JPS5854986B2 - Method for manufacturing a flexible laminate with an uneven pattern on its surface - Google Patents

Description

[Detailed Description of the Invention] The present invention relates to a method for manufacturing a flexible laminate having an uneven pattern on its surface, and more specifically to a method for manufacturing a flexible laminate having an uneven pattern on its surface, and more specifically, for use in the production of footwear soles, architectural flooring and wall materials, non-slip mats, etc. that are extremely superior in terms of design and functionality. The present invention relates to a method of manufacturing a novel laminate having a wide range of applications.

Generally, flexible laminates are easily manufactured by alternately laminating cloth and sheets mainly composed of unvulcanized rubber, thermoplastic rubber, or thermoplastic resin, and then heating and vulcanizing them under pressure. It is intended to achieve the purpose of

In this case, if a coarse-grained cloth is used as the cloth, the upper and lower sheets will be integrally molded through the grain, thereby further increasing the strength of the laminate.

The present invention was completed as a result of research into the application of this type of laminate to footwear soles.

In terms of functionality when walking, the soles of footwear have abrasion resistance, peel strength, anti-slip properties, bending resistance, light weight, etc.
In addition, a new design with a tasteful appearance is required.

The inventor completed the present invention as a result of research into an inexpensive manufacturing method for a diagonal laminate that satisfactorily combines these various properties.

That is, in the present invention, inside a mold with an uneven pattern formed on the inner surface,
A foam sheet mainly composed of vulcanized rubber, thermoplastic rubber, or thermoplastic resin and a coarse cloth are alternately arranged, and the coarse cloth is positioned at least on the outermost surface of the uneven pattern side of the inner surface of the mold. After that, the foamable rubber sheet is heated and foamed under pressure to a foaming ratio of 1.05 to 2.50, so that the coarse cloth located on the outermost surface is This is a method for manufacturing a flexible laminate having an uneven pattern on its surface, characterized by expanding the sheet toward the uneven pattern in the mold through the holes of the mold.

The foamable sheet used in the present invention is a foamable unvulcanized rubber sheet, thermoplastic rubber sheet, or thermoplastic resin sheet based on a known composition mainly composed of known natural or synthetic rubber or natural or synthetic resin. be.

The foaming ratio is not particularly limited, but if the foaming ratio is too high, the amount of foaming gas will be excessive and will remain in the finished product, so be careful as this may cause abnormal deformation, etc. It takes.

If the expansion ratio is too low, the expansion of the sheet through the fabric will be insufficient and the effect of the present invention on the product may be impaired, so it is desirable to have a composition with higher fluidity.

According to the experimental results, it is possible to keep the expansion ratio within the range of 1.05 to 2.50, and the most preferable range is 1.30 to 2.50.
It is 1.70.

The coarse-grained cloth used in the present invention is not limited to the type of fiber or texture of the cloth.

Although the thickness of the thread is arbitrary, the use of cloth woven with relatively thick thread provides a better design effect for the product.

Roughness refers to the presence of gaps through which the foamable sheet can expand.

This varies depending on the foaming pressure of the sheet or the fluidity of the sheet at high temperatures, and can be selectively adopted as appropriate.

The number of threads for both warp and weft is 10 to 18 (25
It is preferable to have a coarse grain of about 100 mm (mm).

A preferred example of the coarse-grained fabric is jute fabric.

In the present invention, as shown in FIG. 1, foamable sheets 1 and coarse cloth 2 are alternately stacked so that the coarse cloth 2 is located on the outermost surface.

As shown in the examples below, when the purpose is to make a footwear sole with a thickness of around 5 mm, it is preferable to use a combination of 3 sheets and 4 layers of cloth, as shown in the examples below. Of course, it can be arbitrarily selected and implemented.

In the present invention, a mold 3 having an uneven pattern 4 formed on its inner surface as shown in FIG. 1 is used.

In this case, the inner surface refers to at least its upper and/or lower surface.

The shape of the unevenness can be formed arbitrarily depending on the design to be expressed in the intended product.

It is preferable that the convex portions 5 of the irregularities are formed nearly vertically.

If the convex portions 5 are gentle, the bulge of the sheet 1 through the grain will be difficult to be clearly seen, which may reduce the effect of the present invention.

The planar shape of the concavo-convex pattern 4 can be a stamped pattern as shown in FIGS. 3 to 4, or any other drawn pattern.

Pressurization and heating in the present invention can be carried out by conventional means.

Generally the pressure is 50 kg to 150 kg/crtt. Select a temperature within the range of 120°C to 160°C.

Since the present invention has the above-described configuration, it exhibits various effects as described below.

That is, in the present invention, the foamable sheet is heated and foamed under pressure so that it bulges out toward the uneven pattern 4 inside the mold through the openings of a coarse cloth placed on the outermost surface. When the sheet 1 passes through the coarse cloth 2 in the recesses 6 of the pattern 4, a leaching phenomenon occurs due to its own expansion pressure (see FIG. 2).

As a result of this leaching, a pattern corresponding to the unevenness inside the mold is formed on the surface of the product.

Furthermore, this leaching phenomenon of the sheet occurs as a result of being interrupted by the woven threads of the cloth, which adds fine and irregular irregularities to the pattern surface, which together with the changes in the color of the sheet on the surface of the cloth. This has the effect of creating an extremely tasteful uneven pattern in appearance.

Moreover, when using the manufacturing method of the present invention, a laminate having the above-mentioned novel uneven pattern can be obtained by an extremely simple operation of heat molding under pressure, and the manufacturing cost is significantly reduced.

Also, when using the manufacturing method of the present invention, in the heating foam molding process,
Excess foaming gas in the foamable rubber sheet easily escapes through the fibers of the cloth, making the product uniform and free from warping or deformation even when left for long periods of time. It is.

Also, a noteworthy effect of the laminate obtained by the present invention is that the cloth on the outermost surface thereof does not peel off easily.

In particular, in order to withstand severe bending and abrasion, such as the soles of footwear, conventional laminates cannot withstand use due to ripping or peeling of the outer fabric, but with the manufacturing method of the present invention, the laminates In this case, the sheet bulges out through the grains of the fabric, acting as if it were nailed to the fabric surface, making the fabric extremely strong without peeling.

Furthermore, the laminate obtained by the present invention is made of alternating coarse cloth and sponge sheets, so it is strong and lightweight, has excellent cushioning properties, and has the above-mentioned external design. The present invention provides a novel laminate that is extremely superior in terms of design and functionality as well as aesthetic effects.

Next, examples of the present invention will be described.

EXAMPLE Rubber is kneaded in a conventional manner based on the following formulation, and then portioned to a thickness of 1.0 mm to obtain a foamable unvulcanized rubber sheet 1.

R BR Sulfur vulcanization accelerator (M, DM, TT) Activator Stearic acid Petroleum resin Hydrous silicic acid Blowing agent (DPT) Foaming aid Anti-aging agent Calcium carbonate Total 15.0 parts by weight 43.0 0.8 0.6 1.6 0.5 3.0 16.0 ■, 5 1.5 0.5 16.0 100.0 Inner surface length 200 mm x width 200 mm x depth 4.51 nr
A grid-like engraving 4 is provided on the lower surface (bottom surface) of the IL mold 3.

The size of the grid is approximately 10 mrn square, and the width of the crosspiece 5 is 1.5 to 2.
．． The height of 0 mm was 2.0 mvt.

Four pieces of jute woven fabric 2 (density: 16 pieces/25 crn vertically, 12 pieces/25 crn horizontally, weight 300 g/m) and the three rubber sheets described above are alternately filled into the lower surface of the mold 3.

Place jute 2 on the outer surface.

Temperature 150°C Pressure (50) ky/cr? Press vulcanization is performed for 10 minutes at L to obtain a jute and rubber laminate.

The obtained laminate is lightweight (specific gravity 0.96), and the rubber leaches through the jute weave in the recesses 6 of the grid-like unevenness on the inner surface of the mold, leaving slightly irregular peaks on the surface of the product. It was revealed that it had an extremely innovative uneven design.

This laminate was heated in the open at 70° C. for 2 hours and tested for shrinkage and deformation. As a result, there was no deformation and the shape remained symmetrical.

[Brief explanation of drawings]

The drawings show an example of the implementation of the present invention, and FIG. 1 is a longitudinal cross-sectional view showing how cloth and sheet are loaded in the mold, and FIG. 2 is a longitudinal sectional view showing the situation after heating and foaming in the mold. 3 is a plan view showing an example of an uneven pattern formed on the inner surface of the mold; FIG. 4 is a sectional view taken along the line A-A in FIG. 3;
FIG. 5 is a sketch showing a portion of a product manufactured according to the present invention. In the figure, 2 is a coarse cloth, 1 is a foamed sheet, 3 is a mold, 4 is an uneven pattern, 5 is a convex portion thereof, and 6 is a concave portion thereof.

Claims (1)

[Claims] 1 In a mold with an uneven pattern formed on the inner surface, foam sheets mainly composed of unvulcanized rubber, thermoplastic rubber, or thermoplastic resin and coarse cloth are alternately placed, and at least on the uneven pattern side of the inner surface of the mold. Load the foam sheet so that the coarse cloth is on the outermost surface, and then pressurize the foam sheet to 1.0
A surface characterized by heating and foaming at a foaming ratio of 5 to 2.50, thereby causing the sheet to bulge out toward the uneven pattern in the mold through the holes of the coarse cloth located on the outermost surface. A method for manufacturing a flexible laminate having an uneven pattern.