Method for manufacturing laminate reinforcing material, laminate reinforcing material, and box, tube, board, or edge protector using laminate reinforcing material

Abstract

To manufacture a laminate reinforcing material that can be reused without separating and crushing wallpaper (composite material), and that is inexpensive and satisfies strength requirements.SOLUTION: A method for manufacturing a laminate reinforcing material includes: a lamination step in which a composite material 2, in which a synthetic resin 2a is bonded to a base material 2b, is laminated in a plurality of layers; and a bonding step of bonding the composite material laminated in the lamination step by pressure bonding. The base material includes paper, woven fabric, or nonwoven fabric, and the synthetic resin includes polyvinyl chloride, polyurethane, polyethylene, etc.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a method for producing a laminated reinforcement material including a composite material formed by laminating a synthetic resin to a substrate, and to a laminated reinforcement material, and more particularly to a method for producing a laminated reinforcement material in which the composite material is wallpaper. [Background technology]

[0002] Wallpapers used as interior finishing materials for walls and ceilings are composite sheets made of paper or fabric with synthetic resin. With the advancement of technology that allows for coloring, delicate unevenness, and subtle texture, many of these wallpapers have highly designed designs, such as plaster, brick, knitted, and polka dot patterns. Furthermore, various additional functions, such as water repellency, deodorizing properties, antibacterial properties, antiviral properties, chemical resistance, stretchability, and ease of application, can be added by adjusting the composition of the synthetic resin, the presence or absence of glue, glue materials, coating techniques, and paper or cloth substrates. Despite these many advantages, wallpapers are widely used as interior finishing materials, especially in Japan, because of their low manufacturing and application costs.

[0003] Conventionally, defective and surplus wallpaper generated during manufacturing and distribution were either discarded as they were or crushed and reused because they were difficult to separate into individual materials due to the fact that they were composite materials (see Patent Documents 1 and 2, etc.).

[0004] On the other hand, edge protectors (also called edge boards, L-shaped angles, tough boards, angles, corner angles, corner guards, corner guards, etc.) are used to protect cargo during transportation. Edge protectors are generally made of cardboard, but some are made of plastic. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 6-31732 [Patent Document 2] Japanese Patent Application Publication No. 6-114838 Summary of the Invention [Problem to be solved by the invention]

[0006] However, there was an issue that disposing of defective and surplus wallpaper that occurs during manufacturing and distribution as is (incinerated) would be an environmental burden.In addition, because wallpaper (composite material) is manufactured to be "strong" despite each sheet being highly flexible due to its intended use, there was an issue that energy is required for crushing and for further pelletizing the crushed material. Furthermore, if the edge protector was made of paper, it would lack strength and be prone to damage to the cargo, while if it was made of plastic, the cost would be high depending on the conditions. [Means for solving the problem]

[0007] Therefore, in order to solve these problems, the inventors worked hard to develop a reinforcing material (an edge protector and a reinforcing material that can be used for purposes other than edge protectors) that can be reused without separating and crushing the wallpaper (composite material), is inexpensive, and meets the strength requirements. In other words, the manufacturing method of a laminated reinforcement material of the present invention is a manufacturing method of a laminated reinforcement material, which includes a lamination process of stacking multiple composite materials each having a synthetic resin bonded to a base material, and a pressing process of pressing the composite laminate stacked in the lamination process, and is characterized in that the base material includes paper, woven fabric, or nonwoven fabric.

[0008] The synthetic resin preferably includes one or more of polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), ethylene vinyl acetate copolymer (EVA), polyurethane (PU), polyolefin including polypropylene (PP) / polyethylene (PE), and ABS resin.

[0009] The lamination process desirably includes one or more of a stacking lamination process in which the composite material is cut and stacked, a roll press lamination process in which the composite material is rolled into a roll and pressed to form a laminated state, and a fold press lamination process in which the composite material is folded and pressed to laminate.

[0010] The bonding step preferably includes welding by heat, high frequency or ultrasonic welding.

[0011] The laminated reinforcing material of the present invention is characterized in that it is produced by the above-mentioned method for producing a laminated reinforcing material.

[0012] The box, cylinder, plate, or edge protector of the present invention is characterized by using the above-mentioned laminated reinforcing material. Effect of the Invention

[0013] According to the present invention, it is possible to manufacture a laminated reinforcing material by reusing defective or surplus wallpaper in sheet form without separating or crushing it, which leads to a reduction in processing steps such as crushing the composite wallpaper material as a raw material, and a reduction in waste, and also provides a reinforcing material that is inexpensive and meets strength requirements. [Brief description of the drawings]

[0014] [Figure 1] FIG. 1(a) shows an example of a cross-sectional view of wallpaper that is the raw material for the laminated reinforcement material of the present invention, FIG. 1(b) shows an example of a composite laminate with the wallpaper of FIG. 1(a) stacked on top, FIG. 1(c) shows an example of a composite laminate in which the wallpaper of FIG. 1(a) is rolled up into a roll and pressed into a laminated state, and FIG. 1(d) shows an example of a composite laminate in which the wallpaper of FIG. 1(a) is folded and pressed into a laminated state. [Diagram 2] Figure 2(a) is an example photograph of wallpaper that is the raw material for the laminated reinforcement material of the present invention, Figure 2(b) is an example photograph of the wallpaper of Figure 2(a) cut using a die, Figure 2(c) is an example photograph of a composite laminate with Figure 2(b) stacked on top of each other, and Figure 2(d) is an example photograph of a composite laminate with Figure 2(a) rolled up and pressed into a laminated state. [Diagram 3] Fig. 3 shows an example of the laminated reinforcement material of the present invention. Fig. 3(a) shows an example of the shape of the laminated reinforcement material, and Fig. 3(b) is an example of a photograph of the laminated reinforcement material. [Figure 4]Figure 4(a) shows an example of the band fastening state when the laminated reinforcement of the present invention is used as an edge protector for transport cargo. Figure 4(b) shows an example of the band fastening state when a conventional edge protector is used for transport cargo. Figure 4(c) shows an example of the band fastening state for transport cargo without an edge protector. [Diagram 5] The laminated reinforcement material of the present invention is used as an edge protector. Figure 5(a) shows an example of the edge protector being used as a corner protector for a band that fastens multiple cargoes for transport, and Figure 5(b) shows an example of the edge protector being used to prevent the collapse of stacked cargoes for transport and to protect the edges. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] The embodiments of the present invention will be specifically described below, but the present invention is not limited to these embodiments.

[0016] The method for producing the laminated reinforcement material 1 of the present invention includes a step of laminating the composite material 2 and a step of pressing the composite laminate 3 together.

[0017] As shown in FIG. 1(a) and FIG. 2(a), a composite material 2 has a structure in which a synthetic resin 2a is bonded to a base material 2b. The base material 2b and the synthetic resin 2a may be bonded together using an adhesive, or may be bonded together by welding the synthetic resin without using an adhesive.

[0018] The substrate 2b includes paper, woven fabric, or nonwoven fabric. Paper is made by intertwining natural fibers into a thin, flat shape, woven fabric is a fabric made by combining fibers lengthwise and widthwise, and nonwoven fabric is made by intertwining fibers without weaving them into a sheet shape. The substrate 2b of the composite material 2, which is the raw material of the laminated reinforcing material 1 used for reinforcement, is preferably paper, but is not limited thereto. Furthermore, the paper used as the base material 2b may include an adhesive layer (glue), a coating layer, etc. When wallpaper is used as the composite material 2, various additives used to enhance the wallpaper function may be contained in the base material 2b.

[0019] Examples of the synthetic resin 2a include one or more of polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), ethylene-vinyl acetate copolymer (EVA), polyurethane (PU), polyolefin including polypropylene (PP) / polyethylene (PE), and ABS resin. When high-frequency welding is performed in the pressure bonding process described below, it is desirable to select a polar resin (dielectric) such as polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), ethylene-vinyl acetate copolymer (EVA), polyurethane (PU), polyolefin, etc. Furthermore, when ultrasonic welding is performed in the compression bonding process described below, it is desirable to select the resin from polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), ethylene vinyl acetate copolymer (EVA), polyolefins including polypropylene (PP) / polyethylene (PE), ABS resin, polyamide (PA), polystyrene (PS), polyester (PET), polyacetal (POM), phenolic resin (PF), urea resin (UF), epoxy resin (EP), etc. The synthetic resin 2a may be one type of synthetic resin alone or two or more types of synthetic resins in combination. In addition, when wallpaper is used as the composite material 2, the synthetic resin 2a may contain various additives used to improve the wallpaper function, as well as various additives normally used in synthetic resins, such as stabilizers and colorants.

[0020] The lamination process of the composite material 2 desirably includes one or more of a stacking lamination process of cutting and stacking the composite material 2 (see Figures 1(b), 2(b), and 2(c)), a roll press lamination process of rolling the composite material 2 into a roll shape and pressing it to form a laminated state (see Figures 1(c) and 2(d)), and a fold press lamination process of folding, pressing, and laminating the composite material 2 (see Figure 1(d)).

[0021] The stacking step involves cutting and stacking composite materials 2 to form a composite laminate 3 (see Figs. 1(b), 2(b) and 2(c)). Cutting may be performed using a die or a cutter. As shown in Fig. 1(b), it is preferable to stack the base material 2b and the synthetic resin 2a so that they alternate, but if the base material 2b contains an adhesive or is thin, the overlapping direction may be random. The number of sheets to be loaded is appropriately selected depending on the use and purpose of the laminated reinforcement material 1, the material and thickness of the composite material 2, etc. When it is desired to manufacture a laminated reinforcement material 1 having the strength of a conventional edge protector, it is preferable to laminate 5 to 30 sheets of the composite material 2, and more preferably 10 to 30 sheets, 10 to 25 sheets, or 10 to 20 sheets.

[0022] In the roll press lamination process, a composite material 2 is rolled into a roll and pressed into a laminated state to form a composite laminate 3 (see Fig. 1(c) and Fig. 2(d)). When rolling the laminated reinforcement material 1 into a roll, the size of the laminated reinforcement material 1 to be manufactured and the number of sheets to be stacked should be taken into consideration. In the examples of Figures 1(c) and 2(d), the laminated reinforcement material 1 is rolled with the base material 2b on the outside, but the laminated reinforcement material 1 may be rolled with the base material 2b on the inside. The number of sheets to be loaded is appropriately selected depending on the use and purpose of the laminated reinforcement material 1, the material and thickness of the composite material 2, etc. When it is desired to manufacture a laminated reinforcement material 1 having the strength of a conventional edge protector, it is preferable to roll 5 to 30 sheets of the composite material 2, and more preferably to roll 10 to 30 sheets, 10 to 25 sheets, or 10 to 20 sheets. In the roll press lamination step, the ends of the composite laminate 3 that will become the folding lines may be cut, if necessary.

[0023] The folding and pressing lamination process involves folding and pressing the composite material 2 into a laminated state to form a composite laminate 3 (see FIG. 1(d)). When folding, the size of the laminated reinforcement material 1 to be manufactured and the number of sheets to be overlapped are taken into consideration. In the example of Fig. 1(d), one sheet of the composite material 2 is folded in an accordion shape, but the folding method is not limited to this. For example, the composite material 2 may be folded once in a mountain fold (or a valley fold) so that either the base material 2b or the synthetic resin 2a faces inward, and then folded in an accordion shape. The number of sheets to be loaded is appropriately selected depending on the use and purpose of the laminated reinforcement material 1, the material and thickness of the composite material 2, etc. When it is desired to manufacture a laminated reinforcement material 1 having the strength of a conventional edge protector, it is preferable to fold the composite material 2 so that 5 to 30 sheets are laminated, and more preferably, 10 to 30 sheets, 10 to 25 sheets, or 10 to 20 sheets are laminated. In addition, the composite laminate 3 formed in the folding and pressing lamination process has a structure in which the base materials 2b face each other. Therefore, this lamination method is effective when the base materials 2b contain an adhesive or when the base materials 2b are thin.

[0024] The lamination process of the composite material 2 may include a step of further stacking a plurality of composite laminates 3 obtained in one or more of the stacking lamination process, the roll pressure lamination process, and the folding pressure lamination process, or a step of further stacking a plurality of composite laminates 3 obtained in the same lamination process.

[0025] The process of pressing the composite laminate 3 is a process of pressing the composite laminate 3 that has been laminated in the process of laminating the composite material 2 . The bonding step preferably includes welding by heat, radio frequency or ultrasonic welding.

[0026] High-frequency welding involves welding the base material 2b and the synthetic resin 2a of the composite laminate 3 by high-frequency dielectric heating. High-frequency dielectric heating is a method of internal heating in which dielectric synthetic resin, through which direct current barely flows, is polarized by applying a voltage, causing the orientation of atoms to change rapidly, generating frictional heat.

[0027] In ultrasonic welding, ultrasonic vibrations are applied to the base material 2b and synthetic resin 2a of the composite laminate 3 by ultrasonic waves, generating heat at the interface.

[0028] The compression bonding step of the composite laminate 3 desirably further includes a step of pressing the composite laminate 3 with dies (upper and lower dies). Specifically, the composite laminate 3 is set in a die that matches the size of the laminated reinforcement material 1, and then welding is performed.

[0029] The conditions of the pressure bonding process are appropriately set depending on the physical properties and size required for the laminated reinforcement material 1. For example, when using a mold for obtaining a laminated reinforcement material 1 having a shape as shown in FIG. 3(a) and FIG. 3(b) (width A of laminated reinforcement material: about 50 mm, width B of laminated reinforcement material: about 50 mm, length L of laminated reinforcement material: about 350 mm, thickness T of laminated reinforcement material: about 2.2 mm, synthetic resin 2a of composite material 2 (wallpaper): vinyl chloride, base material 2b: plain paper, number of layers: 10), the welding conditions of high-frequency welding are generally exemplified as follows: current value 0.6A to 1.5A, synchronization 1.5V to 5.0V, speed 01 to 05 (increasing by 0.01A / sec to 0.05A / sec), welding time 30 seconds to 100 seconds, and cooling time 10 seconds to 100 seconds. The welding conditions vary depending on the equipment, processing surface area, thickness, etc. In addition, since moisture contained in the composite material 2 may be generated inside the mold, in such a case it is desirable to perform the pressing operation several times (for example, about three times). Also, a step of removing moisture from the composite material 2 (wallpaper) may be added before the pressing step or the lamination step.

[0030] A step of cutting the composite laminate 3 may be added to the compression bonding step.

[0031] The laminated reinforcing material 1 of the present invention is produced by the above-mentioned method for producing the laminated reinforcing material 1 (illustrated in Figs. 3(a), 3(b), 4(a), 5(a) and 5(b)). The shape of the laminated reinforcement material 1 can be designed depending on the object or location that requires reinforcement. Examples include boxes and tubes used for transportation, distribution, and carrying, boards when a simple wall or stand is required, and L-shaped edge protectors when edge protection of transported cargo is required. The box-, tube-, plate-, or L-shaped laminated reinforcement material 1 uses highly decorative wallpaper layered as the composite material 2, so the thickness (the number of composite materials 2, etc.) and color can be easily adjusted depending on the application or purpose. This enhances the design of the laminated reinforcement material 1, and by using color-coded laminated reinforcement materials 1, it is also possible to improve the identification of cargo for transportation, for example. EXAMPLES

[0032] The following describes an embodiment of the present invention. A laminated reinforcement material 1 having the shape shown in FIG. 3(a) was produced. The wallpaper of the composite material 2 had a thickness of 0.25 mm, the synthetic resin 2a was polyvinyl chloride (white), the base material 2b was plain paper without adhesive, and was manufactured by Chuetsu Pulp Co., Ltd., model number CP-64. The above wallpaper was cut and 10 sheets were stacked as shown in Figure 1(b) and Figure 2(c) to form a composite laminate 3. For evaluation purposes, a mold was made for the laminated reinforcement 1 with a length L of 350 mm, a thickness T of 2.2 mm, widths A and B of 47 mm, and an L-shaped angle of 90°. The die and composite laminate 3 were set in a bonding machine (manufactured by Yamamoto Vinita, model number VC-10000WF) and bonding was performed. The bonding conditions were current 0.82A, synchronization 25 (2.5V), speed 03, welding time 10 seconds, and cooling time 25 seconds. Bonding was repeated three times, and the die was opened during cooling to allow moisture to evaporate.

[0033] The resulting laminated reinforcement material 1 was evaluated for compressive strength and surface hardness. The compressive strength was measured using a compressive strength meter (Model VGS5F, manufactured by Toyo Seiki Seisakusho Co., Ltd.) The measurement was performed at a compression speed of 100 mm / min, with the sample cut to a length of 50 mm. The surface hardness was measured using a rubber hardness tester (rubber / plastic hardness tester, manufactured by Techlock Corporation, model number GS-706N) by pressing the tester against the surface of the laminated reinforcement material 1. The results of the examples are shown in Table 1.

[0034] Next, the compressive strength and surface hardness of the conventional product were evaluated in the same manner. Conventional product 1 was a reinforcing material made from recycled paper, with a length L of 350 mm, a thickness T of 2.2 mm, widths A and B of 52 mm, and an L-shaped angle of 96°. Conventional product 2 was a reinforcing material made by crushing wallpaper into pellets, with the length L of the reinforcing material being 350 mm, the thickness T being 3.0 mm, the widths A and B being 53 mm, and the L-shaped angle being 102°. The results for the conventional product are also shown in Table 1 along with the examples.

[0035] [Table 1]

[0036] As shown in Table 1, it was found that the laminated reinforcing material of Example 1 had compressive strength and surface hardness equivalent to (or equivalent or greater in some cases) that of conventional products, without the need for separation or crushing of the composite material (wallpaper). Note that, although 10 sheets of wallpaper were layered in Example 1, the desired physical properties can be obtained by increasing or decreasing the number of layers or by changing the type of wallpaper.

[0037] Figure 4(a) shows a photo of the laminated reinforcement material of the present invention used to protect the edges of cargo for transport. Compared to Figure 4(b) where a conventional product made from recycled paper was used as the reinforcement material, it was found that the edges of the cargo for transport were equally protected from the tightening band. In addition, in Figure 4(c) where no reinforcement material was used, it can be seen that the tightening band was digging into the edges of the cargo for transport, causing damage.

[0038] Figure 5(a) shows an example of edge protectors being used as corner protectors for bands used to fasten multiple cargoes for transport, and Figure 5(b) shows an example of edge protectors being used to prevent stacked cargoes for transport from shifting and to protect the edges. In both cases, it was found that the edges of the cargoes for transport were successfully protected.

[0039] The present invention may have the following configurations. [Section 1] A lamination process of laminating a plurality of composite materials each having a base material and a synthetic resin bonded thereto; a compression step of compressing the composite laminate laminated in the lamination step; A method for producing a laminated reinforcement material, comprising: The method for producing a laminated reinforcement material, wherein the substrate comprises paper, woven fabric, or nonwoven fabric. [Section 2] The method for producing a laminated reinforcement material according to item 1, wherein the synthetic resin comprises one or more of polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), ethylene-vinyl acetate copolymer (EVA), polyurethane (PU), polyolefin including polypropylene (PP) / polyethylene (PE), and ABS resin. [Section 3] 3. The method for producing a laminated reinforcement material according to claim 1 or 2, wherein the lamination step includes one or more steps of a loading lamination step of cutting and stacking the composite material, a roll press lamination step of rolling the composite material into a roll shape and pressing it to form a laminated state, and a folding press lamination step of folding and pressing the composite material to laminate it. [Section 4] 4. The method for producing a laminated reinforcement material according to any one of items 1 to 3, wherein the pressure bonding step includes welding by heat welding, high frequency welding, or ultrasonic welding. [Section 5] 6. A laminated reinforcing material produced by the method for producing a laminated reinforcing material according to any one of items 1 to 5. [Section 6] Item 5. A box, a tube, a plate, or an edge protector using the laminated reinforcing material according to item 5. [Explanation of symbols]

[0040] 1 Laminated reinforcement 2 Composite material (wallpaper) 2a Synthetic resin 2b Base material 3 Composite laminate A Width of laminated reinforcement B Width of laminated reinforcement L Length of laminated reinforcement T thickness of laminated reinforcement

Claims

1. A lamination process of laminating a plurality of composite materials each having a base material and a synthetic resin bonded thereto; a compression step of compressing the composite laminate laminated in the lamination step; A method for producing a laminated reinforcement material, comprising: The method for producing a laminated reinforcement material, wherein the substrate comprises paper, woven fabric, or nonwoven fabric.

2. 2. The method of claim 1, wherein the synthetic resin comprises one or more of polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), ethylene vinyl acetate copolymer (EVA), polyurethane (PU), polyolefins including polypropylene (PP) / polyethylene (PE), and ABS resin.

3. 3. The method for manufacturing a laminated reinforcement material according to claim 1 or 2, wherein the lamination process includes one or more of a loading lamination process in which the composite material is cut and loaded, a roll press lamination process in which the composite material is rolled into a roll shape and pressed to form a laminated state, and a folding press lamination process in which the composite material is folded and pressed to laminate.

4. The method for producing a laminated reinforcement material according to claim 1 , wherein the pressure bonding step includes welding by heat welding, high frequency welding or ultrasonic welding.

5. A laminated reinforcement material produced by the method for producing a laminated reinforcement material according to claim 1.

6. A box, a tube, a plate, or an edge protector, which uses the laminated reinforcing material according to claim 5.

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