JP7392977B2 - Manufacturing method of sheet material - Google Patents

Description

The present invention relates to a method for manufacturing a sheet material.

Woven and knitted fabrics containing plants such as hemp, kudzu, and cotton in their tissues are widely used for various purposes. Tatami omote is a woven or knitted fabric that uses rush stems as the weft and linen or cotton yarn as the warp. Patent Document 1 discloses a method of compressing a tatami mat from the front and back into a plate shape in order to facilitate printing of patterns. In the method for producing tatami mats, a tatami mat surface whose front and back surfaces are coated with a fixing agent in advance is subjected to a compression press.

Utility Model Publication No. 5-89680

According to the manufacturing method disclosed in Patent Document 1, the expansion of the tatami surface after compression is suppressed to some extent by the adhesive agent, but this is not sufficient because the expansion effect of natural rush is strong. Moreover, since the adhesive is applied to the tatami facing surface before compression, the adhesive may adhere to the compression press and may not adhere uniformly to the front and back surfaces of the tatami mat surface.

The present invention has been made in view of the above-mentioned circumstances, and an object of the present invention is to provide a method for manufacturing a sheet material that can suppress as much as possible the restoration after compression of a sheet material made of a compressed woven or knitted fabric containing plants in its tissue. do.

The method for manufacturing a sheet material according to the present invention includes:
A compression process in which a cloth-like woven or knitted fabric containing plants in its tissue is compressed from front to back while being heated;
an application step of applying a fixing agent to the compressed woven or knitted fabric;
including.

In this case, the woven or knitted fabric is
It is a tatami mat,
It may also be a thing.

Further, in the compression step, the woven or knitted fabric is heated to 60 to 110°C.
It may also be a thing.

Further, in the compression step, a pressure of 30 to 300 kg/cm ² is applied to the woven or knitted fabric.
It may also be a thing.

Furthermore, in the coating step,
laminating multiple types of fixatives on the woven or knitted fabric;
It may also be a thing.

According to the present invention, recovery after compression of a sheet material obtained by compressing a woven or knitted fabric containing plants in its tissue can be suppressed as much as possible.

Embodiments according to the present invention will be described. Note that the present invention is not limited to the embodiments described below.

(Embodiment)
The method for manufacturing a sheet material according to this embodiment includes a compression step and a coating step. In the compression step, a cloth-like woven or knitted fabric containing plants in its tissue is compressed from front to back while being heated. The plant is not particularly limited as long as it forms the structure of the woven or knitted fabric. Plants include rush, hemp, flax, kudzu, kozo, cotton, kenaf, jute hemp, Manila hemp, sisal, gampi, mitsumata, banana, pineapple, coconut palm, corn, sugarcane, bagasse, palm, papyrus, reed, and esparto. , Sabai grass, wheat, rice, bamboo, coniferous trees, broad-leaved trees, cotton, and the like. Any part of the plant that can be used as fiber (thread) can be used, such as non-woody parts, stems, roots, leaves, and woody parts. Preferably, it is the stem of the rush plant.

A woven or knitted fabric is one in which fibers form a structure, such as a woven fabric or a knitted fabric. A texture of a woven fabric is formed by intersecting warp and weft threads. The woven fabric may be plain weave, twill weave, or satin weave. The texture of knitted fabrics is formed by loops. The woven or knitted fabric may be cloth-like as long as it has a front surface and a back surface, and the shape of the woven or knitted material in plan view from the front or back surface is not particularly limited. The woven or knitted fabric is not limited to a single color, but may be of multiple colors, and a pattern or the like may be added to the surface of the woven or knitted fabric using known processing techniques. Preferably, the woven or knitted fabric is a tatami mat.

In the compression step, the woven or knitted fabric is heated to 60-110°C, 70-100°C, preferably 90-100°C. In the compression step, the woven or knitted fabric is heated using a heating press or the like, and at the same time, the woven or knitted fabric is compressed in the front and back directions. The magnitude of the pressure may be, for example, ¹⁰ to 500 kg, 15 to 450 kg, 20 to 400 kg, 25 to 350 kg, 30 to 300 kg, or 35 to 200 kg, or 20 to 80 kg, 30 to 60 kg, or It may be 35-45 kg. The magnitude of the pressure may be 0.5 to 50 MPa, 1.5 to 45 MPa, 2 to 40 MPa, 2.5 to 35 MPa, 3 to 30 MPa, or 3.5 to 20 MPa, or 2 to 8 MPa, 3 to 20 MPa. It may be 6 MPa or 4 to 5 MPa. The compression time is appropriately adjusted depending on the thickness and material of the woven or knitted fabric. When the woven or knitted fabric has a tatami facing surface, the compression process eliminates unevenness on the surface of the woven or knitted fabric, and the thickness of the woven or knitted fabric becomes about 1/3 of the thickness before the compression process.

In the application step, a fixative is applied to the compressed woven or knitted fabric. The fixative may be applied to the front or back side of the woven or knitted fabric, or to both the front and back sides. The fixing agent is not particularly limited as long as it can solidify the woven or knitted fabric in a compressed state. The fixative is a coating agent containing resins such as urethane, acrylic, and ester. Preferably, the fixative is a synthetic resin paint, such as a urethane resin paint, or an oil-based paint. The synthetic resin paint may contain, for example, ethyl acetate, butyl acetate, oil, wax, fatty white spirit, etc. in addition to the urethane resin. Preferably the fixative is a liquid. The dosage of the fixative is appropriately set depending on the type of fixative or the use of the sheet material. If a liquid fixative is used, the dose of the fixative is 0.1-100 mL, 0.5-50 mL or 1-10 mL per cm ² of woven or knitted fabric. Note that the woven or knitted fabric may be allowed to radiate heat or may be cooled before applying the fixative.

A fixative made of natural materials may be used as the fixative. Examples of natural fixatives include glue, casein, starch, natural rubber, and lacquer. The fixative may be a mixture of multiple natural materials. For example, a fixative containing a mixture of glue and starch can be used. When the woven or knitted fabric is a tatami surface, by using a fixative made of natural materials, the sheet material can maintain the harmful substance adsorption function of rush.

In the coating step, an arbitrary surface treatment agent may be applied to the woven or knitted fabric in addition to the fixing agent. Depending on the use of the sheet material, the surface of the woven or knitted material may be further processed. For example, when the sheet material is used for wallpaper, ceiling walls, etc., a water repellent agent, an anti-fading agent, a fungicide, a gloss agent, etc. may be applied to the woven or knitted fabric. Examples of the water repellent agent include higher fatty acid salts, higher fatty acid amides, waxes, silicone oil, and mixtures thereof. Antifading agents suppress discoloration due to light irradiation and discoloration due to various oxidizing gases such as ozone, active oxygen, NOx, and SOx, and include amino acids such as glycine, alanine, and glutamic acid, salicylic acid, and salts thereof, etc. It is. Examples of the brightening agent include fatty acid ethylene glycol ester, fatty acid polyethylene glycol ester, fatty acid monoethanolamide, and the like.

When the sheet material is used for a floor, a water repellent agent, a strength enhancer, an abrasion resistance agent, etc. may be applied to the woven or knitted fabric. Examples of the strength enhancer include polyethyleneimine, polyamide polyamine epichlorohydrin, urea resin, and melamine resin. Examples of the wear resistance imparting agent include hard filler powder, alumina, and fluororesin powder. Furthermore, by applying an adsorbent to a woven or knitted fabric, the sheet material can be given the ability to adsorb harmful substances. Adsorbents include, for example, activated carbon, synthetic zeolites, porous clay components, and the like. Note that the surface treatment agent, such as the above-mentioned water repellency imparting agent, anti-fading agent, fungicide, gloss imparting agent, strength enhancer or abrasion resistance imparting agent, may also be used as a fixing agent.

In the coating step, a plurality of types of fixatives may be layered on the woven or knitted fabric. In this case, the application process includes a first application process of applying a first fixative to the woven or knitted fabric, and a second application process of applying a second fixative different from the first fixative onto the first fixative. 2 coating process. There may be a drying step of drying the first fixing agent between the first coating step and the second coating step. There may be three or more types of fixatives, and the fixatives are sequentially overcoated to form a layer of multiple types of fixatives. When multiple types of fixatives are laminated, the fixing agent in the uppermost layer with the woven or knitted fabric at the bottom is preferably a resin or the like that has high strength and excellent abrasion resistance. The fixing agent in the uppermost layer may be a fixing agent containing at least one of a water repellency imparting agent, a strength enhancer, an abrasion resistance imparting agent, and the like. By using a fixing agent layer with high strength and excellent abrasion resistance as the top layer, a sheet material suitable for use on floors can be manufactured.

As explained in detail above, according to the method for manufacturing a sheet material according to the present embodiment, the woven or knitted fabric is compressed while being heated, so that the fabric-like woven or knitted fabric containing plants in its tissue can be sufficiently compressed. can. Furthermore, since the fixative is applied to the woven or knitted fabric after compression, the fixative can be efficiently and uniformly spread over the surface of the woven or knitted fabric. By doing so, it is possible to suppress the restoration after compression of the cloth-like woven or knitted fabric containing plants in its tissue as much as possible.

Note that the method for manufacturing a sheet material according to the present embodiment may further include a coloring step of coloring the woven or knitted fabric before the compression step or between the compression step and the coating step. In the coloring step, for example, a coloring agent may be brought into contact with the woven or knitted fabric. Moreover, the method for manufacturing a sheet material according to the present embodiment may further include a surface treatment step before the compression step, between the compression step and the coating step, or after the coating step. In the surface treatment step, a light-reflecting glitter or colorant may be applied to the woven or knitted fabric, or decorative materials such as spheres, polyhedrons, powders, cotton-like and linear forms, or parts of plants, such as plant powder, may be applied to the woven or knitted fabric. A body etc. may be fixed to the surface. When the surface treatment step is performed after the application step, the above-mentioned application step may be further performed following the surface treatment step to apply the fixing agent to the woven or knitted fabric.

The present invention is capable of various embodiments and modifications without departing from the broad spirit and scope of the invention. Further, the embodiments described above are for explaining the present invention, and do not limit the scope of the present invention. That is, the scope of the present invention is indicated by the claims rather than the embodiments. Various modifications made within the scope of the claims and the meaning of the invention equivalent thereto are considered to be within the scope of the present invention.

INDUSTRIAL APPLICATION This invention is suitable for manufacturing the sheet material processed from the cloth-like woven or knitted fabric which contains a plant in its tissue.

Claims (5)

A compression process in which a cloth-like woven or knitted fabric containing plants in its tissue is compressed from front to back while being heated;
an application step of applying a fixing agent to the compressed woven or knitted fabric;
A method of manufacturing a sheet material, including: The woven or knitted fabric is
It is a tatami mat,
A method for manufacturing a sheet material according to claim 1. In the compression step, the woven or knitted fabric is heated to 60 to 110°C.
The method for manufacturing a sheet material according to claim 1 or 2. In the compression step, a pressure of 30 to 300 kg/cm ² is applied to the woven or knitted fabric.
The method for manufacturing a sheet material according to any one of claims 1 to 3. In the coating step,
laminating multiple types of fixatives on the woven or knitted fabric;
The method for manufacturing a sheet material according to any one of claims 1 to 4.