Adhesive resin sheet and adhesive resin tape

Abstract

To provide an adhesive resin sheet and an adhesive resin tape enabling easy bonding using a thermal press machine or iron, having stretch recovery property, and possessing breathability and sufficient bonding strength.SOLUTION: An adhesive resin sheet used for thermal bonding of a fibrous material, the adhesive resin sheet having a mesh structure, wherein partition walls of cells constituting the mesh have convex portions and concave portions.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present invention relates to an adhesive resin sheet and an adhesive resin tape suitably used for adhering stretchable fiber materials.

Background Art

[0002] In recent years, in order to join cut parts of clothing together, instead of sewing with thread using a sewing machine, a method of using a thermoplastic resin sheet as an adhesive has been increasing. The resin used is a thermoplastic elastomer resin that fluidizes at a low temperature, and a sheet-like adhesive called a hot melt adhesive is often used.

[0003] As an adhesion method, a method of joining cut parts together using a hot melt adhesive softened by heat is common. This method is mainly used for fiber materials with low stretchability. On the other hand, for materials with high stretchability, such as underwear represented by undershirts, bras, girdles, compression wear, and outdoor wear with high stretchability, the above method is generally considered difficult to use. This is because when stretching, the adhesive resin sheet cannot follow the stretchability of the fiber material, resulting in a state where the texture called "beko-tsuki" or "warai" is impaired. Furthermore, depending on some applications such as girdles, breathability is also required, and there are concerns about the problem of stuffiness with general resin sheets. Therefore, various adhesion methods other than adhesive resin sheets are used for these fiber materials with high stretchability.

[0004] To solve this problem, methods such as arranging the adhesive in dots, combining an adhesive with a highly stretchable film, and adhesive sheets have been proposed. Regarding the method of disposing the adhesive in dots, a method of directly applying the adhesive resin in dots on the fibrous material and then bonding them has been proposed and can already be found in commercial products. Since such dots of the adhesive resin form spot joints between the fabrics during bonding, it is expected that the occurrence of puckering and warping can be reduced even when bonding stretchable materials. However, in the method of directly applying in dots on this fibrous material, although techniques such as screen printing are used, because it is carried out in a sewing factory, there are problems such as the coating amount not being stable depending on the skill of the operator and difficulty in continuous production, and the problem that new equipment has to be introduced and the production cost increases significantly.

[0005] Several proposals have been made as methods to improve these problems. As a proposal in the method of forming the adhesive in dots, Patent Document 1 discloses an adhesive sheet formed by applying a hot melt adhesive having a flow start point higher than that of the support in dots on a film-like support of the hot melt adhesive. However, although improvement has been made regarding the dropping of the dots, since it is dried at a temperature higher than the flow start point of the support during the processing of the dot-shaped hot melt adhesive, there is concern that stickiness of the resin may occur. When stickiness occurs, continuous production is difficult, so a problem of poor mass productivity is likely to occur, and still, the problem in processing becomes an issue.

[0006] On the other hand, methods that do not use dots have also been proposed. Patent Document 2 proposes a method of combining highly stretchable films. That is, Patent Document 2 discloses an adhesion method using an adhesive sheet provided with a hot-melt adhesive having stretch elasticity on at least one side of a support sheet having stretch elasticity and heat resistance. This adhesive sheet can be obtained by a simple method of adhesion by heat, which enables it to retain its stretchability even when used for adhering stretchable fiber materials with a support having stretch elasticity and heat resistance. However, when the adhesive is thickened to improve the adhesive strength, there will be problems such as unevenness and warping. When the adhesive is thinned, the unevenness and warping are improved, but there is a problem that the adhesive strength decreases. Furthermore, since it has a two-layer structure of a support and an adhesive, there is also a problem that the texture tends to become hard. In addition, a method of punching the adhesive sheet to form a mesh-like process has been tried, but since a very soft resin is used for the highly stretchable adhesive sheet, it is very difficult to make holes by punching and it is hardly used for clothing applications with a large stretchability, which is also clear from the products in stores that handle such clothing.

[0007] As described above, regarding the air permeability required for some applications, there is no problem with dot-like adhesion or punched processing, but in Patent Document 1 and Patent Document 2 using a sheet as a support, there still remains a concern about air permeability.

Prior Art Documents

Patent Documents

[0008]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0009] Therefore, the present invention has been developed in view of the above problems, and an object thereof is to provide an adhesive resin sheet and an adhesive resin tape that can be easily adhered with a heat press machine or an iron, have stretch recovery properties, and have breathability and sufficient adhesive strength.

Means for Solving the Problems

[0010] In order to achieve the above object, the adhesive resin sheet of the present invention has the following configuration. (1) An adhesive resin sheet having a network structure, wherein the partition walls of the cells constituting the network have convex portions and concave portions, the convex portions are present at the intersection portions of the partition walls, and the width of the partition walls is smaller than the diameter of the convex portions. (2) The adhesive resin sheet according to (1) above, wherein the cells are polygonal. (3) The adhesive resin sheet according to (2) above, wherein the polygon is a hexagon. (4) The adhesive resin sheet according to (1) above, wherein the convex portions are columnar. (5) In the adhesive resin sheet, the cells are regularly arranged, and the void portions surrounded by the cells occupy 50% or more of the area of the adhesive resin sheet including the void portions. (6) The adhesive resin sheet according to (1) above, wherein the adhesive resin sheet contains a polyurethane resin. (7) The adhesive resin sheet according to (1) above, which is thermally adhered to a fiber material. (8) An adhesive resin tape obtained by slitting the adhesive resin sheet according to any one of (1) to (7) above.

Effects of the Invention

[0011] The adhesive resin sheet and the adhesive resin tape of the present invention are suitably used for stretchable clothing applications, have both high adhesive strength and good stretchability after adhesion, and have breathability.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Embodiments for Carrying Out the Invention

[0013] The adhesive resin sheet of the present invention is mainly suitably used for adhering fiber materials for clothing applications. In particular, it can exhibit its performance when used for stretchable fiber materials. The adhesive resin sheet of the present invention has a network structure, and the cell walls constituting the network have convex portions and concave portions. The convex portions are present at the intersection portions of the cell walls, and the width of the cell walls is smaller than the major axis width of the convex portions. Examples of the network structure include a mesh shape and the like. Examples of the shape of the convex portions present at the intersection portions of the cell walls include a cylinder, a prism, and the like. Examples of the shape of the cells constituting the network include a circle, a polygon, a sector, etc., but a polygon is preferable. Among them, a hexagon is preferable in terms of having the same shape, being plane-centered, and stretching uniformly in multiple directions. The convex portions are preferably columnar, and the diameter of the circular cross-section is preferably 5 mm or less. The width of the cell walls is preferably 4 mm or less. The width of the cell walls is smaller than the major axis of the convex portions, but the difference is preferably 80% or less. The cells are preferably arranged regularly in order to obtain uniform expansion and contraction. The void portion surrounded by the cells preferably occupies 50% or more of the area of the adhesive resin sheet including the void portion. By being 50% or more, sufficient air permeability can be obtained. As the resin sheet of the present invention, a thermoplastic elastomer resin is used. The thermoplastic resin elastomer is not particularly limited as long as it is a resin used as a hot melt adhesive, such as olefin resins such as polypropylene and polyethylene, polyvinyl chloride resin, polystyrene resin, polyurethane resin, polyester resin, and amide resins such as nylon, as well as copolymers and blended resins thereof. When used for fiber materials and clothing, a polyurethane resin is preferable in view of durability such as wash resistance and dry cleaning resistance. Examples of polyurethane resins include hot melt TPU such as H7711UFL manufactured by Taiwan Free Radical Co., Ltd., but it is appropriately selected according to the materials used. When the adhesive resin sheet is given a maximum elongation in the range of 30% to 100%, it is preferable that the elongation recovery rate obtained by the following formula is 80% or more. Elongation recovery rate (%) = {L(max) - L(1)} / {L(max) - L(0)} × 100 L(max): Sample length at maximum elongation L(0): Original sample length L(1): The length of the sample measured 3 minutes after returning to the grip interval position of the initial value after one elongation. Within this range, problems such as stickiness and warping during expansion and contraction recovery are less likely to occur. The specific measurement method of the elongation recovery rate will be described later. The adhesive resin sheet will be described with reference to FIGS. 1 and 2. FIG. 1 is a photograph taken from above. The adhesive resin sheet has a mesh-like structure and is composed of convex portions and concave portions. The convex portions are arranged in a hexagonal shape and have a structure connected by the concave portions. Furthermore, the size of the convex portions is smaller than the diagonal of the hexagon to form a mesh-like shape with gaps. A concave portion having a width smaller than the major axis of the convex portion is used. FIG. 2 is a cross-sectional view of the resin sheet. It shows that there is a height difference between the convex portion and the concave portion. The convex portion is high and the concave portion is lower than the convex portion. It is preferable that the difference from the convex portion is 10% or more. As a method for manufacturing the adhesive resin sheet of the present invention, there is a method in which a thermoplastic elastomer resin is applied and molded on a release base material such as paper or film having releasability by a coating device. The coating method is not special. The thermoplastic elastomer resin is dissolved in water, a solvent, etc., and applied to paper or film having releasability with unevenness in a mesh shape with a bar coater such as a comma coater and then dried, or resin pellets are prepared and melted and liquefied by an extruder or the like, and there are methods of molding with various applicators. However, considering the viewpoints of continuous productivity and environmental response, etc., a method of melting thermoplastic elastomer resin pellets by an extruder or the like to make them liquid and continuously applying them with a gravure coater is preferable. At this time, if the pattern of the gravure coater is formed into a shape in which convex portions regularly arranged in a hexagonal shape are connected by concave portions, an adhesive resin sheet as shown in FIGS. 1 and 2 can be easily and continuously obtained. The adhesive resin sheet of the present invention can be obtained by slitting to obtain an adhesive resin tape, and can be used instead of sewing with a sewing machine in addition to the hem and hem of clothes.

Example

[0014] Hereinafter, the configuration and effects of the present invention will be described in more detail with reference to examples. Each physical property in the examples was determined by the following method.

[0015] (1) Peel strength A sample is cut out from the adhesive resin sheet to a length of 120 mm and a width of 10 mm to obtain a tape. Next, a stretchable warp-knitted and weft-knitted material (mixing ratio: nylon 72%, polyurethane 25%, basis weight 160 g / m 2 ) composed of nylon and polyurethane as the adherend is obtained by cutting out two pieces each having a length of 150 mm and a width of 25 mm. The cut adherends are placed so that the front and back surfaces overlap, and the cut tape is placed between them. The laminated sample is processed and adhered at a temperature of 150 ° C. and a press pressure of 0.4 MPa for 30 seconds with a flat press machine (plate size 450 mm × 360 mm). Since the general acceptance criterion is 10 N / cm or more, a similar evaluation was carried out.

[0016] (2) Appearance evaluation Measure the elongation rate of the adherend fabric in advance. The elongation rate is calculated by the following method. Cut out the adherend fabric to a length of 150 mm and a width of 25 mm. Then, using a tensilon (manufactured by A&D), it is pulled in the length direction under the conditions of a gripping interval of 100 mm and a pulling speed of 100 mm / min to obtain the length at a stress of 14.7 N. The elongation rate is calculated by the following formula. Since it is an evaluation after bonding, the value obtained by dividing the final value by 2 in the following formula is used as the elongation rate. Elongation rate (%) = [(Length at 14.7 N) - Length of gripping interval] / Length of gripping interval × 100 / 2 Next, as the appearance evaluation, the sample after bonding, prepared in the same manner as (1), is stretched at a speed of 100 mm / min on a tensile testing machine until it reaches the previously determined elongation rate, and then immediately returned to the position where the load becomes 0 N and the sample is removed. Evaluate the appearance 10 minutes after the test. Those with no deflection in appearance are marked as ○, those with a slight deflection are marked as △, and those with a large deflection are marked as ×.

[0017] (3) Air permeability After cutting out the sample to be measured to a size of 15 cm × 15 cm, it is measured using an air permeability tester AP - 360 (manufactured by Dai - Ei Kagaku Seiki Co., Ltd.) in accordance with the JIS L 1096 (2010) Frazier method. When the sample to be measured is the sample after bonding, place it so that the front and back surfaces of the adherend fabric overlap, and sandwich an adhesive resin sheet cut out to the same size in between. The laminated sample is processed and bonded at a temperature of 150 °C and a press pressure of 0.4 MPa for 30 seconds using a flat press machine (plate size 450 mm × 360 mm).

[0018] (4) Elongation recovery rate Cut out a sample from the adhesive resin sheet with a length of 150 mm and a width of 10 mm. Mark the positions 50 mm and 60 mm from the center of the cut sample to both sides to obtain a standard spacing (initial length L0) of 100 mm and a gripping position of 120 mm. Install the marked sample on a tensilon (manufactured by A&D) with a gripping interval of 120 mm, and stretch it under the conditions of 300 mm / min and a maximum elongation of 100%. After measurement, promptly remove it from the testing machine. From this measurement, obtain the maximum elongation length (Lmax) as the standard spacing at 100% and the length (L1) of the standard spacing 3 minutes after the test. Obtain the elongation recovery rate from the following formula using these obtained numerical values.

[0019] Elongation recovery rate (%) = {L(max) - L(1)} / {L(max) - L(0)} × 100 L(max): Sample length at maximum elongation L(0): Original sample length L(1): After one elongation, return to the initial gripping interval position, and measure the length of the sample 3 minutes after the measurement.

[0020] (5) Measurement method for convex parts and partitions Measure the major diameter of the convex part using a ruler or a microscope such as SEM from the upper surface. Measure the height of the convex and concave parts using a thickness gauge or a microscope such as SEM for the cross-section. Measure the width of the partition using a microscope such as SEM from the upper surface. Measure the height of the partition using a microscope such as SEM for the cross-section.

[0021] (6) Porosity The porosity is calculated from the prepared adhesive resin sheet. Arbitrarily determine a 2 cm × 2 cm area on the adhesive resin sheet, and at that point, use a microscope such as SEM in the same manner as in (5) above to measure the major diameter of the convex part, the width and length (cm) of the partition of the concave part, and calculate the area of the resin part (convex part, concave part). Divide the calculated area by 4 cm 2 to obtain the resin area ratio per unit area, and calculate the porosity, which is the part where no resin exists. The area of the resin part may be calculated by an application attached to SEM or the like for measurement. Void ratio (%) = 100 - {(resin part area / 4) × 100} Example 1 A gravure roll engraved so that a formed sheet has a convex height of 250 μm, a concave height of 170 μm, a convex diameter of 1.5 mm, a width of the partition wall of the concave part of 0.5 mm, a concave length of 2 mm, and the arrangement of the convex parts is hexagonal and the convex parts are connected by the concave parts to form a mesh shape is used to coat a thermoplastic polyurethane resin (H7711UFL manufactured by Taiwan Free Radical Co., Ltd.) on a plastic film with releasability to prepare a mesh-shaped adhesive resin sheet.

[0022] As the adherend fabric, a stretchable warp-knitted and interwoven material composed of nylon and polyurethane (mixing ratio: nylon 72%, polyurethane 25%, basis weight 160 g / m 2 ) was prepared. The prepared adhesive resin sheet and the adherend fabric were heat-pressed and adhered at 150 °C and a pressure of 0.4 MPa for 15 seconds to obtain a sample for evaluation. The results of the obtained sample are shown in Table 1.

[0023] Example 2 In the same manner as in Example 1, a mesh-shaped adhesive resin sheet was prepared such that the convex height was 300 μm, the concave height was 150 μm, the convex diameter was 1.0 mm, the width of the partition wall of the concave part was 0.5 mm, and the concave length was 2.0 mm. Using this, a sample for evaluation was prepared in the same manner.

[0024] Example 3 In the same manner as in Example 1, a mesh-shaped adhesive resin sheet was prepared such that the convex height was 200 μm, the concave height was 100 μm, the convex diameter was 1.5 mm, the width of the partition wall of the concave part was 0.5 mm, and the concave length was 2.0 mm. Using this, a sample for evaluation was prepared in the same manner.

[0025] Comparative Example 1 A sample for evaluation was prepared in the same manner as in Example 1, except that a sheet with a width of 100 μm was prepared using a T-die with an extruder so that no holes were formed in the adhesive resin sheet.

[0026] Comparative Example 2 An adhesive resin sheet was prepared in the same manner as in Comparative Example 1 to obtain an adhesive resin sheet with a thickness of 200 μm.

[0027] Comparative Example 3 A sample was prepared in the same manner as in Example 1, except that an adhesive resin sheet with a thickness of 100 μm having regularly punched holes with a diameter of 2 mm was used. The appearance of this adhesive resin sheet is shown in Fig. 3.

[0028] Comparative Example 4 A sample was prepared in the same manner as in Example 1, except that an adhesive resin sheet with a thickness of 200 μm having regularly punched holes with a diameter of 2 mm was used. The appearance from above is the same as that of Comparative Example 3.

[0029] Comparative Example 5 In the same manner as in Example 1, a mesh-shaped adhesive resin sheet was prepared such that the convex portion was 250 μm, the concave portion height was 170 μm, the diameter of the convex portion was 1.5 mm, the width of the partition wall of the concave portion was 1.5 mm, and the length of the concave portion was 2.0 mm. An evaluation sample was prepared in the same manner using this.

[0030] Comparative Example 6 In the same manner as in Example 1, a mesh-shaped adhesive resin sheet was prepared such that the intersection height of the partition walls was 250 μm, the partition wall height was 250 μm, the diameter of the intersection portion was 1.5 mm, the width of the partition wall was 0.5 mm, and the length of the concave portion was 2.0 mm. An evaluation sample was prepared in the same manner using this.

[0031] Comparative Example 7 In the same manner as in Example 1, a mesh-shaped adhesive resin sheet was prepared such that the intersection portion height was 170 μm, the partition wall height was 250 μm, the diameter of the intersection portion was 1.5 mm, the width of the partition wall was 0.5 mm, and the length of the partition wall was 2.0 mm. An evaluation sample was prepared in the same manner using this.

[0032] [Table 1]

Industrial Applicability

[0033] The adhesive resin sheet of the present invention can be suitably used for thermally bonding fiber materials.

Explanation of Reference Numerals

[0034] 1: Adhesive resin sheet 2: Protrusion of adhesive resin sheet 3: Recess of adhesive resin sheet 4: Base film 5: Void portion 6: Diagonal line

Claims

1. An adhesive resin sheet having a mesh structure, wherein the partition walls of the cells constituting the mesh have convex portions and concave portions, the convex portions are present at the intersection portions of the partition walls, and the width of the partition walls is smaller than the diameter of the convex portions.

2. The adhesive resin sheet according to Claim 1, wherein the cells are polygonal.

3. The adhesive resin sheet according to Claim 2, wherein the polygon is a hexagon.

4. The adhesive resin sheet according to Claim 1, wherein the convex portions are columnar.

5. In the adhesive resin sheet, the cells are regularly arranged, and the void portions surrounded by the cells occupy 50% or more of the area of the adhesive resin sheet including the void portions. The adhesive resin sheet according to Claim 1.

6. The adhesive resin sheet according to Claim 1, wherein the adhesive resin sheet contains a polyurethane resin.

7. The adhesive resin sheet according to Claim 1, which is thermally adhered to a fiber material.

8. An adhesive resin tape obtained by slitting the adhesive resin sheet according to any one of Claims 1 to 7.

Images