Laminate manufacturing method and laminate

Abstract

To provide a laminate manufacturing method capable of manufacturing a laminate in which a resin film is sufficiently firmly attached to a strand even if using expanded metal having undulation in its mesh.SOLUTION: A laminate manufacturing method includes the steps of: placing a resin film and a release film upon heated expanded metal in this order and fabricating an overlapped body; and pressing a rubber plate having Shore A hardness of 40-60 against the release film of the overlapped body and bonding the resin film to the expanded metal.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present disclosure relates to a method for producing a laminate and the laminate. [Background technology]

[0002] 2. Description of the Related Art Laminates formed by laminating a film onto an expanded metal have been used in the past as various members (eg, sound absorbing materials) (eg, Patent Documents 1 and 2).

[0003] "Expanded metal" refers to wire mesh made by expanding a metal plate into a mesh shape using the expanding process. More specifically, expanded metal is obtained by expanding a metal plate while making slits in it with a mountain-shaped upper blade and a flat lower blade. Therefore, unlike punched wire mesh, expanded metal has undulations in the mesh (i.e., steps between the strands and bonds). "Strand" refers to the thin parts of the mesh. "Bond" refers to the thick parts where the mesh intersects.

[0004] Patent Document 3 discloses a membrane vibration sound absorbing board. The membrane vibration sound absorbing board disclosed in Patent Document 3 is formed by sandwiching a transparent resin thin film between two plate-shaped bodies having a large number of openings. One of the two plate-shaped bodies is an aluminum expanded metal that has been flattened (hereinafter, also referred to as a "flat processed product"). Patent Document 3 describes that by using the flat processed product, contact with the transparent resin thin film is more sufficient than when an expanded metal with an undulating mesh is used, and the sound absorbing characteristics of the membrane vibration sound absorbing board are improved. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2007-324389 A [Patent Document 2] JP 2020-073318 A [Patent Document 3] JP 2007-303080 A Summary of the Invention [Problem to be solved by the invention]

[0006] Expanded metal is less expensive than flattened products, and so there is a demand for a method for producing a laminate in which the resin film is sufficiently adhered to the strands even when an expanded metal having an undulating mesh is used.

[0007] The present disclosure has been made in consideration of the above circumstances. The problem that the embodiments of the present disclosure aim to solve is to provide a method for producing a laminate that can produce a laminate in which a resin film is sufficiently adhered to the strands, even when an expanded metal having an undulating mesh is used, and the laminate. [Means for solving the problem]

[0008] Specific means for solving the above problems include the following aspects.

[0009] <1> A step of placing a resin film and a release film in this order on the heated expanded metal to produce a laminate; a step of pressing a rubber plate having a Shore A hardness of 40 to 60 against the release film of the laminate to bond the resin film to the expanded metal; A method for producing a laminate, comprising: <2> The material of the resin film is a hot melt resin composition. <1> A method for producing the laminate described in claim 1. <3> The hot melt resin composition includes at least one selected from the group consisting of polyester, polyethylene, polypropylene, polyurethane, polyamide, a thermoplastic elastomer obtained by mixing a styrene-based elastomer and a polyolefin, and a thermoplastic elastomer obtained by mixing an ethylene-based rubber and a polypropylene. <2> A method for producing the laminate described in claim 1. <4> The thickness of the strand of the expanded metal is 500 μm to 8,000 μm, The thickness of the resin film is 15 μm to 500 μm. <2> A method for producing the laminate described in claim 1. <5> The rubber plate includes silicone rubber. <1> ~ <4> 13. A method for producing the laminate according to claim 12. <6> The rubber plate is heated. <1> ~ <5> 13. A method for producing the laminate according to claim 12. <7> Expanded metal and a resin film adhered to at least one main surface of the expanded metal; Equipped with The expanded metal has a plurality of strands and a plurality of bonds connecting three or more of the plurality of strands, a plurality of meshes are formed by the plurality of strands and the plurality of bonds; The ratio of the total number of adhesive meshes to the total number of the plurality of meshes is 80% or more; The bonded mesh refers to a mesh in which all of the strands forming one of the meshes are bonded to the resin film. <8> The material of the resin film is a hot melt resin composition. <7> The laminate according to claim 1. <9> The hot melt resin composition includes one selected from the group consisting of polyester, polyethylene, polypropylene, polyurethane, polyamide, a thermoplastic elastomer obtained by mixing a styrene-based elastomer and a polyolefin, and a thermoplastic elastomer obtained by mixing an ethylene-based rubber and a polypropylene. <8> The laminate according to claim 1. <10> The thickness of the strand is 500 μm to 8,000 μm, The thickness of the resin film is 15 μm to 500 μm. <8> or <9> The laminate according to claim 1. Effect of the Invention

[0010] According to one embodiment of the present disclosure, a method for manufacturing a laminate is provided that can produce a laminate in which a resin film is sufficiently adhered to the strands even when an expanded metal having an undulating mesh is used, and the laminate is provided. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is a perspective view of an expanded metal according to one embodiment of the present disclosure. [Diagram 2] FIG. 2 is a cross-sectional view taken along line C2-C2 in FIG. [Diagram 3] FIG. 3 is a cross-sectional view of a laminate with a rubber plate according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] In the present disclosure, a numerical range expressed using "to" means a range that includes the numerical values ​​before and after "to" as the lower and upper limits. In the present disclosure, when a plurality of substances corresponding to each component are present in the composition, the amount of each component in the composition means the total amount of the plurality of substances present in the composition, unless otherwise specified. In the numerical ranges described in stages in this disclosure, the upper or lower limit value described in one numerical range may be replaced with the upper or lower limit value of another numerical range described in stages. In the numerical ranges described in this disclosure, the upper or lower limit value of the numerical range may be replaced with a value shown in the examples. In this disclosure, combinations of preferred aspects are more preferred aspects.

[0013] (1) Manufacturing method of stacked element The method for manufacturing a laminate of the present disclosure includes a step of placing a resin film and a release film in that order on a heated expanded metal to create a laminate (hereinafter also referred to as the "placing step"), and a step of pressing a rubber plate having a Shore A hardness of 40 to 60 against the release film of the laminate to adhere the resin film to the expanded metal (hereinafter also referred to as the "adhesion step").

[0014] In this disclosure, the term "expanded metal" refers to a metal mesh formed by expanding a metal plate into a net shape, the mesh having undulations (i.e., steps between the strands and bonds). Expanded metal does not include flat processed products. The term "resin film" refers to a film made of resin. The term "release film" includes a film that has releasability relative to a resin film, as well as release paper. "Shore A hardness" refers to Shore A hardness at 23°C.

[0015] The method for producing a laminate according to the present disclosure has the above-described configuration, and therefore, even when an expanded metal having an undulating mesh is used, a laminate in which the resin film is sufficiently adhered to the strands can be produced. This effect is believed to be due to, but not limited to, the following reasons. Conventionally, a thermal laminator and a heat press have been used for laminating resin films. In a thermal laminator, thin, smooth materials (total thickness: 1 mm or less) are passed between a pair of heated rolls to bond the materials together. Expanded metal usually has a total thickness of more than 1 mm and has undulations in the mesh. As a result, there is a risk that the resin film will not adhere sufficiently to the expanded metal strands when using a thermal laminator. In the hot press, multiple materials are thermocompressed with the upper and lower plates of a hot press machine to bond the multiple materials together. However, the upper and lower plates cannot deform the resin film to follow the shape of the expanded metal strands during the thermocompression. As a result, in the hot press, as with the hot laminator, there is a risk that the resin film cannot be sufficiently adhered to the expanded metal strands. On the other hand, in the present disclosure, in the bonding step, a rubber plate having a Shore A hardness of 40 to 60 is pressed against the release film of the laminate to bond the resin film to the heated expanded metal. Therefore, when bonding the resin film to the expanded metal, the rubber plate can deform the resin film to follow the shape of the strands of the expanded metal. As a result, it is presumed that the manufacturing method of the laminated body of the present disclosure can sufficiently adhere the resin film to the strands of the expanded metal.

[0016] The method for producing the laminate of the present disclosure may further include a step of preparing an expanded metal, a resin film, and a release film (hereinafter also referred to as a "preparation step"), a step of heating the expanded metal (hereinafter also referred to as a "heating step"), and a step of peeling the release film from a laminate (hereinafter also referred to as an "adhesive laminate") obtained by carrying out the adhesion step (hereinafter also referred to as a "peeling step"). When the method for producing the laminate of the present disclosure further includes the preparation step, the heating step, and the peeling step, the preparation step, the heating step, the placing step, the adhesion step, and the peeling step are carried out in this order.

[0017] Hereinafter, a method for producing a laminate according to the present disclosure will be described in terms of a case where the method further includes a preparation step and a peeling step.

[0018] (1.1) Laminate The laminate obtained by the lamination method of the present disclosure includes an expanded metal and a resin film. The resin film is adhered to at least one main surface of the expanded metal. The resin film may be directly adhered to the expanded metal, or may be indirectly adhered via an adhesive layer formed by a known adhesive. Details of the laminate will be described later. The laminate is suitably used as a membrane vibration sound absorbing plate.

[0019] In a membrane vibration sound absorbing plate, when sound waves (i.e. vibrating air) enter the resin film from the sound source, the action of the sound waves causes the resin film to vibrate. At this time, energy is lost due to internal friction in the resin film, and sound absorption occurs. A large vibration amplitude is displayed at the natural frequency determined by the contact state between the resin film and the expanded metal, the rigidity of the resin film, etc.

[0020] (1.2) Preparation process In the preparation step, an expanded metal, a resin film, and a release film are prepared.

[0021] The expanded metal, the resin film, and the release film may be prepared by any known method.

[0022] (1.2.1) Expanded Metal The expanded metal has a plurality of strands and a plurality of bonds. Each of the plurality of bonds connects three or more of the plurality of strands. A plurality of meshes are formed by the plurality of strands and the plurality of bonds. The plurality of strands and the plurality of bonds are integrated.

[0023] The shape of the mesh is not particularly limited, and examples thereof include a diamond shape, a tortoise shell shape, etc. When the mesh shape is a diamond shape, four strands are connected to each of the multiple bonds. When the mesh shape is a tortoise shell shape, three strands are connected to each of the multiple bonds.

[0024] The size of the expanded metal is not particularly limited and is appropriately selected depending on the application of the laminate, etc. When the mesh shape is a rhombus, the size of the expanded metal may be the following size or may be the dimensions specified in JIS G 3351.

[0025] Fig. 1 shows a perspective view of an example of an expanded metal. Fig. 2 shows a cross-sectional view taken along line C2-C2 in Fig. 1. In Figs. 1 and 2, reference numeral "10" denotes an expanded metal, reference numeral "11" denotes a strand, and reference numeral "12" denotes a bond. The center-to-center distance SW in the short direction of the mesh (see FIG. 1) is preferably 3,000 μm to 16,000 μm, more preferably 7,000 μm to 10,000 μm. The center-to-center distance LW in the long direction of the mesh (see FIG. 1) is preferably 4,600 μm to 32,000 μm, more preferably 14,000 μm to 20,000 μm. The plate thickness T of the strand 11 (see FIG. 1 and FIG. 2) is preferably 500 μm to 1,500 μm, more preferably 800 μm to 1,000 μm. The pitch width W of the strand 11 (see FIG. 1 and FIG. 2) is preferably 700 μm to 1,700 μm, more preferably 800 μm to 1,000 μm.

[0026] The material of the expanded metal is not particularly limited as long as it is a metal, and examples thereof include iron, copper, nickel, gold, silver, platinum, cobalt, zinc, lead, tin, titanium, chromium, aluminum, magnesium, manganese, and alloys thereof (stainless steel (SUS), aluminum steel, brass, phosphor bronze, etc.).

[0027] The expanded metal may be a commercially available product.

[0028] (1.2.2) Plastic film The thickness of the resin film is not particularly limited and is appropriately selected depending on the application of the laminate. The thickness of the resin film may be 15 μm to 500 μm. When the application of the laminate is a membrane vibration sound absorbing plate, the thickness of the resin film is preferably 30 μm to 400 μm, more preferably 50 μm to 300 μm.

[0029] The material of the resin film is appropriately selected depending on the application of the laminate, etc. Examples of the material of the resin film include a hot melt resin composition and a thermosetting resin composition.

[0030] The term "hot melt resin composition" refers to a resin composition that is solid at 23°C and melts when heat is applied.

[0031] Hereinafter, a resin film made of a hot melt resin composition is also referred to as a “hot melt film.” The softening point of the hot melt film is preferably 80°C to 200°C, and more preferably 100°C to 160°C.

[0032] Among them, the material of the resin film is preferably a hot melt resin composition. When the resin film is a hot melt film, the hot melt film can be directly bonded to the expanded metal by heating the hot melt film without using an adhesive. The hot melt resin composition does not contain an organic solvent. Therefore, by using the hot melt resin composition as the material of the resin film, the laminate can be produced with reduced environmental load.

[0033] Examples of the resin component of the hot melt resin composition include thermoplastic resins (e.g., polyester, polyethylene, polypropylene, polyurethane, polyamide, etc.), thermoplastic elastomers (e.g., thermoplastic elastomers in which a styrene-based elastomer and a polyolefin are mixed, and thermoplastic elastomers in which an ethylene-based rubber and a polypropylene are mixed, etc.), and the like.

[0034] Among them, the hot melt resin composition preferably contains at least one selected from the group consisting of polyester, polyethylene, polypropylene, polyurethane, polyamide, a thermoplastic elastomer obtained by mixing a styrene-based elastomer and a polyolefin, and a thermoplastic elastomer obtained by mixing an ethylene-based rubber and a polypropylene (hereinafter also referred to as a "specific polymer"). This allows the hot melt resin composition to have stronger adhesion to the expanded metal than when the hot melt resin composition does not contain the specific polymer.

[0035] The hot melt resin composition may contain other components as necessary, such as a tackifier resin, a plasticizer, an inorganic filler, a stabilizer, a colorant, etc.

[0036] The resin film may be a product. Examples of the product in which a release film is laminated on one main surface of a hot melt film include the Aronmelt PES series.

[0037] (1.2.3) Release film The release film has the function of preventing the rubber plate from welding to the resin film when the resin film is adhered to the expanded metal.

[0038] The release film is not particularly limited as long as it has the above-mentioned function, and may be any known release film. The release film may be release paper. Examples of the release paper include glassine paper coated with a release agent such as silicone and dried, and may be any known release paper.

[0039] (1.2.4) Preferred embodiments When the resin film is a hot melt film, it is preferable that the sheet thickness of the expanded metal strand is 500 μm to 8,000 μm, and the thickness of the resin film is 15 μm to 500 μm. This makes it difficult for the resin film welded to the expanded metal to bury the expanded metal strand. In other words, the resin film welded to the expanded metal is welded to the main surface of the strand (i.e., the main surface to which the resin film of the expanded metal is welded), and is difficult to weld to the side surface of the strand. Therefore, when sound waves are incident on the resin film of the laminate, the resin film is likely to vibrate. As a result, the laminate is suitably used as a membrane vibration sound absorbing plate.

[0040] The "thickness of the strand of the expanded metal" refers to the thickness T of the strand 11 (see Figs. 1 and 2) when the mesh shape is rhombic.

[0041] The ratio of the thickness of the resin film to the thickness of the expanded metal (hereinafter, "thickness ratio") is not particularly limited, but is preferably 0.1% to 100%, and more preferably 5% to 30%. If the thickness ratio is within the above range, the resin film welded to the expanded metal does not easily embed the strands of the expanded metal. As a result, the laminate is suitably used as a membrane vibration sound absorbing plate.

[0042] (1.3)Heating process In the heating step, the expanded metal is heated. The expanded metal heated in the heating step is used as the heated expanded metal in the placing step.

[0043] The method for heating the expanded metal is not particularly limited and may be any known method. The heating temperature for the expanded metal is appropriately selected depending on the material of the resin film.

[0044] Hereinafter, the softening point of the hot melt film measured in accordance with JIS K6863 will be simply referred to as the "softening point." Here, the "softening point of the hot melt film" refers to the measured softening point of the resin composition constituting the hot melt film.

[0045] When the resin film is a hot melt film, the heating temperature of the expanded metal is preferably within the following range. From the viewpoint of softening the hot melt film and making it easy to follow the steps of the expanded metal, the heating temperature of the expanded metal is preferably (softening point -20°C) or higher, more preferably (softening point -10°C) or higher, and even more preferably (softening point -5°C) or higher. From the viewpoint of suppressing melt breakage of the hot melt film in contact with the strand portion of the expanded metal, the heating temperature of the expanded metal is preferably (softening point +20°C) or lower, more preferably (softening point +15°C) or lower, and even more preferably (softening point +10°C) or lower.

[0046] In the heating step, the rubber plate used in the bonding step may be heated. The rubber plate heated in the heating step is used as the heated rubber plate in the placing step.

[0047] The rubber plate may be heated together with the expanded metal or may be heated separately from the expanded metal.

[0048] The method for heating the rubber plate is not particularly limited and may be any known method. The heating temperature of the rubber plate is appropriately selected depending on the material of the resin film.

[0049] When the resin film is a hot melt film, the heating temperature of the rubber plate may be the same as the heating temperature of the expanded metal exemplified above. The heating temperature of the rubber plate may be the same as the heating temperature of the expanded metal, or may be higher than the heating temperature of the expanded metal, or may be lower than the heating temperature of the expanded metal. In particular, from the viewpoint of the adhesiveness between the hot melt film and the expanded metal, it is preferable that the heating temperature of the rubber plate is the same as the heating temperature of the expanded metal.

[0050] (1.4) Placement process In the placing step, a resin film and a release film are placed in this order on the heated expanded metal to produce a laminate.

[0051] The method for placing the resin film and the release film in this order on the expanded metal is not particularly limited, and any known method may be used.

[0052] (1.5) Adhesion process In the bonding step, a rubber plate having a Shore A hardness of 40 to 60 is pressed against the release film of the laminate to bond the resin film to the expanded metal.

[0053] Hereinafter, the laminate and the rubber plate placed on the release film of the laminate will be collectively referred to as "laminate with rubber plate."

[0054] (1.5.1) Adhesion method The method of pressing a rubber plate against the release film of the laminate to bond the resin film to the expanded metal (hereinafter also referred to as the "bonding method") is not particularly limited and is appropriately selected depending on the type of resin film, etc. The bonding method may be, for example, a method using a known adhesive. When the resin film is a hot melt film, the bonding method may be heat pressing.

[0055] The hot press will be described below with reference to Fig. 3. Fig. 3 shows a cross-sectional view of a laminate with a rubber plate according to one embodiment of the present disclosure. In Fig. 3, reference numeral 10 denotes an expanded metal, reference numeral 21 denotes a resin film, reference numeral 22 denotes a release film, reference numeral 30 denotes a laminate, reference numeral 40 denotes a rubber plate, and reference numeral 50 denotes a laminate with a rubber plate.

[0056] The hot pressing may be a method using a hot pressing machine. The hot pressing machine has an upper plate (not shown) and a lower plate (not shown). In the hot pressing, the laminate 50 with the rubber plate is placed on the lower plate, and the laminate 50 with the rubber plate is sandwiched between the upper plate and the lower plate and thermocompressed to weld the resin film 21 to the expanded metal 10.

[0057] The temperature of the upper plate is appropriately selected according to the material of the resin film 21. The temperature of the upper plate is maintained during the bonding process. When the resin film 21 is a hot melt film, the temperature of the upper plate is preferably in the following range. The heating temperature of the upper plate is preferably (softening point -10°C) or higher, more preferably (softening point -5°C) or higher, and even more preferably the softening point or higher, from the viewpoint of suppressing a temperature drop of the heated rubber plate 40 of the rubber plate-attached laminate 50. The heating temperature of the upper plate is preferably (softening point +50°C) or lower, more preferably (softening point +30°C) or lower, and even more preferably (softening point +20°C) or lower, from the viewpoint of suppressing melt-cutting of the hot melt film in contact with the strand portion of the expanded metal 10. "Melting-cutting of the film" refers to a situation in which the heating temperature of the upper plate is too high, and the hot melt film in the vicinity of the strand of the expanded metal 10 melts, causing the hot melt film to fall off the mesh of the expanded metal 10.

[0058] The temperature of the lower plate is appropriately selected depending on the material of the resin film 21. The temperature of the lower plate is maintained during the bonding process. When the resin film 21 is a hot melt film, the temperature of the lower plate may be the same as that exemplified as the temperature of the upper plate. The temperature of the lower plate may be the same as or different from the temperature of the upper plate.

[0059] The pressing pressure is not particularly limited and is appropriately selected depending on the temperature of the upper plate, the temperature of the lower plate, the material of the resin film 21, etc. When the laminate is used for a membrane vibration sound absorbing plate, the pressing pressure is preferably 0.02 MPa to 0.5 MPa, more preferably 0.03 MPa to 0.3 MPa, and further preferably 0.04 MPa to 0.2 MPa, from the viewpoint of adhesion between the hot melt film and the expanded metal 10.

[0060] The pressing time is not particularly limited and is appropriately selected depending on the temperature of the upper plate, the temperature of the lower plate, the pressing pressure, etc. When the laminate is used for a membrane vibration sound absorbing plate, the pressing time is preferably 0.2 to 20 minutes, more preferably 0.3 to 10 minutes, and further preferably 0.5 to 5 minutes, from the viewpoint of the adhesion between the hot melt film and the expanded metal 10.

[0061] (1.5.2) Rubber Sheet The rubber plate causes the shape of the resin film to conform to the shape of the expanded metal strands during the bonding process.

[0062] The rubber plate has a Shore A hardness of 40 to 60. If the Shore A hardness of the rubber plate is less than 40, the rubber plate becomes too soft when heated, and the rubber surface may be damaged by the steps of the expanded metal during pressure bonding. If the Shore A hardness of the rubber plate is more than 60, the rubber plate cannot deform to follow the steps of the expanded metal, and poor adhesion of the hot melt film to the strands of the expanded metal may occur. The Shore A hardness of the rubber plate may be 50 to 60, or 53 to 58.

[0063] The rubber plate is preferably flat and is appropriately selected depending on the size of the laminate and the material of the rubber plate, and the thickness is preferably 1 mm to 10 mm, more preferably 2 mm to 5 mm.

[0064] The material of the rubber plate is not particularly limited as long as it has a Shore A hardness of 40 to 60, and examples of the material include silicone rubber, natural rubber, styrene rubber, butyl rubber, ethylene propylene rubber, chloroprene rubber, nitrile rubber, acrylic rubber, urethane rubber, and fluororubber.

[0065] In particular, the rubber plate preferably contains silicone rubber, and more preferably is made of silicone rubber. When the rubber plate contains silicone rubber, the durability of the rubber during use under heating is increased, and productivity is excellent, compared to when the rubber plate does not contain silicone rubber.

[0066] The rubber plate is preferably heated, which allows a laminate to be obtained in a shorter pressing time than when the rubber plate is not heated.

[0067] (1.6) Peeling process In the peeling step, the release film is peeled off from the bonded laminate.

[0068] The method for peeling the release film from the adhesive laminate is not particularly limited, and any known method may be used.

[0069] (2) Laminate The laminate of the present disclosure includes an expanded metal and a resin film. The resin film is bonded to at least one main surface of the expanded metal. The expanded metal has a plurality of strands and a plurality of bonds. Each of the bonds connects three or more of the strands. A plurality of meshes are formed by the strands and the bonds. The ratio of the total number of bonded meshes to the total number of meshes (hereinafter, "bonding ratio") is 80% or more. The bonded mesh refers to a mesh in which all of the strands forming one of the meshes are bonded to the resin film. At least a part of each strand of the bonded mesh is bonded to the resin film. The closer the bonding ratio is to 100%, the more preferable it is. In the bonded mesh, the ratio of the total length of the bonded portion between the strand and the resin film to the length of the strand (hereinafter, also referred to as "length of the bonded portion") is preferably 50% or more, more preferably 70% or more, and particularly preferably 90% or more. "Strand length" refers to the distance between the part of the strand connected to the bond on one side and the part of the strand connected to the bond on the other side in the direction in which the strand extends. "Adhesive portion length" refers to the length of the adhesive portion between the strand and the resin film in the direction in which the strand extends. "Adhesive portion length" refers to the length of one adhesive member when one adhesive member is continuously formed in the direction in which the strand extends, and refers to the total length of multiple adhesive members when multiple adhesive members are intermittently formed in the direction in which the strand extends.

[0070] Since the laminate of the present disclosure has the above-mentioned configuration, the resin film is sufficiently adhered to the strands, and therefore the laminate of the present disclosure is suitably used as a membrane vibration sound absorbing plate.

[0071] The ratio of the total number of first adhesion meshes to 25 meshes among the plurality of meshes (hereinafter also referred to as "first adhesion ratio") may be 80% or more. The first adhesion mesh refers to a mesh among the 25 meshes, in which all of the strands forming the mesh are adhered to the resin film. The closer the first adhesion ratio is to 100%, the more preferable it is.

[0072] The laminate of the present disclosure is a sheet-like product. The size of the laminate of the present disclosure is not particularly limited and may be appropriately selected depending on the application of the laminate.

[0073] (2.1) Expanded metal Examples of the expanded metal include the same ones as those exemplified as the expanded metal in the manufacturing method of the stacked element.

[0074] (2.2) Resin film Examples of the resin film include the same resin films as those exemplified in the method for producing a laminate element.

[0075] The material of the resin film is preferably a hot melt resin composition, which allows the laminate of the present disclosure to be produced with a reduced environmental impact compared to a case in which the material of the resin film is not a hot melt resin composition.

[0076] The hot melt resin composition preferably contains one selected from the group consisting of polyester, polyethylene, polypropylene, polyurethane, polyamide, a thermoplastic elastomer obtained by mixing a styrene-based elastomer and a polyolefin, and a thermoplastic elastomer obtained by mixing an ethylene-based rubber and a polypropylene, which allows the hot melt resin composition to have stronger adhesion to the expanded metal than when the hot melt resin composition does not contain the specific polymer.

[0077] (2.3) Preferred embodiments When the resin film is a hot melt film, it is preferable that the thickness of the expanded metal strand is 800 μm to 1,000 μm, and the thickness of the resin film is 50 μm to 300 μm. As a result, the resin film welded to the expanded metal is not embedded in the expanded metal strand. In other words, the resin film welded to the expanded metal is welded to the main surface of the strand (i.e., the main surface to which the resin film of the expanded metal is welded), and is not easily welded to the side surface of the strand. Therefore, when sound waves are incident on the resin film of the laminate, the resin film is likely to vibrate. As a result, the laminate is suitably used as a membrane vibration sound absorbing plate.

[0078] The ratio of the thickness of the resin film to the thickness of the expanded metal (hereinafter, "thickness ratio") is not particularly limited, but is preferably 0.1% to 100%, and more preferably 5% to 30%. If the thickness ratio is within the above range, the resin film welded to the expanded metal does not easily embed the strands of the expanded metal. As a result, the laminate is suitably used as a membrane vibration sound absorbing plate.

[0079] (2.4) Application The uses of the laminate of the present disclosure are not particularly limited, and examples thereof include a membrane vibration sound absorbing plate. EXAMPLES

[0080] Hereinafter, the present disclosure will be described more specifically with reference to examples. However, the present disclosure is not limited to the following examples as long as it does not depart from the gist of the disclosure.

[0081] [1] Examples and Comparative Examples [1.1] Example 1 [1.1.1] Preparation process As the expanded metal, an expanded metal product (material: SUS304, mesh shape: diamond, mesh short-distance center-to-center distance SW: 7 mm, mesh long-distance center-to-center distance LW: 14 mm, strand thickness T: 800 μm, strand pitch width W: 1 mm) was prepared.

[0082] As the resin film and release film, a polyester hot melt film "Aronmelt PES-111EE" (manufactured by Toagosei Co., Ltd., composition: two-layer structure of hot melt film and release paper, softening point of hot melt film measured in accordance with JIS K6863: 125°C, thickness of hot melt film: 100 μm) was prepared.

[0083] Hereinafter, polyester hot melt film will be referred to as "resin film with release film"

[0084] As the rubber plate, a silicone rubber plate product (material: silicone rubber, thickness: 5 mm, Shore A hardness of silicone rubber: 55) was prepared. The Shore A hardness of the silicone rubber plate was measured according to JIS K 6251 using an A-type hardness meter (manufactured by Kobunshi Keiki Co., Ltd.).

[0085] [1.1.2] Heating process The expanded metal and the rubber sheet were placed in a hot air circulation type thermostatic chamber ("HISPEC HT210S", manufactured by Kusumoto Chemicals Co., Ltd.) previously adjusted to 120°C, and heated for 30 minutes or more.

[0086] [1.1.3] Placement process The resin film with a release film was placed on the main surface of the expanded metal removed from the thermostatic chamber to prepare a laminate. In the laminate, the hot melt film of the resin film with a release film was in contact with the expanded metal.

[0087] [1.1.4] Adhesion process Heated silicone rubber was placed on the release paper of the laminate and pressed with a heating press (Toyo Seiki Seisakusho Co., Ltd., model number MP-WNL) to obtain an adhesive laminate. The temperatures of the upper and lower plates of the heating press were adjusted to 120°C. For the expanded metal, the temperature at the time when the rubber plate was pressed against the release film of the laminate (hereinafter also referred to as the "start temperature") was 120°C. The start temperature of the rubber plate was 120°C. The pressing pressure was 0.08 MPa. The pressing time was 1 minute.

[0088] [1.1.5] Peeling process After releasing the pressure, the bonded laminate was left to stand at room temperature (23° C.) for 16 hours or more. Then, the release film was peeled off from the bonded laminate to obtain a laminate.

[0089] [1.2] Examples 2 to 5 and Comparative Examples 1 to 3 A laminate was obtained in the same manner as in Example 1, except that the thickness of the resin film, the presence or absence of a rubber plate, the start temperature of the expanded metal, the start temperature of the rubber plate, the temperature of the upper plate of the heating press, the temperature of the lower plate of the heating press, the pressing pressure and the pressing time were changed as shown in Table 1.

[0090] In Examples 4 and 5 and Comparative Example 3, a polyester hot melt film "Aronmelt PES-111EE" (manufactured by Toagosei Co., Ltd., composition: two-layer structure of hot melt film and release paper, softening point of hot melt film measured in accordance with JIS K6863: 125°C, thickness of hot melt film: 300 μm) was used as the resin film and release film.

[0091] [2] Adhesion evaluation The method for evaluating the adhesion of the laminate is as follows.

[0092] The laminate was fixed to a sample stage. The resin film of the laminate fixed to the sample stage faced the top surface. The expanded metal of the laminate fixed to the sample stage faced the bottom surface. A SUS rod (material: SUS) was prepared. The tip of the SUS rod was smooth and circular (diameter: 3 mm). For one mesh, in an atmosphere of 25°C, the tip of the SUS rod was pressed against the resin film surface in the mesh from the expanded metal side of the laminate at a speed of about 100 mm / min. At this time, it was visually observed whether the resin film was floating from the strands. A mesh in which the resin film was not floating from all four strands forming one mesh was judged to be a mesh in which all four strands forming one mesh were bonded to the resin film (hereinafter also referred to as a "good product"). 24 meshes were randomly selected from the multiple meshes of the expanded metal of the laminate, and the 24 meshes were also confirmed to be good products in the same manner as described above.

[0093] Using the observation results of the 25 meshes, the adhesion of the laminate was evaluated according to the following evaluation criteria. The evaluation results are shown in Table 1. An acceptable adhesion rating for the laminate is "A+" or "A".

[0094] [2.1] Evaluation criteria "A+": The number of non-defective items was 23 to 25. "A": The number of non-defective products was 20 to 22. "B": The number of non-defective products was 10 to 19. "B-": The number of non-defective products was less than 10.

[0095] Based on the implementation of the bonding process, for "A+", the ratio of the total number of bonded meshes to the total number of multiple meshes can be considered to be 92% to 100%. For "A", the ratio of the total number of bonded meshes to the total number of multiple meshes can be considered to be 80% to 88%. For "B", the ratio of the total number of bonded meshes to the total number of multiple meshes can be considered to be 40% to 76%. For "B-", the ratio of the total number of bonded meshes to the total number of multiple meshes can be considered to be less than 40%.

[0096] [Table 1]

[0097] The meanings of the abbreviations in Table 1 are as follows: "EM" stands for expanded metal. "HMF" stands for hot melt film. "SUS" stands for stainless steel. "SR" stands for silicone rubber. "Start temperature" stands for the temperature at the time when the rubber plate is pressed against the release film of the laminate.

[0098] In Comparative Example 1, a rubber plate was not used. In other words, the manufacturing method of the laminate in Comparative Example 1 did not include an adhesion step. Therefore, the adhesion evaluation of the laminate was "B" or "B-". As a result, it was found that the manufacturing methods of the laminates in Comparative Examples 1 to 3 are not manufacturing methods of laminates that can manufacture laminates in which the resin film is sufficiently adhered to the strands, even if an expanded metal having an undulating mesh is used.

[0099] The manufacturing methods of the laminates in Examples 1 to 3 included a placing step and an adhesion step. Therefore, the adhesion evaluation of the laminates was "A+" or "A-". As a result, it was found that the manufacturing methods of the laminates in Comparative Examples 1 to 3 are not manufacturing methods of laminates capable of manufacturing a laminate in which the resin film is sufficiently adhered to the strands, even if an expanded metal having an undulating mesh is used. [Explanation of symbols]

[0100] 10: Expanded metal, 11: Strand, 12: Bond, 21: Resin film, 22: Release sheet, 30: Laminated body, 40: Rubber plate, 50: Laminated body with rubber plate

Claims

1. A step of placing a resin film and a release film in this order on the heated expanded metal to produce a laminate; a step of pressing a rubber plate having a Shore A hardness of 40 to 60 against the release film of the laminate to bond the resin film to the expanded metal; A method for producing a laminate, comprising:

2. The method for producing a laminate according to claim 1 , wherein the material of the resin film is a hot melt resin composition.

3. 3. The method for producing a laminate according to claim 2, wherein the hot melt resin composition comprises at least one selected from the group consisting of polyester, polyethylene, polypropylene, polyurethane, polyamide, a thermoplastic elastomer obtained by mixing a styrene-based elastomer and a polyolefin, and a thermoplastic elastomer obtained by mixing an ethylene-based rubber and a polypropylene.

4. The thickness of the strand of the expanded metal is 500 μm to 8,000 μm, The method for producing a laminate according to claim 2, wherein the resin film has a thickness of 15 μm to 500 μm.

5. The method for producing a laminate according to any one of claims 1 to 4, wherein the rubber plate comprises silicone rubber.

6. The method for producing a laminate according to any one of claims 1 to 4, wherein the rubber plate is heated.

7. Expanded metal and a resin film adhered to at least one main surface of the expanded metal; Equipped with The expanded metal has a plurality of strands and a plurality of bonds connecting three or more of the plurality of strands, a plurality of meshes are formed by the plurality of strands and the plurality of bonds; The ratio of the total number of adhesive meshes to the total number of the plurality of meshes is 80% or more; The bonded mesh refers to a mesh in which all of the strands forming one of the meshes are bonded to the resin film.

8. The laminate according to claim 7 , wherein the material of the resin film is a hot melt resin composition.

9. 9. The laminate according to claim 8, wherein the hot melt resin composition comprises one selected from the group consisting of polyester, polyethylene, polypropylene, polyurethane, polyamide, a thermoplastic elastomer obtained by mixing a styrene-based elastomer and a polyolefin, and a thermoplastic elastomer obtained by mixing an ethylene-based rubber and a polypropylene.

10. The thickness of the strand is 500 μm to 8,000 μm, The laminate according to claim 8 or claim 9, wherein the resin film has a thickness of 15 μm to 500 μm.

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