JP2013006310A - Laminate production apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminate production apparatus in which the facility cost of rollers for forming an uneven pattern can be reduced, and rollers for forming the uneven pattern can be replaced easily in a short time.SOLUTION: The laminate production apparatus includes a back-up roller, a nip roller, and a chill roller in this order in the direction in which a substrate passes. A laminate is produced by drooping a melted thermoplastic resin from a T-die via an extruder to form a resin film, and passing the resin film and a substrate between the back-up roller and the nip roller, and between the nip roller and the chill roller. The nip roller has an uneven pattern formed on the outer circumferential surface thereof, and the nip roller has a diameter smaller than that of the chill roller and is disposed detachably.

Description

  The present invention provides a laminate manufacturing method in which a substrate mainly composed of a plastic film and a resin film formed by extruding a thermoplastic resin into a film shape from a T-die are laminated, and at the same time, a concavo-convex pattern is formed on the surface of the laminated laminate. Relates to the device.

  Conventionally, a thermoplastic resin film melt-extruded from a T-die through an extruder is overlapped with a substrate such as a plastic film, metal foil, synthetic paper, paper, etc. and passed between a chill roll (cooling roll) and a nip roll. It is laminated | stacked by pressing sometimes, and it cools with the chill roll, and the laminated body is manufactured.

  In this case, depending on the performance required for the laminated laminate, various uneven patterns are formed by shaping the uneven pattern formed on the surface of the chill roll on the surface of the laminate, In general, chill rolls are prepared with multiple types of concavo-convex patterns formed on the surface in order to satisfy the performance required for the laminate, such as slipperiness, blocking properties, transparency, and design properties. In addition, a chill roll having an optimal concavo-convex pattern is selected and used from a plurality of chill rolls in consideration of the type of base material, the type of thermoplastic resin to be extruded, and the like. In addition, a chill roll having a special design, logo, or concavo-convex pattern such as a hologram may be used in order to enhance design and brand.

  In order to increase the cooling efficiency of the extruded thermoplastic resin film, a chill roll having a diameter of about 600 mmφ is usually used. Since the chill roll is heavy, it is troublesome to handle and labor-intensive.

  When changing the concavo-convex pattern of the laminate, it is necessary to replace the chill roll having a desired concavo-convex pattern each time. When exchanging the chill roll, first remove the timing belt etc. that is transmitting the drive to the old chill roll, remove the bolt and remove the bearing cover, lift and remove the old chill roll with a crane etc., replace it with a chill roll with the desired uneven pattern, Install in reverse order. These chill roll replacement operations are time-consuming and have problems of excessive replacement time and labor load.

  On the other hand, as a solution to such a problem, an extrusion laminator cooling roll support device for an extrusion laminator in which a cooling roll (chill roll) bearing to be cooled is configured only by a lower support is known. (For example, refer to Patent Document 1).

  The chill roll replacement time was shortened by the support device of Patent Document 1. However, it is necessary to prepare a plurality of chill rolls, and there is a problem that the chill rolls are expensive and equipment costs increase. Further, since chill rolls are heavy, handling is troublesome and there is a limit to shortening the replacement time, and it is actually not sufficient.

  In addition, a metal plate with fine irregularities made up of line-shaped pattern groups is mounted on a cooling roll (chill roll), and a molten synthetic resin extruded from a T-shaped die is extruded onto a cooling roll mounted with a metal plate. A method for producing a sheet having a concavo-convex pattern for forming a fine concavo-convex pattern consisting of a line-shaped pattern group on a resin surface at the same time as cooling to form a film is disclosed (for example, see Patent Document 2).

  However, the technique disclosed in Patent Document 2 requires a skill to mount the metal plate without distortion, and there is a problem that it takes time and effort to mount the metal plate unless it is an expert, and a problem that a fitted joint is generated. There is a demand for development of a laminate manufacturing apparatus that requires a short chill roll replacement time and a low equipment cost.

Japanese Utility Model Publication No. 5-7436 JP 2007-118274 A

  In view of the above problems, the present inventor has found that the chill roll replacement work can be reduced by forming a concavo-convex pattern on the nip roll and making the nip roll detachable as a result of diligent research. That is, the objective of this invention is providing the laminated body manufacturing apparatus which can reduce the installation cost of the roll which forms a concavo-convex pattern, can replace | exchange the roll which forms a concavo-convex pattern easily, and can be replaced in a short time.

  In order to achieve the above object, the present invention according to claim 1 is directed to the heat in which a backup roll, a nip roll, and a chill roll are arranged in this order in the direction in which the substrate passes, and is melted from a T die through an extruder. An apparatus for manufacturing a laminate by passing a resin film formed by dripping a plastic resin and a base material between a backup roll and a nip roll or between a nip roll and a chill roll, on the outer peripheral surface of the nip roll An apparatus for manufacturing a laminate, wherein an uneven pattern is formed, and the diameter of the nip roll is smaller than the diameter of the chill roll and is detachable.

  The present invention described in claim 2 is the laminate manufacturing apparatus according to claim 1, wherein the diameter of the chill roll is 400 to 800 mmφ, and the diameter of the nip roll is 120 to 250 mmφ. is there.

  Moreover, this invention of Claim 3 is a laminated body manufacturing apparatus of Claim 1 or 2 WHEREIN: The said extruder is movable in parallel with the direction through which a base material passes, It is characterized by the above-mentioned. .

  Moreover, this invention of Claim 4 is a laminated body manufacturing apparatus in any one of Claims 1-3, The center of the said backup roll, the said nip roll, and the said chill roll is located substantially horizontal, It is characterized by the above-mentioned. Is.

  In the laminate manufacturing apparatus of the present invention, a backup roll, a nip roll, and a chill roll are arranged in this order in the direction in which the substrate passes, and a resin film and a base formed by dripping a thermoplastic resin melted from a T die through an extruder. Is a device for producing a laminate by passing a material between a backup roll and a nip roll or between a nip roll and a chill roll, wherein an uneven pattern is formed on the outer peripheral surface of the nip roll, and the diameter of the nip roll However, when changing the concavo-convex pattern, only the nip roll is replaced without changing the chill roll as in the prior art, and the nip roll is a chill roll. Compared to, the diameter is small, handling is easy, and the replacement time is shortened. In addition, the nip roll has a smaller diameter and is less expensive than the chill roll, so that the equipment cost can be reduced. Furthermore, since the replacement frequency of the chill roll is reduced, the labor load is reduced. Also, the thermoplastic resin melted from the T-die is suspended between the backup roll and the nip roll to form a resin film, and the substrate and the resin film are passed between the backup roll and the nip roll, pressed, and cooled by the chill roll. By making it, it can laminate | stack simultaneously with forming an uneven | corrugated pattern in the surface of a resin film, or both surfaces of a resin film and a base material. Furthermore, the thermoplastic resin melted from the T-die is suspended between the nip roll and the chill roll to form a resin film, and the substrate and the resin film are passed between the nip roll and the chill roll, pressed, and cooled by the chill roll. Thus, it is possible to form a concavo-convex pattern on the surface of the base material or both surfaces of the base material and the resin film and to laminate them simultaneously.

  Further, in the present invention described in claim 2, since the diameter of the chill roll is 400 to 800 mmφ and the diameter of the nip roll is 120 to 250 mmφ, the nip roll can be reduced in weight and handled more easily.

  Further, in the third aspect of the present invention, since the extruder can move in a direction parallel to the direction in which the substrate passes, the thermoplastic resin melted from the T-die by moving the extruder is transferred to the backup roll and the nip roll. Or a nip roll and a chill roll to form a resin film, which can be easily laminated with the base material.

It is the schematic which shows the laminated body manufacturing apparatus which concerns on this invention. It is the schematic which mounted the laminated body manufacturing apparatus which concerns on this invention in the lamination part of the extrusion laminator. It is the schematic which shows the other example of the laminated body manufacturing method using the laminated body manufacturing apparatus which concerns on this invention.

The above-described present invention will be described in detail below with reference to the drawings.
FIG. 1 is a schematic diagram showing a laminate manufacturing apparatus according to the present invention, FIG. 2 is a schematic diagram in which the laminate manufacturing apparatus according to the present invention is mounted on a laminate portion of an extrusion laminator, and FIG. 3 is a laminate manufacturing according to the present invention. It is the schematic which shows the other example of the laminated body manufacturing method using an apparatus, In the figure, 1 is a base material, 2 is a resin film, 3 'is a laminated body which has an uneven | corrugated pattern, 4 is winding 10 Is a backup roll, 11 is a nip roll, 11a is a concavo-convex pattern, 12 is a chill roll, 13 is a T die, 20 is a first paper feeder, 21 is an AC coating device, 22 is a drying device, 23 is a laminating unit, and 24 is winding. Each device is shown.

  FIG. 1 is a schematic view showing a laminated body manufacturing apparatus according to the present invention, and the laminated body manufacturing apparatus is placed on a laminate portion of an extrusion laminator. As shown in FIG. 1, the laminate manufacturing apparatus includes a backup roll 10, a nip roll 11, and a chill roll 12 arranged in this order in a direction in which the base material 1 passes (hereinafter referred to as a web traveling direction), and an extruder (not shown). For producing a laminate 3 having a concavo-convex pattern by passing a resin film 2 formed by dripping a thermoplastic resin melted from a T die 13 and a base material 1 between a backup roll 10 and a nip roll 11. It is.

  The extruder can also be movable in parallel with the web running direction. In that case, the T-die 13 fixedly installed on the extruder moves in parallel with the web running direction together with the extruder. As will be described later, the resin film 2 formed by dripping the thermoplastic resin melted from the T die 13 between the nip roll 11 and the chill roll 12 can be guided by moving to the portion indicated by the broken line in FIG. The laminate 3 ′ (see FIG. 3) can be manufactured by passing the resin film 2 and the substrate 1 between the nip roll 11 and the chill roll 12. In addition, the broken line in a figure shows the moved T die and the resin film, and the code | symbol is abbreviate | omitted.

The chill roll 12 is provided with driving means, and the traveling speed of the base material in the extrusion laminator is synchronized with the peripheral speed of the chill roll 12. The backup roll 10 and the nip roll 11 are provided with a crimping means so that they can be crimped to the chill roll 12 via, for example, an air cylinder. When the laminated body is manufactured by passing the resin film 2 and the base material 1 between the backup roll 10 and the nip roll 11 or between the nip roll 11 and the chill roll 12, the backup is performed via the nip roll 11 by a pressure bonding means. The roll 10 is pressure-bonded to the chill roll 12.
The backup roll 10 and the nip roll 11 do not need to have a driving means. However, when the resin film 2 and the substrate 1 are laminated between the backup roll 10 and the nip roll 11, the backup roll 10 has a driving means (not shown). It is preferable to provide
The backup roll 10, the nip roll 11, and the chill roll 12 have hollow portions (not shown) that communicate with both ends of the roll in the axial direction. For example, water flows from one end of the roll shaft to the other end through the hollow portion. A cooling means for continuously cooling the resin to an appropriate temperature is provided. Furthermore, in order to increase the cooling capacity of the backup roll 10, a cooling roll (not shown) that is crimped to the backup roll 10 can be provided.

  A concavo-convex pattern 11 a is formed on the outer peripheral surface of the nip roll 11, and the diameter of the nip roll 11 is smaller than the diameter of the chill roll 12 and is detachably provided. Then, as shown in FIG. 1, the base material 1 and the resin film 2 are passed between the backup roll 10 and the nip roll 11, and the backup roll 10 is pressure-bonded to the chill roll 12 via the nip roll 11. The concavo-convex pattern 11a formed on the outer peripheral surface is simultaneously molded and laminated on the surface of the resin film 2 or both surfaces of the resin film 2 and the substrate 1, and then the laminate 3 having the concavo-convex pattern is formed on the surface of the chill roll 12. It is cooled to an appropriate temperature while being wound around. The chill roll 12 rotates in the clockwise direction as indicated by an arrow.

  The concavo-convex pattern 11a provided on the surface of the nip roll 11 is not particularly limited. For example, the concavo-convex pattern 11a is provided with a stone pattern, a cloth pattern, a grain pattern, etc., to improve the sliding property and blocking property of the laminate, or It is possible to enhance the design characteristics by applying a concavo-convex pattern such as a hologram, or to improve the brand characteristics by applying character symbols, lines, abstract patterns, or the like.

  The nip roll 11 is formed by coating a synthetic rubber such as ethylene propylene rubber on the outer peripheral surface of an iron core such as stainless steel or steel having a hollow portion, and further, a silicon rubber having heat resistance and releasability on the outer peripheral surface of the synthetic rubber. Is used and the hardness is appropriately adjusted. Examples of a method for producing the concavo-convex pattern 11a on the outer peripheral surface of the nip roll 11 include a laser processing method, a cutting method using a high-speed drill, a method using a hot needle, and the like. It is formed by engraving on rubber.

  In this way, by forming a concavo-convex pattern on the nip roll 11, when switching to an operation that requires a new concavo-convex pattern, there is no need to replace the chill roll 12 as in the prior art, and only the nip roll 11 is replaced. That's fine. Further, since the diameter of the nip roll 11 is smaller than the diameter of the chill roll 12, the nip roll 11 can be reduced in weight, handled easily, and the replacement time is shortened. Furthermore, the nip roll has a smaller diameter than the chill roll, and the equipment cost can be reduced. Further, the diameter of the chill roll 12 is 400 to 800 mmφ, and the diameter of the nip roll 11 is preferably 120 to 250 mmφ. When the diameter of the nip roll 11 exceeds 250 mmφ, the weight increases, handling is troublesome, and the exchange time is also long. In addition, the cost of the nip roll becomes high. If the diameter of the nip roll 11 is less than 120 mmφ, sufficient cooling performance cannot be obtained.

  Further, the arrangement positions of the backup roll 10, the nip roll 11 and the chill roll 12 may be a straight line with a curve or a gradient connecting the centers of the backup roll 10, the nip roll 11 and the chill roll 12, but as shown in FIG. It is preferable to arrange so that it is located in. Because the hanging position of the resin film 2 is not biased toward the backup roll 10 side, the nip roll 11 side, or the chill roll 12 side, the resin film 2 is applied to the contact point between the backup roll 10 and the nip roll 11 or the contact point between the nip roll 11 and the chill roll 12. Since it can hang down, good adhesive strength between the base material 1 and the resin film 2 can be obtained, or the base material 1 does not abnormally extend due to the heat of the resin film 2, so that the quality is good.

  FIG. 2 is a schematic view in which the laminate manufacturing apparatus according to the present invention is mounted on a laminate portion of an extrusion laminator. As shown in FIG. 2, the extrusion laminator includes a first paper feeding device 20 to which a winding 4 in which a base material 1 is wound in a coil shape is rewound, and a base material 1 fed out from the first paper feeding device 20. AC coating device 21 for applying a dilute solution of anchor agent (AC agent), drying device 22 for drying the diluent of AC agent, base material 1 fed from the first paper feed, and thermoplastic resin from the T die A plurality of guide rolls and other accessory devices configured to include a laminating portion 23 for laminating the extruded resin film and a winding device 24 for winding the laminated body 3 having a concavo-convex pattern into a coil shape, and supporting the web between the devices. Is installed.

The laminate part 23 is equipped with a laminate manufacturing apparatus according to the present invention. FIG. 2 shows a nip roll 11 in which a back-up roll 10 and a concavo-convex pattern 11a are formed on the outer peripheral surface in the direction in which the substrate 1 passes. And the chill roll 12 are arranged in this order, and the resin film 2 formed by dripping the thermoplastic resin melted from the T die 13 through the extruder and the base material 1 are passed between the backup roll 10 and the nip roll 11, By pressing the backup roll 10 on the chill roll 12 via the nip roll 11, the uneven pattern 11 a formed on the outer peripheral surface of the nip roll 11 is formed on the surface of the resin film 2 or both surfaces of the resin film 2 and the substrate 1. The laminated body 3 having a concavo-convex pattern is then cooled to an appropriate temperature while being wound around the surface of the chill roll 12, Via a guide roll wound up in the winding device 24 and serves as a winding.
2 illustrates a single laminator having one laminating section 23 having a T-die. It may be a tandem laminator provided with two laminate parts. In the case of a tandem laminator, the laminate part 23 or No. 2 The laminate manufacturing apparatus of the present invention can be mounted on the laminate part. Although not shown, a second paper feeding device is provided, and the other base material from the second paper feeding device is supplied between the backup roll 10 and the nip roll 11 from the chill roll 12 side. One of the supplied base materials 1 can be sandwich-laminated with the resin film 2.

  FIG. 3 is a schematic view showing another example of a laminate manufacturing method using the laminate manufacturing apparatus according to the present invention, in which the extruder is moved in parallel with the web running direction, and melted from the T die through the extruder. The formed thermoplastic resin is dripped between the nip roll 11 and the chill roll 12 to form the resin film 2, and the substrate 1 and the resin film 2 are passed between the nip roll 11 and the chill roll 12, and the nip roll 11 is passed through the chill roll 12. The base material 1 and the resin film 2 are laminated by pressure-bonding the backup roll 10 via the, and then the laminated body 3 ′ is cooled to an appropriate temperature while being wound around the surface of the chill roll 12.

  In the present invention, the chill roll 12 is preferably provided with a reversible driving means. In the example of FIG. 1 of the laminate manufacturing apparatus of the present invention, the chill roll 12 rotates in the clockwise direction, as shown in FIG. In another example of the laminate manufacturing method, the laminate rotates in the direction opposite to the clockwise direction. In addition, it is preferable that the extruder can be moved in parallel with the web running direction. The position where the resin film formed by extruding the thermoplastic resin melted from the T-die by moving the extruder is suspended, and the substrate 1 is run. The resin film 2 is formed by dripping the thermoplastic resin melted from the T-die 13 between the nip roll 11 and the chill roll 12 through an extruder (not shown) only by changing the position to be moved and the rotation direction of the chill roll 12. Then, the concavo-convex pattern 11a formed on the outer peripheral surface of the nip roll 11 is formed on the surface of the substrate 1 by passing the substrate 1 and the resin film 2 and pressing the backup roll 10 on the chill roll 12 via the nip roll 11. At the same time as being molded on both surfaces of the substrate 1 and the resin film 2, the laminate 3 ′ having an uneven pattern is wound around the surface of the chill roll 12. While vignetting is cooled to a proper temperature.

  By making the extruder move in parallel with the web running direction in this way, the resin film formed by dripping the thermoplastic resin melted from the T-die through the extruder and the base material are made up of a backup roll and a nip roll. It can be laminated easily by passing between or between the nip roll and the chill roll. When the base material 1 and the resin film 2 are laminated between the backup roll 10 and the nip roll 11, the concavo-convex pattern 3 can be formed on the surface of the resin film 2 with emphasis, and between the nip roll 11 and the chill roll 12. When the base material 1 and the resin film 2 are laminated, the concavo-convex pattern 3 can be emphasized and formed on the surface of the base material 1. Needless to say, the extruder has means capable of moving forward and backward in a direction orthogonal to the web running direction as in the conventional case.

  As a base material used in the present invention, polypropylene, polyethylene terephthalate, nylon, polyacrylonitrile, polyvinylidene chloride, polyvinyl alcohol, ethylene / vinyl alcohol copolymer, polyethylene film, cellophane, and polyvinylidene chloride on the above film, A gas barrier resin composition such as polyvinyl alcohol is applied to provide a gas barrier layer, or an inorganic material such as aluminum, aluminum oxide, silicon oxide, indium oxide, tin oxide, or zirconium oxide is deposited to provide a vapor deposition layer. Things can be used. Moreover, as these films, an unstretched film, a film stretched in a uniaxial direction or a biaxial direction can be used, and a single film of the above films or a combination of these films can be used. The unstretched film is preferably supplied from the second paper feeder and sandwiched with the above-mentioned substrates.

  Examples of the thermoplastic resin used in the present invention include low density polyethylene, medium density polyethylene, high density polyethylene, linear (linear) low density polyethylene, polypropylene, ethylene-α olefin copolymer, and ethylene-propylene copolymer. , Ethylene-vinyl acetate copolymer, ionomer, ethylene-acrylic acid copolymer, ethylene-methacrylic acid copolymer, ethylene-acrylic acid ester copolymer, ethylene-methacrylic acid ester copolymer, amorphous Examples thereof include polyester resins.

DESCRIPTION OF SYMBOLS 1 Base material 2 Resin film 3, 3 'Laminated body which has an uneven | corrugated pattern 4 Winding 10 Backup roll 11 Nip roll 11a Irregular pattern 12 Chill roll 13 T-die 20 1st paper feeder 21 AC coating apparatus 22 Drying apparatus 23 Laminating part 24 winding Device

Claims (4)

A backup roll, a nip roll, and a chill roll are arranged in this order in the direction in which the base material passes, and a resin film formed by dripping a thermoplastic resin melted from a T-die through an extruder and a base material are combined with the backup roll and the nip roll. An apparatus for producing a laminate by passing between a nip roll and a chill roll,
A laminate manufacturing apparatus, wherein an uneven pattern is formed on the outer peripheral surface of the nip roll, and the diameter of the nip roll is smaller than the diameter of the chill roll and is detachable. The diameter of the said chill roll is 400-800 mmphi, The diameter of the said nip roll is 120-250 mmphi, The laminated body manufacturing apparatus of Claim 1 characterized by the above-mentioned. The laminate manufacturing apparatus according to claim 1 or 2, wherein the extruder is movable in parallel with a direction in which the substrate passes. The laminate manufacturing apparatus according to any one of claims 1 to 3, wherein centers of the backup roll, the nip roll, and the chill roll are positioned substantially horizontally.

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