JPH106424A - Laminated panel of different kind of synthetic resin layers and lamination method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a laminated panel generating no warpage and having strong bonding strength and good appearance by laminating an acrylic panel and a glass fiber reinforced foamed urethane material. SOLUTION: A plastic flat panel 2 is arranged in the cavity of a lower mold 1 as a decorative surface panel and glass fibers 3a are placed thereon to inject an urethane soln. 3b into the cavity and a foamed plastic sheet 4 is brought into close contact with the glass fibers and glass fibers 5a are again placed thereon to inject a urethane soln. 5b into the cavity. Thereafter, an upper mold 6 is fitted to the lower mold to perform foam molding to obtain a laminated panel of a different kind of integrated synthetic resin layers consisting of the plastic flat plate 2, the foamed plastic sheet 4 and the glass fiber reinforced foamed urethane materials 3, 5.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated panel and a method for laminating different kinds of synthetic resin layers, and more particularly, to a panel having a corrosion resistance and a heat insulating property in which an acrylic plate or the like and a glass fiber reinforced urethane material are laminated. Therefore, the configuration is such that no warpage occurs.

[0002]

2. Description of the Related Art Conventionally, thermosetting laminates are formed by impregnating and drying various fiber base materials with a synthetic resin to form a sheet having a predetermined thickness, and laminating and heating and compressing the sheet. However, in order to impart diversity to the properties of the laminate, panels having different types of synthetic resin layers, including thermoplastic types, are required. In this case, different types of synthetic resin sheets are superposed and bonded, but it has been difficult to prevent warpage.

[0003]

SUMMARY OF THE INVENTION An object of the present invention is to provide a laminated panel and a laminating method having a structure in which an acrylic plate or the like and a glass fiber reinforced urethane foam are laminated to prevent warpage. Still another object is to provide a laminated panel having a strong bonding degree and a good appearance, and a laminated method and a laminated panel structure having a foamed plastic sheet layer interposed therebetween.

[0004]

Means for Solving the Problems The present inventor has proposed that a polyurethane liquid is foamed simultaneously with a foamed plastic sheet for a laminated panel of a plastic flat plate such as an acrylic plate and a glass fiber reinforced urethane sheet as different kinds of synthetic resin layers. The present invention has been completed by finding that the above object can be achieved by joining.

That is, the laminated panel of the different types of synthetic resin layers of the present invention comprises a plastic flat plate layer arranged on a decorative surface,
The glass fiber reinforced urethane foam first layer, the foamed plastic sheet layer and the glass fiber reinforced urethane foam second layer are laminated and integrated in that order.

According to the method of laminating different kinds of synthetic resin layers of the present invention, a plastic flat plate is arranged as a decorative surface plate in a cavity of a lower molding die, a glass fiber is placed thereon, and a urethane liquid is injected. The foamed plastic sheet is brought into close contact therewith, the glass fiber is placed again, and the urethane liquid is injected. Then, the upper mold is fitted and foamed, and the plastic plate, foamed plastic sheet and glass fiber reinforced urethane foam are formed. It is characterized by integrating materials.

[0007] By the above-mentioned laminated panel and laminating method, it is possible to integrate different kinds of synthetic resin sheets having different shrinkage rates or thermal expansion rates without warping due to lamination, and this is because of thermal expansion distortion between different kinds of sheets. By causing the foamed plastic sheet to intervene with a foam or a compression strain or the like, and foaming the polyurethane from a liquid instead of bonding the polyurethane in a sheet state, the occurrence of warpage can be suppressed. Thereby, it is possible to easily manufacture an acrylic decorative composite board having no warp, a strong bonding degree, and a good appearance.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described in detail with reference to the drawings. First, as shown in FIG. )
In order to form a first layer of a glass fiber reinforced urethane foam material thereon, an acrylic plate 2 is disposed.
a), and a polyurethane liquid 3b having a composition that foams 5 to 20 times is injected. An open-cell polyethylene sheet 4 is placed on the polyurethane liquid 3b as a foamed plastic sheet in close contact with the liquid, and glass fibers 5a are formed thereon to form a second layer of glass fiber reinforced urethane foam material. And a polyurethane liquid 5b having a composition that foams 5 to 10 times is injected.

Therefore, if the upper mold 6 is fitted to the lower mold 1 and the polyurethane liquids 3b and 5b are foam-molded, as shown in FIG. A laminated panel in which four layers of the layer 3, the foamed polyethylene sheet 4, and the second layer 5 of the fiber-reinforced urethane foam material are integrated is obtained.

[0010] The plastic of the foamed plastic sheet is a synthetic resin of a thermosetting resin or a thermoplastic resin, and is not particularly limited. A foamed polyolefin sheet such as is preferred. It is particularly preferable to use a urethane foam liquid for bonding the foamed polyolefin sheet.

As the foamed plastic sheet, an open-cell plastic sheet is preferable because it has an anchor effect on the surface. Even if the cells are open cells to the inside, the urethane foam liquid permeates only on the surface. Further, in order to make the penetration of the foamed urethane liquid uniform throughout the entire surface, it is possible to use a three-layer sheet in which an open-cell plastic sheet is joined to both sides of a closed-cell plastic sheet. Further, a closed-cell plastic sheet having an adhesive layer such as an epoxy resin formed on both sides thereof may be used.

[0012]

According to the present invention, a foamed plastic sheet is interposed in a laminate of a plastic flat plate and a fiber-reinforced urethane foam material, and foaming by liquid urethane is performed without bonding the fiber-reinforced foamed polyurethane material in a sheet state. Because it is used, it is possible to produce a product that is accurate in dimensions without warpage, and has less troublesome integration than conventional laminated panels, strong bonding between layers, and excellent appearance. Can be provided.

[Brief description of the drawings]

FIG. 1A is a perspective view showing a structure of a laminated panel of the present invention, and FIG. 1B is a cross-sectional view of a mold for explaining a method of laminating the laminated panel of the present invention.

[Explanation of symbols]

 Reference Signs List 1 lower mold 2 plastic flat plate 3 first layer of fiber-reinforced foamed polyurethane material 3a glass fiber 3b polyurethane liquid 4 foamed plastic sheet 5 second layer of fiber-reinforced foamed polyurethane material 5a glass fiber 5b polyurethane liquid 6 upper mold

Claims (2)

[Claims] 1. A plastic flat layer, a glass fiber reinforced urethane foam first layer, a foamed plastic sheet layer and a glass fiber reinforced urethane foam second layer arranged on a decorative surface are laminated and integrated in that order. Characterized laminated panel of different types of synthetic resin layers. 2. A plastic flat plate as a decorative face plate is placed in the cavity of the lower mold, glass fiber is placed thereon, a urethane liquid is injected, and a foamed plastic sheet is further brought into close contact therewith. After placing the fibers and injecting the urethane liquid, the upper mold is fitted and foamed, and the plastic flat plate, the foamed plastic sheet and the glass fiber reinforced urethane foam material are integrated to form a different kind. A method for laminating a synthetic resin layer.