JPH03118150A - Method and apparatus for producing composite plate - Google Patents

Abstract

PURPOSE:To improve operation efficiency and productivity and to obtain a high quality product of excellent surface flatness through a continuous production by arranging a flat core member, facing members, which are set at both sides of the core member and made of a different material from that of the core member, and reaction-type adhesive layers, which are set between the core and facing members. CONSTITUTION:A composite plate A is composed of a plurality of layers, i.e., a central core member 1 and facing members 3, 3, which are attached to both sides of the core member 1 through adhesive layers 2, 2, or a single facing member 3. A reaction-type hot-melt adhesive is used as the adhesive layers 2, 2. A production apparatus B of the composite plate A is constituted of a transfer device 4 for the core member 1, an application device 6 for the adhesive 2, a supply device 6 for the facing member 3, a hot press device 7, a cold press device 8 and a cutting device 9.

Description

[Detailed Description of the Invention] (Industrial Application Field) The present invention relates to a composite board for interior/exterior materials, door materials, etc. used in the construction industry, a method for manufacturing the composite board, and an apparatus thereof. The reactive adhesive layer improves initial adhesion, improves work efficiency and productivity, enables early shipping and reduces costs, and allows for continuous production and high quality products with excellent surface smoothness. The present invention relates to a composite plate, a method for manufacturing the composite plate, and an apparatus therefor.

(Prior art) Conventionally, composite boards, such as interior/exterior materials and door materials used in the construction industry, are made by applying room-temperature curing epoxy resin to both sides of a polyethylene core material approximately 3 mm thick using Rollsbregou. After applying adhesive in an amount of 120 to 150 g/m, this core material is placed on top of a surface material such as colored aluminum, and then a surface material such as colored aluminum of the same quality is applied to this material. After stacking the next surface material on top, the above process is repeated for each leaf, and when the predetermined number of sheets is reached, they are all pressed together with a cold press at a pressure of 1 to 2 kg/cm, and further, It was fixed using a jig such as a tongue buckle to prevent spring bagging, and left to cure for about 15 to 20 hours until the adhesive reacted and solidified.

After the predetermined period of time has elapsed, the jig is pressed to cut the workpiece to a predetermined width and length, and after inspection and packaging, the workpiece is stored or shipped immediately.

(Problems to be Solved by the Invention) The conventional composite plate and its manufacturing method described above have the following problems.

■Since we use a cold-curing epoxy resin adhesive to bond the core material and the surface materials on both sides, it will gradually harden due to the reaction after application, and the next step will not be performed until approximately 15 to 20 hours have passed. Since the work cannot be carried out, the products are shipped the day after lamination, after cutting and other processing, which makes it impossible to adequately meet the supply and demand of customers.In addition, if mass production is carried out at one time, it is difficult to secure a curing area. Have difficulty.

■Also, when using this adhesive, 15000 ml at room temperature.
Since the viscosity is extremely high at ~20,000 cps, it causes uneven coating on the coated surface, and the adhesive does not flow sufficiently when pressed by cold pressing, resulting in poor surface smoothness of the composite board and reducing its commercial value. decreases.

On the other hand, if the adhesive is reheated after bonding, the adhesive will easily dissolve, causing the two components to separate, resulting in defective products.

■Furthermore, when laminating with this adhesive, for example, polyethylene is used as the core material, a good adhesive effect cannot be obtained unless the wetting index of the surface is 50 dynes (surface tension) or higher; However, after a predetermined period of time has elapsed, a peeling phenomenon occurs between the two members, which may lead to complaints, and the range of use is thus extremely limited.

■Since every step of laminating the core material and the surface materials on both sides is done manually, the quality of the finished product tends to vary, and it is not possible to achieve continuous mass production in a short period of time. This will increase the cost of the product due to the rise in labor costs.

■For the stacking type, if foreign matter such as dirt gets in between the stacked surface materials or between the core material and the surface material, this will push the surface material and cause scratches or unevenness. At the same time, this unevenness is also applied to the surface material of other adjacent materials, which increases the incidence of defective products and makes it difficult for adhesive to adhere to the uneven areas, causing peeling on the finished product. This may cause adhesion failure.

The present invention was made in order to solve the above-mentioned problems, and it improves the initial adhesion by using a reactive adhesive layer, improves work efficiency and productivity, enables early shipment, and reduces costs. The object of the present invention is to provide a composite plate, a method for manufacturing the composite plate, and an apparatus therefor, which can produce high-quality products with excellent surface smoothness.

(Means for Solving the Problems) The means of the present invention for achieving the above-mentioned objects are: (1) a flat core material; (2) a surface material provided on both sides of the core material and made of a material having a different effect from the core material; (1) A composition of a composite board including: (1) a reactive adhesive layer provided between a core material and a surface material; (2) a flat core material; (2) a reactive adhesive layer provided on one side of the core material; A composition of a composite board with a surface material made of a different material, ■ a reactive adhesive layer provided between the core material and the surface material, and ■ a reactive adhesive layer applied to either the core material or the surface material. ■ A process of combining the core material and surface material and hot-pressing them; ■ A process of hot-pressing and then cold-pressing; ■ A cutting process of cutting to a predetermined width and length. The structure of the method for manufacturing a board; (1) a means for transporting the core material; (2) a means for applying a reactive adhesive to the core material or the surface material; A means for supplying a surface material to both sides of the material, ■ A means for hot pressing the supplied core material and a surface material together, ■ A means for cold pressing after hot pressing, and processing to a predetermined width and length. The present invention provides a configuration of a composite plate manufacturing apparatus including a cutting means.

(Function) The composite board manufacturing apparatus according to the present invention has the following effects due to the above-described configuration.

The core material is transported by the transport means in the manufacturing apparatus, and the reactive adhesive is applied to either the core material or the surface material by the application means.

When the coating is completed, the surface materials are fed out by the surface material supply means arranged oppositely above and below the material feeding path, and are added to both or one side of the core material and heated and compressed by the hot pressure means.

The crimped material is transferred and cooled to a predetermined temperature by the cooling means, while being compressed with a predetermined pressure to complete the adhesion during the transfer, and then transported to the cutting means.

After the adhesion is completed, the material is cut to desired width and length by a cutting means, thereby completing a composite board in which surface materials of different properties are laminated on both sides of the core material.

(Example) Next, an example of a composite plate, a method for manufacturing the composite plate, and an apparatus for the same according to the present invention will be described based on the drawings.

In Figures 1 to 4, A is a composite board, which is used for interior/exterior materials, door materials, etc. that require soundproofing and insulation properties in the construction industry, etc., and is formed into a rectangular shape with a predetermined size and a composite board. It is composed of layers, including a central core material 1 and surface materials 3, 3 on both sides attached via adhesive layers 2, 2 above and below the core material 1.
Alternatively, the single-sided facing material 3 is composed of.

The core material 1 is polyethylene with a thickness of 1.0 to 5.5 + nm.

A synthetic resin board such as polypropylene or 15 mm thick plywood is used.

The adhesive layers 2 and 2 use a reactive hot melt adhesive mainly composed of polyester isocyanate prepolymer, and have a viscosity of 7000 to 80 when heated to about 120°C.
00 cps, and has excellent hot melt properties, adhesive properties, heat resistance, low temperature properties, etc., and is expected to shorten solidification time and improve initial adhesive strength.

Further, the coating amount may be about 40 to 50 g/m''.

The surface material 3.3 uses a material with different effects from the core material 1,
A 0.1 to 0.5 m+s colored aluminum sheet, galvanized steel sheet, stainless steel foil, etc. are used.

Incidentally, this surface material 3 may be made of a same-effective material other than a different-effective material.

Usually, a long piece is wound into a coil and then pulled out for use.

In this composite board A, various combinations of the core material 1 and the surface material 3.3 are possible, but a typical one is a polyethylene 1 with a thickness of 2.0 to 5.5 mm, as shown in FIG. One in which colored aluminum 3, 3 with a thickness of 0.1 to 0.2 mm is laminated, or one in which galvanized steel plates 3, 3, 0.5 mm thick are laminated on a 15 mm thick plywood 1, as shown in Fig. 3. Or, as a special example, as shown in FIG. 4, a material in which a 0.1 mm thick stainless steel foil 3 is laminated on a 1.0 mm thick polypropylene L is used.

In FIG. 5, B is a manufacturing apparatus for the composite plate A, and the core material 1 is
, a conveying means 4 , an application means 5 for the adhesive 2 , a supply means 6 for the surface material 3 , a hot press means 7 , a cold press means 8 , and a cutting means 9 .

The conveying means 4 for the core material 1 uses an endless belt conveyor provided at the starting end of the machine frame 1O, and a driving means M such as a motor is used.
The core materials 1 stacked in a predetermined amount are received by the material feeder 11 one by one and transferred to the material feeding path 12.

Note that this material feeding path 12 is horizontal, and is continuous with the machine frame lO.
is formed from the beginning to the end.

The adhesive 2 application means 5 is provided at the end of the conveying means 4 to uniformly apply the adhesive 2 to both sides of the core material 1, as shown in FIG. Although not shown, the rotation of the driving means M is interlocked with a synchronized gear to drive the gluing process. Alternatively, as shown in FIG.
6 and ejects it from a nozzle 17 at the tip.

Although this application means 5 has been described in terms of application to the core material 1, the same effect can be achieved even when it is applied to the surface material 3.3. Glue is applied to the adhesive surface of surface material 3.3 using roller 14 or nozzle 17.
Continuous coating can also be performed by these means 5 by arranging them in opposition.

The supply means 6 for the surface material 3 supplies the core material 1 coated with the adhesive 2.
The surface material 3 is supplied to both sides of the machine frame 10, and the coiled surface material 3, 3 is connected to the coating means 5 in the transfer path 12 and attached to the upper and lower support shafts 18.18.
The surface material adhered to the core material 1 is supported and continuously fed out onto the roll surface of the heat-pressing means 7, which will be described later. 3, always apply a predetermined force, for example, 0.2 to 0.5 kg/cm
By applying tension of the width, the surface material 3 is applied to the core material 1.
is adhered smoothly.

The heat-pressing means 7 applies pressure at the same time as the surface materials 3, 3 are supplied to the core material 1 to adhere the materials 1, 3.3. Use hot rolls.

This hot roll 7.7 has a built-in heater (not shown) and is heated to a surface temperature of about 180°C.
It is preferable to apply a pressing force of about /Cm.

Then, the rotation of the drive means M is transmitted to the hot roll 7.7 which is driven in conjunction with the synchronization gear 7a, and the transfer speed with the conveyance means 4 is synchronized to sequentially convey the materials to the next process.

The cold pressure means 8 presses the two parts 1 and 1 pressed by the hot pressure means 7.
3.3, by applying cooling and pressure, higher initial adhesion and smoothness of the product surface are achieved. In this method, a pair of rolls are used which are arranged oppositely above and below, and it is preferable that about 8 to 10 pairs are arranged in parallel in a continuous series.

Then, each roll 8.8... is linked with a linking member 8a such as a chain to interlock the rotation of the driving means M, or the above-mentioned rolls 8.8... are driven at intervals. The material is fed continuously.

Further, the temperature of the cold pressure is maintained at room temperature or at a constant temperature by inserting a circulation pipe into each roll and circulating a refrigerant such as water, although it is not shown in the drawings.

The cutting means 9 is used to process the pasted material 1, 3゜3 to a predetermined width and continuously to a predetermined length. 9a.

As shown in FIG.
In addition, shirrings 9b, 9b are connected to the slitters 9a, 9a to remove the so-called joint parts protruding from both sides of the material 1, 3.3, which have been processed in the width direction. Then, the trailing edge is cut and processed into a predetermined length.

In FIG. 5, reference numeral 21 denotes a take-out means for taking out the composite plate A that has been processed in a predetermined manner by the cutting means 9;
An endless belt conveyor provided at the end of the conveyor belt is used, and the products are taken out one by one and deposited on a product receiver 22 adjacent to the transfer end.

Although not shown in the drawings, the composite plates A stacked as described above are inspected for surface scratches and smoothness, then packaged, and either stored in stock or shipped immediately.

Next, an example of a method for manufacturing a composite plate according to the present invention and an example implemented using the apparatus will be described.

・Core material...3.0mm thickness, 900 x 2000
mm thick polyethylene plate/surface material...1.0 mm thick, 900 x 2000
mm thick color aluminum sheet (same material for top and bottom) ・Adhesive: Reactive hot melt When lamination processing was performed in the manufacturing equipment A described above,
It takes 0.5 hours from supplying the product to device A to taking it out (completed), compared to the 15 to 20 hours that it takes in the past.The bond is in good condition and the surface is smooth. A quality product was obtained.

In addition, the unit price per sheet was 180 yen, which was a significant cost reduction compared to the conventional 290 yen.

(Effects of the Invention) As described above, the composite plate, the method for manufacturing the composite plate, and the apparatus thereof according to the present invention achieve excellent initial adhesion by performing hot bonding and pressure bonding using a reactive adhesive and then cold pressing. By completely eliminating the peeling phenomenon, it is possible to carry out the next process such as cutting the width, length, etc. immediately after hot pressing and cold pressing to produce the final product. Products transported to the warehouse can be shipped immediately, fully meeting the demands of customers, and can be shipped on the same day, minimizing inventory space.

When using a reactive adhesive, in addition to the above effects, only a small amount of the adhesive is applied, so there is no possibility of uneven application (
Furthermore, by applying hot and cold pressure after applying the adhesive, the surface after adhesion is finished smooth and the commercial value is improved.

Compared to conventional bonding work for each leaf, processing is performed in a continuous series, which improves work efficiency and saves labor, leading to cost reductions.

Since crimping after adhesion is not done by stacking multiple sheets and pressing them together as in conventional processing, even if dust gets mixed in between the two parts, only that product will be defective, and other products will be affected by the dust. Therefore, the incidence of defective products is extremely low and the yield is good.

It has an exceptional effect.

[Brief explanation of drawings]

FIG. 1 is a perspective view showing an embodiment of a composite plate according to the present invention, and FIG. 2 is a partially enlarged sectional view of the same. FIG. 3 is a partially enlarged sectional view showing another example same as the above. FIG. 4 is a partially enlarged sectional view showing still another example of the same as the above, and FIG.
The figure is a schematic diagram showing an embodiment of a composite plate manufacturing apparatus according to the present invention. FIG. 6 is an enlarged view of the application means in the same as above. 7th
This figure is an explanatory diagram showing another example same as the above, and FIG. 8 is an explanatory diagram showing a slitter in the cutting means. In the figure, A is a composite board, I is a core material, 2.2 is a reactive adhesive layer, 3, 3 is a surface material, 4 is a conveying means, 5 is a coating means,
6 is a supply means, 7 is a hot pressure means, 8 is a cold pressure means, and 9 is a cutting means. 20

Claims (4)

[Claims] (1) A plate-shaped core material, a surface material provided on both sides of the core material and made of a material having different effects on the core material, and a reactive adhesive layer provided between the core material and the surface material. A composite board characterized by: (2) A flat core material, a surface material provided on one side of the core material and made of a material having a different effect from the core material, and a reactive adhesive layer provided between the core material and the surface material. A composite board characterized by: (3) a step of applying a reactive adhesive to the core material or surface material;
Manufacture of a composite board characterized by comprising a step of combining a core material and a surface material and hot pressing, a step of hot pressing and then cold pressing, and a cutting step of cutting into a predetermined width and length. Method. (4) A means for conveying the core material, a means for applying a reactive adhesive to the core material or the surface material, and a means for supplying the surface material to both sides of the core material by disposing them above and below the transported core material. A means for combining and hot-pressing the supplied core material and surface material, a means for cold-pressing after the hot-pressing, and a cutting means for cutting into a predetermined width and length. Composite board manufacturing equipment.