JP2767355B2 - Method and apparatus for producing decorative laminate molded article - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for producing a decorative laminate molded article, and more particularly, to a method and an apparatus for producing a decorative laminate sheet used for interior parts of automobiles and the like. About.

[0002]

2. Description of the Related Art Conventionally, decorative laminate sheets used for interior parts of automobiles, that is, decorative laminate molded products are disclosed in Japanese Patent Laid-Open No. 2-28.
It was formed by a method as disclosed in JP-A-1925. This conventional method basically involves laminating a thermoplastic resin in a highly heat-softened state on a belt-like stretchable skin material supplied continuously and laminating each other with a pressure roller to form a laminated sheet. there were.

[0003]

However, this type of conventional laminated molded article is mainly made of a polyester nonwoven fabric which functions as a decorative material, for example, as a stretchable skin material, on a sheet-like substrate formed by extruding polypropylene. Was laminated. As described above, the conventional decorative laminate is required to have weather resistance and wear resistance since it is used for interior parts of automobiles and the like, and as a result, a material different from the base material has been used.

However, when such a conventional decorative laminate molded article is to be used for waste material recycling, it cannot be treated as an integrated product because both materials are different from each other. And it was very difficult to completely recycle. Therefore, development of a laminated sheet that facilitates waste material treatment has been desired. That is, the laminated molded article that facilitates waste material treatment means that the base material and the laminate material are made of the same material.

[0005] However, in order to obtain a decorative laminated molded product, the base material and the laminated material are made of the same material, and a conventional molding method, that is, a molding method as described in JP-A-2-281925 is used. It was not possible to form a laminated sheet. Because, when a nonwoven polypropylene nonwoven fabric of the same material is laminated on a base material to be melt-extruded, for example, a polypropylene sheet, the polypropylene sheet is extruded at a temperature of about 180 ° to 230 ° into a sheet shape, so that the temperature is extremely high, As a result, the nonwoven fabric of the same quality to be laminated is melted, and a desired laminated product cannot be obtained.

In other words, since the conventional polyester nonwoven fabric has a high melting point of about 280 to 290 degrees, lamination using a polypropylene sheet as a base material was possible. From this viewpoint, it can be said that the selection of the conventional base material and the laminate material is limited. That is, the relationship between the base material and the laminate material must be such that the latter has a higher melting point than the former.

Of course, in the past, it was possible to laminate the same type of base material and laminate material, for example, polypropylenes. However, in this case, a laminate material is simply welded to the base material, and a decorative material cannot be laminated. This is because, for example, when the laminated material is processed as a non-woven fabric, or the printed material is laminated on the surface of the laminated material with a substrate extruded by a conventional method, the decorative portion is provided. Is melted, and the merchantability as a product is greatly impaired.

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned conventional problems. It is an object of the present invention to make it possible to laminate a decorative thermoplastic laminate of the same material with an extruded molten thermoplastic substrate. It is an object of the present invention to provide a method of manufacturing a decorative laminated molded product and a device therefor, which can maintain the commercial appeal and enable recycling of waste materials.

[0009]

SUMMARY OF THE INVENTION The present invention relates to a method for producing a decorative laminate molded article by continuously laminating a homogeneous thermoplastic base material on a decorative thermoplastic laminate sheet by melt extrusion. Immediately before laminating the molten thermoplastic base material extruded from the extruder onto the decorative thermoplastic laminate material, an appropriate amount of liquid mixed with air is sprayed on the laminate material to make the appearance of the thermoplastic laminate material apparent. Is characterized in that the melting temperature is higher than the temperature during melt extrusion of the thermoplastic substrate.

Further, the apparatus for producing a decorative laminate molded article of the present invention comprises a supply section for sequentially supplying a decorative thermoplastic laminate sheet, and a molten thermoplastic base material of the same quality as the thermoplastic laminate sheet. An extruder for extruding, a pressure roller for laminating the melted thermoplastic base material and the decorative thermoplastic laminate sheet extruded from the extruder, and then pressing the laminate, and the decorative thermoplastic laminate sheet. Immediately before laminating the molten thermoplastic base material, the decorative thermoplastic laminate sheet comprises a mixed liquid spraying device for spraying a liquid mixed with air.

[0011]

According to the method and apparatus for producing a decorative laminate molded article of the present invention, a decorative thermoplastic laminate sheet is sequentially fed from a supply section to a die side of an extrusion molding machine. An appropriate amount of a liquid mixed with air, ie, a mixed liquid, is sprayed on the thermoplastic laminate sheet just before the die. This increases the apparent melting temperature of the thermoplastic laminate sheet. On the other hand, a molten thermoplastic base material of the same quality as the thermoplastic laminate sheet is extruded from the extruder, and is laminated into the above-described thermoplastic laminate sheet.

Normally, a thermoplastic laminate sheet of the same quality as the molten thermoplastic substrate melts due to the melting temperature of the substrate. The substrate is laminated on the thermoplastic laminate sheet. Immediately before the air mixture is sprayed and the apparent melting temperature is higher than the melting temperature of the base material, the two layers are pressed together without saying that the thermoplastic laminate sheet melts, Is formed.

[0013]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view showing a method of manufacturing a decorative laminated molded article according to the present invention. FIG. 1 schematically shows an apparatus 1 for manufacturing a decorative laminated molded product according to one embodiment of the present invention. The manufacturing apparatus 1 includes a continuous extruder 3 for extruding a molten thermoplastic resin as a base material 2 from a die at a tip. A pair of pressure rollers 4 is provided in front of the continuous extruder 3 (to the right in FIG. 1). A transport conveyor 5 is arranged further forward of the pair of pressure rollers 4.

On the other hand, a roll 7 around which a decorative thermoplastic laminate sheet 6 of the same quality as that of the base material 2 is wound is provided below the transport conveyor 5, and the thermoplastic laminate sheet 6 is And is passed between the pressure rollers 4 with the surface thereof facing downward, and further placed on a conveyor 5. In the vicinity of the roll 7 around which the thermoplastic laminate sheet 6 is wound, the thermoplastic laminate sheet 6 pulled out from the roll 7 is provided.
A mixed liquid spraying device 8 for spraying a mixed liquid of air and water is provided on the upper surface (the back surface when viewed from the laminate material itself).

The mixed liquid spraying device 8 is configured as shown in FIGS. FIG. 2 is a bottom view of the mixed liquid spraying device 8 as viewed from below, and FIG. 3 is a side view thereof. The mixed liquid spraying device 8 includes a plurality of mixed liquid jet nozzles 10 arranged and fixed in a line on a support member 9, and each mixed liquid jet nozzle 10 extends to one side of the support member 9 along a water flow pipe extending along the same. 11 is connected by a tube 12. This water flow pipe 11 is connected to a pressurized water supply source via a strainer 13, a regulator 14, and the like.

Further, each of the mixed liquid ejection nozzles 10 is provided with two air pipes 1 extending along the other side of the support member 9.
5 is connected to the air tube 15 by a tube 16.
Is connected to an air supply source via a solenoid valve 17 and a regulator 18. As an example of the air mixture supply source, FIG. 4 shows a movable air mixture supply device 19. The air mixture supply device 19 is provided with a tank device 22 mounted on a cart 21 having casters 20.
The tank device 22 includes a water storage tank portion 22a at a lower portion and a pressurized air tank portion 22b at an upper portion.

A liquid pressure regulator 23, a pressurized air supply side valve 24, and the like are mounted on the upper part of the pressurized air tank section 22b, and are provided with components necessary for supplying pressurized air and pressurized water. Reference numeral 25 indicates a control device for controlling the discharge pressure when discharging air and pressurized water from each of the tank portions 22a and 22b. The control device 25 is attached to the cart 21.

The operation of the thus-constructed decorative laminate molded article manufacturing apparatus 1 will be described below. Decorative thermoplastic laminate sheet 6 drawn from roll 7
Before the liquid is passed between the pressure rollers 4, the mixed liquid spraying device 8 sprays water mixed with air over the entire surface, thereby increasing the apparent melting temperature. that time. When water is mixed with air and sprayed, the water is evenly sprayed on the thermoplastic laminate sheet 6. Then, immediately before the thermoplastic laminate sheet 6 enters the pressure roller 4, the continuous extruder 3
The melted thermoplastic base material 2 continuously extruded from the substrate is placed thereon and pressed by a pressing roller 4. The decorative laminate sheet thus laminated is sent to a necessary next step, for example, a molding machine or the like by the conveyor 5 to be formed into a desired shape.

Example 1 Thickness of polypropylene (PP) substrate 2.0 [mm] Surface temperature of polypropylene (PP) substrate 210 [° C] Weight of laminated sheet (polypropylene (PP) nonwoven fabric) 150 [g / m ^2] Water spray amount 0 [l / hr] When the decorative laminate sheet was formed under these conditions, the surface nonwoven fabric was melted and wrinkles were generated on the substrate side, and a desired decorative laminate sheet was not obtained.

Example 2 Thickness of polypropylene (PP) substrate 2.0 [mm] Surface temperature of polypropylene (PP) substrate 210 [° C] Weight of laminated sheet (polypropylene (PP) nonwoven fabric) 150 [g / m ^2] ] Water spraying amount 22 [l / hr] Air spraying amount 178 [l / min] When the decorative laminate sheet was formed under these conditions, the decorative thermoplastic laminate sheet was not melted, and a very good sprayability was obtained. A decorative laminated sheet and product were obtained.

Example 3 Thickness of polypropylene (PP) substrate 3.5 [mm] Surface temperature of polypropylene (PP) substrate 190 [° C] Weight of laminated sheet (polypropylene (PP) nonwoven fabric) 130 [g / m ^2] ] Water spraying amount 48 [l / hr] Air spraying amount 266 [l / min] When the decorative laminate sheet was formed under these conditions, there was no melting of the decorative thermoplastic laminate sheet, and very good sprayability was obtained. A decorative laminated sheet and product were obtained.

Example 4 Thickness of Polypropylene (PP) Base 1.0 [mm] Surface Temperature of Polypropylene (PP) Base 210 [° C.] Weight of Laminated Sheet (Polypropylene (PP) Nonwoven Fabric) 140 [g / m ^2] ] Water spray amount 15 [l / hr] Air spray amount 102 [l / min] When the decorative laminate sheet was formed under these conditions, there was no melting of the decorative thermoplastic laminate sheet, and very good sprayability was obtained. A decorative laminated sheet and product were obtained.

Example 5 Thickness of polypropylene (PP) substrate 2.0 [mm] Surface temperature of polypropylene (PP) substrate 230 [° C] Weight of laminated sheet (polypropylene (PP) nonwoven fabric) 150 [g / m ^2] Spraying amount of mixed liquid 30 [l / hr] When a decorative laminate sheet was formed under these conditions, the decorative thermoplastic laminate sheet was not melted, and a very good decorative laminate sheet and product were obtained. Was done.

Example 6 Thickness of polypropylene (PP) substrate 3.5 [mm] Surface temperature of polypropylene (PP) substrate 190 [° C] Weight of laminated sheet (polypropylene (PP) nonwoven fabric) 130 [g / m ^2] Spraying amount of mixed liquid: 40 [l / hr] When the decorative laminate sheet was formed under these conditions, the decorative thermoplastic laminate sheet was not melted, and a very good decorative laminate sheet and product were obtained. Was done.

As is clear from the above-described embodiments, the spray amount of the mixed solution is determined by the heat capacity of the polypropylene substrate (determined by the thickness of the substrate and the surface temperature of the substrate). Further, in each of the above-described embodiments, a mixture obtained by mixing air with water was used as the liquid mixture, but the present invention is not limited to this, and the mixture of air with alcohol or the like instead of water is used. Needless to say, it is good.

[0026]

As described above, according to the method and apparatus for manufacturing a decorative laminate molded article of the present invention, a homogeneous thermoplastic thermoplastic sheet is formed on a decorative thermoplastic laminate sheet by an extrusion molding machine. And a decorative laminate sheet having the same quality as the substrate and the decorative laminate sheet can be provided. As a result, even when this decorative laminate molded product is used as an interior product of an automobile,
Thereafter, complete recycling becomes possible, and an excellent effect that resources can be effectively used is exhibited.

[Brief description of the drawings]

FIG. 1 is a configuration explanatory view schematically showing an apparatus for manufacturing a decorative laminate molded product according to one embodiment of the present invention.

FIG. 2 is a bottom view showing a mixed liquid spraying apparatus constituting the apparatus for manufacturing a decorative laminate molded article shown in FIG.

FIG. 3 is a side view of the mixed liquid spraying device shown in FIG. 2;

FIG. 4 is a side view showing a mobile mixed liquid supply device for supplying air mixed water to the mixed liquid spraying device.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Apparatus of decorative laminated molded product 2 Melt thermoplastic base material 3 Continuous extrusion molding machine 4 Compression roller 5 Conveyor 6 Decorative thermoplastic laminate sheet 7 Roll 8 Mixed liquid spraying device

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ identification symbol FI B32B 31/12 B32B 31/12 (58) Investigated field (Int.Cl. ⁶ , DB name) B32B 31/30 B29C 47/02 B29C 47/06 B29D 9/00 B32B 27/00 B32B 31/12

Claims (2)

(57) [Claims] 1. A method for producing a laminated molded article by continuously laminating a homogeneous thermoplastic base material on a decorative thermoplastic laminate sheet by melt extrusion, wherein a molten thermoplastic base extruded from an extruder is provided. Immediately before laminating the material on the decorative thermoplastic laminate material, an appropriate amount of air-mixed liquid is sprayed on the laminate material to raise the apparent melting temperature of the thermoplastic laminate material to the melting point of the thermoplastic base material. A method for producing a decorative laminated molded product, wherein the temperature is higher than the temperature at the time of extrusion. 2. A supply section for sequentially supplying a decorative thermoplastic laminate sheet, an extruder for melt-extruding a molten thermoplastic base material of the same quality as the thermoplastic laminate sheet, and an extruder extruded from the extruder. A pressure roller for laminating the melted thermoplastic base material and the decorative thermoplastic laminate sheet and then pressing the same, and the decorating process immediately before laminating the molten thermoplastic base material on the decorative thermoplastic laminate sheet. And a mixed liquid spraying device for spraying a liquid in which air is mixed with the thermoplastic laminate sheet.