TWI507290B - 離型片、離型片之製造方法及合成皮革 - Google Patents
離型片、離型片之製造方法及合成皮革 Download PDFInfo
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- TWI507290B TWI507290B TW100103286A TW100103286A TWI507290B TW I507290 B TWI507290 B TW I507290B TW 100103286 A TW100103286 A TW 100103286A TW 100103286 A TW100103286 A TW 100103286A TW I507290 B TWI507290 B TW I507290B
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- Prior art keywords
- pattern
- thermoplastic resin
- release sheet
- substrate
- sheet
- Prior art date
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2317/00—Animal or vegetable based
- B32B2317/08—Natural leather
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
- B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2209/00—Properties of the materials
- D06N2209/16—Properties of the materials having other properties
- D06N2209/1664—Releasability
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2211/00—Specially adapted uses
- D06N2211/12—Decorative or sun protection articles
- D06N2211/28—Artificial leather
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/10—Coatings without pigments
- D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
- D21H19/20—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D21H19/22—Polyalkenes, e.g. polystyrene
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/02—Patterned paper
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Laminated Bodies (AREA)
- Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
- Shaping Of Tube Ends By Bending Or Straightening (AREA)
Description
本發明係關於離型片,離型片之製造方法及合成皮革。
離型片稱為澆鑄紙(casting paper),已用於製造由聚胺基甲酸酯樹脂及氯乙烯樹脂製成之合成皮革。
離型片藉由以下方法製造:將諸如聚丙烯樹脂及聚甲基戊烯樹脂之熱塑樹脂疊層於基板紙(基板片)表面上,且用在表面上具有微小不規則外形(亦即凹形及凸形)之壓印滾筒(例如如圖4A所示配置)壓印熱塑樹脂層。離型片僅在疊層於基板紙(基板片)41上之熱塑樹脂層42上具有壓印圖案。
表面上轉印壓印圖案的合成皮革藉由以下方法製造:藉由擠壓諸如聚胺基甲酸酯樹脂及氯乙烯樹脂之材料塗覆離型片表面;乾燥聚胺基甲酸酯樹脂、氯乙烯樹脂及其類似物以固化離型片;及剝離離型片以轉印離型片上之圖案。
離型片之另一實例於專利文獻1中揭示,其包括紙層及於紙層上提供之熱塑樹脂壓印層。專利文獻1中揭示之整個離型片(亦即紙層及壓印層)彎曲成波形。在該種離型片中,在製造期間施加之壓印壓力到達紙層(參見圖4B,其中參考數字43表示紙層且參考數字44表示壓印層)。
以下專利文獻2揭示用於製造粗糙(亦即無光澤)物品之另一種離型片,該離型片包括:基板片;在基板片上提供之具有微小不規則外形之粗糙層;及於粗糙層表面上提供之離型層;離型層藉由含有超細粒子之離型樹脂塗覆層提供。離型層未經壓印,但其表面具有由粗糙層之微小不規則外形產生之較多微小不規則外形。
然而,已知離型片之熱塑樹脂層僅具有一種藉由壓印熱塑樹脂層提供之壓印圖案,或具有粗糙形狀之微小不規則外形。因此,僅可提供較少類型之壓印圖案,使得難以製造具有較豐富紋理之合成皮革物品。
[專利文獻1]
JP-A-2007-296672
[專利文獻2]
WO 2006/006713
本發明之目的為提供能夠製造具有豐富紋理之合成皮革之離型片,離型片之製造方法及使用該離型片製造之合成皮革。
本發明內容如下所列者:
[1] 根據本發明之一態樣之離型片包括:基板片及疊層於該基板片上之熱塑樹脂層,其中於熱塑樹脂層之表面上形成兩種或兩種以上不同壓印圖案。
[2] 在根據以上態樣[1]之離型片中,兩種或兩種以上不同壓印圖案中一者之不規則外形的深度可小於另一壓印圖案不規則外形之深度。
[3] 在根據[1]或[2]之離型片中,基板片及熱塑樹脂層可經各別壓印,且在基板片上形成之壓印圖案顯現在熱塑樹脂層表面上。
[4] 在根據[3]之離型片中,藉由壓印熱塑樹脂層提供之壓印圖案之不規則外形的深度可小於藉由壓印基板片提供之壓印圖案之不規則外形的深度。
[5] 根據本發明之一態樣之離型片的製造方法包括:壓印基板片之第一壓印步驟;將熱塑樹脂層疊層於壓印基板片上之疊層步驟;及壓印疊層熱塑樹脂層之第二壓印步驟,其中第一壓印步驟及第二壓印步驟所提供之壓印圖案的不規則外形彼此不同。
[6] 藉由使用根據[1]至[4]中任一者之離型片製造合成皮革。
根據本發明,由於在離型片之熱塑樹脂層表面上提供兩種或兩種以上不同壓印圖案,所以可製造具有較豐富紋理之合成皮革。
下文參考隨附圖式描述本發明之例示性具體實例。
圖1為根據本發明之例示性具體實例之離型片的截面。
離型片1包括基板片2及熱塑樹脂層3。熱塑樹脂層3疊層於基板片2上。在熱塑樹脂層3之表面上提供兩種不同壓印圖案(亦即第一壓印圖案及第二壓印圖案)。壓印圖案之詳細描述將於下文提及。
基板片
此例示性具體實例之基板片2可藉由適於支撐熱塑樹脂層3之任何紙或膜基底提供。基板片2之特定實例為:紙基底,諸如面紙(tissue paper)、牛皮紙(kraft paper)、棉絨紙(Iinter paper)、含磨木漿紙(wood containing paper)、道林紙(woodfree paper)、浸漬紙(impregnated paper)、塗佈紙(coat paper)、銅版紙(art paper)、植物紙(vegetable paper)及玻璃紙(glassine paper);聚烯烴樹脂膜,諸如聚乙烯及聚丙烯;乙烯樹脂膜,諸如聚氯乙烯、聚偏二氯乙烯、聚乙烯醇、乙烯-乙酸乙烯酯共聚物及乙烯-乙烯醇共聚物;聚酯樹脂膜,諸如聚對苯二甲酸乙二酯、聚對苯二甲酸丁二酯及聚萘二甲酸乙二酯;及其他合成樹脂膜,諸如聚苯乙烯、丙烯腈丁二烯苯乙烯共聚物、三乙醯基纖維素、賽路凡(cellophane)及聚碳酸酯。順帶而言,就耐熱性及熱成形性而言紙基底較佳。其中,就極佳耐熱性及尺寸穩定性而言,牛皮紙、含磨木漿紙、道林紙及浸漬紙較佳。
基板片2之厚度及尺寸不受特別限制,但可以任何方式根據離型片1之用途、基板片2之類型及其類似者選擇。舉例而言,當基板片2為紙基底時,基板片之基重較佳在30 g/m2
至200 g/m2
,更佳80 g/m2
至140 g/m2
之範圍內。當基板片2為合成樹脂膜時,基板片之厚度較佳在5 μm至500 μm,更佳15 μm至300 μm之範圍內。基板片2可為連續帶形或滾筒形紙或膜。
當基板片2之基重小於30 g/m2
或合成樹脂膜之厚度小於5 μm時,因為基板片2較薄且基板片剛性較弱,所以在隨後製程期間基板片2可能在處理及耐熱性方面較差。另一方面,當基板片2之基重超過200 g/m2
或基板片2之厚度超過500 μm時,因為基板片2之單位面積重量增加,所以離型片1可能在每個滾筒所纏繞之米數或運輸期間重量限制方面引起問題。特定言之,當限制每個滾筒之重量並遵照重量限制纏繞片時,產生每個滾筒所纏繞之米數減少之問題。此外,當對滾筒直徑無限制且每個滾筒纏繞所需纏繞米數時,產生每個滾筒之重量增加之問題。
當使用紙基底作為基板片2時,較佳可在紙基底背面(亦即與塗覆有熱塑樹脂層之側相對之側)上進行防捲曲處理。防捲曲處理防止基板片2因熱、吸水或乾燥捲曲而使離型片1變形。藉由例如在紙基底背面塗覆合成樹脂,諸如丙烯酸樹脂、聚苯乙烯樹脂及苯乙烯-丁二烯共聚物,或疊層聚烯烴樹脂膜及其類似物來施加防捲曲處理。
在此例示性具體實例之基板片2上提供基底壓印圖案(參見圖3B)。基底壓印圖案之深度(亦即凸部分頂部與凹部分底部之間的距離)h1較佳大於第二壓印圖案深度h3(參見圖3B及3D)。當熱塑樹脂層3疊層於基板片2上提供之基底壓印圖案之不規則外形上時,基底壓印圖案顯現於熱塑樹脂層3表面上以提供第一壓印圖案。因此,預先於基板片2上提供對應於第一壓印圖案外形之基底壓印圖案。
熱塑樹脂層
藉由相對於形成合成皮革之樹脂展現極佳可離型性及可塗覆性之樹脂提供熱塑樹脂層3,該樹脂之實例為聚烯烴聚合物。聚烯烴聚合物之實例為α-烯烴均聚物及共聚物。α-烯烴之實例為乙烯、丙烯、1-丁烯、2-甲基-1-丁烯、1-戊烯、2-甲基-1-戊烯、1-己烯、2,2-二甲基-1-丁烯、2-甲基-1-己烯、4-甲基-1-戊烯、1-庚烯、2-甲基-1-己烯、3-甲基-1-己烯、2,2-二甲基-1-戊烯、3,3-二甲基-1-戊烯、2,3-二甲基-1-戊烯、3-乙基-1-戊烯、2,2,3-三甲基-1-丁烯、1-辛烯及2,2,4-三甲基-1-辛烯。其中,乙烯、丙烯及4-甲基-1-戊烯聚合物尤佳。
熱塑樹脂層3之厚度及尺寸不受特別限制,但可以任何方式根據離型片1之用途及熱塑樹脂層3之類型選擇。
熱塑樹脂層3之厚度較佳在5 μm至200 μm,更佳10 μm至100 μm範圍內。當熱塑樹脂層3之厚度小於5 μm時,由於薄,故可用於第二壓印圖案之設計較少,且熱塑樹脂層無法形成統一厚度之膜。另一方面,當熱塑樹脂層3之厚度超過200 μm時,由於使熔融樹脂固化需要長時間,所以可能降低生產力,且可能掩埋第一壓印圖案。
第一壓印圖案、第二壓印圖案
由於在基板片2之基底壓印圖案上提供熱塑樹脂層3,所以藉由與基底壓印圖案一致之不規則外形提供第一壓印圖案。此時,第一壓印圖案之不規則外形的深度h2與基底壓印圖案之不規則外形的深度h1大致相同。
第二壓印圖案提供比第一壓印圖案更多的微小不規則外形,且在具有第一壓印圖案之區域內與第一壓印圖案之不規則外形一致。
第一壓印圖案之不規則外形的深度h2較佳大於第二壓印圖案之不規則外形的深度h3(參見圖3C及3D)。
離型片之製造方法
其次,下文將參考隨附圖式描述離型片1之製造方法。
圖2示意性展示離型片製造裝置10。
離型片製造裝置10包括第一壓印單元11、擠壓器12及第二壓印單元13。
第一壓印單元11壓印基板片2。第一壓印單元11包括第一壓印滾筒11a及第一壓力滾筒11b。第一壓印滾筒11a由金屬製成且其外圓周具有對應於第一壓印圖案(第一壓印圖案之不規則外形在圖2中未示)之不規則外形。第一壓力滾筒11b由橡膠製成,其外表面實質上平坦。
擠壓器12擠壓熱塑樹脂以塗覆熱塑樹脂於基板片2上。擠壓器12包括T字模。通過T字模將熱塑樹脂擠壓至基板片2上以便於其上疊層。
第二壓印單元13壓印熱塑樹脂層3。第二壓印單元13包括第二壓印滾筒13a及第二壓力滾筒13b。第二壓印滾筒13a由金屬製成且其外表面具有對應於第二壓印圖案之不規則外形。向第二壓印滾筒13a內部供應冷卻水。因此,第二壓印滾筒13a亦用作冷卻及固化疊層於基板片2上之熱塑樹脂層3的冷卻滾筒。第二壓力滾筒13b由橡膠製成,其外表面實質上平坦。
離型片1之製造步驟關於各別步驟中基板片2及熱塑樹脂層3之截面於圖3A至3D中展示。
第一壓印步驟
第一壓印單元11之第一壓印滾筒11a及第一壓力滾筒11b垂直相對安置。向離型片製造裝置10中供應之基板片2(參見圖3A)實質上水平饋入,且夾於第一壓印滾筒11a與第一壓力滾筒11b之間。諸如所施加壓力及溫度之壓印條件根據基板片2之材料及第一壓印滾筒11a之不規則外形確定。藉由蒸汽或熱空氣加熱滾筒表面之機構較佳於第一壓印滾筒11a內部之滾筒中提供。
將預先於第一壓印滾筒11a表面上提供之不規則外形轉印於與第一壓印滾筒11a接觸之基板片2表面上(參見圖3B)。不規則外形提供於熱塑樹脂層3表面上提供之第一壓印圖案之基底壓印圖案。當提供基底壓印圖案時,較佳加熱第一壓印滾筒11a表面以對基板片2施加熱。藉由在加熱基底片2同時形成基底壓印圖案,可將基底壓印圖案之不規則外形更清楚地轉印至基板片2上。
基板片2之製造步驟與壓印步驟可組合(亦即在線內設備(inline equipment)中)。特定言之,離型片製造裝置10中之第一壓印步驟可在基板片2之製造單元之後進行以提供線內離型片製造裝置。使用該種線內設備,可提高離型片1之製造效率。
舉例而言,當基板片2由紙基底製成時,可以線內製程共同進行紙形成步驟及壓印步驟。
此時,紙形成方法不受限制,但紙漿均勻分散於水中之紙材料(紙漿漿料)可例如於筒紙機(cylinder paper machine)、長網造紙機(Fourdrinier paper machine)、雙網造紙機(twin-wire paper machine)及單層斜網造紙機(single-layer inclined wire paper machine)中之單一一種或其組合(多重形成)中供應。
可在紙基底經乾燥器處理之後,或者在紙基底半乾燥時經乾燥器處理之前,例如在加熱紙基底的同時施加壓印。在後種情況中,乾燥步驟必須在壓印後提供。
當紙基底為樹脂浸漬紙時,可在紙形成步驟期間藉由施膠塗佈機(size press)及其類似物用樹脂浸漬紙,且可在浸漬樹脂的同時施加壓印,隨後進行熱乾燥。欲浸漬之樹脂不受限制,但適合使用SBR(苯乙烯-丁二烯橡膠)、NBR(丙烯腈-丁二烯橡膠)、MBR(甲基丙烯酸甲酯-丁二烯橡膠)、氯乙烯樹脂、丙烯酸系樹脂、乙酸乙烯酯樹脂、EVA(乙烯-乙酸乙烯酯)樹脂、聚乙烯醇、澱粉及其類似物中之單一一種或其組合。該樹脂可以水基乳液、水溶液或有機溶劑溶液形式浸漬。然而,就可加工性及安全性而言,水基乳液或水溶液較佳。用於浸漬之樹脂溶液中可另外添加施膠劑(size agent)、蠟、交聯劑、著色劑及消泡劑。
紙形成步驟及第一壓印步驟可於單一步驟中同時進行,且熱塑樹脂之疊層步驟及第二壓印步驟可在各別製程中進行。
當基板片2為樹脂膜材料時,樹脂片(膜材料)之擠壓步驟與第一壓印步驟可在線內製程中共同進行。此時,較佳可在第一壓印滾筒11a中提供冷卻機構,使得自擠壓器擠壓之熔融熱塑樹脂(亦即膜基底材料)得以冷卻,同時轉印不規則外形。
疊層步驟
自擠壓器12之模擠壓熔融熱塑樹脂以便在已進行第一壓印步驟之基板片2上疊層,且形成熱塑樹脂層3。疊層的熱塑樹脂層3與基板片2表面上提供之不規則外形一致,且提供第一壓印圖案(參見圖3C)。
諸如加熱溫度之擠壓器12之條件根據熱塑樹脂層3之熱塑樹脂熔點及熔融流動速率設定。
第二壓印步驟
第二壓印單元13之第二壓印滾筒13a及第二壓力滾筒13b水平相對安置。基板片2(參見圖3C)在進行疊層步驟後實質上向下饋入,且夾於第二壓印滾筒13a與第二壓力滾筒13b之間。諸如所施加壓力及溫度之壓印條件根據熱塑樹脂之材料及第二壓印滾筒13a之不規則外形確定。
預先於第二壓印滾筒13a表面上提供之不規則外形轉印於與第二壓印滾筒13a接觸之熱塑樹脂層3上,在此期間使熱塑樹脂層3冷卻。轉印及冷卻提供第二壓印圖案(參見圖3D)。第二壓印圖案沿第一壓印圖案之不規則外形形成。
因此,製造出離型片1。
其他步驟
藉由滾筒中之纏繞機(winding machine)(圖中未示)纏繞進行第二壓印步驟後製造之離型片。在使用前將經纏繞離型片1切成與其應用相對應之尺寸。
合成皮革之製造方法
將諸如聚胺基甲酸酯樹脂及氯乙烯樹脂之合成皮革樹脂塗覆於離型片1之熱塑樹脂層3表面上。乾燥及固化經塗覆合成皮革樹脂後,經由黏著劑將底布(ground fabric)附著於表面合成皮革樹脂上,將其乾燥並久置。隨後,剝離離型片1,隨後提供合成皮革。合成皮革在自離型片1剝離後將第一壓印圖案及第二壓印圖案轉印至熱塑樹脂層3上。
順帶而言,可能不附著底布,而可能獨立使用所製造之合成皮革樹脂層。
例示性具體實例之優勢
根據上述例示性具體實例,可獲得以下優勢。
(1)因為在離型片1之熱塑樹脂層3表面上提供兩種不同壓印圖案(亦即第一壓印圖案及第二壓印圖案),所以可使用離型片1製造紋理豐富的合成皮革,其具有習知離型片無法提供之多種圖案。
(2)因為離型片1之第一壓印圖案之不規則外形的深度大於第二壓印圖案之不規則外形的深度,所以可清楚地雕刻出兩種壓印圖案。
(3)因為提供在具有第一壓印圖案之區域內與第一壓印圖案之不規則外形一致的第二壓印圖案,所以相較於藉由習知離型片製造者,該離型片可提供更接近天然皮革紋理及木紋之圖案。
(4)因為在離型片1之基板片2上提供基底壓印圖案,所以顯現於熱塑樹脂層3表面上之第一壓印圖案係由基底壓印圖案之不規則外形支撐。因此,即使在形成第二壓印圖案時對第一壓印圖案施加熱及壓力,亦可防止第一壓印圖案模糊。
具體實例之修改
本發明範疇不限於上述例示性具體實例,而是包括如下修改形式。
儘管對應於基板片2上基底壓印圖案之第一壓印圖案在熱塑樹脂層3上經由基板片2形成,但第一壓印圖案及第二壓印圖案可在熱塑樹脂層3上直接形成,而不在基板片2上形成基底壓印圖案。以上直接形成可藉由例如在疊層熱塑樹脂層3後,在壓印期間使用預先具有不同的第一及第二壓印圖案之壓印滾筒達成。
離型片1表面上之壓印圖案數目不限於兩種,而是可能為三種或三種以上。在熱塑樹脂層3上提供更多數目之壓印圖案相較於藉由兩種壓印圖案所提供者可更接近地仿造天然皮革及其類似物之紋理。當例如欲提供三種壓印圖案時,可在基板片2上提供第一壓印圖案之基底壓印圖案,且可在熱塑樹脂層3上施加第二及第三壓印圖案。或者,熱塑樹脂層3可為中間層與表面層疊層而成,第一壓印圖案之基底壓印圖案可於基板片2上形成,第二壓印圖案之基底壓印圖案可在中間層上形成,且第三壓印圖案可在表面層上形成。此時,各不規則外形之深度可較佳為(第一壓印圖案深度)>(第二壓印圖案深度)>(第三壓印圖案深度)。
儘管在上述例示性具體實例中第一及第二壓印圖案之不規則外形(亦即凹形及凸形)以規則間隔實質上規則地提供,但可能存在其他配置。可隨機提供第一及第二壓印圖案。不規則外形之間隔及形狀可改變,以便更接近地模擬天然皮革及其類似物之組態。
可例如使用具有平板的平壓機(flat press)而不使用壓印滾筒進行壓印,該平板具有對應於壓印圖案之不規則外形。
儘管在例示性具體實例中,第二壓印滾筒13a與第二壓力滾筒13b水平(亦即左右方向)相對安置,但第二壓印滾筒13a與第二壓力滾筒13b亦可如第一壓印滾筒11a與第一壓力滾筒11b一樣垂直相對安置。在此配置中,在進行第一壓印後,藉由擠壓器12將熱塑樹脂疊層於基板片2上,形成熱塑樹脂層3,隨後將其夾於第二壓印滾筒13a與第二壓力滾筒13b之間,同時實質上水平饋入基板片2。
此外,儘管在以上例示性具體實例中,與壓印滾筒11a、13a各別配對之壓力滾筒11b、13b由橡膠製成,但可替代地根據基板片及熱塑樹脂片之材料使用金屬滾筒、合成樹脂滾筒或金屬平台。
實施例
儘管以下將參考實施例詳細描述本發明,但應瞭解本發明範疇絕不會受該等實施例限制。
順帶而言,不規則外形之深度藉由表面粗糙度計(surface roughness gauge)(由Accretech(中國)有限公司製造,型號:SURCOM480A)量測。
實施例1
使用具有120 g/m2
基重之樹脂浸漬紙(由LINTEC公司製造,型號:FLEX-A)作為基板片。向以上例示性具體實例中所述之離型片製造裝置中供應樹脂浸漬紙。在第一壓印步驟中,在樹脂浸漬紙表面上形成基底壓印圖案,同時第一壓印滾筒(由LINTEC公司製造,型號:R-101,具有仿造一種牛皮之所謂的「犢牛皮」圖案)溫度設定為130℃。第一壓印滾筒表面上形成之不規則外形的深度為60 μm。樹脂浸漬紙上形成之基底壓印圖案之不規則外形的深度為60 μm。
其次,使用擠壓器,將聚丙烯(由SunAllomer有限公司製造,PHA03A)與低密度聚乙烯(由SunAllomer有限公司製造,PH800C)之混合樹脂疊層於具有基底壓印圖案之樹脂浸漬紙上。擠壓器溫度為290℃,且熱塑樹脂層厚度為35 μm。此時,對應於基底壓印圖案之不規則外形之第一壓印圖案於熱塑樹脂層表面形成。第一壓印圖案之不規則外形的深度為60 μm。
在第二壓印步驟中,形成第二壓印圖案,同時冷卻藉由以上混合樹脂形成之熱塑樹脂層,第二壓印滾筒(由LINTEC公司製造,型號:R-70-1,具有仿造一種牛皮之「仔牛皮」圖案)之溫度設定為290℃。因此,獲得具有兩種壓印圖案(亦即犢牛皮圖案及仔牛皮圖案)之離型片。第二壓印滾筒表面上形成之不規則外形的深度為30 μm。第二壓印圖案之不規則外形的深度為30 μm。
使用如此製造之離型片製造合成皮革。將聚胺基甲酸酯樹脂(由Suzhou finechemical ind.有限公司製造,型號:FB930)塗覆於離型片之熱塑樹脂層表面上。乾燥經塗覆聚胺基甲酸酯樹脂後,經由黏著劑(由Suzhou finechemical ind.有限公司製造,型號:FB7500)將底布(由Zhejiang Hexin ind.有限公司製造,厚度:0.55 mm)附著於聚胺基甲酸酯樹脂表面上,將其乾燥並久置。隨後,剝離離型片獲得合成皮革。在剝離離型片後,將熱塑樹脂層之第一壓印圖案(犢牛皮圖案)及第二壓印圖案(仔牛皮圖案)轉印至合成皮革上。
實施例2
以與實施例1相同之方式製造離型片及合成皮革,例外之處為:將實施例1中之熱塑樹脂改為聚甲基戊烯(由Mitsui Chemicals公司製造,TPX(註冊商標),型號:DX231);擠壓器溫度設定為290℃;且第二壓印步驟中所用之壓印滾筒改為另一個第二壓印滾筒(由LINTEC公司製造,型號:R-135,具有仿造牛皮,仿造山羊皮之「羊羔皮」圖案)。因此,獲得在表面上具有兩種壓印圖案(亦即犢牛皮圖案及羊羔皮圖案)之離型片及合成皮革。
第一壓印滾筒表面上形成之不規則外形的深度為60 μm。樹脂浸漬紙上形成之基底壓印圖案之不規則外形的深度為60 μm。第一壓印圖案之不規則外形的深度為60 μm。第二壓印滾筒表面上形成之不規則外形的深度為30 μm。第二壓印圖案之不規則外形的深度為30 μm。
比較實施例1
以與實施例1相同之方式製造離型片,例外之處為不進行第一壓印步驟。第二壓印圖案的深度為30 μm。以與實施例1相同之方式製造合成皮革。因此,所製造之離型片及合成皮革僅具有仔牛皮壓印圖案。
在實施例1及2之離型片表面上形成第一及第二壓印圖案。此外,提供在形成第一壓印圖案之區域內與第一壓印圖案之不規則外形一致的第二壓印圖案。換言之,因為具有較小深度之圖案在具有較大深度之另一圖案中形成,所以可獲得之離型片相較於使用具有單一壓印圖案之離型片製造之合成皮革(如比較實施例1中)可製造出具有更豐富紋理之合成皮革。實際上,於藉由實施例1及2之離型片製造之合成皮革表面上形成紋理較多之圖案。
產業利用性
本發明適用於離型片、離型片之製造方法及合成皮革。
1...離型片
2...基板片
3...熱塑樹脂層
10...離型片製造裝置
11...第一壓印單元
11a...第一壓印滾筒
11b...第一壓力滾筒
12...擠壓器
13...第二壓印單元
13a...第二壓印滾筒
13b...第二壓力滾筒
h1...基底壓印圖案之不規則外形之深度
h2...第一壓印圖案之不規則外形之深度
h3...第二壓印圖案之不規則外形之深度
圖1為根據本發明之例示性具體實例之離型片的截面。
圖2為示意性展示根據例示性具體實例之離型片之製造方法的圖。
圖3為示意性展示根據例示性具體實例之離型片之製造方法的圖,其中:圖3A展示第一壓印步驟前之基板片;圖3B展示第一壓印步驟後之基板片;圖3C展示進行疊層步驟後之疊層片;及圖3D展示第二壓印步驟後獲得之離型片。
圖4A為根據相關技術之離型片之截面。
圖4B為根據另一相關技術之離型片之截面。
1...離型片
2...基板片
3...熱塑樹脂層
Claims (4)
- 一種離型片,其包含:基板片;及疊層於該基板片上之熱塑樹脂層,其中在該熱塑樹脂層之表面上形成包含第一壓印圖案及第二壓印圖案的兩種以上壓印圖案,該第二壓印圖案之不規則外形的深度小於該第一壓印圖案之不規則外形的深度,於形成有該第一壓印圖案的區域內沿著該第一壓印圖案之不規則外形而形成該第二壓印圖案。
- 如申請專利範圍第1項之離型片,其中該基板片及該熱塑樹脂層經各別壓印,及該基板片上形成之基底壓印圖案顯現於該熱塑樹脂層之表面上而作為該第一壓印圖案。
- 一種製造具有壓印圖案之離型片之方法,該方法包含如下步驟:壓印基板片,形成基底壓印圖案之第一壓印步驟;將熱塑樹脂層疊層於該壓印基板片之該基底壓印圖案上,形成第一壓印圖案之疊層步驟;及壓印該疊層熱塑樹脂層,形成第二壓印圖案之第二壓印步驟;該第二壓印圖案之不規則外形的深度小於該基底壓印圖案之不規則外形的深度。
- 一種合成皮革,其藉由使用申請專利範圍第1項或第 2項之離型片製造。
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KR101509157B1 (ko) * | 2014-04-29 | 2015-04-07 | (주)아셈스 | 접착성 원단을 이용한 입체 문양 형성방법 |
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JP7456089B2 (ja) * | 2018-11-27 | 2024-03-27 | 大日本印刷株式会社 | 離型紙、被賦形体および合成皮革の製造方法 |
CN110000987A (zh) * | 2019-04-25 | 2019-07-12 | 深圳市新世纪自动化科技有限公司 | 热压防粘垫及其制备方法、成型模具和锂电池热压装置 |
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- 2010-02-02 EP EP10845015.6A patent/EP2531351A4/en not_active Withdrawn
- 2010-02-02 KR KR1020127022824A patent/KR20120124472A/ko not_active Application Discontinuation
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Also Published As
Publication number | Publication date |
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EP2531351A4 (en) | 2014-01-22 |
JP5627141B2 (ja) | 2014-11-19 |
JP2013518738A (ja) | 2013-05-23 |
EP2531351A1 (en) | 2012-12-12 |
KR20120124472A (ko) | 2012-11-13 |
CN102985254A (zh) | 2013-03-20 |
TW201134658A (en) | 2011-10-16 |
WO2011094930A1 (en) | 2011-08-11 |
CN102985254B (zh) | 2015-09-02 |
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