JP3024458B2 - Manufacturing method of thermoplastic resin laminate - 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 for producing a laminate based on a thermoplastic resin.

[0002]

2. Description of the Related Art Conventionally, as a method of manufacturing a resin laminate using a roll, a plurality of layers to be laminated are each extruded as a flow of a molten resin by separate extruders, and the layers are laminated to form a laminate. Extruder molding method: An extrusion lamination method in which a substrate such as paper, aluminum foil, cellophane, or plastic film that has been wound up in advance is fed out and a molten resin layer extruded from an extruder is stacked thereon. Are laminated by an adhesive or a hot press.

[0003]

In the coextrusion molding method, each layer to be laminated can be a different kind of layer,
One layer itself can be applied only to a layer having a single composition.

In the extrusion lamination method, since the base material is wound and wound on a take-out roll, it is not suitable for a laminate composed of a thin base material and a thin resin sheet, but one of which is suitable for a thick body.

[0005] The method of laminating a plurality of layers prepared in advance by means of an adhesive or a hot press requires many steps, is complicated, and has low productivity.

Accordingly, the present invention uses a well-known resin sheet manufacturing apparatus, can adjust the thickness of the base material arbitrarily, can apply various materials for the other material to be laminated, and has a large adhesive strength. Provided is a method for manufacturing a laminate having high productivity.

[0007]

According to the present invention, when a molten thermoplastic resin is produced through three or more finishing roll units to form a resin sheet, the second and subsequent rolls of the roll unit are used. Into the gap, a separately prepared sheet-like material is sandwiched via the guide roll and the expander roll, and the surface of the sheet-like resin at the upstream portion of the gap between the roll and the roll that sandwiches the sheet-like material (the surface not in contact with the roll) ) Is a process for producing a thermoplastic resin laminate.

As the thermoplastic resin in the present invention, a resin which can be plastically processed by heating, such as an acrylic resin, a polycarbonate, a styrene resin, a vinyl chloride resin, a polyolefin, a polyester, a polyacetal, a fluororesin, or a polyamide, is applicable. . One of the layers constituting the desired laminated plate may be selected from these.

As a method for producing a resin sheet from the molten thermoplastic resin of the present invention through three or more finishing roll units, there is a well-known representative method for producing a resin plate / sheet / film (hereinafter referred to as sheets). Is a typical method. For example, "Plastic Processing Technology Handbook" (October 20, 1979)
Nikkan Kogyo Shimbun) Pages 254 to 260: "Plastic sheet extrusion technology" (May 29, 1969, published by the Industrial Research Institute, Inc.): "Plastics" vol.3
3, NO. 10 (issued by the Industrial Research Institute, October 1982, pp. 49-56), "Plastic sheet molding technology with improved appearance": As described in JP-B-61-46305, etc. Extruder, Die, Polished roll unit (polishing roll machine), Roller table, Edge cutting device, Take-up roll, Cutting and stacking device There is an extrusion molding method. In addition, 32 of the above "Handbook of Plastic Processing Technologies"
As described on pages 3 to 360, a “kneading device” for resin,
There is a so-called calendering method using an apparatus having a “calender roll” configuration.

The finishing roll unit cools the molten resin sheets and is usually a glossy roll for smoothing the surface. As a special case, a roll with a grain may be used.

In the above-mentioned molding method and processing method, the molten resin formed into a sheet in the preceding step is first sandwiched between the first and second rolls of the finishing roll unit, and the thickness of the sheet-shaped resin is set to a predetermined value. Shall be And this one
At the entrance of the gap between the second and second rolls, a resin pool called a bank is generated.

[0012] In the present invention, the finishing roll unit 2
The gaps between the second and subsequent rolls are expressed in the order of the rolls along the flow of the sheet-like resin, and the second and third gaps, or the third and fourth gaps, and the subsequent gaps depending on the number of rolls. It refers to the gap between rolls, and may be any of roll gaps other than the gap between the first and second rolls.

A separately prepared sheet material is sandwiched between the second and subsequent rolls of the finishing roll unit. By sandwiching the sheet-like material in the gap between the first and second rolls of the finishing roll unit, the amount of banks existing in the gap fluctuates and the molding is performed, despite restrictions on the apparatus. Bank mark on the sheet,
It is not preferable because surface defects such as pocking occur.

When a sheet material separately prepared is sandwiched from one place in the gap between the finishing rolls and the second and subsequent rolls, a laminated plate having a two-layer structure is formed, and the sheet material is sandwiched from two places in the gap. For example, a laminate having a three-layer structure can be produced.

In order to enhance the adhesion between the sheet resin and the separately prepared sheet, the surface of the sheet resin upstream of the gap between the rolls that sandwiches the separately prepared sheet (the surface not in contact with the roll) ) Can be heated to further develop the tackiness.

To heat the surface of the sheet resin,
A non-contact type external heater can be applied, and an infrared heater is generally used.

The separately prepared sheet material is referred to as a sheet or film depending on its thickness. The material may be any material as long as it can be thermally fused with the sheet-like resin. For example, there are paper, cellophane, metal foil such as aluminum foil, and various thermoplastic resins. Moreover,
The sheet-like material may have a multilayer structure and may have various functions. In other words, on the surface of this sheet,
Examples include a scratch-resistant film, an ultraviolet-curable film, and a strong adhesive film.

When the sheet-like material is preferably applied to the production method of the present invention, it is desirable that the sheet-like material can be sequentially fed out from a roll.

If the sheet is rigid and has a so-called stiffness, it may be simply unwound and successively sandwiched between the rolls. However, the sheet may be thin and soft. It is necessary to apply a tension in the flow direction and the width direction to maintain a uniform flat surface for those which are easily kinked.
A known method may be used for applying the two tensions.

In order to apply tension in the flow direction, it is not necessary to unwind the sheet by unwinding, but to apply a certain amount of braking force to unwind the sheet. Is required. In order to further equalize the tension, one of the simple methods is to set a guide roll movable up and down or left and right according to the tension between the feeding device and the roll gap to buffer the fluctuation of the tension.

In order to apply tension in the width direction, one of the simple methods is to use a so-called expander roll in which the diameter at the center is maximum and the diameter at the end is small between the feeding device and the gap between the rolls. .

[0022]

According to the method of the present invention, a laminate can be manufactured with high productivity by using a general apparatus for manufacturing a thermoplastic resin sheet. In addition, a multifunctional laminated plate can be obtained by using multifunctional sheets for lamination.

[0023]

EXAMPLES The present invention will be described below with reference to examples.
The present invention is not limited by these examples. The apparatus used in the examples is shown in FIG. The equipment used is as follows.・ Extruder: Screw diameter 150mm, single shaft, Toshiba Machine Co., Ltd.
・ Flat die: 1500mm width, 4mm lip gap ・ Finishing roll: diameter 500mm, width 1500mm, 3 pieces, temperature was 90 ℃, 100 ℃, 110 ℃ in order.・ Sheet feeding device: Powder brake ・ Creel stand with tension controller (Mitsubishi Electric Corp. LD-X, tension 1.2Kgf) ・ Guide roll: 35mm in diameter, 1400mm in width ・ Expander roll: 125mm in diameter, 1300mm in width (Fiken Industry Co., Ltd. FE-S type) ・ External heater: infrared heater, 6kw

Example 1 Acrylic resin (Sumipex B Sumitomo Chemical Co., Ltd.)
Resin temperature from the extruder-flat die
It was extruded at 70 ° C. at a flow rate of 600 kg / Hr and about 4 m / min to obtain a resin sheet having a thickness of 1.3 mm. As a sheet, 6
A 5μ polyethylene terephthalate film is coated with a urethane-based UV-curable hard coat agent (Koei Hard T-6
5, manufactured by Koei Chemical Co., Ltd.) and supplied in such a direction that the coating agent application surface is in contact with the extruded resin sheet.
The obtained laminate was obtained by sufficiently bonding the hard coat agent to an acrylic resin sheet.

Example 2 In Example 1, the thickness of the acrylic resin sheet was set to 2.
The procedure was performed in the same manner except that a sheet having a thickness of 0 mm was used and a 0.3 mm thick film of an impact-resistant acrylic resin (SUMIPEX HT41X, manufactured by Sumitomo Chemical Co., Ltd.) was used as the sheet-like material to be bonded. The obtained laminate did not peel even when a blade of a cutter knife was inserted between the layers to cause peeling, and had good adhesion.

[Brief description of the drawings]

FIG. 1 is a diagram of an apparatus used in a manufacturing method of the present invention.

[Explanation of symbols]

 1: 1st finishing roll 2: 2nd finishing roll 3: 3rd finishing roll 4: flat die 5: resin sheet 6: sheet material 7: sheet material feeding device 8: guide roll 9: expander roll 10: external heating Unit 11: laminated resin plate

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Sadamura Satomura 5-1 Sokai-cho, Niihama-shi, Ehime Prefecture Sumitomo Chemical Industries Co., Ltd. (56) References JP-A-5-177728 (JP, A) JP-A-5-177728 60-6056 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B29C 47/00-47/96 B32B 31/30

Claims (1)

(57) [Claims] When producing a resin sheet through a molten thermoplastic resin through three or more finishing roll units,
In the gap between the second and subsequent rolls of the roll unit, a separately prepared sheet is sandwiched via a guide roll and an expander roll , and the sheet is formed.
Sheet in the upstream part of the gap between rolls that sandwich the object
Heat the resin surface (the surface not in contact with the roll)
And a method for producing a thermoplastic resin laminate.