Thermoplastic resin sheet having hairlike bodies and molded product thereof

Patent metadata

Field	Value
Publication number	US-12036715-B2
Application number	US-201916961893-A
Country	US
Kind code	B2
Filing date	Jan 23, 2019
Priority date	Jan 24, 2018
Publication date	Jul 16, 2024
Grant date	Jul 16, 2024

Abstract

A resin sheet having hairlike bodies arranged regularly on at least one surface of an underlayer can be manufactured by forming the bodies by: melt extruding, from a die with an extrusion molding method, a thermoplastic resin having, on a log-log graph having elongational viscosity η(t) (unit: Pa·S) as measured at a strain rate of 0.5 (unit: S−1) and at a temperature at which elongation is possible as the vertical axis and elongation time t (unit: S) as the horizontal axis, a region in which the slope (log η/log t) in the interval 0.1<t<1.0 is no greater than 0.5 and by the temperature range wherein the adhesive force in probe tack measurement is 0.05-0.25 N/mm2 at least partially overlapping with the temperature at which elongation is possible; and casting using a transfer roll on which a relief process has been performed and a touch roll.

First claim

The invention claimed is:

1. A manufacturing method for a resin sheet having hairlike bodies arranged regularly on at least one surface of an underlayer, the hairlike bodies being formed by:
melt extruding, from a die with an extrusion molding method, a thermoplastic resin having, on a log-log graph having elongational viscosity η(t) (unit: Pa·S) as measured at a strain rate of 0.5 (unit: S −1 ) and at a temperature at which elongation is possible as the vertical axis and elongation time t (unit: S) as the horizontal axis, a region in which the slope (log η/log t) in the interval 0.1<t<1.0 is no greater than 0.5 and by the temperature range in which the adhesive force in probe tack measurement is 0.05-0.25 N/mm 2 at least partially overlapping with the temperature at which elongation is possible; and
adjusting a temperature of a transfer roll to the temperature of the thermoplastic resin at which elongation is possible and the temperature at which the adhesive force of the thermoplastic resin in probe tack measurement is 0.05-0.25 N/mm 2 and casting with a pinch pressure between the transfer roll and a touch roll of 30-120 Kg/cm 2 ,
wherein the hairlike bodies extend hairlike in a direction away from the underlayer in a shape in which the hairlike bodies thin approaching a tip, the average height of the hairlike bodies is no less than 100 μm and no greater than 1,200 μm, the average diameter of the hairlike bodies is no less than 1 82 m and no greater than 50 μm, and the average spacing of the hairlike bodies is no less than 20 μm and no greater than 200 μm,
the elongation viscosity is measured by using an elongation viscosity measuring instrument, retaining a 2 mm diameter cylindrical test piece on a roll with a width of 100 mm in an oil bath maintained at the temperature of the thermoplastic resin at which elongation is possible and stretching the test piece by rotating the roll at a fixed speed of 0.5 S −1 ,
the adhesive force is measured using a tackiness tester and, under the following conditions, placing a sample material on a stage, contacting a bottom surface of a columnar probe with a sample adhesive surface from above at a designated speed and with a designated load control and penetration control method, removing the probe from the sample at a set speed, and the resistance experienced by the probe due to the adhesive force at this time is measured as the load value:
Temperature: temperature at which elongation is possible of each thermoplastic resin,
Contact rate: 120 mm/minute,
Release rate: 600 mm/minute,
Contact load: 500 gf (0.25 N/mm 2 ),
Contact time: 15 seconds,
Probe shape: Columnar, ø 5 mm,
Probe material: Chromium oxide, and
the temperature at which elongation is possible is temperatures positioned between those of the rigid state and the molten state when a strand is set in a uniaxial elongation viscometer and stretched.

2. The manufacturing method according to claim 1 , wherein at least part of the transfer roll surface is ceramic sprayed and a relief process has been performed on the ceramic-sprayed surface.

Assignees

• Denka Company Ltd

Inventors

• Maeda Keishi
• Fujiwara Junpei

Classifications

• B32B3/26 Primary

  characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids {(foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205); characterised by an apertured layer} · CPC title

• B32B2605/003

  Interior finishings · CPC title

• B32B2439/40

  Closed containers · CPC title

• B32B27/40

  comprising polyurethanes · CPC title

• B32B27/32

  comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} · CPC title