JPH0780997A - Method and apparatus for laminating decorative plate - Google Patents

Abstract

PURPOSE:To effectively prevent an external appearance malfunction such as wrinkle, sag, perforation malfunction, etc., while maintaining a grain pattern of a skin preferable by laminating a TPO skin tensioned by a small tension on a surface side of a board regulated to a specific temperature. CONSTITUTION:A board 11 is extruded in a sheet state from an extrusion molding machine 10, and the board 11 is regulated to a thickness of a gap between an upper roll 20 and an intermediate roll 30 and a temperature of 160-180 deg.C by a temperature regulating roll mechanism. A TPO skin 51 and the board 11 supplied from a raw fabric roll 50 are laminated by a pressure roller mechanism having the roll 30 and a lower roll 40, and conveyed to a cooling side. As a material of the board 11, PP composite resin material in which cellulose filler of wood chips, etc., is mixed with PP resin or organic fiber filler of polyester, rayon, cotton yarns, hemp, etc., is mixed is used.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminating method and a laminating apparatus for a decorative plate suitable for interior plates for automobiles or wall materials, ceiling materials and the like in bath units and kitchen units.

[0002]

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

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

As a conventional example, a laminating method and a laminating apparatus for a decorative plate in which an olefinic 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 board was manufactured by extruding the substrate 1 from the machine 3 and laminating the TPO skin 2 on the front surface side of the substrate 1 by a pressure roll mechanism including an upper roll 4 and an intermediate roll 5.

[0005]

As described above, conventionally, immediately after the substrate 1 is extruded, the substrate 1 is pressed by the pressure-bonding roll mechanism.
And the TPO skin 2 were laminated, but the temperature of the substrate 1 extruded from the extrusion molding machine 3 is about 200 ° C., and the radiant heat softens the TPO skin 2 and easily causes wrinkles and wrinkles. There was a problem.

As a measure against this, the TPO skin 2 has about 1.3
If 5 times the tension is applied, the occurrence of tarmi, wrinkles, etc. will disappear, but in that case, the texture pattern etc. formed on the surface of the TPO skin 2 will be extended and the commercial value as a decorative sheet will be significantly reduced. There was a drawback that

Furthermore, when the TPO skin 2 is laminated on the substrate 1, if there are incompletely melted pellets or incompletely dispersed fibers on the surface of the substrate 1, unevenness is likely to occur at that portion, and the surface side of the substrate 1 When the surface of the decorative plate has irregularities, the surface of the decorative plate cannot be smoothed, and a perforation phenomenon may occur in the TPO skin 2, which is a factor that significantly reduces the commercial value of the decorative plate.

The present invention has been made in view of the above circumstances, and reliably prevents the appearance of wrinkles and tarmi on the surface of the TPO, as well as the appearance of defects such as perforations, while maintaining the good texture of the TPO surface. It is an object of the present invention to provide a method of laminating a decorative board and a laminating apparatus that can be used.

[0009]

In order to achieve the above-mentioned object, the present invention laminates a TPO skin on the surface side of a substrate made of a PP composite resin material mixed with a cellulosic filler or an organic fiber filler. In the laminated method of a decorative plate, the substrate is extruded into a sheet by an extruder, and then the thickness and temperature of the substrate are adjusted by an upper roll and an intermediate roll to adjust the substrate temperature to 1
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 intermediate and lower rolls.

The decorative plate substrate used in the method of the present invention is P
Based on P resin, with some PE (polyethylene)
May be mixed.

The cellulose-based filler mixed in the PP resin is 2 parts with respect to 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,
Even if you mix organic fiber filler such as hemp, PP100
It is set in the range of 20 to 120 parts by weight with respect to 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 decreases.

Further, the roll temperature of the upper roll and the intermediate roll for adjusting the plate 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 and T
When the temperature exceeds 120 ° C., the adhesiveness with the PO skin deteriorates, and when the temperature exceeds 120 ° C., there is a problem that the substrate is cut off by taking it up.

Further, in order to prevent the warp of the substrate, immediately after the substrate is extruded, a warp-preventing non-woven fabric is formed on the back surface of the substrate, for example, polyester, rayon simple substance and fused fibers such as PP, low melting point polyester, EVA, etc. The mixture may be laminated on the back surface side of the substrate at a basis weight of 20 to 100 g / m ² .

The substrate and the TPO skin may be laminated by the intermediate roll and the pressure bonding roll immediately after passing through the plate thickness / temperature adjusting roll mechanism.

Next, the decorative plate laminating apparatus used in the method of the present invention comprises an upper roll for adjusting the plate thickness of the substrate after extrusion molding, a plate thickness consisting of an intermediate roll, a temperature adjusting roll mechanism, and a plate thickness. It is characterized in that it is composed of an intermediate roll for laminating a TPO skin on the surface side of the temperature-controlled substrate and a pressure roll mechanism consisting of a lower roll.

[0018]

As is apparent from the above structure, according to the method of the present invention, the sheet-like substrate extruded from the extruder is
The plate thickness and temperature are adjusted by the upper and middle rolls, and when the substrate and the TPO skin are laminated by the middle roll and the lower roll, the temperature of the substrate is set to 160 to 180 ° C. The radiant heat of the TPO does not soften the TPO epidermis, and wrinkles and tarmi do not occur on the TPO epidermis.

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

Further, the board thickness is adjusted by the upper roll and the intermediate roll, and at the same time, the smoothness of the board is improved and there is almost no unevenness on the surface. Therefore, even if the TPO skin is laminated, the TPO skin is torn. Is not generated, and good smoothness is obtained on the product surface.

In addition, even after the plate thickness and temperature are adjusted by the upper roll and the intermediate roll and then the intermediate roll and the lower roll are used, the cellulose-based filler or the organic fiber filler mixed in the substrate is used. Since the heat storage property is high, a strong bond between the substrate and the TPO skin can be expected.

[0022]

Embodiments of the method for laminating a decorative board and the 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 construction of a first embodiment of a decorative board laminating apparatus used in the method of the present invention, and FIG. 2 is a sectional view showing the construction of a decorative board laminated by the same apparatus. FIG. 4 is each explanatory view showing a modified example 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 form from the extrusion molding machine 10, the thickness and temperature of the substrate 11 are adjusted by the plate thickness / temperature adjusting roll mechanism including the upper roll 20 and the intermediate roll 30. The TPO skin 51 and the substrate 11 supplied from the original roll 50 are formed by the pressure-bonding roll mechanism including the intermediate roll 30 and the lower roll 40.
And are laminated and conveyed to the cooling side.

As described above, in this embodiment, the plate thickness of the substrate 11 extruded from the extrusion molding machine 10, the plate thickness for adjusting the temperature, and the temperature adjusting roll mechanism (composed of the upper roll 20 and the intermediate roll 30). ), Substrate 11 and TPO skin 5
1. A pressure bonding roll mechanism (intermediate roll 30
And a lower roll 40).

More specifically, as the material for the substrate 11, a PP composite resin material in which a cellulose-based filler such as wood powder is mixed with PP resin or an organic fiber filler such as polyester, rayon, cotton thread, or hemp is mixed. The amount of filler used is set to 20 to 120 parts by weight with respect to 100 parts by weight of the base PP resin.

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

Next, the roll temperature of the rolls 20, 30, 40 and the clearance between the rolls will be described. The roll temperature of each roll 20, 30, 40 is 80.
The temperature is set to 120 ° C., and if it is lower than 80 ° C., the cooling of the substrate 11 is accelerated, and good laminate 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 2 mm when 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. 0.1 mm, and the clearance between the intermediate roll 30 and the lower roll 40 is set to the thickness of the decorative plate, that is, 2.35 mm.

Therefore, the substrate 11 extruded from the extrusion molding machine 10 has its thickness adjusted between 2.05 and 2.1 mm by the upper roll 20 and the intermediate roll 30, and at the time of extrusion. 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
Substrate 11 is 160 to 1 by the pressure bonding roll mechanism by
When it is at 80 ° C, it is laminated with the TPO skin 51,
A strong laminate that does not peel off can be expected.

Thus, according to the method of the present invention, the plate thickness,
The temperature adjustment roll mechanism smoothes the surface of the substrate 11 and properly adjusts the temperature, so that the product surface has irregularities, and the surface irregularities of the substrate 11 cause the TPO skin 51 to be cut or the like. 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 resin heat as in the conventional case, so that it is not necessary to apply a strong tension and the elongation property is excellent. TPO skin 51
There is no problem 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, and FIG. 3 shows a substrate 11 laminated with a warp prevention nonwoven fabric 60.
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. For the lamination of the substrate 11 and the TPO skin 51, the first embodiment shown in FIG. 1 is used. To do.

In this embodiment, when the substrate 11 and the TPO skin 51 are laminated, the cooling of the TPO skin 51 is slow and the decorative plate tends to warp to the TPO skin 51 side. By keeping the cooling rate of 1 and the tension of the front and back sides constant, it is possible to prevent the veneer from warping.

As the non-woven fabric 60 for warpage prevention,
Unit weight 20-100g / m ² , material, polyester,
The rayon itself or a mixture of these and PP, a low melting point polyester, a heat fusion fiber such as EVA is used.

Next, FIG. 4 shows the substrate 11 and the TPO skin 5.
The substrate 11 is laminated with the upper roll 20
And immediately after passing through the intermediate roll 30,
This is a method of enhancing the laminating strength between the substrate 11 and the TPO skin 51, and for that purpose, a pressure bonding roll 70 is attached to the side portion of the intermediate roll 30.

[0039]

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

(1) According to the method of the present invention, the temperature of the substrate is adjusted by the plate thickness / temperature adjusting roll mechanism consisting of the upper roll and the intermediate roll, and the temperature of the substrate at the time of laminating the substrate and the TPO skin is Since it is set to 160-180 ° C, softening phenomenon due to radiation heat of the resin does not occur on the TPO skin, so that a good laminate without wrinkles and tarmi can be expected, and excessive TPO skin is prevented to prevent wrinkles and tarmi. Since it does not need to be applied with a small amount of tension, a small amount of tension is sufficient, and the texture pattern etc. formed on the surface of the TPO skin is not stretched and deformed, and a beautiful surface appearance such as a texture pattern can be obtained. It has an effect that a plate can be provided.

(2) According to the method of the present invention, the board thickness is adjusted by the board thickness and temperature adjusting roll mechanism composed of the upper roll and the intermediate roll, and the front and back surfaces thereof have almost no unevenness. Since it is formed on a smooth surface, when a decorative board is manufactured by laminating the substrate and the TPO skin,
It has an effect that it is possible to provide a decorative plate having an excellent surface feel without causing an appearance defect such as unevenness on the product surface or tearing the TPO skin due to the unevenness.

(3) The laminating apparatus according to the present invention has a simple structure in which a plate thickness, a temperature adjusting roll mechanism and a pressure bonding roll mechanism are constituted by three rolls of an upper roll, an intermediate roll and a lower roll. It has the effect of being highly practical.

[Brief description of drawings]

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

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

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

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

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

[Explanation of symbols]

 10 Extrusion Molding Machine 11 Substrate 20 Upper Roll 30 Intermediate Roll 40 Lower Roll 50 Original Roll 51 TPO Skin 60 Nonwoven Fabric 70 Crimping Roll

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display area // B29L 9:00

Claims (4)

[Claims] 1. A method for laminating a decorative plate, which is formed by laminating a TPO skin (51) on the surface side of a substrate (11) made of a PP composite resin material mixed with a cellulose-based filler or an organic fiber filler, The substrate (11) is extruded into a sheet by the extrusion molding machine (10), and then the thickness and temperature of the substrate (11) are adjusted by the upper and intermediate rolls (20, 30) to adjust the temperature of the substrate (11). After adjusting to 160-180 ℃,
By the intermediate and lower rolls (30, 40), the substrate (11)
On the surface side of the TPO with a slight tension
A method for laminating a decorative board, which comprises laminating an outer skin (51). 2. After extrusion molding of the substrate (11), the substrate (1)
On the back side of 1), a warp-preventing non-woven fabric (60) is provided on the upper side,
The method for laminating a decorative board according to claim 1, wherein the method is performed by laminating with an intermediate roll (20, 30). 3. The substrate (11) is on the upper side, and the intermediate roll (2
(0, 30) immediately after passing through the intermediate roll (30) and the pressure bonding roll (70), T is applied to the front surface side of the substrate (11).
The method for laminating a decorative board according to claim 1, wherein a PO skin (51) is laminated. 4. A laminating apparatus for a decorative plate, which comprises laminating a TPO skin (51) on the surface side of a substrate (11) made of a PP composite resin material mixed with a cellulosic filler or an organic fiber filler. The apparatus comprises a plate thickness and temperature adjusting roll mechanism including an upper roll (20) and an intermediate roll (30) for adjusting the plate thickness and temperature of the substrate (11) after extrusion molding.
It is characterized by comprising a pressure roll mechanism comprising an intermediate roll (30) for laminating a TPO skin (51) on the surface side of a substrate (11) whose plate thickness and temperature are adjusted, and a lower roll (40). Laminating device for decorative plates.