Method for producing synthetic resin film laminate and lamination apparatus therefor

Abstract

To provide a method for producing a synthetic resin film laminate, enabling removal of overlapping fabric fibers that are not fusion-bonded, and ensuring reliable fusion-bonding between the fabric fibers and a synthetic resin film.SOLUTION: A strip-shaped fabric fiber 23 is placed and dispersed on a transport device 3, and a first synthetic resin film 21 is overlaid on the fabric fiber 23 and heat-welded by a first roller 41. Then, the fabric fiber 23 is wound up by the first roller 41 so that it is positioned on the outer side, and in a space section 6, the fabric fiber 23 that has not been welded to the first synthetic resin film 21 is allowed to fall under its own weight. Thereafter, a second synthetic resin film 22 is laminated on the surface of the fabric fiber 23, and pressed by a second roller 82 having needle-like portions 82. Then, heat welding is executed in a state where the second synthetic resin film 22 has been stretched by the needle-like portions 82 and penetrates through to the inside of the fabric fiber 23.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a synthetic resin film laminate in which cloth fibers are sandwiched between synthetic resin films, and more particularly, to a method for manufacturing a synthetic resin film laminate capable of preventing peeling from the inside of the synthetic resin film, and to a laminating apparatus therefor.

Background Art

[0002] Conventionally, a synthetic resin film laminate in which cloth fibers and a synthetic resin film are laminated has been proposed as a wall material for buildings, a covering material for agricultural facilities, etc. (see Patent Document 1). This synthetic resin film laminate sandwiches cloth fibers between synthetic resin films and heats and welds them using a high-frequency welder, and the strength and durability are enhanced by the cloth fibers sandwiched inside.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, when manufacturing such a synthetic resin film laminate, there are the following problems.

[0005] That is, when laminating cloth fibers to a synthetic resin film, if the cloth fibers overlap each other, the overlapping cloth fibers will not be welded, resulting in peeling occurring vertically from that part.

[0006] Also, when sandwiching the cloth fibers in this way, the cloth fibers may be manually arranged uniformly so that they do not overlap. However, there is a problem that it takes time and cost to completely prevent the cloth fibers from overlapping.

[0007] Therefore, the present invention has been made paying attention to the above problems, and an object thereof is to provide a method for manufacturing a synthetic resin film laminate in which overlapping cloth fibers that are not heat-welded are removed, and the cloth fibers and the synthetic resin film are surely heat-welded.

Means for Solving the Problems

[0008] That is, in order to solve the above problems, the present invention includes a step of dispersing and placing cloth fibers on a conveying device, covering the cloth fibers placed on the conveying device with a first synthetic resin film, and heating from above the first synthetic resin film to weld the first synthetic resin film and the cloth fibers, a step of conveying the first synthetic resin film welded to the cloth fibers through a space where the cloth fibers not welded to the first synthetic resin film fall, and a step of laminating and heat-welding a second synthetic resin film on the surface of the cloth fibers after dropping excess cloth fibers in the space, thereby manufacturing a synthetic resin film laminate.

[0009] In this way, by conveying through the space so that the cloth fibers face downward, the cloth fibers that have not been welded can be dropped, so that the overlapping cloth fibers can be removed and welded. As a result, it becomes possible to prevent peeling from the inside of the synthetic resin film laminate by eliminating the overlapping cloth fibers.

[0010] Also, in such an invention, when conveying through a space where the cloth fibers not welded to the first synthetic resin film fall, the first synthetic resin film welded to the upper surface of the cloth fibers is wound up so as to contact a first roller, and the cloth fibers located outside the first roller are dropped downward.

[0011] By doing so, since the first synthetic resin film is conveyed while being in contact with the first roller, it becomes possible to prevent the first synthetic resin film from being deflected during conveyance.

[0012] Furthermore, when conveying through the space where the cloth fibers not welded to the first synthetic resin film fall, the first synthetic resin film welded to the upper surface of the cloth fibers is wound up so as to contact the first roller, and the cloth fibers located outside the first roller are dropped downward. When laminating and heat-welding the second synthetic resin film, when winding up the first synthetic resin film with the first roller, the cloth fibers are positioned outside the first roller, and the second synthetic resin film is laminated from the outside of the cloth fibers and heat-welded.

[0013] By doing so, by winding up the cloth fibers so that they are located outside by the first roller, the second synthetic resin film can be further covered from the outside thereof, and it becomes possible to easily laminate and weld the second synthetic resin film.

[0014] Also, when laminating and heat-welding the second synthetic resin film, a needle-shaped portion is pressed from above the second synthetic resin film to heat-weld the cloth fibers.

[0015] By doing so, even when the cloth fibers partially overlap other cloth fibers, by penetrating the needle-shaped portion, it becomes possible to weld with the second synthetic resin film interposed inside the cloth fibers.

[0016] Also, when pressing the needle-shaped portion from above the second synthetic resin film for heat-welding, the needle-shaped portion is made to protrude from the outer periphery of the roller for heat-welding.

[0017] With such a configuration, when continuously feeding and laminating the second synthetic resin film, while conveying, the needle-like part is pressed so as to penetrate the cloth fibers, enabling the second synthetic resin film to be welded.

[0018] Further, a foaming agent that foams by heating is provided on the surface of the first synthetic resin film or the second synthetic resin film on the side where the cloth fibers are provided.

[0019] In this way, when heat-welding the first synthetic resin film and the second synthetic resin film, the foaming agent expands and enters the cloth fibers, enabling the overlapped portions of the cloth fibers to be welded.

Advantages of the Invention

[0020] According to the present invention, a synthetic resin film laminate is manufactured by including a step of dispersing and placing cloth fibers on a conveying device, a step of covering the cloth fibers placed on the conveying device with a first synthetic resin film and heating from above the first synthetic resin film to weld the first synthetic resin film and the cloth fibers, a step of conveying the first synthetic resin film welded to the cloth fibers through a space where the cloth fibers not welded to the first synthetic resin film fall, and a step of laminating and heat-welding a second synthetic resin film on the surface of the cloth fibers after dropping excess cloth fibers in the space. Therefore, by conveying through the space so that the cloth fibers face downward, the cloth fibers that were not welded can be dropped, and the overlapped cloth fibers can be removed and welded. As a result, it becomes possible to prevent peeling from the inside of the synthetic resin film laminate by eliminating the overlapped cloth fibers.

Brief Description of the Drawings

[0021]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Mode for Carrying Out the Invention

[0022] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0023] The synthetic resin film laminate 2 in this embodiment is used as a film-like agricultural material, a board-like building material, etc., and is laminated by sandwiching cloth fibers 23 between synthetic resin films. Characteristically, when manufacturing this synthetic resin film material with the laminating device 1, as shown in FIG. 1, the cloth fibers 23 are uniformly arranged on the conveying device 3, and from above, the first synthetic resin film 21 is placed and heat-welded with the first welding device 4. Then, when the first synthetic resin film 21 is wound up with the first roller 41, the surplus cloth fibers 23 that were not welded to the first synthetic resin film 21 are dropped, and with the cloth fibers 23 facing upward, the second synthetic resin film 22 is covered from above and heat-welded. In this embodiment, it is configured with three layers of the first synthetic resin film 21, the cloth fibers 23, and the second synthetic resin film 22, but further, the cloth fibers 23 and the second synthetic resin film 22 may be laminated thereon to form a configuration of five layers or more. Hereinafter, this embodiment will be described in detail.

[0024] First, the conveying device 3 conveys the cloth fibers 23 in a state where they are arranged uniformly, and its upper surface is composed of an endless belt or the like with a planar configuration. When arranging the cloth fibers 23 uniformly on this conveying device 3, the cloth fibers 23 may be arranged uniformly by manual operation, or the cloth fibers 23 may be dropped by a machine and dispersed uniformly. At this time, when arranging the cloth fibers 23 uniformly on the conveying device 3 by manual operation, place the cloth fibers 23 on the belt of the conveying device 3 made of rubber or the like to make it difficult to slip, and move the hand in the planar direction from above the non-slip cloth fibers 23, so as to shift the other cloth fibers 23 overlapping thereon in the planar direction and arrange them uniformly.

[0025] As such cloth fibers 23, in particular, waste materials such as used clothes are used. Those obtained by cutting natural fibers such as cotton and hemp into strip shapes or defibrated filamentous ones are used. Here, although strip-shaped cloth fibers 23 composed of natural fibers are taken as an example for explanation, those containing chemical fibers may also be used. As such a chemical fiber material, the same material as the first synthetic resin film 21 or the second synthetic resin film 22, or a material with a lower melting point than these first synthetic resin film 21 and second synthetic resin film 22 is used. Thereby, when heat-welding the first synthetic resin film 21 or the like, it is made to be welded together with the cloth fibers 23 and the first synthetic resin film 21 or the like.

[0026] When providing such cloth fibers 23, cut used clothes or the like into strip shapes with a shredder and arrange them in a state where their longitudinal directions are aligned. Also, when further laminating cloth fibers 23 on the second synthetic resin film 22 to make five or more layers, arrange them so that the longitudinal direction intersects with that of the lower-layer cloth fibers 23.

[0027] The first synthetic resin film 21 is a thin sheet-like material placed on top of this cloth fiber 23. As a thermoplastic plastic film, film-like materials such as polyethylene, polypropylene, polyethylene naphthalate, polyvinyl chloride, polystyrene, and fluororesin are used. At this time, polyvinyl chloride is preferably used as a material that is easily heat-welded at 180°C to 210°C and has stretchability. Such a first synthetic resin film 21 is fed out from the first feeding device 5 and covered on the cloth fiber 23.

[0028] The first welding device 4 is configured to heat from above the first synthetic resin film 21 covered on the cloth fiber 23 to heat-weld the first synthetic resin film 21 and the cloth fiber 23. Here, it is composed of a roll-shaped first roller 41. This first roller 41 is provided with a heating device inside. After the cloth fiber 23 is heat-welded by this heating device, the cloth fiber 23 is wound so as to be located on the outside. And by winding the cloth fiber 23 in this way so that it is located on the outside, a space portion 6 is formed in the lower lateral portion of the first roller 41, and the excess cloth fiber 23 that has not been welded is dropped into this space portion 6. At this time, the cloth fiber 23 that completely overlaps other cloth fibers 23 or the cloth fiber 23 with weak welding falls into the space portion 6 by its own weight, but the cloth fiber 23 that is strongly welded even only partially is wound together with the first synthetic resin film 21.

[0029] The second feeding device 7 is provided on the side of this first roller 41 and is configured to be able to feed out the second synthetic resin film 22 above the cloth fiber 23.

[0030] As the second synthetic resin film 22, films such as polyethylene, polypropylene, polyethylene naphthalate, polyvinyl chloride, polystyrene, and fluororesin are used as thermoplastic plastic films. Preferably, a film made of the same material as the first synthetic resin film 21 is used. By using a film made of the same material as the first synthetic resin film 21, when the second synthetic resin film 22 is heat-welded, it is easier to bond with the first synthetic resin film 21.

[0031] The second welding device 8 is for heat-welding the second synthetic resin from above. Here, it is composed of a second roller 81 having a heating device inside. This second roller 81 rotates at the same rotational speed as the first roller 41. At the portion in contact with this second roller 81, the second synthetic resin film 22 is heated and welded to the cloth fiber 23.

[0032] When joining the cloth fiber 23 and the first synthetic resin film 21 on the conveying device 3, in some cases, a part overlaps with other cloth fibers 23 and the other part is welded to the first synthetic resin film 21. In such a case, even when heat-welding from above the second synthetic resin film 22, it is impossible to weld the portion where the overlapping cloth fibers 23 are in contact with each other. For this reason, here, in order to make it easier to join the cloth fibers 23 even at the portion where the cloth fibers 23 overlap, a needle-like portion 82 is provided on the outer peripheral surface of the second roller 81. As shown in FIG. 2, this needle-like portion 82 is made to penetrate from the second synthetic resin film 22 into the gap between the cloth fibers 23 and toward the first synthetic resin film 21, and is heat-welded to the first synthetic resin film 21. This needle-like portion 82 is configured to have a rounded tip shape so that it can be pressed while stretching the second synthetic resin film 22, and thus it is pushed between the cloth fibers 23 so as not to make a hole in the second synthetic resin film 22.

[0033] Also, here, the first synthetic resin film 21 and the second synthetic resin film are fed out from the first feeding device 5 and the second feeding device 7 alone, but a foaming agent 9 may be sandwiched between the first synthetic resin film 21 and the second synthetic resin film on the surface side (the side where the cloth fiber 23 contacts). As such a foaming agent 9, a powdery material or a sheet-like material that expands by heating and penetrates into the fibers of the cloth fiber 23 is used, and a material that welds to the front and back first synthetic resin film 21 and second synthetic resin film 22 is used. At this time, as shown in FIG. 3, if the foaming agent 9 is provided only on the second synthetic resin film 22 side, unnecessary cloth fibers 23 can be dropped by the first roller 41, and the foaming agent 9 sandwiched between the second synthetic resin film 22 can be expanded and impregnated into the cloth fiber 23 to be welded.

[0034] Then, the second synthetic resin film 22 is heat-welded and joined to the cloth fiber 23 and the first synthetic resin film 21 in this way.

[0035] Next, a method for manufacturing the synthetic resin film laminate 2 using such a laminating device 1 will be described.

[0036] First, the cloth fibers 23 cut into strips are placed on the conveying device 3 and conveyed in a flattened state.

[0037] Next, the first synthetic resin film 21 is fed out from the first feeding device 5 and covered on the cloth fiber 23. At this time, the feeding speed from the first feeding device 5 and the conveying speed of the conveying device 3 may be the same, or may be different speeds. When the respective conveying speeds are different, there is an advantage that the overlapping cloth fibers 23 are displaced along the plane direction due to the speed difference between the upper and lower first synthetic resin films 21 and the conveying device 3 and are arranged uniformly.

[0038] Then, with respect to the fabric fibers 23 conveyed by the conveying device 3, they are pressed from above by the first roller 41 and heat-welded. At this time, the fabric fibers 23 in contact with the first synthetic resin film 21 are welded to the first synthetic resin film 21, and the portions where the fabric fibers 23 overlap with each other are not welded.

[0039] Next, the first synthetic resin film 21 welded in this way is wound up so that the fabric fibers 23 are positioned outside the first roller 41. Then, due to this winding, among the fabric fibers 23 located outside the first roller 41, the fabric fibers 23 that were not welded to the first synthetic resin film 21 will fall by their own weight. As a result, many overlapping fabric fibers 23 can be removed.

[0040] And after dropping the fabric fibers 23 that were not welded, the fabric fibers 23 are conveyed upward, and the second synthetic resin film 22 is fed out from the adjacent second feeding device 7 and covered on the fabric fibers 23.

[0041] At this time, when the foaming agent 9 is provided on the lower surface side of the second synthetic resin film 22, the sheet-like or powdery foaming agent 9 is sandwiched between the second synthetic resin film 22 and the fabric fibers 23.

[0042] Then, the second synthetic resin film 22 is pressed by the second roller 81 and heat-welded.

[0043] At this time, the needle-shaped portion 82 provided on the surface of the second roller 81 enters the gaps between the fabric fibers 23 while stretching the second synthetic resin film 22, is pressed to the side of the first synthetic resin film 21, and is heat-welded in that state.

[0044] Also, when the foaming agent 9 is provided, the foaming agent 9 expands while melting by heating and enters into the overlapping fibers. As a result, even when the fabric fibers 23 overlap, the overlapping portions can be surely welded.

[0045] Then, with the first synthetic resin film 21 and the second synthetic resin film 22 sandwiched in this front-and-back manner, the synthetic resin film laminate 2 is wound up.

[0046] According to the above-described embodiment in this way, there are provided a step of dispersing and placing the cloth fibers 23 on the conveying device 3, a step of covering the cloth fibers 23 placed on the conveying device 3 with the first synthetic resin film 21, and heating from above the first synthetic resin film 21 to weld it to the cloth fibers 23, a step of conveying the first synthetic resin film 21 to which the cloth fibers 23 are welded through a space portion 6 where the cloth fibers 23 not welded to the first synthetic resin film 21 fall, and after dropping the excess cloth fibers 23 in the space portion 6, a step of laminating and heat-welding the second synthetic resin film 22 on the surface of the cloth fibers 23. Thus, when manufacturing the synthetic resin film laminate 2, when the cloth fibers 23 are conveyed through the space portion 6 so as to face downward, the cloth fibers 23 that have not been welded can be dropped, and the overlapping cloth fibers 23 can be removed and welded. As a result, the overlapping cloth fibers 23 can be excluded, and peeling from the inside of the synthetic resin film laminate 1 can be prevented.

[0047] Note that the present invention is not limited to the above-described embodiment, and can be implemented in various modes.

[0048] For example, in the above-described embodiment, it is configured with five layers of the first synthetic resin film 21, the cloth fibers 23, and the second synthetic resin film 22, but it may be configured with five or more layers by further laminating the cloth fibers 23 and other synthetic resin films.

[0049] Also, in the above-described embodiment, heat welding is performed using the first roller 41 and the second roller 81, but it may be performed by pressing the synthetic resin film with a planar press or the like while welding.

[0050] Furthermore, in the above-described embodiment, the cloth fibers 23 placed on the conveying device 3 are conveyed as they are. However, in order to be able to disperse the cloth fibers 23 piled up in a mountain shape substantially uniformly, a roller that rotates in the reverse direction may be provided above the conveying device 3, and thereby, the piled-up cloth fibers 23 may be removed.

[0051] Also, in the above-described embodiment, above the first roller 41, the second synthetic resin film 22 is heat-welded while being pushed in by the second roller 81 having the needle-like portions 82. However, at this time, at portions other than the needle-like portions 82, it becomes impossible to press and weld on the side of the cloth fibers 23. In such a case, as shown in FIG. 4, an upstream side of the second roller 81 having the needle-like portions 82 is provided with a third roller 81a without the needle-like portions 23 and is pressed against the second roller 41, and then, the second synthetic resin film 22 may be pushed between the cloth fibers 23 by the second roller 81 having the needle-like portions 82 and welded.

[0052] Also, at this time, the second synthetic resin film 22 is pushed in by the needle-like portions 82 and welded to the first synthetic resin film 21. However, when the second synthetic resin film 22 is difficult to stretch, as shown in FIG. 5, needle-like portions 41a are also provided on the side of the first roller 41 so that it can be pushed in from the side of the first synthetic resin film 21, and the synthetic resin film may be stretched from above and below and welded among the cloth fibers 23.

Explanation of Reference Numerals

[0053] 1 ··· Laminating device 2 ··· Synthetic resin film laminate 21 ··· First synthetic resin film 22 ··· Second synthetic resin film 23 ··· Cloth fibers 3 ··· Conveying device 4 ··· First welding device 41 ··· First roller 5 ··· First pay-out device 6 ··· Space portion 7 ··· Second pay-out device 8 ··· Second welding device 81 ··· Second roller 82 ··· Needle-like part 9 ··· Foaming agent

Claims

1. A step of dispersing and placing cloth fibers on a conveying device; A step of covering the cloth fibers placed on the conveying device with a first synthetic resin film, and heating from above the first synthetic resin film to weld the first synthetic resin film and the cloth fibers together; A step of conveying the first synthetic resin film welded to the cloth fibers through a space where the cloth fibers not welded to the first synthetic resin film fall; A step of laminating and heat-welding a second synthetic resin film on the surface of the cloth fibers after dropping excess cloth fibers in the space; A method for manufacturing a synthetic resin film laminate, characterized by comprising the above steps.

2. The step of conveying through a space where the cloth fibers not welded to the first synthetic resin film fall is such that the first synthetic resin film welded to the upper surface of the cloth fibers is wound around so as to contact a first roller, and the cloth fibers located outside the first roller are dropped downward. The method for manufacturing a synthetic resin film laminate according to Claim 1.

3. The step of conveying through a space where the cloth fibers not welded to the first synthetic resin film fall is such that the first synthetic resin film welded to the upper surface of the cloth fibers is wound around so as to contact a first roller, and the cloth fibers located outside the first roller are dropped downward. The step of laminating and heat-welding the second synthetic resin film is such that when the first synthetic resin film is wound around by the first roller, the cloth fibers are positioned outside the first roller, and the second synthetic resin film is laminated and heat-welded from the outside of the cloth fibers. The method for manufacturing a synthetic resin film laminate according to Claim 1.

4. The step of laminating and heat-welding the second synthetic resin film is such that a needle-like portion is pressed from above the second synthetic resin film for heat-welding. The method for manufacturing a synthetic resin film laminate according to Claim 1.

5. The step of laminating and heat-welding the second synthetic resin film is such that a needle-like portion is pressed from above the second synthetic resin film for heat-welding. The method for manufacturing a synthetic resin film laminate according to Claim 1, wherein the needle-like portion is disposed on the outer circumference of a roller for heat-welding.

6. The manufacturing method of the synthetic resin film laminate according to claim 1, wherein the first synthetic resin film or the second synthetic resin film is provided with a foaming agent that foams by heating on the surface on the side where the cloth fibers are provided.

7. A conveying device for placing and conveying cloth fibers, A first feeding device that feeds out a first synthetic resin film so as to cover the cloth fibers placed on the conveying device, A first heat welding device that heat-welds the first synthetic resin film fed out by the first feeding device, In the conveying path of the first synthetic resin film to which the cloth fibers are welded, a space portion formed so that the cloth fibers not welded to the first synthetic resin film fall, A second feeding device that feeds out a second synthetic resin film so as to cover the surface of the cloth fibers after the excess cloth fibers have fallen in the space portion, A second welding device that laminates and heat-welds the second synthetic resin film fed out by the second feeding device, A synthetic resin film laminating apparatus, characterized by comprising:

8. The synthetic resin film laminating apparatus according to claim 7, wherein the second welding device includes a needle-shaped portion that presses the second synthetic resin film toward the cloth fiber side while stretching the second synthetic resin film.

Images