JP2005238727A - Thermoplastic resin panel and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a thermoplastic resin panel having a decorative material embedded in the absence of a bubble and showing excellence in design and formability, and to provide its manufacturing method. <P>SOLUTION: The thermoplastic resin panel P comprises a plurality of thermoplastic resin sheets 1 and one or a plurality of decorative materials 2, both being integrally formed into one body using no adhesive agent by heating and pressing wherein the bubble substantially does not exist between the resin sheets, the decorative material is embedded in the panel in the state that the bubble substantially does not exist in the circumferential margin, and the panel has substantially uniform thickness including the decorative material-embedded portion. The manufacturing method of the thermoplastic resin panel is characterized in that the decorative material is embedded by heating and pressing the composite laminate S with a heating and pressing means to melt and unify the resin sheets. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a thermoplastic resin panel having a design property and moldability, which is composed of a resin sheet and a decorating material and is used as a display, a display case, a lighting cover, a shelf board, a top plate and the like, and a method for producing the same.

Conventionally, there is an acrylic resin plate in which a woven sheet or the like is laminated with an adhesive.
In addition, a method of manufacturing a laminated plate in which a woven sheet is sandwiched between acrylic resin plates (see Patent Document 1), or two woven fabric pieces are placed between two thermoplastic transparent or translucent resin plates. An amulet (see Patent Document 2) that is integrated by intercalating and thermocompression bonding with a sacred body is disclosed.

Japanese Patent Application Laid-Open No. 11-10804. Japanese Patent No. 27869797.

However, in the case of laminating a woven sheet or the like with an adhesive in an acrylic resin plate, the thickness of the adhesive coating layer must always exceed the thickness of the woven sheet or the like, and the particle size of glass cullet, tile fragments, etc. When a non-constant decorating material is used, there is a problem that it is difficult to make the product thickness uniform and to position the decorating material in the center from the front and back. In addition, in the manufacturing method of Patent Document 1, an acrylic resin having a glass transition temperature lower than that of an acrylic resin plate is used in order to prevent air bubbles from being mixed when a fabric is sandwiched between two acrylic resin plates and heat-pressed. It is necessary to use a film having a main component, and in Patent Document 2, it is necessary to use a heat-sensitive sheet in order to integrate the sacred body and the fabric. However, even if a film is interposed, an acrylic resin plate having a large area has a problem that it is difficult to produce a panel without air bubbles because air and volatile components remain inside.
The present invention is designed to solve the above-mentioned problems, and without using an adhesive, a design property in which a decorative material is embedded between a plurality of thermoplastic resin sheets substantially without air bubbles, It aims at providing the thermoplastic resin panel excellent in the moldability, and its manufacturing method.

  The thermoplastic resin panel according to claim 1 of the present invention comprises a plurality of laminated thermoplastic resin sheets, and one or a plurality of decorating materials arranged between the plurality of thermoplastic resin sheets. It is a thermoplastic resin panel integrated by heating and pressing without using an agent, the resin panel is substantially free of bubbles between the plurality of resin sheets, and the decorative material is The resin sheet is formed of a material having a melting temperature higher than the melting temperature of the resin sheet, and is embedded in the panel in a state where air bubbles are not substantially present at the periphery thereof. The thickness is substantially uniform including the material-buried portion.

  According to a second aspect of the present invention, the thermoplastic resin sheet is transparent or translucent.

A third aspect of the present invention is the first or second aspect, wherein the decorating material is a granular material.
According to a fourth aspect of the present invention, the particulate material is at least one selected from the group consisting of glass cullet, resin pellets, sand, stones, earth, beads, glass balloons, shell fragments, tile fragments, and inorganic ceramic materials. It's a seed.
Further, in the present invention, the decorating material is at least one selected from the group consisting of wire mesh, Japanese paper, cloth, non-woven fabric, leaf, and flower.

  According to a sixth aspect of the present invention, in any one of the first to fifth aspects, the thickness of each of the upper and lower resin portions in the decorative material embedded portion of the resin panel is about 1 mm or more.

  According to a seventh aspect of the present invention, there is provided a method for producing a thermoplastic resin panel, comprising: a step of preparing a plurality of thermoplastic resin sheets; and a material that does not deform at a melting temperature of a material for forming the thermoplastic resin sheet. A step of preparing one or a plurality of decorating materials, and a flat plate member having a melting temperature higher than that of the thermoplastic resin sheet forming material and not compatible with the forming material is disposed on the upper and lower parts, A step of preparing a composite laminate in which a plurality of resin sheets are laminated between two flat plate members and a decorating material is disposed between the two sheets, and a step of storing and sealing the composite laminate in a container In the state where the gas suction means is connected to the storage body and the storage body is in a degassed state, the composite laminate is heated to a temperature equal to or higher than the melting temperature of the material for forming the thermoplastic resin sheet by the heating and pressurizing means. Melting temperature of the material Pressurized with heating under, and having a resin sheet integral step of burying the decorative material with is integrated melting the plurality of resin sheets.

  According to an eighth aspect of the present invention, in the composite laminated body preparation step according to the seventh aspect, the thermoplastic resin sheet is disposed between a peripheral edge portion of the upper and lower flat plate members and a peripheral edge portion of the plurality of resin sheet laminates. A molten resin outflow inhibiting member having a surface portion formed of a material that is not compatible with the forming material is disposed.

  According to a ninth aspect of the present invention, in the eighth aspect, the thickness of the molten resin outflow inhibiting member is substantially the same as or slightly thinner than the sum of the thicknesses of the plurality of thermoplastic resin sheets.

  According to a tenth aspect of the present invention, in the method according to any one of the seventh to ninth aspects, the step of housing and sealing the composite laminate in a housing body includes, as the housing body, a base member and a sheet material sealed on the upper surface thereof. And the lower surface and side surfaces of the composite laminate are placed on a base member, and the upper surface of the composite laminate including the breathable sheet is further placed on the base member. The composite laminate is sealed by being sealed by the base member in an encapsulated state.

  An eleventh aspect of the present invention is the method according to the tenth aspect, wherein a buffer material is interposed between the sheet material and the composite laminate in the step of housing and sealing the composite laminate in a storage body.

  According to a twelfth aspect of the present invention, in any one of the seventh to eleventh aspects, the resin sheet integration step is a heating process until the composite laminate reaches a predetermined temperature not higher than a melting temperature of the thermoplastic resin sheet. Then, the inside of the container is depressurized to a predetermined degree of decompression, and after the composite laminate reaches the predetermined temperature, the inside of the container is depressurized to a degree of decompression higher than the predetermined degree of decompression.

  A thirteenth aspect of the present invention is the process according to any one of the seventh to eleventh aspects, wherein the resin sheet integration step is a heating process until the composite laminate reaches a predetermined temperature not higher than a melting temperature of the thermoplastic resin sheet. Then, after depressurizing the storage body to a predetermined degree of decompression, and the composite laminate reaches the predetermined temperature, the composite body is decompressed to a decompression degree higher than the predetermined decompression degree. Is heated to a temperature equal to or higher than the melting temperature of the thermoplastic resin sheet.

According to the thermoplastic resin panel of the present invention, it is composed of a plurality of laminated thermoplastic resin sheets and one or a plurality of decorating materials arranged between the plurality of thermoplastic resin sheets. Integrating by heating and pressing without using, substantially no bubbles between the plurality of resin sheets, and the decorating material is formed of a material having a melting temperature higher than the melting temperature of the resin sheet In addition, it is embedded in the panel in a state where air bubbles are not substantially present at the periphery thereof, and the resin panel has a substantially uniform thickness including the decorative material embedded portion. Panels with excellent design and moldability can be provided.
In the case of two thermoplastic resin sheets, one or a plurality of decorating materials are arranged between the resin sheets and integrated by heating and pressing, so the decorating material is positioned at the center in the thickness direction of the thermoplastic resin panel. The distance from the flat plate surface to the decorating material is even, and the product can be made without any front or back.
By making the resin sheet transparent or translucent, the interior decorating material can be seen from the outside, and the design can be made excellent.
By embedding a granular material as a decorating material, various design properties and a sense of taste can be given.
The granular material is at least one selected from the group consisting of glass cullet, resin pellets, sand, stone, earth, beads, glass balloons, shell fragments, tile fragments, inorganic ceramic materials, or When the decorating material is at least one selected from the group consisting of wire mesh, Japanese paper, cloth, non-woven fabric, leaves, and flowers, a resin panel that meets the taste and demand can be provided.
Resin panels such as acrylic are light transmissive as well as light transmissive.When light is radiated from a flat plate surface, the buttock surface is irradiated from one lip and the other lip is shielded. The flat surface can be illuminated. In this case, the glass cullet or, in particular, the one in which the fluorescent molding resin pellet is embedded is in a state in which only the decorating material shines in the air, enabling a mysterious production. Accordingly, it is possible to increase the added value of a product configured using this panel.
The thickness of each of the upper and lower resin portions in the decorative material-embedded portion of the resin panel is about 1 mm or more, and a thermoplastic resin sheet that does not crack or the like can be provided.

  According to the method for producing a thermoplastic resin panel of the present invention, the step of preparing a plurality of thermoplastic resin sheets and the 1 or 2 formed in a material that does not deform at the melting temperature of the thermoplastic resin sheet forming material A step of preparing a plurality of decorating materials, and a flat plate member having a melting temperature higher than the forming material of the thermoplastic resin sheet and having no compatibility with the forming material is disposed at the upper and lower portions, A step of preparing a composite laminate in which a plurality of resin sheets are laminated between the flat plate members and a decorating material is disposed between the two, a step of storing and sealing the composite laminate in a storage body, In a state where the gas suction means is connected to the storage body and the storage body is in a deaerated state, the composite laminate is heated above the melting temperature of the material for forming the thermoplastic resin sheet by the heating and pressurizing means and Below melting temperature Since it is manufactured by a resin sheet integration step of heating and pressurizing, melting and integrating the plurality of resin sheets and embedding the decorating material, without using an adhesive, in a deaerated state In the panel, the bubble is substantially absent between a plurality of resin sheets, and the decorative material is embedded in the panel with substantially no bubbles at its periphery. In addition, it is possible to provide a panel having a substantially uniform thickness, including the decorative material embedded portion, and having excellent design and formability.

  According to the method for manufacturing a thermoplastic resin panel of the present invention, in the composite laminate preparation step, the thermoplastic resin sheet is disposed between a peripheral portion of the upper and lower flat plate members and a peripheral portion of the plurality of resin sheet laminates. Since a molten resin outflow inhibiting member having a surface portion formed of a material that is not compatible with the forming material is disposed, it is possible to prevent the molten resin from flowing out and to prevent unevenness of pressure applied to the surroundings. By making the thickness of the resin outflow inhibiting member substantially the same as or slightly thinner than the sum of the thicknesses of the plurality of thermoplastic resin sheets, the thermoplastic resin sheet is deformed during pressure molding in a deaerated state. Can be fused without any problem.

  According to this invention, in the resin sheet integration step, in the heating process until the composite laminate reaches a predetermined temperature not higher than the melting temperature of the thermoplastic resin sheet, the storage body is depressurized to a predetermined depressurization degree. And after the said composite laminated body reaches | attains the said predetermined temperature, as the inside of a storage body is pressure-reduced to the decompression degree higher than the said predetermined decompression degree, a thermoplastic resin sheet does not generate | occur | produce a crack with a decorating material. A gas-free product can be formed by degassing the gas between the resin sheets.

According to the present invention, the resin sheet integration step includes the step of storing the resin sheet integration step in the heating process until the composite laminate reaches a predetermined temperature not higher than the melting temperature of the thermoplastic resin sheet. After the inside of the body is depressurized to a predetermined degree of decompression and the composite laminate reaches the predetermined temperature, the inside of the storage body is decompressed to a degree of decompression higher than the predetermined degree of decompression, and the composite laminate is By heating up to the melting temperature of the resin sheet or more, there are substantially no bubbles between the resin sheets, and there are substantially bubbles at the periphery of the decorating material in the molten state of the resin sheets. A product having a substantially uniform thickness including the decorative material embedded portion can be formed.
Therefore, according to the present invention, a product with high added value can be produced without causing cracks or the like in the thermoplastic resin sheet even if a granular material having various shapes is embedded as a decorating material.

  Embodiments of a thermoplastic resin panel and a manufacturing method thereof according to the present invention will be described with reference to the drawings. FIG. 1 is a partially broken plan view of a thermoplastic resin panel in which a glass cullet is embedded, FIG. 2 (a) is a sectional view showing a thermoplastic resin sheet and a glass cullet, and FIG. 2 (b) is a diagram of a molded thermoplastic resin panel. Sectional view, FIG. 3 is a partially broken plan view of a thermoplastic resin panel in which a wire mesh is embedded, FIG. 4 (a) is a cross-sectional view showing a thermoplastic resin sheet and a wire mesh, and FIG. 4 (b) is a molded thermoplastic resin panel. FIG.

1 to 4, 1 is a thermoplastic resin sheet, 2 is a decorating material, and P is a thermoplastic panel. Embodiment demonstrates the case where an acrylic resin sheet is used as the thermoplastic resin sheet 1 and a decorating material is arrange | positioned between two resin sheets.
In FIG.1 and FIG.2, when using glass cullet as a decorating material, as shown to FIG. 2 (A), it shape | molds by sandwiching the glass cullet 2a as the decorating material 2 between two acrylic resin sheets. As shown in FIGS. 1 and 2 (b), an acrylic resin panel P having a glass cullet 2a embedded therein is formed.
In FIG.3 and FIG.4, when using a metal mesh as a decorating material, as shown to FIG. 4 (A), it shape | molds by sandwiching the metal mesh 2b as the decorating material 2 between two acrylic resin sheets. As shown in FIG. 3 and FIG. 4B, the acrylic resin panel P in which the wire mesh 2b is embedded is formed.

The thermoplastic resin panel P according to the present invention comprises two laminated thermoplastic resin sheets 1 and one or a plurality of decorating materials 2 arranged between the two thermoplastic resin sheets 1. , A thermoplastic resin panel integrated by heating and pressing without using an adhesive, the resin panel being substantially free of air bubbles between the two resin sheets, and the decorating material 2 Is formed of a material having a melting temperature higher than the melting temperature of the resin sheet, and is embedded in the panel in a state where air bubbles are not substantially present at the periphery thereof. The thickness is substantially uniform including the decorative material buried portion.
Between the two thermoplastic resin sheets 1 to be laminated, gas or moisture, volatile components, etc. contained in the decorating material 2 are present, and gas or the like is generated from the resin sheet or decorating material even during heating and pressurization. The gas, moisture, and volatile matter can be degassed by a gas suction means at the time of heat and pressure molding to embed the decorating material 2 in a state where bubbles are not substantially present, thereby providing a resin panel free of bubbles.
The thermoplastic resin sheet 1 is transparent or translucent so that the decorating material 2 sandwiched between the sheets can be seen through from the outside, and the resin panel P having excellent design is formed. This resin sheet can also have a desired color.
The resin sheet has a desired thickness of at least about 1.5 mm. In the case of the embodiment, the thickness of the two resin sheets 1 is set to 3 mm, for example, the thickness of the glass cullet of the decorating material is set to about 4 mm or less, and pressure-molded to obtain a panel having a thickness of about 6 mm. The resin panel P can be made from a thickness of about 2 mm or more to a thickness equivalent to tens of mm.
And the thickness H of each upper and lower resin part in the said decoration material embedding part of the said resin panel P shall be about 1 mm or more so that a thermoplastic resin sheet may not crack.
When the resin sheet 1 has the same thickness, the thermoplastic resin panel P can place the decorating material in the center in the thickness direction, and the distance from the flat plate surface to the decorating material is uniform, and there is no front or back product. And can.
Further, the thermoplastic resin panel P is easy to polish the end surface, and when polished, the mirror surface property almost equal to the flat plate surface can be obtained. Therefore, it is possible not only to show a flat plate as a decorative material, but also to make a work with a front end.
The resin panel P is light transmissive as well as light transmissive. When light is irradiated from a flat plate surface, the top surface is irradiated from one end and the other end is shielded. The flat surface can be illuminated. In addition, the thermoplastic resin panel P can be bent and has higher impact resistance than glass.
The thicknesses of the two thermoplastic resin sheets 1 are not limited to the same, and those having different thicknesses may be used. If the thermoplastic resin sheets on the front and back sides have different thicknesses, the depth to the embedded decorative material changes, and it is possible to obtain front and back properties and a deeper sense of depth. If it changes, the way of refraction changes, so that the commercial value can be increased as various products. Even when the thickness is reduced, the thickness H of the upper and lower resin portions in the decorative material-embedded portion of the resin panel P must be about 1 mm or more so as not to cause cracks.
The case where the resin sheet is made of two acrylic resin sheets and a decorating material is arranged between them is the best mode. However, the present invention is not limited to this, and a plurality of resin sheets are used to decorate each sheet. Materials can also be placed and molded.

The decorating material 2 is a granular material. And the granular material is inorganic ceramics such as glass cullet (including recycled glass), molding resin pellets, sand, stone, earth, sandblast beads, beads for handicrafts, glass balloons, shell fragments, tile fragments, etc. At least one selected from the group consisting of materials.
The decorating material 2 is at least one selected from the group consisting of wire mesh, Japanese paper, cloth, non-woven fabric, leaves, and flowers.
When a large number of the granular materials, leaves, flowers and the like are used as the decorating material 2, they can be regularly or irregularly scattered on the entire surface of the acrylic resin sheet having a large area.
As a decorative material, glass cullet (including recycled glass) of the above granular material, resin pellets for molding, sand, stone, earth, sandblast beads, beads for handicrafts, glass balloons, shell fragments, tile fragments, etc. inorganic By embedding at least one selected from the group consisting of ceramic materials, or the above-mentioned wire mesh, Japanese paper, cloth, non-woven fabric, leaves, flowers, it is possible to give various design and hobbies, and thermoplastic resins When the panel P is irradiated with light from a flat plate surface, the substance put into the surface is exposed when the light is irradiated from the end of the mouth, and a mysterious effect is made possible.
In particular, when a glass cullet is embedded in an acrylic resin panel, a higher level of depth can be obtained due to the difference in refractive index between glass and acrylic resin, and the design can be enhanced due to the difference in refractive index between materials. . In this case, the glass cullet or, in particular, the one in which the fluorescent molding resin pellet is embedded is in a state in which only the decorating material shines in the air, enabling a mysterious production.
Accordingly, it is possible to increase the added value of a product configured using this panel. Further, the thermoplastic resin panel such as acrylic resin of the present invention can be bent, and has an effect such as stronger impact resistance than glass.

  FIG. 5 is a schematic front view showing a state before gas suction in the step of preparing the thermoplastic resin sheet and the decorating material 2 of the present invention, FIG. 6 is a schematic front view showing a state after the gas suction, and FIG. 12 is an enlarged cross-sectional view of the main part of the molding apparatus at stage A, FIG. 8 is an enlarged cross-sectional view of the main part of the molding apparatus at stage B, and FIG. 9 is an enlarged cross-sectional view of the main part of the molding apparatus at stages C to D. FIG. 10 is a schematic side view of the autoclave apparatus provided with the molding apparatus, FIG. 11 is a transverse sectional view thereof, and FIG. 12 is a graph showing the relationship between time, temperature, can internal pressure, and negative pressure.

5 to 9, a molding apparatus for carrying out the thermoplastic resin panel manufacturing method of the present invention will be described.
3 is a flat plate member having a melting temperature higher than the forming material of the thermoplastic resin sheet 1 and not compatible with the forming material. In the embodiment, a stainless plate having a mirror surface polished on one side is used. An acrylic resin sheet 1 sandwiching the decorating material 2 is placed between the mirror surfaces of two stainless steel plates. The resin sheet 1 is shorter than the stainless steel plate 3, and a space 14 is provided between the peripheral edge portion of the stainless steel plate 3 and the peripheral edge portions on both sides of the sheet 1. When the upper and lower surfaces of the resin sheet 1 sandwiched between the mirror surfaces of the upper and lower stainless steel plates 3 are pressed so that the decorating material is fused to the sheets, the upper and lower surfaces of the resin sheet 1 can be formed into a straight mirror surface without distortion. It is.
S is a resin sheet laminate S1 composed of two flat plate members 3, 3 and a plurality of resin sheets, in the embodiment two resin sheets 1, 1 and a decorating material 2 arranged between the resin sheets; The composite laminated body which consists of.
4 is a base member on which the composite laminate S is placed, 5 is a sheet material having air permeability such as a fabric interposed between the base member 4 and the stainless steel plate 3, and the lower surface and both sides of the lower stainless steel plate are covered with the sheet material. It is wrapped and placed on the base member 4 so that the gas can be extracted through the sheet material when the gas is sucked.
Reference numeral 6 denotes a molten resin outflow inhibiting member, which is called a dam for damming the resin, and is placed in the space 14 around the resin sheet laminate S1 as the same material as the thermoplastic resin, and around the resin sheet laminate S1. It serves to prevent unevenness in the applied pressure and also serves to block outflow of molten resin. In the case of the acrylic resin sheet 1, a stick-shaped acrylic dam is used. In the case of two thermoplastic resin sheets, the thickness of the molten resin outflow inhibiting member 6 is approximately the same as or slightly thinner than the sum of the thicknesses. The decorative material can be embedded without causing deformation of the sheet. When there are a plurality of resin sheets, the thickness of the molten resin outflow inhibiting member 6 is approximately the same as or slightly thinner than the sum of the thicknesses.
7 is encapsulated with a release film as a surface portion by a material not compatible with the thermoplastic resin sheet forming material. For example, a fluororesin film is used as a release film, and the entire molten resin outflow inhibiting member is encapsulated to prevent fusion between the molten resin outflow inhibiting member and the resin sheet.
8 is a cushioning material having air permeability interposed between the sheet material 9 and the composite laminate S. For example, a sheet of polyester fiber, nylon fiber, glass fiber, or the like is used. The purpose of inserting the cushioning material 8 is to create a passage for air between the flat plate member 3 and a storage body 9 to be described later, and to effectively perform vacuuming, and to secure a passage for the air and prevent breakage of the storage body. It is preferable to cover the entire flat plate member, resin sheet, dam, and the like placed on the foundation member. If this is not inserted, the container and the flat plate member are brought into close contact with each other only around the vacuum port when evacuating, and the evacuation cannot be effectively performed toward the end portion. In addition, if this is not present, there is a risk that the container directly hits the corners of the flat plate member or the like and breaks during curing.
Reference numeral 9 denotes a storage body for storing the composite laminate S, and a heat resistant film (referred to as a bagging film) having various heat resistant temperatures such as 176 ° C., 204 ° C., and 230 ° C. is used. In the embodiment, a nylon film having an elongation of about 400% to 500% is used. This film is covered and sealed over the entire cushioning material 8 having air permeability over the laminated plate member, resin sheet, dam, and the like. A vacuum port 10 is provided at an appropriate position of the sealed housing 9, for example, at the top. 11 is a rubber-like adhesive tape having a tackiness before semi-curing (referred to as a sealant tape), which is adhered around the base member 4, and the heat-resistant film 9 is sealed with the adhesive tape 11 and sealed. To do.
12 is a thermocouple for detecting the temperature inside the can. The thermocouple is placed on the flat plate member 3 on the upper side, and its connecting cord 13 passes through the adhesive tape 11 to the outside of the can body and is attached to a thermometer 30 or the like. Connecting.

  According to the method for producing a thermoplastic resin panel of the present invention, when forming a panel with two thermoplastic resin sheets and a decorating material, a step of preparing two resin sheets 1 and the thermoplastic resin sheet 1 A step of preparing one or a plurality of decorating materials 2 formed in a material that does not deform at the melting temperature of the forming material, and a melting temperature higher than the forming material of the thermoplastic resin sheet 1 at the upper and lower portions And the flat plate member 3 which does not have compatibility with this forming material is arrange | positioned, and the two resin sheets 1 and 1 are laminated | stacked between these two flat plate members 3 and 3, and the decorating material 2 is between them. A step of preparing the disposed composite laminate S, a step of housing and sealing the composite laminate S in the storage body 9, and connecting the gas suction means to the storage body 9 to deaerate the storage body. In such a state, the composite laminate is heated by a heating and pressing means. Is heated to a temperature equal to or higher than the melting temperature of the forming material of the thermoplastic resin sheet 1 and equal to or lower than the melting temperature of the decorating material, and the two resin sheets 1 and 1 are melted and integrated to form the decorating material. 2 is embedded in the resin sheet integration step, and is included in the decoration material 2 or the gas existing as described above between the two thermoplastic resin sheets 1 at the time of heat and pressure molding in these steps. Moisture, volatile matter, and the like are degassed by a gas suction means, and the decorating material 2 is embedded in a state where bubbles are not substantially present, so that a resin panel without bubbles can be manufactured.

  In the composite laminate preparation step, the thermoplastic resin sheet forming material is not compatible between the peripheral portions of the upper and lower flat plate members 3 and 3 and the peripheral portions of the two resin sheet laminates S1. The molten resin outflow inhibiting member 6 having a surface portion formed of a material is arranged to prevent the resin from flowing out and to prevent uneven pressure applied to the surroundings.

  The step of housing and sealing the composite laminate S in the housing 9 uses the base member 4 and the sheet material 9 sealed on the upper surface thereof, and the bottom and side surfaces of the composite laminate S are air permeable. What is encapsulated with the sheet 5 is placed on the base member 4, and the sheet material 9 is sealed to the base member 4 in a state where the entire upper surface of the composite laminate including the breathable sheet is encapsulated. Thus, the composite laminate S is sealed. In the next step, the sealed housing 9 is connected to a vacuum pump 29 as a gas suction means so that it can be deaerated.

  In the step of storing the composite laminate S in the housing 9 and sealing it, a buffer material 8 is interposed between the sheet material 9 and the composite laminate S, and an air passage between the flat plate member 3 and the housing 9 is provided. Make a vacuum, effectively evacuate, and serve as a cushion to prevent the container from tearing.

In the resin sheet integration step, in the heating process until the composite laminate S reaches a predetermined temperature not higher than the melting temperature of the thermoplastic resin sheet 1, the inside of the storage body 9 is depressurized to a predetermined depressurization degree, After the composite laminate reaches the predetermined temperature, the storage body is depressurized to a degree of decompression higher than the predetermined degree of decompression.
When a high negative pressure is applied to a resin sheet with a pointed part such as glass cullet, the resin is hard, so that the resin is cracked from the pointed part because it is hard. In the case of the material 2, in the heating process until reaching a predetermined temperature, the inside of the storage body 9 is depressurized to a predetermined pressure reduction degree, and after the composite laminated body reaches the predetermined temperature, the storage body is The product can be molded without cracks and without bubbles by depressurizing to a degree of decompression higher than a predetermined degree of decompression to degas the gas, moisture, etc. between the two resin sheets.

  In the resin sheet integration step, in the heating process until the composite laminate S reaches a predetermined temperature not higher than the melting temperature of the thermoplastic resin sheet 1, the inside of the storage body 9 is depressurized to a predetermined depressurization degree, After the composite laminate S reaches the predetermined temperature, the inside of the container is decompressed to a degree of decompression higher than the predetermined decompression degree, and the composite laminate S is brought to a melting temperature or higher of the thermoplastic resin sheet 1. Since it is heated, the gas, moisture, etc. between the two resin sheets are degassed by the same action as described above, and the resin sheet is in a molten state, so there is no cracking even when pressed, and the periphery of the decorating material It is possible to embed in a state where there are substantially no bubbles, and to form a product having a substantially uniform thickness including the decorative material burying portion.

  10 and 11, a can-like autoclave device 20 is shown as a heating and pressurizing means for heating and pressurizing the entire composite laminate S sealed with the storage body. This autoclave device 20 is provided with a lid 21a at one end of a can 21 that can be opened and closed. The other end of the can 21 has a fan motor 22, a fan 23, an electric heater 24, and compressed air supplied as a heating and pressurizing device. A pipe 25 is provided. The compressed air supply pipe 25 is provided with a compressed air cylinder 28, a compressor 27 as a compressed air supply source, a valve (not shown), and the like. The vacuum nozzle 26 is connected to a vacuum pump 29 as a gas suction means by piping. The vacuum pump 29, fan motor 22, red heat heater 24, compressor 27, thermocouple 12, thermometer and the like can be controlled in association with a control device (not shown). Reference numeral 31 denotes a movable base on which the base member 4 in which the composite laminate S is sealed by the storage body 9 is placed, and is provided movably in the can body 21.

  In the method for manufacturing a thermoplastic resin panel according to the present invention, the base member 4 in which the composite laminate S is sealed with the storage body 9 is placed on the movable base 31 of the autoclave device 20 and the vacuum port 10 of the sealed storage body 9 is placed. Is connected to a vacuum pump 29 through a vacuum nozzle 26 of the autoclave device 20, and the gas inside the container 9 is sucked by the vacuum pump 29 to a predetermined temperature while being heated by the red heat heater 24 and the fan 23 of the autoclave device 20. When the pressure reaches, the compressed air from the compressor 27 is supplied into the can body 21 with the valve opened to perform pressure molding.

The manufacturing method of a thermoplastic resin panel is demonstrated based on an Example.
In FIG. 7, a woven fabric sheet 5 is placed on a foundation member 4, a stainless steel plate 3 polished on one side is placed thereon, an acrylic resin sheet 1 is placed thereon, the sizes are uneven, and the height is almost constant or less. A large number of aligned glass cullets 2 are placed, an acrylic resin sheet 1 is placed, and a stainless steel plate 3 polished on one side is placed.
A bar-shaped acrylic dam 6 is placed in the space 14 around the acrylic resin sheet 1.
A stainless steel plate 3 is covered with a cushioning material 8 having air permeability, and the whole is wrapped with a bagging film 9, a sealant tape 11 is attached around the base member 4, and the bagging film 9 is bonded to the sealant tape 11. The thermocouple 12 faces the upper surface of the upper stainless steel plate 3, and the connection cord 13 is bonded together with the bagging film 9 with the sealant tape 11 and connected to the outside. This is put into the autoclave apparatus 20 shown in FIG. 10, the vacuum port 10 of the bagging film 9 is connected to the vacuum pump 29 through the vacuum nozzle 26 of the can 21, and heated and pressurized by the heating and pressurizing means of the autoclave apparatus 20.

7 and 8 show a state in which the temperature is increased from 30 ° C. to about 90 ° C. by evacuating, for example, 300 mmHg in the range of step A shown in FIG. The air flow in this state is indicated by arrows, moisture, and volatile content by circles. The dam and the stainless steel plate on both sides are air that stays because there is a gap of the thickness of the decorating material between the resin sheets, and air, moisture, volatiles, etc. that are generated from acrylic resin or decorating material by heating Meanwhile, the air is sucked into the vacuum port through a cushioning material having air permeability between the stainless steel plate and the bagging film.
12 shows a state in which the evacuation in the range of Step B shown in FIG. 12 is changed from 300 mmHg to 760 mmHg, for example, and the temperature rises from about 90 ° C. to around 170 ° C. In this state, the acrylic resin sheet becomes soft and the interior decorating material 2 begins to enter the resin. Air, moisture, and volatile matter are sucked into the vacuum port through the narrowed dam and the stainless steel plate, through the buffer material between the stainless steel and the bagging film, or through the gap.
Since the temperature rises to around 170 ° C., if the amount of moisture, volatile matter, etc. is larger than that in step A, the temperature raising time is lengthened or kept at an appropriate temperature. When the temperature is around 170 ° C., the acrylic resin sheet is almost adhered.
FIG. 9 shows a state where the maximum pressure in the can of the autoclave apparatus in the range of Step C shown in FIG. 12 is 9.5 kg / cm ² . When changing to this process, the surrounding acrylic dam and the acrylic resin sheet may be slightly thinner than the original thickness by being pressurized and heated. In particular, since the acrylic dam is as thin as the acrylic resin sheet, the pressure can be made uniform.
If you use a dam whose thickness does not change, the pressure applied to the surrounding acrylic resin sheet will be lower than the central part, causing pressure unevenness, leaving bubbles, and creating an unfused part. There is.
If there is no dam, it will be transmitted to the pressure plate member in the autoclave can, but the melted acrylic will protrude from the end, and the acrylic will crack from the protruding acrylic part due to the shrinkage of the plate member and the acrylic resin sheet entering the cooling process. Because it occurs, it is necessary to provide the above dam.
Process D shown in FIG. 12 shows the same state as process C, but the pressure is maintained until the temperature reaches 40 ° C. for cooling.

FIG. 12 is a graph showing the relationship between time, temperature, can internal pressure, and negative pressure. The molding method using the autoclave apparatus will be described. Hot air is sent into the can by a red heat heater and a fan, and the can is heated until the temperature in the can reaches around 170 ° C. In step A, the vacuum pressure (negative pressure) is continuously pulled at, for example, 300 mmHg until the acrylic temperature reaches a predetermined temperature of about 90 ° C. Then, in Step B exceeding about 90 ° C., the vacuum pressure is increased to 760 mm / Hg, and the vacuum is continued until the acrylic temperature reaches around 170 ° C. of the melting temperature, thereby preventing remaining bubbles. The time for evacuation varies depending on the decorating material. For example, a material that contains moisture and volatile matter has a longer evacuation time, a gentler temperature gradient, and a simultaneous temperature step change.
When the decorating material 2 has a sharp portion, for example, in the case of glass cullet, shell fragments, tile fragments, etc., the negative pressure by the gas suction means is a low negative pressure up to a predetermined temperature of about 90 ° C. of the acrylic resin sheet. For example, 300 mmHg, the acrylic temperature is maintained at a high negative pressure, for example, 760 mmHg until the acrylic temperature reaches around the melting temperature of 170 ° C., or after that, and the negative pressure is lowered at a low temperature up to a predetermined temperature of about 90 ° C. After that, the resin sheet is prevented from cracking at a sharp point, and thereafter, the negative pressure is increased to a high negative pressure as the temperature rises, so that the gas in the pack can be completely exhausted and a product without bubbles can be molded.
In the case where the decorating material 2 does not have a pointed portion, for example, in the case of spheres such as handcraft beads, glass balloons, wire nets, natural materials, etc., the negative pressure by the gas suction means is the melting temperature of the acrylic resin sheet, for example 170 The product is maintained at a high negative pressure, for example, 760 mmHg until the temperature is lowered to 0 ° C., and thereafter, the gas inside the pack is completely removed to form a product without bubbles.

After reaching around 170 ° C. in step C, compressed air is supplied into the can by a compressor, and the pressure is 9.5 kg / cm ² at maximum. Pressurize until about 30 minutes, and then stop heating. In Step D, pressurization is continued until the internal temperature of the can reaches 40 ° C. When the temperature reaches 40 ° C, the pressurization is released.
In this manufacturing method, one or a plurality of decorating materials 2 are fused and integrated between two acrylic resin sheets 1 by heat and pressure in a degassed state, so that there is substantially no bubbles, and the design property The acrylic resin panel P having excellent moldability can be formed. Moreover, also when bending the two acrylic resin sheets 1 on both sides of the decorating material 2, it can be formed by fusing the decorating material inside. As a decorating material, a product with high added value can be produced without causing cracks in the thermoplastic resin even when various shapes of granular materials, wire mesh, Japanese paper, etc. are embedded.
In addition, although the said manufacturing method demonstrated in the case of manufacturing by putting a decorating material between the two thermoplastic resin sheets, it is not restricted to this, Each of the 3 or more sheets of several resin sheet It can also be produced in the same manner with a decorative material in between. In this case, the decorating material put between the sheets is not limited to the same one, but different types can be added to add value by making them appear to overlap each other from the outside.
The acrylic resin panel P can be used for various applications such as displays, display cases, lighting covers, shelves, top plates, partitions, decorative columns with light sources, decorative wall surfaces, monuments, reception counters, etc. .

  In addition, this invention is not limited to the said embodiment, A various form can be implemented in the range which does not deviate from the summary of this invention.

It is a partially broken top view of the thermoplastic resin panel which embedded the glass cullet of this invention. (A) is sectional drawing which shows a thermoplastic resin sheet and a glass cullet, (b) is sectional drawing of the shape | molded thermoplastic resin panel. It is a partially broken top view of the thermoplastic resin panel which embedded the metal mesh. (A) is sectional drawing which shows a thermoplastic resin sheet and a wire net, (b) is sectional drawing of the shape | molded thermoplastic resin panel. It is a schematic front view which shows the state before gas suction at the process of preparing the thermoplastic resin sheet and decorating material 2 of this invention. It is a schematic front view which shows the state after the gas suction. It is a principal part expanded sectional view of the shaping | molding apparatus of the step of A of FIG. It is a principal part expanded sectional view of the shaping | molding apparatus of the same B step. It is a principal part expanded sectional view of the shaping | molding apparatus of the stage of said C-D. It is the schematic side view with which the said shaping | molding apparatus was equipped in the autoclave apparatus. FIG. It is a graph which shows the relationship between time, temperature, can internal pressure, and negative pressure.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Thermoplastic resin sheet 2 Decorating material 3 Flat plate member 4 Base member 5 Sheet material 6 Dam 7 Release film 8 Buffer material 9 Storage body 10 Vacuum port 11 Adhesive material 12 Thermocouple 20 Autoclave device 21 Can body 22 Fan motor 23 Fan 24 Red Heater 26 Vacuum Nozzle 27 Compressor 29 Vacuum Pump K Gas P Thermoplastic Resin Panel S Composite Laminate S1 Resin Laminate

Claims (13)

Heat composed of a plurality of laminated thermoplastic resin sheets and one or a plurality of decorating materials disposed between the plurality of thermoplastic resin sheets, and integrated by heating and pressing without using an adhesive The resin panel is substantially free of bubbles between the plurality of resin sheets, and the decorating material is made of a material having a melting temperature higher than the melting temperature of the resin sheet. And is embedded in the panel in a state where air bubbles are not substantially present at the periphery thereof, and the resin panel has a substantially uniform thickness including the decorative material embedded portion. A thermoplastic resin panel characterized by being made. The thermoplastic resin panel according to claim 1, wherein the thermoplastic resin sheet is transparent or translucent. The thermoplastic resin panel according to claim 1, wherein the decorating material is a granular body. The particulate material is at least one selected from the group consisting of glass cullet, resin pellets, sand, stone, earth, beads, glass balloons, shell fragments, tile fragments, and inorganic ceramic materials. The thermoplastic resin panel described in 1. The thermoplastic resin panel according to claim 1 or 2, wherein the decorating material is at least one selected from the group consisting of wire mesh, Japanese paper, cloth, nonwoven fabric, leaves, and flowers. The thermoplastic resin panel according to any one of claims 1 to 5, wherein a thickness of each of the upper and lower resin portions in the decorative material embedded portion of the resin panel is about 1 mm or more. A step of preparing a plurality of thermoplastic resin sheets, a step of preparing one or a plurality of decorating materials formed in a material that does not deform at the melting temperature of the material for forming the thermoplastic resin sheet, and the upper portion And a flat plate member having a melting temperature higher than that of the thermoplastic resin sheet forming material and not compatible with the forming material, and a plurality of resin sheets are laminated between the two flat plate members. And a step of preparing a composite laminate in which a decorating material is disposed between the two, a step of storing and sealing the composite laminate in the storage body, and connecting the gas suction means to the storage body to remove the storage body. In the gas state, the composite laminate is heated and pressurized to a temperature not lower than the melting temperature of the thermoplastic resin sheet forming material and not higher than the melting temperature of the decorating material by means of heat and pressure, and the plurality of sheets Resin sheet Method for producing a thermoplastic resin panel; and a resin sheet integral step of burying the decorative material with melted and integrated. In the composite laminate preparation step, a surface portion is formed between a peripheral portion of the upper and lower flat plate members and a peripheral portion of the plurality of resin sheet laminates by a material that is not compatible with the thermoplastic resin sheet forming material. The method for producing a thermoplastic resin panel according to claim 7, wherein a molten resin outflow inhibiting member formed with a resin is disposed. The method for manufacturing a thermoplastic resin panel according to claim 8, wherein the thickness of the molten resin outflow inhibiting member is substantially the same as or slightly thinner than the sum of the thicknesses of the plurality of thermoplastic resin sheets. The step of storing and sealing the composite laminate in a storage body uses a base member and a sheet material sealed on the upper surface as the storage body, and uses a breathable sheet on the lower surface and side surfaces of the composite laminate. The encapsulated material is placed on the base member, and the sheet material is sealed to the base member in a state where the entire upper surface of the composite laminate including the air-permeable sheet is encapsulated. The method for producing a thermoplastic resin panel according to any one of claims 7 to 9, wherein the body is sealed. The method for producing a thermoplastic resin panel according to claim 10, wherein a buffer material is interposed between the sheet material and the composite laminate in the step of housing and sealing the composite laminate. In the resin sheet integration step, in the heating process until the composite laminate reaches a predetermined temperature not higher than the melting temperature of the thermoplastic resin sheet, the inside of the storage body is depressurized to a predetermined degree of decompression, and the composite laminate is 12. The method for manufacturing a thermoplastic resin panel according to claim 7, wherein after the temperature reaches the predetermined temperature, the inside of the housing is depressurized to a degree of depressurization higher than the predetermined depressurization degree. In the resin sheet integration step, in the heating process until the composite laminate reaches a predetermined temperature not higher than the melting temperature of the thermoplastic resin sheet, the inside of the storage body is depressurized to a predetermined degree of decompression, and the composite laminate is After the temperature reaches the predetermined temperature, the storage body is depressurized to a degree of depressurization higher than the predetermined depressurization degree, and the composite laminate is heated to a temperature equal to or higher than the melting temperature of the thermoplastic resin sheet. The manufacturing method of the thermoplastic resin panel in any one of 7 thru | or 11.

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