JP3020779B2 - Method for laminating decorative board and laminating apparatus - 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 apparatus for laminating a decorative board suitable for an automobile interior board, or a wall material or a ceiling material in a bath unit or a kitchen unit.

[0002]

2. Description of the Related Art For example, as a decorative plate used for an interior plate in a trunk room of an automobile, a wall material of a bath unit or a kitchen unit, a ceiling material, and the like, a polypropylene (hereinafter referred to as PP) composite resin mixed with a filler is used. 2. Description of the Related Art In order to improve the feel and appearance on the surface of a plate, a plate made of a thermoplastic resin sheet having a textured surface or the like attached to the surface is conventionally known.

Recently, as a skin of a decorative board, a thermoplastic elastomer (Thermoplastics Elas) which is easy to mold and has rubber-like elasticity is used.
tomer: TPE) is attracting attention.

[0004] As a conventional example, a laminating method and a laminating apparatus for a decorative plate in which an olefin-based TPE (hereinafter referred to as TPO) skin 2 is laminated on the surface of a PP composite resin plate 1 will be described with reference to FIG. The decorative plate was manufactured by extruding the substrate 1 from the machine 3 and laminating the TPO skin 2 on the surface side of the substrate 1 by a pressing roll mechanism including an upper roll 4 and an intermediate roll 5.

[0005]

As described above, in the related art, immediately after the substrate 1 is extruded, the substrate 1 is pressed by a pressure roll mechanism.
And the TPO skin 2 were laminated, but the temperature of the substrate 1 extruded from the extruder 3 is about 200 ° C., and the radiant heat softens the TPO skin 2 and easily causes tarmi, wrinkles and the like. There was a problem.

[0006] As a countermeasure against this, about 1.3 pieces of TPO
If a tension of 5 times is applied, there will be no generation of wrinkles, wrinkles, etc., but in such a case, the grain pattern formed on the surface of the TPO skin 2 will be elongated, and the commercial value of the decorative board will be significantly reduced. There was a drawback to make it.

Further, when laminating the TPO skin 2 on the substrate 1, if the surface of the substrate 1 contains incompletely melted pellets or incompletely dispersed fibers, irregularities are likely to be generated at the portion, and the surface side of the substrate 1 If the surface of the decorative plate has irregularities, smoothness cannot be obtained on the surface of the decorative plate, and a perforation phenomenon may occur in the TPO skin 2, which significantly reduces the commercial value of the decorative plate.

The present invention has been made in view of such circumstances, and reliably prevents the appearance defects such as wrinkles and tarmi of the skin as well as defective perforations while maintaining a good texture of the TPO skin. It is an object of the present invention to provide a method for laminating a decorative plate and a laminating apparatus.

[0009]

In order to achieve the above object, the present invention provides a method of laminating a TPO skin on the surface of a substrate made of a PP composite resin material mixed with a cellulosic filler or an organic fiber filler. In the laminating method for a decorative plate configured, the substrate is extruded into a sheet shape by an extruder, and then the thickness and temperature of the substrate are adjusted by the upper and intermediate rolls, and the temperature of the substrate is reduced by one.
After adjusting the temperature to 60 to 180 ° C., a TPO skin pulled by a slight tension is laminated on the surface side of the substrate by the middle and lower rolls.

The substrate of the decorative board used in the method of the present invention is P
Based on P resin and partially PE (polyethylene)
May be mixed.

The cellulose filler mixed into the PP resin is 2 parts by weight based on 100 parts by weight of the base PP resin.
It is in the range of 0 to 120 parts by weight.

Similarly, polyester, rayon, cotton yarn,
When organic fiber filler such as hemp is mixed, PP100
The weight is set in the range of 20 to 120 parts by weight.

When the amount of the filler is less than 20 parts by weight, the desired heat storage property cannot be obtained, the cooling rate of the substrate is increased, and the strong adhesion to the TPO skin cannot be obtained. Also, 1
If the amount exceeds 20 parts by weight, there is a problem that the strength is reduced.

The roll temperature of the upper roll and the intermediate roll for adjusting the thickness and temperature of the substrate is preferably in the range of 80 to 120 ° C. If it is less than 80 ° C., the cooling of the substrate is accelerated,
In addition to poor adhesion to the PO skin, when the temperature exceeds 120 ° C., there is a problem that the substrate is cut off by taking off the board.

Further, in order to prevent the warpage of the substrate, immediately after the substrate is extruded, a nonwoven fabric for preventing warpage, such as polyester or rayon alone, and a fusion fiber of PP, low melting point polyester, EVA or the like are formed on the back surface of the substrate. The mixture may be laminated on the back surface side of the substrate at a basis weight of 20 to 100 g / m ² .

Further, the substrate and the TPO skin may be laminated with the intermediate roll and the pressure roll immediately after passing through the plate thickness and temperature adjusting roll mechanism.

Next, the decorative plate laminating apparatus used in the method of the present invention comprises a plate thickness and temperature control roll mechanism comprising an upper roll and an intermediate roll for adjusting the plate thickness and the temperature of the extruded substrate; And an intermediate roll for laminating a TPO skin on the surface side of the substrate whose temperature has been adjusted, and a pressure roll mechanism comprising a lower roll.

[0018]

As is apparent from the above constitution, according to the method of the present invention, the sheet-like substrate extruded from the extruder is:
Thickness adjustment and temperature adjustment are performed by the upper and middle rolls. When laminating the substrate and the TPO skin with the intermediate roll and the lower roll, the temperature of the substrate is set to 160 to 180 ° C. The radiant heat does not soften the TPO skin, so that wrinkles and tarmi do not occur on the TPO skin.

Therefore, the tension applied to the TPO skin may be a weak tension of 1.1 times or less.

Further, the thickness of the substrate is adjusted by the upper roll and the intermediate roll, and at the same time, the smoothness of the substrate is improved and the surface has almost no irregularities. Does not occur, and good smoothness is obtained on the product surface.

In addition, even if the thickness and temperature are adjusted by the upper roll and the intermediate roll, and then the adjustment is performed by the intermediate roll and the lower roll, the cellulosic filler or the organic fiber filler mixed in the substrate may be used. Since the heat storage property is high, strong bonding between the substrate and the TPO skin can be expected.

[0022]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of a decorative board laminating method and a laminating apparatus according to the present invention will be described below in detail with reference to the accompanying drawings.

FIG. 1 is an explanatory view showing the structure of a first embodiment of a decorative board laminating apparatus used in the method of the present invention. FIG. 2 is a sectional view showing the structure of a decorative board laminated by the same apparatus. FIG. 4 is an explanatory view showing a modification of the laminating apparatus used in the method of the present invention.

Referring to FIG. 1, a first embodiment of a laminating apparatus used in the present invention will be described.

After the substrate 11 is extruded into a sheet from the extruder 10, the thickness and temperature of the substrate 11 are adjusted by a thickness and temperature adjusting roll mechanism composed of an upper roll 20 and an intermediate roll 30, and The TPO skin 51 supplied from the raw roll 50 and the substrate 11 are pressed by a pressure roll mechanism composed of an intermediate roll 30 and a lower roll 40.
And are transported to the cooling side.

As described above, in this embodiment, the thickness and temperature of the substrate 11 extruded from the extruder 10 and the thickness and temperature adjusting roll mechanism (the upper roll 20 and the intermediate roll 30 are constituted). ), Substrate 11 and TPO skin 5
Roll mechanism (intermediate roll 30)
And a lower roll 40).

More specifically, as a material of the substrate 11, a PP resin material obtained by mixing a cellulosic filler such as wood powder into a PP resin or an organic fiber filler such as polyester, rayon, cotton yarn, and hemp is used. The amount of the filler used is set to 20 to 120 parts by weight based on 100 parts by weight of the base PP resin.

The TPO skin 51 is a typical thermoplastic elastomer, and has a moldability comparable to that of a general-purpose resin and rubber-like elasticity at room temperature. Uses a crystal phase as a constraint mode, PP as a hard segment, and EPDM as a soft segment.

Next, the roll temperatures of the rolls 20, 30, and 40 and the clearance between the rolls will be described.
When the temperature is lower than 80 ° C., the cooling of the substrate 11 is accelerated, and good lamination strength with the TPO skin 51 cannot be expected. May be cut.

The clearance between the upper roll 20 and the intermediate roll 30 is such that the thickness of the substrate 11 shown in FIG.
When the thickness of the PO skin 51 is 0.35 mm, the substrate 11 extruded from the extruder 10 is 2.8 to 3.2 mm, and the clearance between the upper roll 20 and the intermediate roll 30 is 2.05 to 2 mm. .1 mm, and the clearance between the intermediate roll 30 and the lower roll 40 is set to the thickness of the decorative board, that is, 2.35 mm.

Therefore, the thickness of the substrate 11 extruded from the extruder 10 is adjusted by the upper roll 20 and the intermediate roll 30 to a thickness of 2.05 to 2.1 mm. The temperature of the substrate 11 is adjusted from the resin temperature of 200 ° C. to the optimum laminating temperature of 160 to 180 ° C.

Then, the intermediate roll 30 and the lower roll 40
The substrate 11 is 160-1
When it is at 80 ° C., it is laminated with the TPO skin 51,
A strong laminate that does not cause peeling or the like can be expected.

As described above, according to the method of the present invention, the plate thickness,
The temperature adjustment roll mechanism smoothes the surface of the substrate 11 and performs appropriate temperature adjustment, so that the product surface has irregularities, and the TPO skin 51 has cuts and the like due to the surface irregularities of the substrate 11. Defects can be reliably prevented.

Further, since the temperature of the substrate 11 is adjusted to the optimum laminating temperature, there is no softening phenomenon of the TPO skin 51 due to the heat of the resin as in the prior art, so that it is not necessary to apply a strong tension, and the elongation characteristics are excellent. TPO skin 51
There is no defect such as deformation of the grain pattern, and there is an advantage that a decorative plate having an excellent surface appearance can be easily formed.

Next, FIGS. 3 and 4 show another embodiment of the method of the present invention. FIG. 3 shows a substrate 11 laminated with a nonwoven fabric 60 for preventing warpage.
The non-woven fabric 60 is laminated on the back side of the substrate 11 extruded from the upper roll 20 and the intermediate roll 30. The lamination of the substrate 11 and the TPO skin 51 employs the first embodiment shown in FIG. I do.

In this embodiment, when laminating the substrate 11 and the TPO skin 51, the cooling of the TPO skin 51 is slow, and the decorative board tends to warp to the TPO skin 51 side. By keeping the cooling rate constant and the tension on the front and back sides constant, it is possible to prevent the decorative board from warping.

As the nonwoven fabric 60 for preventing warpage,
20 to 100 g / m ² , material, polyester,
Use is made of rayon alone or a mixture of these with heat-fused fibers such as PP, low-melting polyester, EVA and the like.

Next, FIG. 4 shows the substrate 11 and the TPO skin 5.
1 is laminated on the upper roll 20.
And immediately after passing through the intermediate roll 30,
This is a method of increasing the lamination strength between the substrate 11 and the TPO skin 51, and for this purpose, a pressure roll 70 is provided on the side of the intermediate roll 30.

[0039]

As described above, the present invention has the following special functions and effects.

(1) According to the method of the present invention, the temperature of the substrate is adjusted by the thickness and temperature adjusting roll mechanism composed of the upper roll and the intermediate roll, and the temperature of the substrate during lamination of the substrate and the TPO skin is reduced. Since the temperature is set to 160 to 180 ° C., the softening phenomenon of the resin due to radiant heat does not occur on the TPO skin, so that good lamination without wrinkles and tarls can be expected. Because it is not necessary to apply a tension, a small tension is sufficient, and a crimped pattern formed on the surface of the TPO skin does not expand and deform, and a beautiful grained surface appearance can be obtained. This has the effect of providing a board.

(2) According to the method of the present invention, the thickness of the substrate is adjusted by the thickness and temperature adjusting roll mechanism composed of the upper roll and the intermediate roll, and the front and back surfaces of the substrate have almost no irregularities. Because it is formed on a smooth surface, when the decorative board is manufactured by laminating the substrate and the TPO skin,
There is no effect of appearance defects such as unevenness on the product surface or tearing of the TPO skin due to the unevenness, and it is possible to provide a decorative plate excellent in surface feel.

(3) The laminating apparatus according to the present invention has a simple structure in which the three rolls of the upper roll, the intermediate roll, and the lower roll constitute a plate thickness, temperature adjusting roll mechanism, and a pressure roll mechanism. And has the effect of being practically useful.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing the configuration of a first embodiment of a laminating apparatus used in the method of the present invention.

FIG. 2 is a cross-sectional view showing a configuration of a decorative board manufactured by applying the method of the present invention.

FIG. 3 is an explanatory view showing a modification of the laminating apparatus used in the method of the present invention.

FIG. 4 is an explanatory view showing a further modified example of the laminating apparatus used in the method of the present invention.

FIG. 5 is a sectional view showing a conventional example of a decorative plate laminating apparatus.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Extruder 11 Substrate 20 Upper roll 30 Intermediate roll 40 Lower roll 50 Raw fabric roll 51 TPO skin 60 Nonwoven fabric 70 Press roll

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification code FI // B29L 9:00

Claims (4)

(57) [Claims] 1. A method of laminating a decorative board comprising a TPO skin (51) laminated on a surface side of a substrate (11) made of a PP composite resin material mixed with a cellulosic filler or an organic fiber filler. The substrate (11) is extruded into a sheet by an extruder (10), and the thickness and temperature of the substrate (11) are adjusted by the upper and intermediate rolls (20, 30). After adjusting to 160-180 ° C,
Substrate (11) by middle and lower rolls (30, 40)
TPO pulled by a slight tension on the surface side of
A method for laminating a decorative board, comprising laminating a skin (51). 2. Extrusion of the substrate (11), followed by the substrate (1).
On the back side of 1), a nonwoven fabric (60) for preventing warpage is placed on the upper side.
2. The method for laminating a decorative board according to claim 1, wherein the laminate is laminated by an intermediate roll. 3. A substrate (11) having an upper side and an intermediate roll (2).
0, 30), the intermediate roll (30) and the pressure roll (70) are used to apply T to the surface of the substrate (11).
The method for laminating a decorative plate according to claim 1, wherein the PO skin (51) is laminated. 4. A decorative board laminating apparatus in which a TPO skin (51) is laminated on a surface side of a substrate (11) made of a PP composite resin material mixed with a cellulosic filler or an organic fiber filler, etc. The apparatus comprises a plate thickness and temperature adjusting roll mechanism comprising an upper roll (20) and an intermediate roll (30) for adjusting the thickness and temperature of the substrate (11) after extrusion molding;
It is characterized by comprising an intermediate roll (30) for laminating a TPO skin (51) on the surface side of the substrate (11) whose thickness and temperature have been adjusted, and a pressure roll mechanism comprising a lower roll (40). Plywood laminating equipment.