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CN-115996834-B - Method for producing long foam sheet, method for producing composite material, and long foam sheet

CN115996834BCN 115996834 BCN115996834 BCN 115996834BCN-115996834-B

Abstract

A method for producing a long foam sheet, which can produce a long foam sheet with a high degree of accuracy without being limited by the material and thickness of the foam, wherein a step of slicing a foam block (35) to produce a foam sheet (14) is performed, and a sheet adhering step of adhering a plurality of foam sheets (14) produced in the slicing step to one surface of a long base sheet (11A) to produce a long foam sheet (12) in which the plurality of foam sheets (14) are connected to each other in the longitudinal direction of the base sheet (11A).

Inventors

  • Yonei Tomoya

Assignees

  • 米岛毛毡产业株式会社

Dates

Publication Date
20260508
Application Date
20211012
Priority Date
20201015

Claims (9)

  1. 1. A method for producing a long foam sheet, characterized by comprising the steps of, A sheet adhering step of adhering a plurality of rectangular foam sheets to one surface of a long base sheet with no gap in the longitudinal direction of the long base sheet, Thereby producing a long foam sheet in which the plurality of foam sheets are connected in the longitudinal direction of the base sheet, In the sheet adhering step, the foam sheet is adhered to the base sheet using an adhesive, In the long foam sheet, the foam sheet is attached to the base sheet by the adhesive in a transferable manner, A dicing step of dicing the foam block to obtain a foam sheet, and a sheet extending step of reducing curl characteristics of the foam sheet obtained by the dicing step by using an extending device for extending the foam sheet, In the sheet adhering step, a foam sheet having the curl characteristics reduced by the sheet extending step is adhered to the base sheet, The stretching device is provided with a plurality of rollers for conveying the foam sheet and stretching the foam sheet, The plurality of rollers includes a heated roller that heats the foam sheet.
  2. 2. A method for producing a long foam sheet, characterized by comprising the steps of, A sheet adhering step of adhering a plurality of rectangular foam sheets to one surface of a long base sheet with no gap in the longitudinal direction of the long base sheet, Thereby producing a long foam sheet in which the plurality of foam sheets are connected in the longitudinal direction of the base sheet, In the sheet adhering step, the foam sheet is adhered to the base sheet using an adhesive, In the long foam sheet, the foam sheet is attached to the base sheet by the adhesive in a transferable manner, A step of slicing the foam block to obtain a foam sheet, a step of inspecting the foam sheet obtained by the slicing step to examine at least one of the weight and the thickness of the foam sheet, and a step of screening the foam sheet satisfying the screening criterion, In the sheet adhering step, a foam sheet satisfying the screening criterion in the inspection step is adhered to the base sheet.
  3. 3. The method of producing an elongated foam sheet according to claim 1 or 2, wherein the foam sheet is a sheet of a rigid foam.
  4. 4. A method for producing a composite material, characterized in that a sheet bonding step is performed in which a plurality of foam sheets are arranged and bonded to one surface of a long base sheet, Thereby producing a long foam sheet in which the plurality of foam sheets are connected in the longitudinal direction of the base sheet, In the sheet adhering step, the foam sheet is adhered to the base sheet using an adhesive, In the long foam sheet, the foam sheet is attached to the base sheet by the adhesive in a transferable manner, A cutting step of dividing the foam sheet constituting the long foam sheet manufactured by the sheet adhering step into a plurality of plate-like sheets by cutting; a lamination step of sandwiching the plurality of plate-like sheets divided by the cutting step between a pair of sheets for an outer skin material, Thereby manufacturing a composite material.
  5. 5. A method of manufacturing a composite material according to claim 4, wherein, After the sheet adhering step and before the cutting step, a sheet joining step is further performed to join adjacent foam sheets on the base sheet by a joining member.
  6. 6. The method of manufacturing a composite material according to claim 5, wherein, And winding up and removing the chips except the plurality of plate-shaped sheets in the foam sheet after the cutting processing.
  7. 7. The method for producing a composite material according to claim 4 to 6, In the cutting step, an intermediate sheet is produced by adhering the plurality of plate-like sheets to the base sheet, After the cutting step, a transfer step of transferring the plurality of plate-like sheets on the intermediate sheet to one of the pair of sheets for a surface material is performed, In the laminating step, the other of the pair of sheets for an outer skin material is laminated to the plurality of plate-like sheets transferred by the transfer step.
  8. 8. The method for producing a composite material according to claim 4 to 6, In the cutting step, an intermediate sheet is produced by adhering the plurality of plate-like sheets to the base sheet, In the laminating step, the intermediate sheet is sandwiched between the pair of sheets for an outer skin material.
  9. 9. A method of manufacturing a composite material, characterized by performing: A long foam sheet manufacturing step of manufacturing a long foam sheet in which a plurality of foam sheets are connected by performing a sheet connecting step of arranging the plurality of foam sheets in a predetermined direction and connecting the foam sheets by a connecting member; a cutting step of dividing the foam sheet constituting the long foam sheet manufactured by the long foam sheet manufacturing step into a plurality of plate-like pieces by cutting; a lamination step of sandwiching the plurality of plate-like sheets divided by the cutting step between a pair of sheets for an outer skin material, Thereby manufacturing a composite material.

Description

Method for producing long foam sheet, method for producing composite material, and long foam sheet Technical Field The present invention relates to a method for producing an elongated foam sheet used for a material such as a composite material. Background Conventionally, a composite material in which a core material is provided between skin materials has been known. As a material of the core material, a foam can be preferably used. Patent document 1 describes a fiber-reinforced composite laminate comprising a core portion containing a foaming resin and a surface layer portion containing a thermosetting resin containing carbon fibers. On the other hand, patent document 2 describes cutting (slicing) a square-shaped foam using a cutting machine as a method for producing a thermoplastic resin foamed film laminated on an aluminum foil. Patent document 3 describes a method for producing a foam sheet from a cylindrical foam block. In this method, a cylindrical foam block is continuously sliced off from the outer peripheral surface by a slicing blade to produce a foam sheet having a long and thin shape. Prior art literature Patent literature Patent document 1 Japanese patent application laid-open No. 2019-6037 WO2010/047274 international publication pamphlet Patent document 3 Japanese patent laid-open No. 63-19235 Disclosure of Invention Technical problem to be solved by the invention However, there are foam sheets produced in a thin sheet form by extrusion foaming or the like from the time of foam molding, but many foam sheets are produced by cutting out a foam block at a predetermined thickness. In this case, the foam sheet is necessarily in the form of paper. The foamed film (foamed sheet) produced by the method for producing a thermoplastic resin foamed film described in patent document 2 is also in the form of a sheet. On the other hand, the present inventors completed an application relating to a composite material having an island-like structure in which a core layer is composed of a plurality of plate-like sheets, and made a patent application (japanese patent application laid-open No. 2020-24756). As a method for obtaining a core layer composed of a plurality of plate-like sheets, there is a method of press working a foam sheet. However, when the foam sheet is in the form of paper, it is difficult to continuously perform press working. Further, when the foam sheet is in the form of paper, it is difficult to perform continuous processing even when continuous lamination of the foam sheet to a long roll such as a metal film or a fiber-reinforced resin is desired. Accordingly, the present inventors have considered preparation of a long foam sheet in order to achieve continuous processing and to improve productivity. However, in the method for producing the long foam sheet described in patent document 3, it is necessary to form the foam in a cylindrical shape. Further, in the processing by a slicing machine matching with the cylindrical foam, the foam which can be processed is very limited in terms of material, thickness and accuracy. The present invention has been made in view of such circumstances, and an object thereof is to provide a method for producing a long foam sheet, which can produce a long foam sheet with a high-precision thickness without being limited by the material and thickness of the foam. Solution to the above technical problems A1 st aspect for solving the above-described problems is a method for producing a long foam sheet, wherein a sheet adhering step of adhering a plurality of foam sheets to one surface of a long base sheet is performed to produce a long foam sheet in which a plurality of foam sheets are connected in the longitudinal direction of the base sheet. In claim 2, in claim 1, before the sheet adhering step, a dicing step of dicing the foam block to obtain a foam sheet, and a sheet extending step of reducing curl characteristics of the foam sheet obtained in the dicing step are further performed, and in the sheet adhering step, the foam sheet having the curl characteristics reduced in the sheet extending step is adhered to the base sheet. In the 3 rd aspect, the step of forming a foam sheet by slicing the foam block and the step of inspecting the foam sheet formed by the step of slicing are performed before the step of adhering the sheet, and the step of inspecting at least one of the weight and the thickness is performed with respect to the foam sheet formed by the step of slicing, and the foam sheet satisfying the screening criterion is screened, and the step of adhering the foam sheet satisfying the screening criterion in the step of inspecting is performed to the base sheet. The 4 th aspect is the foam sheet according to any one of the 1 st to 3 rd aspects, wherein the foam sheet is a hard foam sheet. The 5 th aspect is a method for producing a composite material, comprising a cutting step of dividing a foam sheet constituting the long foam sheet produced by the production m