral sheet (S2), a cylinder (87) for moving the
laterally moving chucks (83) and (84) in the lateral direction
along the lateral rail (81), cylinders (88) and (89) for moving the
longitudinal moving chucks (85) and (86) in the longitudinal
direction along the rail (82), and a cutter for cutting the sheets
for a face material into a given length. Each of the chucks (83),
(84), (85) and (86) has a cylinder and a spring, is closed by
pressing action of the cylinder, and is opened by spring pressure
when the cylinder is released.
[0412] In the lateral sheet supplying means having the
above-mentioned structure, the lateral sheet (S2) is grasped by the
laterally moving chucks (83) and (84) to be fully pulled out in the
width direction along the lateral rail (81). Thereafter, the
lateral sheet (S2) is cut into a given length by the cutter (90)
and a cut piece (108) is passed to the longitudinal moving chucks
(85) and (86). After the laterally moving chucks (83) and (84) are
returned to their original position, the longitudinal moving chucks
(85) and (86) move toward the heating rolls (4) along the
longitudinal rail (82) and the cut piece (108) is supplied to a
position (73) where the longitudinal sheet (S1) starts to contact
the heating rolls (4).
[0413] Thereafter, the longitudinal moving chucks (85) and (86)
also return to their original position. This process is repeatedly
performed. The next cut piece of the lateral sheet (S2) is supplied
in such a manner that the tip of the cut piece in the longitudinal
direction is jointed to the terminal end of the previous cut piece
in the longitudinal direction. This makes it possible to connect a
great number of the cut pieces for the lateral sheet to each other
continuously.
[0414] The lateral sheet (S2) wherein a great number of the cut
pieces are continuously connected is inserted between the heating
rolls (4) and the longitudinal sheet (S1) and pressed by them. The
lateral sheet (S2), together with the longitudinal sheet (S1), is
carried along the peripheral face of the heating rolls (4), and the
longitudinal sheet (S1) and the lateral sheet (S2) are heated.
Further the longitudinal sheet (S1) and the lateral sheet (S2) are
compressed on the core material (C) at a contact portion (72)
between the core material (C) and the heating rolls (4), to produce
a face material sheet in an orthogonal form.
[0415] After the thermocompression, a cooling roll, an air cooler
or the like may be arranged right at the lower stream of the
heating rolls (4) if necessary.
[0416] Another lateral sheet supplying means is illustrated in
FIGS. 16(a) to 16(d). In this example, an upper belt (100) is
stretched on an upper heating roll (4) and three upper cooling
rolls (5). A lower belt (100) is stretched on a lower heating roll
(4) and three lower cooling rolls (5). The respective belts (100)
are driven at the same speed by the driving of the heating rolls
(4). As illustrated in FIGS. 16(a), 16(b), and 16(c), a large
number of holes (101) for attracting are made at portions outer
than the width of the longitudinal sheet (S1) in the belts (100),
and the lower face of the belts (100) is provided with a vacuum
device (102). The vacuum device (102) is made of a hollow air
chamber or a sintered metal, and is connected to a vacuum pump
(103) outside the belts.
[0417] A mechanism for pulling out the lateral sheet (S2) is the
same described on the basis of FIGS. 15(a) to 15(c).
[0418] As illustrated in FIGS. 16(c) and 16(d), a pair of the
lateral sheets (S2) is fully pulled out in the width direction by
chucks (105) and (107), and then is hold by the chucks (105) and
(107) and chucks (104) and (106). The pair is then cut by a cutting
device (109). The resultant pair of cut pieces (108) is attracted
by attracting devices (110) and (111). Thereafter, the chucks (105)
and (107) returns to their original position. The attracting
devices (110) and (111) make an approach to the surface of the belt
(100) by a cylinder (113) for elevation and descent, and the pair
of the cut pieces (108) is fixed on the surface of the belt (100)
by attracting from the rear face of the belt (100). By stopping the
attraction of the attracting devices (110) and (111), the lateral
sheet (S2) is delivered to the belt (100). This process is
repeatedly performed. The next cut piece of the lateral sheet is
supplied in such a manner that the tip of the cut piece in the
longitudinal direction is jointed to the terminal end of the
previous cut piece in the longitudinal direction. This makes it
possible to connect a great number of the cut pieces for the
lateral sheet to each other continuously.
[0419] The lateral sheet (S2) wherein a great number of the cut
pieces are continuously connected is supplied at a position (73)
where the longitudinal sheet (S1) starts to contact the heating
rolls (4) by the belts (100), and inserted between the heating
rolls (4) and the longitudinal sheet (S1) and pressed by them. The
lateral sheet (S2), together with the longitudinal sheet (S1), is
carried along the peripheral face of the heating rolls (4), and the
longitudinal sheet (S1) and the lateral sheet (S2) are heated and
further the longitudinal sheet (S1) and the lateral sheet (S2) are
compressed on the core material (C) at a contact portion (72)
between the core material (C) and the heating rolls (4) to produce
a face material sheet in an orthogonal form.
[0420] In this way, produced are continuously laminated composites
wherein the face material in a longitudinal and laterally
orthogonal form, having a width of 1000 mm, is laminated on the
core material having a thickness of 10 mm and a width of 1200
mm.
EXAMPLE 12
[0421] The production device for a laminated composite of this
Example (the production device of claim 13) is an embodiment
different from the longitudinal sheet supplying means and the
lateral sheet supplying sheet of Example 11. As illustrated in FIG.
17(a), a pair of upper and lower longitudinal sheet supplying means
each has a first reel (45) for supplying an upper longitudinal
sheet wherein narrow longitudinal sheets (S5) are arranged in
parallel at intervals of a lateral direction distance corresponding
to the width of the single narrow longitudinal sheet (S5), and a
second reel (46) for supplying a lower longitudinal sheet wherein
narrow longitudinal sheets (S6) are arranged to be shifted from the
narrow longitudinal sheets (S5) of the upper longitudinal sheet in
the lateral direction by the interval corresponding to the width of
the single narrow longitudinal sheet. The upper longitudinal sheet
and the lower longitudinal sheet are supplied to be arranged
alternately in the lateral direction. A lateral sheet supplying
means is a means for supplying lateral sheets (S2) successively
between the upper longitudinal sheet supplied from the first reel
(45) and the lower longitudinal sheet supplied from the second reel
(46), so as to be arranged in parallel.
[0422] In the production method for a laminated composite of this
Example (the production method of claim 14) a longitudinal sheet
supplying step is a step of arranging the upper longitudinal sheet
and the lower longitudinal sheet alternately in the lateral
direction so as to be supplied, and a lateral sheet supplying step
is a step of supplying the lateral sheets successively between the
upper longitudinal sheet and the lower longitudinal sheet so as to
be arranged in parallel.
[0423] The lateral sheet supplying means is the same as the lateral
sheet supplying device (3) illustrated in FIGS. 15(a) to 15(c). At
a position where the narrow longitudinal sheets (S5) and (S6) start
to contact heating rolls (4) of a sheet thermocompression-bonding
means, a cut piece (108) of the lateral sheet (S2) can be supplied
between the narrow longitudinal sheets (S5) and (S6).
[0424] According to the production device of this Example, as
illustrated in FIG. 17(b), the narrow longitudinal sheets (S5) of
the lower longitudinal sheet are first supplied onto the core
material (C), and the cut piece (108) of the lateral sheet is
supplied onto this. Furthermore, the narrow longitudinal sheets
(S6) of the upper longitudinal sheet are supplied onto the lateral
sheets (S2). This is continuously repeated, thereby obtaining a
laminated composite having uniformity in reinforcing-strength in
the longitudinal direction and the lateral direction, wherein the
narrow longitudinal sheets (S5) and (S6) and the lateral sheets
(S2) are alternately woven.
EXAMPLE 13
[0425] As a core material, a polypropylene foamed body having a
foaming magnification of 10 times, a thickness of 10 mm and a width
of 1200 mm was used. As a sheet for a face material, a polyethylene
drawn sheet having a thickness of 0.2 mm and a width of 1000 mm and
a polyethylene drawn sheet having a thickness of 0.2 mm and a width
of 300 mm were used.
[0426] As illustrated in FIGS. 18(a) and 18(b), the production
device for a laminated composite of this Example (the production
device of claim 15) includes a core supplying means for supplying a
core material (C) in the longitudinal direction, a longitudinal
sheet supplying means for supplying a longitudinal sheet (S1) for a
face material in the longitudinal direction onto at least one face
of the core material (C), a lateral sheet supplying means for
supplying a lateral sheet (S2) for the face material in the lateral
direction onto the upper or lower face of the longitudinal sheet
(S1), a sheet thermocompression-bonding means for pressing the
longitudinal sheet and the lateral sheet, stacked in an orthogonal
form, against the core material under heating, a suction roll (an
example of an attracting roll) (120) set at a position where the
longitudinal sheet (S1) starts to contact a heating roll (4) of the
sheet thermocompression-bonding means, and a single sheet supplying
means for supplying cut pieces (121) of the lateral sheet (S2) one
by one to the suction roll (120).
[0427] The method for producing a laminated composite of this
Example (the production method of claim 16) includes a core
supplying step of supplying a core material (C) in the longitudinal
direction, a longitudinal sheet supplying step of supplying a
longitudinal sheet (S1) for a face material in the longitudinal
direction onto at least one face of the core material (C), a
lateral sheet supplying step of supplying a lateral sheet (S2) for
the face material in the lateral direction onto the upper face of
the longitudinal-sheet (S1), a sheet thermocompression-bonding step
of pressing the longitudinal sheet and the lateral sheet, stacked
in an orthogonal form, against the core material under heating,
wherein the lateral sheet supplying step includes a single sheet
supplying step of supplying cut pieces of the lateral sheet (S2)
one by one to an attracting roll (4) set at a position where the
longitudinal sheet (S1) starts to contact the heating roll (4)
during the sheet thermocompression-bonding step.
[0428] In FIG. 18(a), the core material (c) is supplied to a device
frame (119) in which heating rolls (4) are positioned at a line
speed of 1 m/minute by supplying rolls (1) of the core material
supplying means, and is then heated and pressed by the heating
rolls (4) having a diameter of 300 mm and a clearance of 10 mm.
[0429] Next, in the same way as in Example 10, the longitudinal
sheet is pulled out from reels (2) of a pair of upper and lower
longitudinal sheet supplying means, carried along the periphery of
suction rolls (120) arranged outside the heating rolls (4) and
further along the periphery of the heating rolls (4) so as to be
passed between the core material (C) and the heating rolls (4), and
pressed by the rolls (4). As a result, the core material (C) and
the longitudinal sheet (S1) are melted and bonded to each
other.
[0430] The single sheet supplying means has a structure as
illustrated in FIGS. 19(a) to 19(f). That is, the lateral sheet is
beforehand cut to have a necessary width. The resultant cut pieces
(121) in large numbers are put in a cassette (122). One of the cut
pieces (121) is pulled out from the cassette (122) and reversed at
180.degree. by an attracting and carrying device (123), to be
supplied to suction rolls (120). Thereafter, the attracting and
carrying device (123) is returned to its original position. This
operation is repeatedly performed. As illustrated in FIG. 18(b), a
great number of holes (124) are made at portions outer than the
width of the longitudinal sheet (S1) in the suction rolls (120).
The cut pieces (121) are attracted from the carrying device through
the holes (124). The lateral sheet (S2) made of the cut pieces
(121) in large numbers, together with the longitudinal sheet (S1),
is fed to the heating rolls (4), supplied between the heating rolls
(4) and the longitudinal sheet (S1) at a position (73) where the
longitudinal sheet (S1) starts to contact the heating rolls (4),
carried along the periphery of the heating rolls (4) in the same
manner as in Example 11 to be fed together with the longitudinal
sheet (S1), and pressed at a contact portion (127) between the
heating rolls (4) and the core material (C) under heating. As a
result, the lateral sheet (S2) and the longitudinal sheet (S1) are
melted and bonded to the core material (C).
[0431] The step of supplying the lateral sheet (S2) to the suction
roll will be described in detail on the basis of FIGS. 19(a) to
19(f). As illustrated in FIG. 19(a), the lateral sheet (S2) is
first cut to have a necessary width, and the resultant cut pieces
in large numbers are put in the cassette (122). A pushing spring is
set on the bottom of the cassette (122). Thus, as the cut pieces
decrease, the cut pieces are successively pushed out toward the top
from the bottom so that each of cut pieces (121) is easily caught
by the attracting type carrying device (144). An inward projection
(142) is formed at an outlet portion of the cassette (122) so that
the cut pieces (121) are stopped.
[0432] Next, an attracting section (145) of the attracting type
carrying device (144) connected to a vacuum pump (143) goes to take
up one of the cut pieces (121) at the outlet of the cassette (122)
and contacts the cut piece (121). At this time, the vacuum pump
(143) acts to attract this cut piece (121).
[0433] Next, as illustrated in FIG. 19(c), the attracting section
(145) is rotated at 180.degree. by a servo motor (146) fitted to
the carrying device (144), to carry the cut piece (121) at a
position parallel to the surface of the suction roll (120) (FIG.
19(c)).
[0434] As illustrated in FIGS. 19(d) and 19(e), a great number of
holes (124) are made at portions outer than the width of the
longitudinal sheet (S1) in the suction rolls (120). The cut piece
(121) is attracted through the holes (124) by attracting force of
the vacuum pump (125). The cut piece (121) is moved from the
carrying device (144) toward the suction roll (120) by weakening
the attracting force of the carrying device (144). Thereafter, the
attracting and carrying device (123) is returned to its original
position. This operation is repeated.
[0435] The supply of the lateral sheets (S2) may be continuously
performed as illustrated in FIG. 19(f). A mechanism for the
continuous supply is the same as in Example 9.
[0436] As illustrated in FIG. 20, a great number of narrow
longitudinal sheets (S1) maybe sent out in a hound-tooth check
form. In other words, it is allowable that the sheets are composed
of sheets (161) supplied to the suction roll (160) in the feed
direction and sheets (162) supplied in the reverse feed direction,
only the former embrace the suction roll (160), and the latter
embrace another intermediate roll, thereby supplying the
longitudinal sheets to the heating rolls (4). In this method,
attracting holes (164) can be made in the entire surface of the
suction rolls (160) in the width direction.
[0437] In this way, produced are continuously laminated composites
illustrated in FIG. 4 wherein the face material in a longitudinal
and laterally orthogonal form, having a width of 1000 mm, is
laminated on the core material having a thickness of 10 mm and a
width of 1200 mm.
EXAMPLE 14
[0438] As illustrated in FIG. 21, the production device for a
laminated composite of this Example (the production method of claim
17) includes a core material supplying means for supplying a core
material (C) in the longitudinal direction, a longitudinal sheet
supplying means for supplying a longitudinal sheet (S1) for a face
material, in the longitudinal direction, onto at least one face of
the core material (C), a first thermocompression-bonding means for
pressing the longitudinal sheet (S1)and the core material (C) under
heating to form an intermediate lamination, a first cutting means
for cutting the intermediate lamination, a carrying means for
carrying cut pieces (L1) of the intermediate lamination in a
direction having a given angle (90.degree. in the present Example)
to the longitudinal direction, a lateral sheet supplying means for
supplying a lateral sheet (S2) for the face material, in the
carriage direction, onto the upper face or the lower face of the
cut pieces (L1), a second thermocompression-bonding means for
pressing the cut pieces (L1) of the intermediate lamination and the
lateral sheet (S2), which are stacked, under heating to form a
final lamination (L2), and a second cutting means for cutting the
final lamination (L2).
[0439] The production method for a laminated composite of this
Example (the production method of claim 18) includes a core
material supplying step of supplying a core material (C) in a
longitudinal direction, a longitudinal sheet supplying step of
supplying a longitudinal sheet (S1) for a face material, in the
longitudinal direction, onto at least one face of the core material
(C); a first thermocompression-bonding step of pressing the
longitudinal sheet (S1) and the core material (C) under heating to
form an intermediate lamination (L1), a first cutting step of
cutting the intermediate lamination, a carrying step of carrying
cut pieces (L1) of the intermediate lamination in a direction
having a given angle (90.degree. in the present Example) to the
longitudinal direction, a lateral sheet supplying step of supplying
a lateral sheet (L2) for the face material, in the carriage
direction, onto the upper face or the lower face of the cut pieces
(L1) of the intermediate lamination, a second
thermocompression-bonding step of stacking and pressing the
intermediate lamination (L1) and the lateral sheet (S2) under
heating to form a final lamination (L2), and a second cutting step
of cutting the final lamination (L2).
[0440] In these Examples, the core material supplying means and the
longitudinal sheet supplying means are the same as in Example 9,
and the first thermocompression-bonding means is the same as the
thermocompression-bonding means in Example 9. About the first
cutting means, its structure itself is the same as that of the
cutting means in Example 9 but the arrangement position thereof is
not just after the lateral sheet supplying means but just after
threatening rolls (4) as the thermocompression-bonding means. Only
by adhering the longitudinal sheet (S1) to the core material (C),
an intermediate lamination cut into a constant size is first
formed. This intermediate lamination is sent out in the advance
direction (in the longitudinal direction), and runs off from the
carrying line in the longitudinal direction. Thereafter, the
lamination is carried in the lateral direction by a cylinder
(55).
[0441] The lateral sheet supplying means for pulling out the
lateral sheet (S2) to the upper face of the cut pieces (L1) of the
intermediate lamination has the same structure as the longitudinal
sheet supplying means. Namely, this means is composed of a reel
(56) on which the lateral sheet (S2) is wound, and a pushing roll
(57) for pushing, against the intermediate lamination, the lateral
sheet (S2) pulled out from the reel (56) to the surface of the
intermediate lamination along this. This pulling-out direction is
different from the longitudinal sheet supplying means by
90.degree.. In this way, the lateral sheet (S2) is supplied and
thermocompression-bonded in the same manner as the longitudinal
sheet (S1) while the cut pieces (L1) of the intermediate lamination
move in the lateral direction.
[0442] The second thermocompression-bonding means has the same
structure as the first thermocompression-bonding means. Namely, the
second means has a pair of heating rolls (58). By heating and
pressing the cut pieces (L1) of the intermediate lamination and the
lateral sheet (S2), which are stacked, a final lamination (L2) is
formed. About the final lamination (L2), the lateral sheet (S2)
portion thereof is cut at positions corresponding to size of the
respective cut pieces (L1) of the intermediate lamination by the
second cutting means.
[0443] In this way, produced are continuously laminated composites
illustrated in FIG. 4 wherein the face material in a longitudinal
and laterally orthogonal form, having a width of 1000 mm, is
laminated on the core material having a thickness of 10 mm and a
width of 1200 mm.
EXAMPLE 15
[0444] As illustrated in FIG. 22, the production device for a
laminated composite of this Example (the production device of claim
19) includes a core material supplying means for supplying a core
material (C) in the longitudinal direction, a longitudinal sheet
supplying means for supplying a longitudinal sheet (S1) for a face
material, in the longitudinal direction, onto at least one face of
the core material, a first thermocompression-bonding means for
pressing the longitudinal sheet (S1) and the core material (C)
under heating to form an intermediate lamination, a first cutting
means for cutting the intermediate lamination, a carrying means for
rotating cut pieces (L1) of the intermediate lamination at an angle
of 90.degree. to carry the cut pieces in the longitudinal
direction, a lateral sheet supplying means for supplying a lateral
sheet (S2) for the face material, in the longitudinal direction,
onto the upper face or the lower face of the cut pieces (L1), a
second thermocompression-bonding means for pressing the cut pieces
(L1) of the intermediate lamination and the lateral sheet (S2),
which are stacked, under heating to form a final lamination (L2),
and a second cutting means for cutting the final lamination
(L2).
[0445] The production method for a laminated composite of this
Example (the production method of claim 20) includes a core
material supplying step of supplying a core material (C) in the
longitudinal direction, a longitudinal sheet supplying step of
supplying a longitudinal sheet (S1) for a face material, in the
longitudinal direction, onto at least one face of the core material
(C), a first thermocompression-bonding step of pressing the
longitudinal sheet (S1) and the core material (C) under heating to
form an intermediate lamination, a first cutting step of cutting
the intermediate lamination, a carrying step of rotating cut pieces
(L1) of the intermediate lamination at an angle of 90.degree. to
carry the cut pieces in the longitudinal direction, a lateral sheet
supplying step of supplying a lateral sheet (L2) for the face
material, in the longitudinal direction, onto the upper face or the
lower face of the cut pieces (L1), a second
thermocompression-bonding step of stacking and pressing the cut
pieces (L1) of the intermediate lamination and the lateral sheet
(S2) under heating to form a final lamination (L2), and a second
cutting step of cutting the final lamination (L2).
[0446] In this Example, the core material supplying means and the
longitudinal sheet supplying means are the same as in Example 9,
and the first thermocompression-bonding means is the same as the
thermocompression-bonding means in Example 9. About the first
cutting means, its structure itself is the same as that of the
cutting means in Example 9 but the arrangement position thereof is
not just after the lateral sheet supplying means but just after the
heating rolls (4) as the thermocompression-bonding means. Only by
adhering the longitudinal sheet (S1) to the core material (C), an
intermediate lamination cut into a constant size is first formed.
This intermediate lamination is sent out in the advance direction
(in the longitudinal direction), and the direction is rotated at
90.degree. by attracting pads (61). Furthermore, the intermediate
lamination is continuously carried in a carrying line along the
longitudinal direction.
[0447] The lateral sheet supplying means for pulling out the
lateral sheet (S2), in the longitudinal direction, onto the upper
face of the cut pieces (L1) of the intermediate lamination has the
same structure and as the longitudinal sheet supplying means.
Namely, this means is composed of a reel (62) on which the lateral
sheet (S2) is wound, and a pushing roll (63) for pushing, against
the intermediate lamination, the lateral sheet (S2) pulled out from
the reel (62) to the surface of the intermediate lamination along
this. The pulling-out direction is also the same as in the case of
the longitudinal sheet supplying means. In this way, the lateral
sheet (S2) is supplied and thermocompression-bonded in the same
manner as the longitudinal sheet (S1) while the cut pieces (L1) of
the intermediate lamination move in the longitudinal direction.
[0448] The second thermocompression-bonding means has the same
structure as the first thermocompression-bonding means. Namely, the
second means has a pair of heating rolls (64). By heating and
pressing the cut pieces (L1) of the intermediate lamination and the
lateral sheet (S2), which are stacked, the final lamination (L2) is
formed. About the final lamination (L2), the lateral sheet (S2)
portion thereof is cut at positions corresponding to size of the
respective cut pieces (L1) of the intermediate lamination by the
second cutting means.
[0449] In this way, produced are continuously laminated composites
illustrated in FIG. 4 wherein the face material in a longitudinal
and laterally orthogonal form, having a width of 1000 mm, is
laminated on the core material having a thickness of 10 mm and a
width of 1200 mm.
INDUSTRIAL APPLICABILITY
[0450] A device and a method for producing a laminated composite
according to the present invention are those for laminating at
least one sheet on at least one face of a sheet-form core material,
and can be used as a production method and a production device for
obtaining a civil engineering and construction material, a
construction material including a tatami mat core material, a
material for vehicles, and the like.
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