JP2011020359A - Apparatus and method for manufacturing synthetic resin sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve stability and recyclability of identification information when the identification information such as characters is provided on the surface of a protrusion in a synthetic resin sheet in which many protrusions are formed. <P>SOLUTION: A first sheet 11 which has a melting point or above is supplied to a forming roll 22 having a constitution in which a concave portion 220 corresponding to a protrusion is formed on the outer peripheral surface, and air can be suctioned from a suction opening provided on a lid member arranged at the bottom of the concave portion 220. A protrusion is formed in the first sheet 11 on the outer peripheral surface of the molding roll 22 by suctioning air from the suction opening. On the surface of the lid member, there is formed the visible identification information. When suctioning the first sheet 11, the first sheet 11 is pressed to the surface of the lid member 221, and the identification information formed on the lid member 221 is transcribed to the first sheet 11. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an apparatus and a method for manufacturing a synthetic resin sheet on which a large number of protrusions are formed.

  Conventionally, it is possible to provide arbitrary characters, designs, etc. by printing on the surface of a bubble sheet formed by bonding a flat sheet to a concavo-convex sheet made of synthetic resin on which a large number of protrusions are formed to form a bubble portion. It has been proposed (see Patent Document 1).

JP 2002-177123 A

  However, since a non-polar polyolefin-based resin such as polyethylene or polypropylene is frequently used as the material for the bubble sheet, there is a problem that the fixability of the ink used for printing on the surface of the bubble sheet is extremely poor. To deal with such problems, it is conceivable to modify the surface of the bubble sheet by corona treatment to impart polarity to the bubble sheet, but the problem of ink fixability cannot be solved completely.

  In addition, when printing on a flexible material, it is necessary to use an ink containing a component such as vinyl chloride in order to improve the fixability of the ink. As described above, when a vinyl chloride ink is used, it is difficult to separate the polyolefin bubble sheet and the vinyl chloride ink, and there is a problem in terms of recyclability.

  In view of the above points, the present invention aims to improve the stability and recyclability of identification information when providing identification information such as characters on the surface of the projection of a synthetic resin sheet on which a large number of projections are formed. To do.

In order to achieve the above object, according to the first aspect of the present invention, there is provided a first sheet supply means (20) for supplying a first sheet (11) made of a synthetic resin having a melting point or higher, and the protrusion on the outer peripheral surface. A concave portion (220) corresponding to the portion (11a) is formed, a lid member (221) is disposed at the bottom of the concave portion (220), and air is sucked from a suction port provided in the lid member (221). And a forming roll (22) capable of forming the protrusion (11a) on the first sheet (11) supplied from the first sheet supply means (20),
Visible identification information is formed on the surface of the lid member (221), and when the first sheet (11) is sucked by the recess (220) of the molding roll (22), the lid The first sheet (11) is pressed against the surface of the member (221), and the identification information is transferred to the first sheet (11).

  Thereby, identification information can be provided in the protrusion part (11a) of a 1st sheet | seat (11). According to the configuration of the present invention, identification information is provided on the melted first sheet (11) itself when the protrusion (11a) is formed on the first sheet (11). For this reason, unlike the case where the characters of the first sheet (11) are printed and provided, the problem of fixability does not occur, and the identification information can be stably provided on the first sheet (11). Further, since the identification information is integrally provided on the first sheet (11) itself, it is not necessary to separate the identification information portion when discarding, and the recyclability is excellent.

  In the second aspect of the invention, the second sheet (12) heated to the melting point or higher is supplied to the opening-side surface of the protrusion (11a) in the first sheet (11). An external force is applied so as to press the sheet supply means (21) and the second sheet (12) against the first sheet (11) to join the first sheet (11) and the second sheet (12). A plurality of bubble portions (13) in which a gas is sealed between the protrusions (11a) of the first sheet (11) and the second sheet (12). It is characterized by that.

  Thereby, when forming the projection part (11a) which comprises a bubble part (13), identification information can be provided in a projection part (11a).

  According to a third aspect of the present invention, the second sheet (12) that supplies the second sheet (12) heated to the melting point or more to the protrusion tip side of the protrusion (11a) in the first sheet (11). Supply means (21) and a pressing force for applying an external force so as to press the second sheet (12) against the first sheet (11) and joining the first sheet (11) and the second sheet (12) And means (23).

  In the present invention, identification information can be provided even in a laminated sheet having no such bubble portion.

  According to a fourth aspect of the present invention, the lid member (221) has a disk shape in which a notch (221a) functioning as the suction port is formed in an outer peripheral portion, and faces the recess (220). The identification information is formed on a plate surface.

  Thus, by providing the notch part (221a) in the outer peripheral part of the cover member (221), the area near the center of the cover member (221) becomes large, and identification information can be easily provided.

  In the invention described in claim 5, the lid member (221) is characterized in that the periphery of the identification information on the plate surface facing the recess (220) is formed in an uneven shape.

  Thereby, when the identification information of the lid member (221) is transferred to the projection (11a) of the first sheet (11), the identification information portion of the projection (11a) becomes smooth, and the lid member 221 Irregularities are given to the portions corresponding to the irregularities. For this reason, the part of the identification information appears to be raised at the protrusion (11a) of the first sheet (11).

  The inventions according to claims 6 to 10 specify the invention according to the manufacturing apparatus according to claims 1 to 5 as a manufacturing method, and have the same effects as the inventions according to claims 1 to 3. Obtainable.

  In addition, the code | symbol in the bracket | parenthesis of each said means shows the correspondence with the specific means as described in embodiment mentioned later.

It is a perspective view of a synthetic resin laminate sheet. It is a conceptual diagram which shows the main components of a laminated sheet manufacturing apparatus. It is sectional drawing which expanded the forming roll partially. It is a top view of a lid member. It is process drawing which shows the process in which a projection part is formed in a 1st sheet | seat. It is a top view which shows the modification of a cover member. It is a top view which shows the modification of a cover member. It is a perspective view which shows the modification of a lamination sheet.

  Hereinafter, embodiments of the present invention will be described with reference to FIGS. FIG. 1 is a perspective view of a synthetic resin laminated sheet 10 showing an embodiment of the present invention.

  As shown in FIG. 1, the laminated sheet 10 of the present embodiment includes a first sheet (uneven sheet) 11 having a large number of uneven protrusions 11 a and a flat second sheet (flat sheet) 12. It has a two-layer structure. In the first sheet 11 of the present embodiment, a large number of columnar protrusions 11 a are embossed, and the second sheet 12 is joined to the protrusion opening side of the first sheet 11. Thereby, the lamination sheet 10 of this embodiment is comprised as a bubble sheet in which the bubble part 13 by which air was sealed was formed between the uneven | corrugated 1st sheet | seat 11 and the flat 2nd sheet | seat 12. FIG. .

In the present embodiment, a polyolefin resin such as polyethylene or polypropylene is used as the synthetic resin constituting the laminated sheet 10, and it is desirable to use polyethylene when used for applications that require flexibility. Moreover, when the use requires the softness | flexibility like a packaging material for the synthetic resin laminated sheet 10, it is desirable that the weight per unit area (weight per unit area) is 20 to 300 g / m ² .

  As shown in FIG. 1, characters are provided on the surface of the bubble portion 13 of the laminated sheet 10. In the present embodiment, the characters are formed so as to rise (project) in a flat portion at the top of the bubble portion 13. In the example shown in FIG. 1, characters formed of “> PE <” indicating “polyethylene” which is a material of the laminated sheet 10 are provided in the bubble portion 13. As will be described later, when the first sheet 11 is vacuum-sucked by the forming roll 22 to form the protrusion 11a, characters are provided on the surface of the protrusion 11a.

  FIG. 2 shows an example of main components of a laminated sheet manufacturing apparatus that manufactures the laminated sheet 10 of the present embodiment. As shown in FIG. 2, two synthetic resin sheet supply units 20 and 21 are provided. Each of these sheet supply units 20 and 21 is composed of a flat die connected to an extruder (not shown). Then, the melted first sheet 11 is supplied from the first sheet supply unit 20, and the melted second sheet 12 is supplied from the second sheet supply unit 21. Further, the laminated sheet manufacturing apparatus is provided with a forming roll 22, a pressure roll 23, and a peeling roll 24. The outer peripheral surface of the forming roll 22 is provided with a large number of recesses for forming an uneven pattern on the first sheet 11, and these recesses have the same configuration.

  FIG. 3 is a cross-sectional view in which the forming roll 22 is partially enlarged. In FIG. 3, the upper side is the outer peripheral surface side of the forming roll 22. As shown in FIG. 3, a recess 220 is formed on the outer peripheral surface of the forming roll 22. The concave portion 220 has a shape corresponding to the bubble portion 13 of the laminated sheet 10 and is configured as a cylindrical recess. A large number of the recesses 220 are arranged corresponding to the arrangement pattern of the protrusions 11 a formed on the first sheet 11. A lid member 221 is provided at the bottom of the recess 220. The lid member 221 is configured as a separate member from the forming roll 22. In this embodiment, the lid member 221 is attached to the recess 220 by fitting, and can be removed from the recess 220 and replaced. The lid member 221 can be fixed to the recess 220 by fitting, or can be fixed to the recess 220 by screwing by configuring the lid member 221 itself as a screw. Below the lid member 221, a suction passage 222 communicating with a vacuum pump (not shown) is provided.

  FIG. 4 is a plan view of the lid member 221. The lid member 221 has a disk shape, and is provided with a notch 221a on the outer peripheral portion so as to allow the recess 220 and the suction passage 222 to communicate with each other. The notch 221a is formed in an intermittent ring formed by a circle concentric with the outer periphery of the lid member 221. In the example shown in FIG. 4, four notches 221a are provided. For this reason, the cover member 221 has four protrusions formed on the outer peripheral edge thereof, and is supported on the bottom of the recess 220 by these protrusions. Since the recess 220 and the suction passage 222 communicate with each other via the notch 221a, the notch 221a functions as a suction port for the recess 220.

  Characters are formed on the surface of the lid member 221 of the present embodiment. This character is in a state of being recessed with respect to the surface of the lid member 221, and is in a state of being engraved on the surface of the lid member 221. The characters provided on the surface of the lid member 221 are for transferring to the protrusions 11 a of the first sheet 11 when the laminated sheet 10 is formed. For this reason, the character pattern is obtained by horizontally inverting the character provided on the surface of the laminated sheet 10, and in the example illustrated in FIG. When the first sheet 11 is vacuum-sucked by the concave portion 220 of the forming roll 22, the protrusion 11 a of the first sheet 11 is strongly pressed near the center of the lid member 221, so that characters are provided near the center of the lid member 221. It is desirable. In addition, the character provided on the surface of the cover member 221 shows a specific example of the identification information of the present invention.

  Next, the manufacturing method of the lamination sheet 10 using the manufacturing apparatus of FIG. 2 is demonstrated. The first sheet 11 in a plasticized state at a high temperature supplied from the first sheet supply unit 20 is sucked in vacuum on the forming roll 22, thereby forming an uneven pattern constituting the bubble part 13.

  Here, the formation of the protruding portion 11a of the first sheet 11 will be described with reference to FIG. FIG. 5 is a process diagram illustrating a process in which the protrusion 11 a is formed on the first sheet 11.

  First, the first sheet 11 before the formation of the protruding portion 11a supplied to the forming roll 22 is vacuum-sucked by the concave portion 220 (FIG. 5A). Thereby, the site | part corresponding to the recessed part 220 in the 1st sheet | seat 11 is drawn in into the recessed part 220, and is formed as the projection part 11a (FIG.5 (b)). When the first sheet 11 is further vacuumed, the tip end portion of the protrusion 11a of the first sheet 11 is pressed against the lid member 221 (FIG. 5C). Thereby, the character stamped on the lid member 221 is inverted and transferred to the protrusion 11a of the first sheet 11 to form a desired character.

  Then, the high temperature 2nd sheet | seat 12 supplied from the 2nd sheet | seat supply part 21 is pressed against the 1st sheet | seat 11 in which many protrusion parts 11a were formed with the press roll 23, and the peeling roll 24 is used after that. Is peeled off. Thereby, the 1st sheet | seat 11 and the 2nd sheet | seat 12 are fuse | melted and joined, and the lamination sheet 10 by which gas was enclosed with the bubble part 13 is shape | molded.

  Through the above steps, characters can be provided in the bubble portion 13 of the laminated sheet 10. According to the configuration of the present embodiment, when the laminated sheet 10 is formed, characters are provided on the first sheet 11 itself in a molten state. For this reason, unlike the case where the characters of the laminated sheet 10 are printed and provided, the problem of fixability does not occur, and the characters can be stably provided on the laminated sheet 10.

  Further, according to the configuration of the present embodiment, since the characters are integrally provided on the first sheet 11 itself of the laminated sheet 10, there is no need to separate the character portions when discarding, and the recyclability is also improved. Are better. Furthermore, when the character which shows the material of the lamination sheet 10 is provided, when discarding, it can isolate | separate easily.

  Further, according to the configuration of the present embodiment, by replacing the lid member 221 disposed in the concave portion 220 of the forming roll 22 with the lid member 221 on which characters of different patterns are engraved, the characters provided on the laminated sheet 10 can be easily obtained. Can be changed.

  Further, since the lid member 221 of the present embodiment is provided with a notch 221a that functions as a suction port at the periphery, when the first sheet 11 supplied to the surface of the forming roll 22 is sucked by the recess 220, Air present in the recess 220 is sucked from the periphery. For this reason, in the protrusion part 11a of the first sheet 11, the extension toward the peripheral edge proceeds earlier than the vicinity of the center is solidified, and the entire protrusion part 11a can be sucked relatively uniformly. Can be made as uniform as possible.

  Further, by providing a cutout portion 221 a that functions as a suction port on the outer peripheral portion like the lid member 221 of the present embodiment, the area near the center of the lid member 221 increases, and the bubble portion 13 of the laminated sheet 10 Characters (identification information) for transferring can be easily provided.

  In addition, according to the configuration of the present embodiment, it is possible to provide characters (identification information) on the leading end side of the protrusions 11a of the first sheet 11 where it is difficult to provide characters by printing (identification information).

(Other embodiments)
As mentioned above, although the Example of this invention was described, this invention is not limited to this, Unless it deviates from the range described in each claim, it is not limited to the description word of each claim, and those skilled in the art Improvements based on the knowledge that a person skilled in the art normally has can be added as appropriate to the extent that they can be easily replaced.

  For example, in the above-described embodiment, the specific information “> PE <” has been described as the identification information provided in the bubble portion 13 of the laminated sheet 10. However, the identification information is not limited to this and may be any meaning. Often, any letter, number, symbol, design, etc. can be used.

  Moreover, in the said embodiment, although it comprised so that the character (identification information) of the same pattern might be provided in all the bubble parts 13 of the lamination sheet 10, a different pattern is formed in the cover member 221 of each recessed part 220 of the forming roll 22. FIG. Thus, different characters may be provided in each bubble portion 13. For example, the characters “>”, “P”, “E”, and “<” may be provided in each of the four bubble portions 13 arranged in a line.

  Moreover, in the said embodiment, although it comprised so that a character (identification information) might be provided in all the bubble parts 13 of the lamination sheet 10, not only this but identification information is given only to the one part bubble part 13 of the lamination sheet 10. You may comprise so that it may provide.

  Moreover, in the said embodiment, although the cover member 221 which provided the four notches 221a in the outer periphery was used, the cover member 221 should just be provided with the notch part 221a used as a suction port, and the cover member 221 is different. It is good also as a shape. For example, as shown in FIG. 6 (a), a large number of notches 221a may be provided around the lid member 221, or as shown in FIG. 6 (b), a semicircular shape is formed around the lid member 221. A notch 221a may be provided.

  Moreover, in the said embodiment, although the character (identification information) of the state (engraved state) dented in the cover member 221 was formed, not only this but the identification information provided in the cover member 221 is contacted with the 1st sheet | seat 11. It is only necessary that the transfer can be performed. For example, identification information in a state of rising from the surface of the lid member 221 may be formed. In this case, characters provided on the laminated sheet 10 are indented. Alternatively, the identification information may be formed as a through hole in the lid member 221.

  Further, in addition to the configuration of the lid member 221 of the above embodiment, a portion other than the portion where the identification information is provided is formed in an uneven shape on the surface of the lid member 221 where the protrusion 11a of the first sheet 11 contacts. Also good. For example, as shown in FIG. 7A, the surface of the lid member 221 is satin-finished, or as shown in FIG. 7B, a lattice pattern is provided on the surface of the lid member 221, etc. Asperities can be provided on the surface of the substrate. As a result, when the identification information of the lid member 221 is transferred to the protrusion 11a of the first sheet 11, the portion of the identification information of the protrusion 11a becomes smooth and the periphery thereof (the part corresponding to the unevenness of the lid member 221). ) Is uneven. For this reason, in the projection part 11a of the 1st sheet | seat 11, the part of identification information comes to appear floating.

Moreover, although the said embodiment demonstrated the example using the laminated sheet 10 which has a softness | flexibility, this invention is applicable also to the laminated sheet which has bending rigidity. A laminated sheet having such a bending composition is configured to be thick, and the weight per unit area (weight per unit area) is about 300 to 3000 g / m ² .

  Moreover, although the said embodiment demonstrated the example using the lamination sheet 10 in which the bubble part 13 was provided by joining the 2nd sheet | seat 12 to the opening side of the projection part 11a of the 1st sheet | seat 11, this invention is described. The present invention is also applicable to the laminated sheet 10 that does not include the bubble portion 13. Specifically, as shown in FIGS. 8A and 8B, the laminated sheet 10 can be configured to join the second sheet 12 to the tip end side of the protruding portion of the first sheet 11. It is desirable that the laminated sheet 10 not having such a bubble portion 13 is configured as a laminated sheet having the above-described thickness and bending rigidity. In the example shown in FIG. 7, a large number of recesses are formed on the surface of the laminated sheet 11 (the lower surface in FIG. 7) by the protrusions 11 a of the first sheet 11. In this case, identification information is provided on the bottom surface of the concave portion of the laminated sheet 10.

  Moreover, although the said embodiment demonstrated the example using the lamination sheet 10 which joined the 2nd sheet | seat 12 to the opening side of the projection part 11a of the 1st sheet | seat 11, this invention is not limited to this, and this invention has many projection parts. The present invention can be applied only to the first sheet 11 on which 11a is formed. When using only such a 1st sheet | seat 11, it is desirable to comprise as a sheet | seat which has the above-mentioned thickness and bending rigidity.

  Moreover, in the said embodiment, although the recessed part 220 of the forming roll 22 was made into the column shape, and the protrusion part 11a of the 1st sheet | seat 11 was comprised in the column shape, it is not restricted to this, The recessed part 220 of the forming roll 22 and the 1st sheet | seat 11 are comprised. The protrusion 11a may have a shape other than the cylindrical shape. For example, the concave portion 220 of the forming roll 22 and the protruding portion 11a of the first sheet 11 can be configured as irregular column shapes other than a circle such as an ellipse, a polygon, and a heart shape.

  Moreover, although the said embodiment demonstrated the example which provided the one cover member 221 in the recessed part 220 of the forming roll 22, it is not restricted to this, Even if it provides the several cover member 221 in the recessed part 220 of the forming roll 22 Good.

  DESCRIPTION OF SYMBOLS 10 ... Laminated sheet, 11 ... 1st sheet, 12 ... 2nd sheet, 13 ... Bubble part, 22 ... Molding roll, 220 ... Recessed part, 221 ... Lid member.

Claims (10)

First sheet supply means (20) for supplying a first sheet (11) made of synthetic resin having a melting point or higher;
A concave portion (220) corresponding to the protruding portion (11a) is formed on the outer peripheral surface, a lid member (221) is disposed at the bottom of the concave portion (220), and a suction port provided in the lid member (221). A molding roll (22) capable of forming the protrusion (11a) on the first sheet (11) supplied from the first sheet supply means (20) by sucking air;
Visible identification information is formed on the surface of the lid member (221), and when the first sheet (11) is sucked by the recess (220) of the molding roll (22), the lid The synthetic resin sheet manufacturing apparatus, wherein the first sheet (11) is pressed against a surface of a member (221), and the identification information is transferred to the first sheet (11). Second sheet supply means (21) for supplying the second sheet (12) heated to the melting point or higher to the opening side surface of the protrusion (11a) in the first sheet (11);
An external force is applied so as to press the second sheet (12) against the first sheet (11), and pressing means (23) for joining the first sheet (11) and the second sheet (12) is provided. ,
The plurality of bubble portions (13) in which a gas is sealed are formed between the protrusions (11a) of the first sheet (11) and the second sheet (12). The manufacturing apparatus of the synthetic resin sheet | seat of description. Second sheet supply means (21) for supplying the second sheet (12) heated to a melting point or higher to the protrusion tip side of the protrusion (11a) in the first sheet (11);
An external force is applied so as to press the second sheet (12) against the first sheet (11), and pressing means (23) for joining the first sheet (11) and the second sheet (12) is provided. The synthetic resin sheet manufacturing apparatus according to claim 1.   The lid member (221) has a disk shape in which a notch (221a) functioning as the suction port is formed on the outer peripheral portion, and the identification information is formed on a plate surface facing the recess (220). The synthetic resin sheet manufacturing apparatus according to any one of claims 1 to 3, wherein   The said cover member (221) is comprised by the uneven | corrugated shape of the circumference | surroundings of the said identification information in the plate surface facing the said recessed part (220), The one of Claim 1 thru | or 4 characterized by the above-mentioned. Synthetic resin sheet manufacturing equipment. A recess (220) corresponding to the protrusion (11a) is formed on the outer peripheral surface, and air can be sucked from a suction port provided in a lid member (221) arranged at the bottom of the recess (220). A first sheet supply step for supplying the first sheet (11) having a melting point or higher to the forming roll (22);
A protrusion that sucks air from the suction port toward the inside of the forming roll (22) to form the protrusion (11a) on the first sheet (11) on the outer peripheral surface of the forming roll (22). Part forming step,
Visible identification information is formed on the surface of the lid member (221), and when the first sheet (11) is sucked in the protrusion forming step, the surface of the lid member (221) is formed. The first sheet (11) is pressed against the cover member (221), and the identification information formed on the lid member (221) is transferred to the first sheet (11). A second sheet supplying step of supplying the second sheet (12) heated to a melting point or higher to the opening side surface of the protrusion (11a) in the first sheet (11);
An external force is applied so as to press the second sheet (12) against the first sheet (11) by the first pressurizing means (23), and the first sheet (11) and the second sheet (12) are joined. And a joining process to
The plurality of bubble portions (13) in which a gas is sealed are formed between the protrusions (11a) of the first sheet (11) and the second sheet (12). The manufacturing method of the synthetic resin sheet | seat of description. A second sheet supply step of supplying the second sheet (12) heated to a melting point or higher to the protrusion tip end side of the protrusion (11a) in the first sheet (11);
An external force is applied so as to press the second sheet (12) against the first sheet (11), and a joining step of joining the first sheet (11) and the second sheet (12) is provided. The synthetic resin sheet manufacturing apparatus according to claim 6.   The lid member (221) has a disk shape in which a notch (221a) functioning as the suction port is formed on the outer peripheral portion, and the identification information is formed on a plate surface facing the recess (220). The method for producing a synthetic resin sheet according to any one of claims 6 to 8.   10. The lid member (221) according to any one of claims 6 to 9, wherein the periphery of the identification information on the plate surface facing the recess (220) is configured to be uneven. A method for producing a synthetic resin sheet.

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