Teijin Limited

Tadayuki Katoh

Tadasi Imoto

Akira Omori

Isao Okamura

A composite structure is prepared by extruding a molten thermoplastic resin and foaming agent through a die and simultaneously quenching and taking-up the extrudate under such conditions that the extrudate is fibrillated just as it leaves the die exit without passing through the foamed state. The unopened, sheet-formed and reticulated fibrous structures thus obtained are laminated, pulled apart and pressed. The composite product consists of a fine and uniform fibrillar structure having superior mechanical strength and pliability and are useful for a wide range of applications such as paper substitute, artificial wood veneer and the like. Colored products are also described.

Process for making laminates of sheet-formed, reticulated fibrous

A process for the preparation of unopened sheet-formed and reticulated fibrous structures, which comprises: A. extruding a molten thermoplastic resin containing a foaming substance through a die with a slit clearance of 0.1 - 1.0mm; B. quenching the extrudate at a point less than 5mm away from the die surface to a temperature below the glass transition temperature of the resin; and C. simultaneously drafting the extrudate at a draft ratio between the maximum draft ratio possible under the conditions and one-third thereof, thereby fibrillating the extrudate just as it leaves the die exit.

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Tokyo, Japan

Tadayuki Katoh