Flexible sheet and method for manufacturing a flexible sheet

Abstract

The present invention provides a flexible sheet and a method for manufacturing the same, which imparts tensile strength to thin-film materials that cannot maintain a flat shape on their own, and enables surface decoration. [Solution] The flexible sheet 1 includes a thin film-like substance 2 that cannot maintain a flat shape on its own, and resin sheets 3a and 3b that are in close contact with both sides of the substance 2.

Description

Technical Field

[0001] The present invention relates to a flexible sheet and a method for manufacturing the flexible sheet.

Background Art

[0002] Hitherto, for a sheet that cannot maintain its form flat by itself, the workability of manufacturing operations has been improved by attaching it to a strong base material.

[0003] However, an object that cannot maintain its form flat by itself when attached to such a base material has a problem that the handleability as a sheet is inevitably reduced and the usefulness as a sheet cannot be maintained.

[0004] For example, as a self-extinguishing sheet containing a fire extinguishing substance, an inorganic paint in which digestive microcapsules containing a digestive agent are uniformly dispersed inside capsules is applied onto a base material, and then the paint is dried. A self-extinguishing sheet (Patent Document 1), a self-extinguishing sheet-shaped molded body containing coated resin-type fire extinguishing agent particles and a matrix made of resin (Patent Document 2), and a fire extinguishing film formed by kneading a slurry or powder containing a fire extinguishing agent component and a thermoplastic resin (Patent Document 3) are known.

[0005] However, these self-extinguishing sheets are too soft or have a small tensile strength when alone, and thus have extremely poor workability. Therefore, they must be attached to a strong base material or base, and the workability is extremely poor.

[0006] In addition, since the self-extinguishing sheet is too soft or has a small tensile strength, direct printing cannot be performed, so its use as an interior material such as a decorative board in a room is limited.

[0007] For example, as mentioned above, because it is too soft or has low tensile strength, when applied directly to an existing room, it is unavoidable that after attaching the self-extinguishing sheet, additional necessary materials, such as films or decorative materials, must be applied on top of the self-extinguishing sheet to provide strength and decorative properties to the room. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] Japanese Patent Application Publication No. 5-84873 [Patent Document 2] Japanese Patent Publication No. 2010-31127 [Patent Document 3] Japanese Patent Publication No. 2021-137345 [Overview of the Initiative] [Problems that the invention aims to solve]

[0009] The object of the present invention is to provide a flexible sheet and a method for manufacturing the same that imparts tensile strength to a thin film-like material that cannot maintain a flat shape on its own, and enables surface decoration. [Means for solving the problem]

[0010] The present invention relates to a thin film-like material that cannot maintain a flat shape on its own, The flexible sheet is characterized by comprising a resin sheet that adheres to both sides of the aforementioned substance.

[0011] Furthermore, the present invention is characterized in that the thin film-like substance includes a self-extinguishing sheet containing a fire extinguishing agent component and a binder.

[0012] Furthermore, the present invention is characterized in that the resin sheet is either a decorative sheet having at least a pattern or color, or an adhesive sheet having an adhesive layer.

[0013] Furthermore, the present invention includes a first step of preparing a thin film-like material that cannot maintain a flat shape on its own, The second step is to prepare the resin sheet, A method for manufacturing a flexible sheet, characterized by comprising a third step of adhering the resin sheet to both sides of the aforementioned substance in a gas-free state. [Effects of the Invention]

[0014] According to the present invention, a flexible sheet is constructed by adhering a resin sheet to a thin film or sheet that cannot maintain a flat shape on its own, thereby improving handling when performing certain tasks. If the thin film is, for example, a self-extinguishing sheet, it is thin (200 μm) and easily torn, so it cannot be used as is. However, by making the self-extinguishing sheet into the form of a flexible sheet, it can be used as an interior material for houses, furniture, vehicles, ships, etc.

[0015] Furthermore, according to the present invention, since both sides of a thin film-like substance that cannot maintain a flat shape on its own are composed of resin sheets, patterns, colors, etc., can be applied to the surface of the resin sheets, and it can be used in many applications in real estate such as houses and factories, and in automobiles and other movable property.

[0016] Furthermore, according to the present invention, if the thin film material that cannot maintain a flat shape on its own is, for example, a self-extinguishing sheet, since both sides of the self-extinguishing sheet are composed of resin sheets, airtightness, waterproofness, and light resistance are provided, preventing deterioration of the fire extinguishing agent contained in the self-extinguishing sheet, and allowing the flexible sheet to be used as a fire extinguishing agent for a long period of time.

[0017] In addition, when the thin-film-like substance is a self-extinguishing sheet, if a paint or decorative material is applied on it after attaching the self-extinguishing sheet to impart decorativeness, the overall thickness will vary. Therefore, in case of a fire, the fire extinguishing agent from the self-extinguishing sheet will be released separately from the areas with a small thickness of the decorative layer on the self-extinguishing sheet, and will not be released simultaneously, resulting in a poor fire extinguishing effect. On the contrary, in the flexible sheet of the present invention, since a pattern or the like can be applied to its surface, the thickness of the resin sheet adhered to the fire extinguishing sheet is always constant, and the fire extinguishing agent is released simultaneously from the self-extinguishing sheet in case of a fire, so that an excellent fire extinguishing effect can be obtained.

Brief Description of the Drawings

[0018] [Figure 1] It is a cross-sectional view schematically showing the configuration of the flexible sheet 1 according to an embodiment of the present invention. [Figure 2] It is a cross-sectional view schematically showing a state in which a printing layer 6, an adhesive layer 4a and a release paper 5 are laminated on the resin sheet 3a. [Figure 3] It is an exploded cross-sectional view schematically showing the joined state of the substance 2 and the resin sheet 3a. [Figure 4] It is a flowchart for explaining the manufacturing method of the flexible sheet 1.

Modes for Carrying Out the Invention

[0019] FIG. 1 is a cross-sectional view schematically showing the configuration of a flexible sheet 1 according to an embodiment of the present invention. FIG. 2 is a cross-sectional view schematically showing a state in which a printing layer 6, an adhesive layer 4a, and a release paper 5 are laminated on a resin sheet 3a. FIG. 3 is an exploded cross-sectional view schematically showing a joined state between a substance 2 and a resin sheet 3a. The flexible sheet 1 of the present embodiment includes a thin-film-like substance 2 (hereinafter sometimes referred to as “inner sheet 2”) that cannot maintain a flat shape by itself, resin sheets 3a and 3b (hereinafter generically referred to as “resin sheet 3” when collectively referred to) adhered to both surfaces 2a and 2b of the substance 2, an adhesive layer 4a that adheres the substance 2 and one resin sheet 3a, and a second adhesive layer 4b that adheres the substance 2 and the other resin sheet 3b. At least the resin sheet 3a and the printing layer 6 are included to form a decorative sheet. Such a decorative sheet may also include an adhesive layer 4a and a release paper 5 so that it can be transported alone, and the release paper 5 may be attached to the adhesive layer 4a to protect the adhesive layer 4a.

[0020] In the present embodiment, the thin-film-like substance 2 that cannot maintain a horizontal shape by itself means that the substance itself is very soft, and when grasped by an operator by hand, the whole greatly deflects due to its own weight and becomes in an inconvenient state such as breaking or bending under the action of an external force as small as a slight breeze, and it is a material that is extremely difficult to handle even for a skilled manufacturing worker.

[0021] Also, in the present embodiment, “adhesion” means a state in which no bubbles such as gas exist between the substance 2 and the resin sheets 3a and 3b, and no bubbles such as gas are mixed between the opposing surfaces 2a, 31a; 2b, 31b of the substance 2 and the resin sheets 3a and 3b.

[0022] One resin sheet 3a, when manufactured as flexible sheet 1, has an adhesive layer 4a applied to it and a release paper 5 attached to the adhesive layer 4a, as shown in Figure 2, before being bonded to substance 2. The other resin sheet 3b is constructed similarly to the first resin sheet 3a. Each resin sheet 3a and 3b is made of, for example, polyvinyl chloride resin with a thickness of 80 μm. The adhesive layers 4a and 4b are made of a relatively low molecular weight resin with a thickness of 10 μm. Substance 2 is made of, for example, a white self-extinguishing sheet in which an inorganic potassium compound, an organic potassium compound, and a binder are mixed in a predetermined ratio. The adhesive layer 4a may also be an adhesive layer, and as the adhesive, acrylic adhesives, silicone adhesives, rubber adhesives, etc., described later can be used.

[0023] The thickness of the resin sheets 3a and 3b is not limited to 80 μm, but can be appropriately set within the range of 25 μm to 350 μm depending on the required strength, weather resistance, and other specifications. Furthermore, the self-extinguishing sheet may have a configuration in which fire-extinguishing microcapsules are uniformly dispersed. These fire-extinguishing microcapsules may have a core material consisting of, for example, halides such as promotrichrometane, carbon tetrachloride, tetrabromethane, haladone 114B2 (1,2-dibromo-1,1,2,2-tetrafluoroethane), p-nitroaniline, triiodoethane, or water. Such fire-extinguishing microcapsules may be dispersed in an inorganic coating such as a metal alkoxide of aluminum, silicon, manganese, iron, or titanium. The self-extinguishing sheet may also be constructed by curing the inorganic coating in which the fire-extinguishing microcapsules are dispersed into a sheet.

[0024] Furthermore, in the flexible sheet 1 of this embodiment, the inner sheet 2 and the resin sheets 3a and 3b are tightly bonded together by adhesive layers 4a and 4b. The flexible sheet 1 of this embodiment may also be so-called pouch-processed, in which the peripheral edge of one resin sheet 3a and the peripheral edge of the other resin sheet 3b are joined together by heat fusion or the like around the inner sheet 2.

[0025] Furthermore, the flexible sheet 1 of this embodiment may have patterns or colors on one or both sides by covering or decorating the resin sheet 3a with a printed layer 6.

[0026] Furthermore, the flexible sheet 1 of this embodiment may have a thickness of 250 to 550 μm, preferably 300 to 400 μm, and more preferably 350 to 380 μm.

[0027] In this embodiment, the internal sheet 2 can be, for example, a self-extinguishing sheet, lead foil, gold foil or other metal foil.

[0028] The self-extinguishing sheet can be any known self-extinguishing sheet and is not particularly limited, but some examples include a sheet obtained by kneading a fire extinguishing agent component with a binder resin.

[0029] As for the fire extinguishing agent components, any substance that possesses the four elements of fire extinguishing (removal action, cooling action, suffocation action, and negative catalytic action) is acceptable. Suitable candidates include halogenated compounds, water, inorganic oxidizing agents, compositions containing potassium compounds such as potassium-containing organic compounds and potassium chlorate, and radical generating agents such as sodium salts, ammonium polyphosphate, phosphate esters, and general fire extinguishing agents (including powder-type fire extinguishing agents mainly composed of potassium salts, as well as general powder-type fire extinguishing agents such as sodium bicarbonate and phosphates).

[0030] These fire extinguishing agents may be in powder form, liquid form, or embedded in a base material, such as in microcapsules.

[0031] In this embodiment, plastic resins and thermosetting resins can be used as the binder resin. Examples of thermoplastic resins include polyolefin resins such as polypropylene resins, polyethylene resins, poly(1-)butene resins, and polypentene resins, polystyrene resins, acrylonitrile-butadiene-styrene resins, methyl methacrylate-butadiene-styrene resins, ethylene-vinyl acetate resins, ethylene-propylene resins, polycarbonate resins, polyphenylene ether resins, acrylic resins, polyamide resins, and polyvinyl chloride resins.

[0032] Examples of thermosetting resins include natural rubber (NR), isoprene rubber (IR), butadiene rubber (BR), 1,2-polybutadiene rubber (1,2-BR), styrene-butadiene rubber (SBR), chloroprene rubber (CR), nitrile rubber (NBR), butyl rubber (IIR), ethylene-propylene rubber (EPR, EPDM), chlorosulfonated polyethylene (CSM), acrylic rubber (ACM, ANM), epichlorohydrin rubber (CO, ECO), polyvulcanized rubber (T), silicone rubber (Q), fluororubber (FKM, FZ), urethane rubber (U), and other types of rubber, as well as polyurethane resins, polyisocyanate resins, polyisocyanurate resins, phenolic resins, epoxy resins, and the like.

[0033] The thickness of the internal sheet 2 is not particularly limited; it should be a thickness that allows both surfaces 2a and 2b of the internal sheet 2 to be in close contact without any gas present.

[0034] For example, one such example is a material with a thickness of 150 to 250 μm, preferably 170 to 230 μm, and more preferably 190 to 210 μm.

[0035] Furthermore, the resin sheets 3a and 3b that adhere to both surfaces 2a and 2b of the internal sheet 2 are not particularly limited, but examples include polyalkylene resin sheets such as polyvinyl chloride resin sheets, polyethylene resin sheets, and polypropylene resin sheets, and polyethylene terephthalate resin sheets.

[0036] These resin sheets 3a and 3b may contain known additives such as plasticizers, stabilizers, and ultraviolet absorbers.

[0037] The resin sheets 3a and 3b are not particularly limited in thickness as long as they can be tightly bonded to both sides of the internal sheet without the presence of gas. For example, they may have a thickness of 25 to 175 μm, preferably 80 to 100 μm, and more preferably 70 to 90 μm.

[0038] In this embodiment, polyvinyl chloride resin, polypropylene resin, and polyethylene terephthalate resin are preferred, and polypropylene resin and polyethylene terephthalate resin are particularly preferred in terms of flexibility.

[0039] In the flexible sheet of the present invention, when the internal sheet and the resin sheet are bonded together with an adhesive, the adhesive is not particularly limited, but acrylic adhesives, epoxy adhesives, silicone adhesives, polyolefin adhesives, urethane adhesives, polyvinyl ether adhesives, or composite adhesives thereof can be used.

[0040] In this embodiment, preferred adhesives include acrylic adhesives and polyolefin adhesives.

[0041] Furthermore, the flexible sheet of the present invention may be configured such that an adhesive is applied to the surface that will be attached as an interior material, and a release liner is attached on top of the adhesive layer. Alternatively, one surface of the flexible sheet of the present invention, for example the surface that will be exposed as an interior material, may be coated with a pattern such as wood grain, and the other surface, for example the surface that will be attached to a wall or the like as an interior material, may be configured to have an adhesive and a release liner. This makes it possible to improve work efficiency by allowing the flexible sheet of the present invention to be attached to the desired location simply by peeling off the release liner when using it as an interior material.

[0042] In the above case, the adhesive is not particularly limited, but acrylic adhesives, silicone adhesives, rubber adhesives, etc., can be used. Examples of acrylic adhesives include adhesives containing acrylic polymers, such as FineTack (CT-3088, CT-3850, CT-6030, CT-5020, CT-5030, all manufactured by Dainippon Ink, Inc.), QuickMaster (SPS-900-IV, QuickMaster SPS-1040NT-25, both manufactured by Dainippon Ink, Inc.), and OriPine (registered trademark, manufactured by ToyoChem Co., Ltd.).

[0043] Examples of silicone-based adhesives include adhesives containing silicone polymers, such as polymers manufactured using KR-3704 (main component) and CAT-PL-50T (platinum catalyst) (manufactured by Shin-Etsu Chemical Co., Ltd.). Examples of urethane-based adhesives include adhesives containing urethane polymers, such as Ori-Siapine (registered trademark, manufactured by Toyo Chem Co., Ltd.).

[0044] Figure 4 is a flowchart illustrating the manufacturing method of the flexible sheet 1. In this embodiment, the flexible sheet 1 is manufactured by first preparing the inner sheet 2 in step s1, and second preparing the resin sheets 3a and 3b in step s2. In step 3, the release paper 5 is peeled off to expose the adhesive layer 4a to the outside, and both surfaces 2a and 2b of the inner sheet 2 are covered with the resin sheets 3a and 3b and pressed together. This allows the resin sheets 3a and 3b to adhere closely to both surfaces 2a and 2b of the material 2 without any gas present, thereby manufacturing the flexible sheet 1.

[0045] Alternatively, it can be manufactured by first pressing a resin sheet 3a onto one surface 2a of the internal sheet 2, and then pressing a resin sheet 3b onto the other surface 2b.

[0046] Before pressing, the resin sheets 3a and 3b may be coated with adhesive or decorated as needed. Preferably, the adhesive is applied to the surface 31a of the resin sheets 3a and 3b that comes into contact with the inner sheet 2, and the decoration with the printed layer 6 is applied to the surface that does not come into contact with the inner sheet 2.

[0047] The crimping can be carried out using known laminating or pouching equipment, and when using known equipment, it can be performed under pressure at room temperature or under heating.

[0048] The bonding process can be judged by visually checking the adhesion state of each resin sheet 3a, 3b to the inner sheet 2 to see if they are in close contact. There are no particular restrictions on the conditions for this, however, it is necessary that they do not contain gas or other air bubbles, and after manufacturing, it is necessary to ensure that gas or other air bubbles do not enter the adhesive layers 4a, 4b, the interfaces between the adhesive layers 4a, 4b and each resin sheet 3a, 3b, and the interfaces between the adhesive layers 4a, 4b and the inner sheet 2, so that they are in close contact.

[0049] The appropriate bonding conditions involve balancing the feed rate, bonding pressure, and adhesive. If the adjustment is not appropriate, wrinkles may form in the inner sheet 2, or gas may remain inside the flexible sheet 1, which is undesirable. An example of appropriate conditions would be a feed rate of 5 to 10 m / min, preferably 7 to 8 m / min, a bonding pressure of 0.4 to 0.8 MPa, preferably 0.5 to 0.6 MPa, and an adhesive of any of the above types. If the feed rate exceeds 10 m / min, the inner sheet 2 may tear, and if the feed rate is less than 4 m / min, creases may form in the inner sheet 2 during pouch lamination, which is undesirable. Furthermore, if the bonding pressure is 0.3 MPa, the adhesion to the flexible sheet 1 will be low, and gas may remain inside the flexible sheet 1, and if the bonding pressure is 0.9 MPa or higher, the inner sheet 2 may tear, which is undesirable.

[0050] Furthermore, when the flexible sheet of the present invention is configured to have an adhesive applied to its adhesive surface, it can be manufactured by applying the adhesive to the adhesive surface of the flexible sheet obtained above using a known method, and then further attaching a release liner to the adhesive layer.

[0051] The flexible sheet obtained in this way is not particularly limited in its planar shape and may be square, rectangular, or even in the form of a roll.

[0052] The present invention will be described below with reference to examples, but this will not limit the scope of the present invention.

[0053] Example 1 As the internal sheet, a 200μm thick, A4-sized self-extinguishing sheet (product name: K / SMOKE PANEL, manufactured by Yamato Protec Co., Ltd.) is used, and both the top and bottom surfaces of this sheet are sandwiched between two polyvinyl chloride resin sheets, each 80μm thick, 300cm long, and 210cm wide, coated with an acrylic ester copolymer adhesive, so that the adhesive-coated surfaces are in contact with the top and bottom surfaces of the self-extinguishing sheet. Next, a flexible, self-extinguishing sheet was obtained by laminating it using a laminating machine (MH1406WH, manufactured by Intercosmos Inc.) at a pressure of 0.5 MPa and a feed rate of 8 m / min. The resulting self-extinguishing, flexible sheet had no gas present in the pouch and was wrinkle-free.

[0054] Example 2 A flexible, self-extinguishing sheet was obtained by following the same procedure as in Example 1, except that a polypropylene resin sheet (70 μm thick) was used as the resin sheet. The obtained self-extinguishing flexible sheet did not contain any gas in the pouch and was wrinkle-free.

[0055] Example 3 A flexible, self-extinguishing sheet was obtained by following the same procedure as in Example 1, except that a polyethylene terephthalate resin sheet (60 μm thick) was used as the resin sheet. The obtained self-extinguishing flexible sheet did not contain any gas in the pouch and was wrinkle-free.

[0056] Comparative Example 1 A flexible, self-extinguishing sheet was obtained by pouch processing in the same manner as in Example 1, except that two 40 μm thick polyvinyl chloride resin sheets were used as the resin sheet. Long wrinkles formed inside the pouch of the obtained self-extinguishing, flexible sheet.

[0057] Comparative Example 2 A flexible, self-extinguishing sheet was obtained by pouch processing in the same manner as in Example 1, except that two 20 μm thick polyvinyl chloride resin sheets were used as the resin sheet. Long wrinkles formed inside the pouch of the obtained self-extinguishing, flexible sheet.

[0058] Although embodiments of the present invention have been described in detail above, the present invention is not limited to the embodiments described above, and various modifications and improvements are possible without departing from the spirit of the invention. It goes without saying that all or part of each of the above embodiments can be combined as appropriate and in a non-contradictory manner. [Explanation of Symbols]

[0059] 1. Flexible sheet 2 substances 2a,2b;31a,31b surface 3a, 3b Resin sheet 4a,4b Adhesive layer 5. Release paper 6 printing layer

Claims

1. A thin film-like substance that cannot maintain a flat shape on its own, A flexible sheet characterized by comprising a resin sheet that adheres to both sides of the aforementioned substance.

2. The flexible sheet according to claim 1, characterized in that the thin film-like substance includes a self-extinguishing sheet containing a fire extinguishing agent component and a binder.

3. The flexible sheet according to claim 1 or 2, characterized in that the resin sheet is at least a decorative sheet having a pattern or color, or an adhesive sheet having an adhesive layer.

4. The first step involves preparing a thin film-like material that cannot maintain a flat shape on its own, The second step is to prepare the resin sheet, A method for manufacturing a flexible sheet, characterized by comprising a third step of adhering the resin sheet to both sides of the aforementioned substance in a gas-free state.

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