JP3638897B2 - Method for producing decorative foam composite - Google Patents

Description

[0001]
【Technical field】
The present invention relates to a method for producing a decorative foam composite used in the fields of civil engineering, building materials, etc., such as concrete formwork, wall materials, flooring materials, ceiling materials, shelf materials, partitions, and the like. The present invention relates to a method for producing a decorative foam composite to which is applied.
[0002]
[Prior art]
Conventionally, a method is known in which a thermoplastic resin containing a foaming agent is extruded from an extruder and foamed to form a foamed core material, and the outer periphery of the foamed core material is coated with a skin material to form an extruded foam composite. ing. When the extruded foam composite is used as a building material such as a wall material, flooring, etc., the surface of the extruded foam composite is made to have a stone-like texture, wood grain in order to make the surface of the extruded foam composite beautiful. A decorative sheet having a design such as a tone is bonded.
[0003]
As a method of pasting the decorative sheet on the surface of the extruded foam composite, there is a method of pasting and composite using a vacuum press method or a lapping machine. In these conventional methods, the extruded foam composite is first manufactured, and then a decorative sheet is bonded to the surface of the extruded foam composite.
[0004]
[Problems to be solved]
However, in the conventional manufacturing method described above, the production of the extruded foam composite and the bonding of the decorative sheet are performed on separate production lines. That is, it is necessary to provide a production line for the extruded foam composite and another production line (outline) to bond the decorative sheet. For this reason, there is a problem that the manufacturing process becomes complicated and the manufacturing cost increases.
[0005]
The present invention was made in view of such conventional problems, and a decorative sheet having design properties can be bonded to the surface of an extruded foam composite with good adhesion, and at a simple and low cost. It is an object of the present invention to provide a method for producing a decorative foam composite.
[0006]
[Means for solving problems]
According to a first aspect of the present invention, a foamable resin for a foam core material made of a thermoplastic resin containing a foaming agent is extruded from a first die of a first extruder, while a non-foamable thermoplastic resin or a low-foamable thermoplastic resin. The outer cover material is extruded from the second die of the second extruder, and the foamable core material is extruded from the first die and foamed to form the foam core material. And extruding the skin material to the outside of the foam core material and coating the skin material on the surface of the foam core material to form an extrusion intermediate,
In addition, the extruded intermediate is immediately led to a cooling sizing die, cooled and shaped to a desired shape, and an extruded foam composite comprising the surface of the foam core material coated with the skin material,
Next, a method for producing a decorative foam composite by pasting a decorative sheet on the surface of the extruded foam composite,
In pasting the decorative sheet, the temperature of the surface of the extruded foam composite at the outlet of the cooling sizing die is in a temperature range 0 ° C. to 50 ° C. lower than the softening point or crystallization temperature of the skin material. It is in a cooling sizing die, and a decorative sheet is pasted on the surface of the extruded foam composite sent out from the cooling sizing die. (Claim 1) .
[0007]
In the present invention, when the decorative sheet is bonded, the temperature of the surface of the extruded foam composite at the exit of the cooling sizing die is 0 ° C. to 50 ° C. lower than the softening point or crystallization temperature of the skin material. Cooling in the cooling sizing die so that it is in the range.
Therefore, the skin material is not completely cooled and solidified, maintains sufficient flexibility, and is smoothly fed in the cooling sizing die.
[0008]
Therefore, it can be prevented that the skin material is rubbed with the cooling shaping die surface in the cooling sizing die and scratches are generated on the surface of the extruded foam composite.
Moreover, since the said skin material exists in the said temperature range, the surface has a softness | flexibility and has a residual heat. For this reason, when the decorative sheet is bonded, the back surface of the decorative sheet and the skin material are sufficiently adhered and can be fused with good adhesion.
[0009]
In the present invention, when the temperature of the surface of the extruded foam composite is lower than the softening point or crystallization temperature of the skin material by more than 50 ° C., the adhesiveness is lowered and the bonding becomes insufficient. . On the other hand, when the temperature difference is smaller than 0 ° C., that is, when the surface temperature of the extruded foam composite is higher than the softening point or crystallization temperature of the skin material, the temperature of the skin material is high. A decorative foam composite having a smooth surface with too soft a surface cannot be obtained.
[0010]
Moreover, in this invention, a decorative sheet is bonded to the surface of the extrusion foam composite sent out from the said cooling sizing die.
Therefore, the production of the extruded foam composite and the bonding of the decorative sheet to the extruded foam composite can be performed in one production line, that is, in-line. Therefore, the manufacturing process of the decorative foam composite can be simplified, the productivity can be improved, and the manufacturing cost of the decorative foam composite can be reduced.
[0011]
Therefore, according to the present invention, a decorative sheet having a design property can be bonded to the surface of an extruded foam composite with good adhesion, and a method for producing a cosmetic foam composite easily and at low cost is provided. can do.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
In the first invention, the cooling sizing die is a cooling mold for obtaining a desired shape.
Cooling shaping to the desired shape means that the extrusion intermediate is pressed against the cooling shaping die surface of the cooling sizing die with the foaming pressure of the foaming resin for the foam core material while cooling the skin material with the cooling sizing die. It means shaping while cooling.
[0013]
As the skin material, a non-foaming or low-foaming thermoplastic resin is used. The non-foaming thermoplastic resin does not use a foaming agent, while the low foaming thermoplastic resin uses a small amount of foaming agent.
Examples of the thermoplastic resin include polystyrene, styrene resins such as acrylic, butadiene, and styrene (ABS) resins, various polyethylene and polypropylene resins, polyolefin resins such as copolymers of polypro and α-olefin, and polyvinyl chloride. There are resins, vinyl acetate resins, various nylon resins, various acrylic resins, polycarbonate resins, and mixed resins thereof.
In addition, fillers such as talc, calcium carbonate, mica, etc., or various pigments can be added to these resins.
[0014]
In particular, when a filler is added to a styrene resin or polypropylene resin, the rigidity is high and it is relatively inexpensive. In order to improve the appearance of the product, it is preferable to add a small amount of a foaming agent to the above-described skin material to make a low foam.
[0015]
In addition, as the foamable resin for the foam core material, a thermoplastic resin containing a foaming agent is used. As the thermoplastic resin, those similar to the thermoplastic resin shown for the skin material can be used. The foaming agent may be added to the thermoplastic resin in an extruder.
Further, as the foaming agent, volatile foaming such as aliphatic hydrocarbons such as propane, n-butane, i-butane, pentane and hexane, or cyclic aliphatic hydrocarbons such as cyclobutane, cyclopentane and cyclohexane. And decomposable foaming agents such as azodicarbonamide, azobisisobutylnitrile, and sodium bicarbonate. Further, air, carbon dioxide, nitrogen or the like can be used as the inorganic foaming agent. Moreover, these foaming agents can be used by being appropriately mixed.
[0016]
The amount of the foaming agent added to the foamable resin for the foam core material is preferably 3 to 15 wt%. The volatile foaming agent can be added by using the foamed resin beads contained therein or, for example, the foaming agent can be injected in an extruder. The magnification of the foam can be adjusted freely according to the amount of foaming agent added, the nozzle diameter, the number of revolutions of the extruder, the temperature, and the take-up speed.
[0017]
Further, as a nucleating agent used for obtaining a more uniform foam cell, polyethylene wax, ethylenebisamide, hexabromocyclododecane, and a methacrylic acid lower alkyl ester heavy polymer containing 5% by weight or more of a lower alkyl ester unit are included. At least one selected from organic nucleating agents such as coalescence, inorganic nucleating agents such as talc and silica, and water is used. These nucleating agents are contained in an amount of 0.2 to 5 wt%, preferably 0.4 to 2.0 wt%, relative to the foamable resin for the foam core material.
[0018]
The decorative sheet includes polyolefin resin, polystyrene (PS) resin, acrylic-butadiene-styrene (ABS) resin, polycarbonate (PC) resin, polyamide resin, vinyl chloride resin, etc. A thermoplastic resin formed into a sheet or film shape and printed on the surface thereof with a design property such as a stone tone, wood tone, marble tone, or the like can be used.
Further, as the decorative sheet, a laminate obtained by laminating a thermoplastic adhesive film on the back surface opposite to the printed surface of the decorative sheet can be used.
[0019]
For example, when obtaining a foam core material with a high expansion ratio of 7 to 50 times, a gap may be provided between the extrusion outlet of the foamable resin for the foam core material and the extrusion outlet of the skin material. preferable.
[0020]
The cooling shaping die surface of the cooling sizing die is preferably made of a metal such as steel, brass or aluminum. Thereby, cooling efficiency and moldability are improved. Further, it is desirable that the surface of the cooling shaping surface is polished by, for example, sandblasting # 150 to 400, and plated if necessary to reduce wear resistance.
[0021]
Next, the decorative sheet is bonded to the surface of the extruded foam composite while being pressed by a bonding roll at a bonding line pressure of 1 to 15 kg / cm,
Furthermore, it is preferable to shape the decorative sheet while pressing the decorative sheet to the extruded foamed composite with a cooling roll behind it (claim 2).
In this case, the decorative sheet and the extruded foam composite can be sufficiently bonded.
If the above-mentioned bonding linear pressure is less than 1 kg / cm, the decorative sheet may not be sufficiently bonded to the surface of the extruded foam composite.
On the other hand, when the bonding line pressure exceeds 15 kg / cm, the decorative sheet or the extruded foam composite may be damaged by the bonding line pressure of the bonding roll.
[0022]
Next, it is preferable that the decorative sheet is bonded to the side surface of the extruded foam composite while being crimped by a side bonding roll.
In this case, a decorative sheet can be smoothly bonded to the side surface of the extruded foam composite with good adhesion.
[0023]
Next, it is preferable to cool the extruded foam composite by spraying cooling water onto the cooling roll or the extruded foam composite.
In this case, since the cooling water is sprayed directly on the cooling roll or the extruded foam composite from the vertical direction, the width direction, or both directions, the decorative foam composite can be efficiently cooled. .
[0024]
Next, it is preferable to circulate cooling water inside the cooling roll.
In this case, since the cooling roll itself is directly cooled from the inside, the decorative foam composite can be efficiently cooled without being wetted by the cooling water, and its handling is easy.
[0025]
Next, it is preferable that the cooling roll is disposed in a water tank containing cooling water and cooled while the decorative foam composite is pressed by the cooling roll.
In this case, since the decorative foam composite is immersed in the water tank and cooled while the decorative foam composite is pressure-bonded by the cooling roll, the decorative foam composite can be efficiently cooled.
[0026]
Next, the foamable resin for the foam core material extruded from the first die is preferably formed into the foam core material by foaming at a foaming ratio of 7 to 50 times (Claim 7).
In this case, an extruded foam composite having a light weight and high strength can be obtained.
When the foaming rate is less than 7 times, the weight of the extruded foam composite is insufficient, which may increase the cost.
On the other hand, when it exceeds 50 times, the closed cell property is lowered and there is a possibility that the foam becomes weak.
[0027]
Next, the decorative sheet preferably has a thickness of 0.05 to 0.5 mm.
When the thickness is less than 0.05 mm, if the skin material of the extruded foam composite has irregularities, the irregularities may appear and a flat surface may not be obtained.
On the other hand, if it exceeds 0.5 mm, the material cost of the decorative sheet is increased and lacks practicality.
[0028]
Next, a thermoplastic adhesive film having a thickness of 0.01 to 0.1 mm is supplied between the surface of the extruded foam composite and the decorative sheet, and the decorative sheet and the extruded foam composite are melted by melting the thermoplastic adhesive film. Is preferably pasted (claim 9).
In this case, the decorative sheet can be firmly bonded to the surface of the extruded foam composite.
When the thickness of the thermoplastic adhesive film is less than 0.01 mm, the extruded foam composite and the decorative sheet may not be sufficiently bonded.
On the other hand, when the thickness exceeds 0.1 mm, the material cost of the thermoplastic adhesive film increases, and the practicality is lacking.
[0029]
Next, the thermoplastic adhesive film is a T A polyethylene resin produced using a locene catalyst, having an MFR (melt flow rate) of 1.0 to 20 g / 10 min and a density of 0.88 to 0.92 g / cm. ^Three The DSC melting point is preferably 55 to 110 ° C.
In this case, since the thermoplastic adhesive film has a relatively low melting point, the decorative sheet and the extruded foam composite can be bonded even at a low temperature.
In addition, MFR shows the measured value by JISK-6767, a density shows the measured value of JISK-6767, and DSC melting | fusing point shows the measured value of JISK-7121.
[0030]
When the MFR is less than 1.0 g / 10 min, there is a problem that when forming a thin film, there is no spreadability and it is difficult to make. On the other hand, when it exceeds 20 g / min, there is a problem that film formation is difficult due to excessive fluidity.
The density is 0.88 g / cm. ^Three When the ratio is less than 0.92, it is difficult to produce the polyethylene resin. On the other hand, when it exceeds 0.92, the melting point becomes high, and the adhesiveness at low temperature is lowered.
In addition, when the DSC melting point is less than 55 ° C, it is difficult to produce the polyethylene resin. On the other hand, when the DSC melting point is higher than 110 ° C, the melting point becomes high and the adhesiveness at low temperature is lowered. is there.
[0031]
Next, the thermoplastic adhesive film is preferably a maleated polypropylene resin, a polyethylene resin, EBR (ethylene butadiene rubber), or a maleic acid modified thermoplastic resin.
In this case, the thermoplastic adhesive film has excellent adhesiveness even at low temperatures.
[0032]
Next, it is preferable to perform the bonding while applying an adhesive to the back surface of the decorative sheet or the surface of the extruded foam composite.
In this case, the decorative sheet can be firmly bonded to the surface of the extruded foam composite with good adhesion.
[0033]
【Example】
(Example 1)
A method for producing a decorative foam composite according to an embodiment of the present invention will be described with reference to FIGS.
In this example, as shown in FIG. 1 to FIG. 2, the foamable core material foaming resin 10 made of a thermoplastic resin containing a foaming agent is extruded from the first die 2 of the first extruder 1, while not foamed. A skin material 30 made of a heat-resistant thermoplastic resin or a low-foaming thermoplastic resin is extruded from the second die 33 of the second extruder 3.
[0034]
Then, the foamable core material 100 is formed by extruding and foaming the foamable resin 10 for the foamed core material from the first die 2, while the skin material is placed outside the foamed core material from the second die 33. And the skin material 30 is coated on the surface of the foam core material 100 to form an extruded intermediate.
[0035]
Then, the extruded intermediate is immediately guided to the cooling sizing die 4, cooled and shaped into a desired shape, and an extruded foam composite 80 in which the surface of the foam core material 100 is coated with the skin material 30 is manufactured.
Next, the decorative foam 7 is bonded to the surface of the extruded foam composite 80 to produce the decorative foam composite 8.
[0036]
In pasting the decorative sheet 7, the temperature of the surface of the extruded foam composite 80 at the outlet of the cooling sizing die 4 is in a temperature range 0 to 50 ° C. lower than the softening point or crystallization temperature of the skin material 30. Cooling is performed in the cooling sizing die 4 as shown.
Then, the decorative sheet 7 is bonded to the surface of the extruded foam composite 80 fed from the cooling sizing die 4.
[0037]
As shown in FIG. 3, the decorative foam composite 8 to be obtained in this example comprises a plurality of rows and a plurality of rows, that is, 12 rows and two rows of unit core materials 104 formed by foaming a foamable resin for a foam core material. A foamed core material 100, a skin material 30 made of a non-foamed thermoplastic resin or a low-foaming thermoplastic resin that integrally covers the periphery of the core material, and a decorative sheet that covers the surface of the skin material 30 7 and so on.
[0038]
Moreover, the skin layers 15 of the adjacent portions of the unit core members 104 in the plurality of rows and steps are fused to each other. That is, each unit core material 104 is composed of a large number of foamed particles 101, and the periphery thereof is surrounded by the skin layer 15. The skin layers 15 are fused to each other. As a result, a foam core material 100 in which unit core materials 104 in a plurality of rows and stages are integrated is formed. The skin layer 15 is formed when discharged from the nozzle of the first die 2 during molding (FIG. 2).
In addition, the decorative sheet 7 is bonded to the skin material 30 via an adhesive 96 in this example.
[0039]
Next, the manufacturing method of the decorative foam composite of this example will be described in detail.
First, as shown in FIG. 2, a foamable core material foaming resin 10 made of a thermoplastic resin containing a foaming agent is extruded from the first die 2 of the first extruder 1, while a non-foamed thermoplastic resin or a low-foaming resin is used. A skin material 30 made of a heat-resistant thermoplastic resin is extruded from the second die 33 of the second extruder 3.
And the outer skin material 30 is coat | covered on the outer periphery of the foam core material 100 which consists of the said foamable resin for foam core materials in the exterior of the said 1st die | dye 2 and the 2nd die | dye 33 which were provided in the front-end | tip of both extruders.
[0040]
From the first die 2, while the foamable core material 100 is formed by extruding and foaming the foamable resin 10 for foamed core material from the nozzles 25 arranged in a plurality of rows and stages, The skin material 30 is extruded from the two dies 33 to the outside of the foamed core material 100 in a plurality of rows and stages, and these are immediately guided to the cooling sizing die 4.
At this time, the skin material 30 is pressed against the inner surface of the cooling sizing die 4 by the foaming force of the foamable resin for the foam core material, and the foam core material 100 formed of the foamable resin for the foam core material is used. The skin material 30 is coated on the outer surface.
[0041]
In the cooling sizing die 4, the skin material 30 is pressed against the cooling shaping die surface 400 of the cooling sizing die 4 by the foaming force of the foam core material 10.
The extruded intermediate is cooled and formed into a desired shape, and becomes an extruded foam composite 80 in which the surface of the foam core material is coated with a skin agent.
The cooling in the cooling sizing die 4 is performed in a temperature range in which the surface temperature of the extruded foam composite 80 at the outlet of the cooling sizing die is 0 to 50 ° C. lower than the softening point or crystallization temperature of the skin material 30. Do as you see.
[0042]
As shown in FIG. 1, the decorative sheet 7 is bonded to the surface of the extruded foam composite 80 at the outlet of the cooling sizing die 4. An adhesive 96 is applied in advance to the back surface of the decorative sheet 7 in the adhesive supply unit 9, and the applied adhesive 96 is dried in a drying furnace 91. The decorative sheet 7 is sent to a bonding roll 71 through a feed roll 79.
[0043]
The decorative sheet 7 is sent out from the sheet roll machine 99. And the decorative sheet 7 sent to the said bonding roll 71 is crimped | bonded to the surface of the extrusion foam composite 80 by the bonding roll 71. FIG. In addition, the said bonding roll 71 is heated at 60 degreeC. Therefore, at the time of the pressure bonding, the adhesive 96 is melted by heat, and the decorative sheet 7 is bonded to the extruded foam composite 80.
[0044]
The extruded foam composite 80 on which the decorative sheet 7 is bonded is sent to the roll cooling unit 5. The roll cooling unit 5 includes a lower cooling roll 541, an upper cooling roll 542, and a side cooling roll 543. In the roll cooling unit 5, the cooling foam 541, 542, and 543 are used to cool and shape the extruded foam composite 80 and the decorative sheet 7 while being crimped to obtain a decorative foam composite 8.
Note that the strength of pressure bonding of the decorative foam composite 8 is performed by controlling the lifting device 52 of the upper cooling roll 542.
[0045]
Further, a take-up machine 6 is installed further rearward of the roll cooling unit 5. The take-up machine 6 has a caterpillar take-up machine 62 arranged in the upper part and a caterpillar take-up machine 61 arranged in the lower part. And behind the take-up machine 6, it has the cutting machine 65 for cut | disconnecting the cooling foam-shaped decorative foam composite 8 to desired length.
[0046]
Thus, the extruded intermediate body, which is extruded from the first die 2 and the second die 3 and is composed of the foamable resin 10 for the core material and the skin material 30 covering the surface thereof, is cooled and shaped in the cooling sizing die 4. The decorative sheet 7 is bonded by the bonding roll 71, and further drawn out by the caterpillar take-out machine 61 while being completely cooled and shaped by the roll cooling unit 5.
Then, the decorative foam composite 8 is cut to a desired length by the cutting machine 65, and becomes the final decorative foam composite 8 (FIG. 3).
[0047]
Next, in this example, the material and apparatus used for the production of the decorative foam composite will be specifically described.
As the skin resin for the skin material 30, acrylic, butadiene, styrene (ABS) resin is used, and the second extruder 3 uses two 30 mm diameter full-flight screws, and the resin at the outlet of the second die 33. The temperature of was 200 ° C.
[0048]
As the foamable resin 10 for the core material, a polystyrene resin containing 7 wt% of butane was used. Moreover, 1.2 wt% of talc was mixed with the foaming resin as a nucleating agent. The first extruder 1 used a 65 mm aperture full flight screw, and the die outlet temperature of the core foamable resin 10, that is, the temperature at the nozzle 25 was 130 ° C.
[0049]
The decorative sheet used was a polyolefin resin film with a wood grain design printed on the surface. Further, as the adhesive 96, a urethane two-component adhesive was used.
[0050]
The first die 2 and the second die 3 have the shape shown in FIG. 2, and a rectangular slit 28 having an inner side of 45 mm × 595 mm and an outer side of 50 mm × 600 mm is provided between the first die 2 and the second die 3. There was a slit gap of 2.5 mm.
The first die 2 has a die shape in which 12 nozzles 25 having a small diameter of 2.5 mmφ are arranged in two rows in the center in the vertical direction. The gap 29 between both dies was 2 mm in the vertical direction (product thickness direction) and 3 mm in the horizontal direction (product width direction).
[0051]
The shape of the cooling shaping die surface 400 of the cooling sizing die 4 was a box shape having a cross section of 52 mm in length and 602 mm in width, and a length of 500 mm.
At the outlet of the cooling sizing die 4, the surface temperature of the skin material 30 was set to 60 ° C., which is 20 ° C. lower than the softening point of the skin material 30. The take-off speed of the extruded intermediate 80 was 0.5 m / min.
[0052]
As the bonding roll 71, one having a roll diameter of 200 mmφ and a length of 700 mm was used.
[0053]
In addition, as the cooling rolls 541 and 542 in the roll cooling unit 5, thirteen rolls having a roll diameter of 60 mmφ and a length of 700 mm were installed one above the other. In addition, three side cooling rolls having a roll diameter of 120 mmφ and a length of 48 mm were installed on both sides of the roll cooling unit 5.
[0054]
Next, the effect of this example will be described.
In this example, when bonding the decorative sheet 7, the temperature of the surface of the extruded foam composite 80 at the outlet of the cooling sizing die 4 is 0 to 50 higher than the softening point or crystallization temperature of the skin material 30. Cooling is performed in the cooling sizing die 4 so as to be in a temperature range lower than the ° C.
Therefore, the skin material 30 is not completely cooled and solidified, maintains sufficient flexibility, and is smoothly fed forward in the cooling sizing die 4.
[0055]
Therefore, it can be prevented that the skin material 30 is rubbed with the cooling shaping die surface 400 in the cooling sizing die 4 to cause scratches on the surface of the extruded foam composite 80. Further, since the skin material 30 is in the temperature range, the surface thereof has flexibility and residual heat. Therefore, when the decorative sheet 7 is bonded, the back surface of the decorative sheet 7 and the skin material 30 are sufficiently adhered and can be fused with good adhesion.
[0056]
Moreover, in this example, the decorative sheet 7 is bonded to the surface of the extruded foam composite 80 sent out from the cooling sizing die 4.
Therefore, the production of the extruded foam composite 80 and the bonding of the decorative sheet 7 to the extruded foam composite 80 can be performed in one production line, that is, in-line. Therefore, the manufacturing process of the decorative foam composite 8 can be simplified, the productivity can be improved, and the manufacturing cost of the decorative foam composite 8 can be reduced.
[0057]
Therefore, according to this example, a decorative foam sheet having a design property can be bonded to the surface of the extruded foam composite with good adhesion, and a method for producing a cosmetic foam composite easily and at low cost. Can be provided.
[0058]
(Example 2)
In this example, as shown in FIGS. 4 and 5, an example in which the decorative foam composite 8 is manufactured using a thermoplastic adhesive film 95 instead of the adhesive 96 of Example 1 is shown.
[0059]
As shown in FIGS. 4 and 5, in this example, an adhesive film supply unit 91 for supplying a thermoplastic adhesive film 95 is provided between the cooling sizing die 4 and the bonding roll 71. The adhesive film supply unit 91 includes a film resin supply unit 92 and an adhesive film extruder 93. The thermoplastic adhesive film 95 extruded in a flat shape from the T-die at the tip of the adhesive film extruder 93 is inserted between the extruded foam composite 80 and the decorative sheet 7.
[0060]
The thermoplastic adhesive film 95 inserted between the extruded foam composite 80 and the decorative sheet 7 is melted in the same manner as the adhesive 96 in Example 1, and the decorative sheet 7 is formed on the extruded foam composite 80. Glue.
[0061]
Also in this example, the same effect as in Example 1 could be obtained.
[0062]
(Example 3)
In this example, as shown in FIG. 6, an example of producing a decorative foam composite 8 in which a decorative sheet 7 is bonded to the side surface in addition to the top surface of the extruded foam composite 80 will be described.
[0063]
That is, in this example, as shown in FIGS. 7 to 9, a large number of laminating rolls 71 and a large number of slanted or vertically arranged between the outlet of the cooling sizing die 4 of Example 1 and the roll cooling unit. Side bonding roll 72 is provided. And the side surface bonding roll 72 is arrange | positioned gradually in the perpendicular direction as it goes to the advancing direction of the extrusion foaming composite 80.
That is, as shown in FIG. 8, the side surface bonding roll 72 is arranged so that the first side surface bonding roll 721 disposed at the location closest to the outlet of the cooling sizing die 4 is substantially parallel to the upper surface of the extruded foam composite. It is arranged vertically as it approaches the final side surface bonding roll 722 disposed at the position farthest from the first side surface bonding roll 721.
[0064]
On the other hand, as the decorative sheet 7, a decorative sheet having a width larger than the width of the extruded foam composite 80 is prepared. The width of this decorative sheet is large by the amount to be bonded to the side surface portion of the extruded foam composite 80.
Then, the decorative sheet 7 is bonded to the extruded foam composite in the same manner as in Example 1. At this time, as shown in FIG. 8, the width of the decorative sheet 7 is larger than that of the extruded foam composite 80, and therefore there is an excess portion 75.
[0065]
And as shown in FIG. 7, FIG. 8, the said side surface bonding roll 72 bend | folds the excessive part 75 located in the left and right of the said decorative sheet 7 gradually so that it may become in parallel with the side surface of the extrusion foam composite 80. Go. Thus, the side surface bonding roll 72 presses the surplus portion 75 of the decorative sheet 7 to the side surface of the extruded foam composite 80 by the final side surface bonding roll 722 in the final stage.
[0066]
Therefore, according to this example, the decorative sheet 7 can be efficiently bonded also to the side surface of the extruded foam composite 80.
In this example, as shown in FIG. 6, the decorative sheet 7 is bonded so as to cover a part of the side surface of the extruded foam composite, but the length of the decorative sheet 7 in the width direction is increased. Thereby, the said decorative sheet 7 can be bonded to the whole side surface of the extrusion foam composite 80.
In addition, also in this example, the same effect as Example 1 was able to be acquired.
[0067]
(Example 4)
As shown in FIG. 10, this example is the same as that in Example 1, in the roll cooling unit 5, both the extruded foam composite 80 to which the decorative sheet 7 is bonded and the cooling rolls 541 and 542 are cooled. In this example, water is sprayed to cool these.
That is, in this example, the cooling water jet pipes 551 and 552 are disposed below the lower cooling roll 541 and above the upper cooling roll 542 in the roll cooling unit 5 shown in the first embodiment.
[0068]
And cooling water 560 was sprayed with respect to each cooling roll and extrusion foaming composite, and these were cooled.
And when manufacturing the extrusion foaming composite on the conditions of Example 1, the temperature of said cooling water was ejected at 20 degreeC.
As a result, the same effect as in Example 1 could be obtained.
[Brief description of the drawings]
FIG. 1 is a side view showing an entire decorative foam composite manufacturing apparatus according to a first embodiment.
FIG. 2 is an explanatory diagram of an extruder and a cooling sizing die of the decorative foam composite manufacturing apparatus according to the first embodiment.
3 is a cross-sectional perspective view of the decorative foam composite obtained in Example 1. FIG.
4 is an explanatory view showing a method for adhering an extruded foam composite and a decorative sheet according to Example 2. FIG.
FIG. 5 is an explanatory view showing an adhesive film supply unit according to a second embodiment.
6 is a cross-sectional perspective view of a decorative foam composite obtained in Example 3. FIG.
7 is a perspective view showing a method for bonding an extruded foam composite and a decorative sheet in Example 3. FIG.
8 is a plan view showing a method for bonding an extruded foam composite and a decorative sheet in Example 3. FIG.
FIG. 9 is an explanatory view showing a change in the inclination of the side surface bonding roll in Example 3.
10 is an explanatory diagram of a roll cooling unit in Embodiment 4. FIG.
[Explanation of symbols]
1. . First extruder,
10. . . Foamable resin for foam core material,
100. . . Foam core material,
2. . . First die,
25. . . nozzle,
3. . . Second extruder,
30. . . Skin material,
4). . . Cooling sizing die,
5. . . Roll cooling section,
6). . . Take-up machine,
7). . . Decorative sheet,
71. . . Pasting roll,
8). . . Decorative foam composite,
80. . . Extruded foam composite,

Claims (12)

A foamable resin for a foam core material made of a thermoplastic resin containing a foaming agent is extruded from the first die of the first extruder, while a skin material made of a non-foamable thermoplastic resin or a low-foamable thermoplastic resin is extruded. 2 Extruding from the second die of the extruder, and extruding and foaming the foamable resin for the foam core material from the first die to form the foam core material, while forming the skin material from the second die Extruding to the outside of the foam core and covering the surface of the foam core with the surface of the foam core to form an extrusion intermediate,
In addition, the extruded intermediate is immediately led to a cooling sizing die, cooled and shaped to a desired shape, and an extruded foam composite comprising the surface of the foam core material coated with the skin material,
Next, a method for producing a decorative foam composite by pasting a decorative sheet on the surface of the extruded foam composite,
In pasting the decorative sheet, the temperature of the surface of the extruded foam composite at the outlet of the cooling sizing die is in a temperature range 0 ° C. to 50 ° C. lower than the softening point or crystallization temperature of the skin material. A method for producing a decorative foam composite, which is cooled in a cooling sizing die, and a decorative sheet is bonded to the surface of the extruded foam composite delivered from the cooling sizing die. In Claim 1, the said decorative sheet is bonded to the surface of the said extrusion foaming composite_body | complex, crimping | bonding with the bonding line pressure of 1-15 kg / cm with the roll for bonding,
A method for producing a decorative foam composite, further comprising forming a decorative sheet while being pressed against the extruded foam composite by a cooling roll behind the roll. 3. The method for producing a decorative foam composite according to claim 1, wherein the decorative sheet is bonded to the side surface of the extruded foam composite while being pressed by a side bonding roll. 4. The method for producing a decorative foam composite according to claim 2, wherein cooling water is sprayed on the cooling roll or the extruded foam composite to cool the extruded foam composite. The method for producing a decorative foam composite according to any one of claims 2 to 4, wherein cooling water is circulated inside the cooling roll. 5. The cooling roll according to claim 2, wherein the cooling roll is disposed in a water tank containing cooling water and is cooled while pressure-bonding the decorative foam composite by the cooling roll. A method for producing a decorative foam composite. The foamable resin for a foam core material extruded from the first die is formed in the foam core material by foaming at a foaming ratio of 7 to 50 times according to any one of claims 1 to 6. A method for producing a decorative foam composite. The decorative sheet according to any one of claims 1 to 7, wherein the decorative sheet has a thickness of 0.05 to 0.5 mm. The thermoplastic adhesive film having a thickness of 0.01 to 0.1 mm is supplied together between the surface of the extruded foam composite and the decorative sheet, and the thermoplastic adhesive film is melted. The decorative sheet and the extruded foam composite are bonded together, thereby producing a decorative foam composite. In claim 9, the thermoplastic adhesive film is a polyethylene resin produced by using the meta Rothen catalyst, its MFR (Melt Flow Rate) of 1.0 to 20 g / 10 min, density of 0. A method for producing a decorative foam composite, characterized by having 88 to 0.92 g / cm ³ and a DSC melting point of 55 to 110 ° C. 10. The method for producing a decorative foam composite according to claim 9, wherein the thermoplastic adhesive film is a maleated polypropylene resin, a polyethylene resin, EBR (ethylene butadiene rubber), or a maleic acid modified thermoplastic resin. The manufacturing of the cosmetic foam composite according to any one of claims 1 to 8, wherein the bonding is performed while applying an adhesive to the back surface of the decorative sheet or the surface of the extruded foam composite. Method.

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