Manufacturing method and manufacturing apparatus for laminate

Patent metadata

Field	Value
Publication number	US-2022001659-A1
Application number	US-201917282760-A
Country	US
Kind code	A1
Filing date	Oct 28, 2019
Priority date	Oct 29, 2018
Publication date	Jan 6, 2022
Grant date	—

Abstract

A manufacturing method including a first conveying step of conveying the sheet in a lateral or oblique lateral direction along a sheet pass line below the discharge port; a receiving step of receiving a tip part of the film raw material with the sheet on the sheet pass line, the tip part being discharged and hanging down from the discharge port; a second conveying step of conveying the sheet and the film raw material after the tip part overlaps the sheet on the sheet pass line, the second conveying step conveying the sheet and the film raw material in a mutually overlapping state along the sheet pass line; and an introducing step of introducing the sheet and the film raw material in the mutually overlapping state to the joining part from the sheet pass line.

First claim

1 . A manufacturing method. for manufacturing a laminate W by laminating a thermoplastic film F on a sheet S 1 at a joining part after a pass line forming process of forming a pass line for a film-formed film raw material M, the film raw material M becoming the thermoplastic film F, the pass line forming process comprising:
a hanging-down step of causing a resin in a molten state to hang down from a discharge port TO of a discharger T, the resin becoming the film raw material M, and the hanging-down step continuously discharging the film raw material M;
a first conveying step of conveying the sheet S 1 in a lateral or oblique lateral direction along a sheet pass line 1 below the discharge port TO;
a receiving step of receiving a tip part E of the film raw material M with the sheet S 1 on the sheet pass line 1 , the tip part E being discharged and hanging down from the discharge port TO;
a second conveying step of conveying the sheet S 1 and the film raw material M after the tip part E overlaps the sheet S 1 on the sheet pass line 1 , the second conveying step conveying the sheet S 1 and the film raw material M in a mutually overlapping state along the sheet pass line 1 ; and
an introducing step of introducing the sheet S 1 and the film raw material M in the mutually overlapping state to the joining part from the sheet pass line 1 .

2 . The manufacturing method according to claim 1 , wherein the thermoplastic film F is an elastomer film F and the film raw material M is a film-formed pre-elastomer M.

3 . The manufacturing method according to claim 2 , comprising a bonding step of bonding the elastomer F, obtained by solidifying the pre-elastomer M, to the sheet S 1 and laminating each other at the joining part to produce the laminate W.

4 . manufacturing method according to claim 3 , wherein the sheet S 1 and the elastomer film F are conveyed in an overlapping manner along an outer peripheral surface of a bonding roll Ar serving as the joining part and the bonding step is performed on the bonding roll Ar.

5 . The manufacturing method according to claim 4 , comprising a first cooling step of cooling the film-formed pre-elastomer M hanging down from the discharge port TO by winding the pre-elastomer M on an outer peripheral surface of a first cooling roll T 1 after the introducing step.

6 . The manufacturing method according to claim. 5 , wherein:
the first cooling roll T 1 is provided movably and is capable of contacting and moving away from the film-formed pre-elastomer M hanging down in the hanging-down step, and the first cooling step is started to cool the pre-elastomer M after the tip part E of the pre-elastomer M and the sheet S 1 are wound on the bonding roll Ar.

7 . The manufacturing method according to claim 6 , wherein:
the first cooling roll T 1 is arranged to face one side surface of the pre-elastomer M hanging down from the discharge port TO in the hanging-down step, a pressing roll is arranged to face another side surface opposite to the one side surface of the pre-elastomer M in the hanging-down step, and the manufacturing method further includes a step of moving the pressing roll in a direction intersecting a hanging direction of the pre-elastomer M to increase a contact distance of the pre-elastomer M with the first cooling roll T 1 .

8 . The manufacturing method according to claim 7 , wherein:
the pressing roll is a second cooling roll T 2 , and the manufacturing method includes a second cooling step of further cooling the pre-elastomer which has been cooled by the first cooling roll T 1 , by the second cooling roll T 2 .

9 . The manufacturing method according to claim 6 , wherein:
a nip roll Nr for sandwiching the elastomer film F is provided further upstream than the bonding roll Ar, and the manufacturing method includes a stretching step of stretching the elastomer film F before being bonded to the sheet S 1 in a conveying direction by a conveying speed V of the elastomer film on the bonding roll Ar larger than a conveying speed Vs of the elastomer film F on the nip roll Nr, the stretching step being performed after the first cooling step is started.

10 . A manufacturing apparatus for manufacturing a laminate W by laminating a thermoplastic film F on a sheet S 1 at a joining part after a pass line forming process of forming a pass line for a film-formed film raw material M, the film raw material M becoming the thermoplastic film F, the manufacturing apparatus comprising:
a discharger T for causing a resin in a molten state to hang down from a discharge port TO, the resin becoming the film raw material. M, and the discharger continuously discharging the film raw material M;
a sheet pass line 1 for conveying the sheet S 1 in a lateral or oblique lateral direction below the discharge port TO, the sheet pass line 1 receiving a tip part E of the film raw material M with the sheet S 1 , the tip part E being discharged and hanging down from the discharge port TO, and the sheet pass line 1 conveying the sheet S 1 and the film raw material M in a mutually overlapping state after the tip part E overlaps the sheet S 1 ; and
the joining part configured such that the sheet S 1 and the film raw material M in the mutually overlapping state are introduced to the joining part from the sheet pass line 1 .

11 . The manufacturing apparatus according to claim 10 , wherein the thermoplastic film F is an elastomer film F and the film raw material M is a film-formed pre-elastomer M.

12 . The manufacturing apparatus according to claim 11 , wherein the laminate W is produced at the joining part by laminating the elastomer film F, obtained. by solidifying the pre-elastomer M, to the sheet S 1 and bonding the elastomer film F to the sheet S 1 .

13 . The manufacturing apparatus according to claim 12 , wherein a bonding roll Ar constitutes at least a part of the joining part, the bonding roll Ar configured such that the sheet S 1 and the elastomer film F are conveyed in an overlapping manner along an outer peripheral surface of the bonding roll Ar.

14 . The manufacturing apparatus according to claim 13 , comprising a first cooling roll T 1 for cooling the film-formed pre-elastomer M, the pre-elastomer M hanging down from the discharge port TO and wound on an outer peripheral surface of the first cooling roll T 1 .

15 . The manufacturing apparatus according to claim 14 , wherein the first cooling roll T 1 is provided movably and is capable of contacting and moving away from the film-formed pre-elastomer MI hanging down from the discharge port TO.

16 . The manufacturing apparatus according to claim 15 , wherein:
the first cooling roll T 1 is arranged to face one side surface of the pre-elastomer M hanging down from the discharge port TO, and the manufacturing apparatus further includes a pressing roll arranged to face another side surface opposite to the one side surface of the pre-elastomer M and configured to move in a direction intersecting a hanging direction of the pre-elastomer M to increase a contact distance of the pre-elastomer M with the first cooling roll T 1 .

17 . The manufacturing apparatus according to claim 16 , wherein the pressing roll is a second cooling roll T 2 for further cooling the pre-elastomer M having been cooled by the first cooling roll T 1 .

18 . The manufacturing apparatus according to claim 17 , wherein:
a nip roll Nr for sandwiching the elastomer film F is provided further upstream than the bonding roll Ar, and a conveying speed V of the elastomer film F on the bondin

Assignees

• Zuiko Corp

Inventors

• Nakamura Hideyuki

Classifications

• B29C48/305

  having a wide opening, e.g. for forming sheets · CPC title

• B32B37/206

  Laminating a continuous layer between two continuous plastic layers · CPC title

• B29C48/154

  Coating solid articles, i.e. non-hollow articles · CPC title

• B32B38/0012

  Mechanical treatment, e.g. roughening, deforming, stretching · CPC title

• B32B2305/20

  in the form of a non-woven mat · CPC title