JPS6371332A - Manufacture of laminate material - Google Patents

Abstract

PURPOSE:To prevent unevenness, crimps, scars, deformation and see-through distortion by providing a sheet-shaped material between a plastic film for laminating and a plastic film for backing, by hermetically sealing ancl press adhering the surrounding area of both films under the deaerated state in a vacuum chamber, and cutting the surrounding portions of the films. CONSTITUTION:A plastic film 22 for laminating and a glass sheet 12 are placed on a support bed 27 of a lower vacuum chamber 25, while a plastic film 23 for backing is provided as a partition for dividing an upper vacuum chamber 24 and the lower vacuum chamber 25, and said both vacuum chambers are vacuum extracted, the film for backing being heated with a heating plate 26. When degree of vacuum and heating of plastic film 23 for backing are sufficient and the material becomes soft, the support bed 27 is raised up, and the surrounding area of both films is pressed down and sealed, and by releasing vacuum, the glass sheet 12 is covered with both films in a deaerated state. The same is heated up in the vacuum chamber, and the sheet-shaped material and the plastic film for laminating of the vacuum bag-type laminate material are fixed by pressure firmly.

Description

[Detailed description of the invention] [Industrial application field] The present invention relates to a method for manufacturing a laminate.

[Prior Art] As a conventional method for manufacturing laminated glass in which two glass plates are laminated and laminated with an interlayer film, there is a method using a pre-pressing rubber bag. In this method, a laminate with a laminated interlayer film sandwiched between two glass plates is placed in a pre-pressing rubber bag, the bag is evacuated, the entire bag is heated, and the glass plates and the laminated interlayer film are bonded by thermocompression. However, for example, when manufacturing pie layer type safety glass in which a plastic film is bonded to a glass plate, if the above-mentioned pre-pressed rubber bag method is used, unevenness and wrinkles on the inside of the pre-pressed rubber bag will be removed from the plastic film. A problem was discovered in which the glass was transferred to the surface of the glass, resulting in a serious drawback as a safety glass. In addition, as an improved manufacturing method for the safety glass mentioned above, a cover glass plate having the same shape as the safety glass to be manufactured is stacked on the plastic film for lamination of the laminate of the glass plate and the plastic film for lamination, and pre-press bonded. A method of obtaining the above-mentioned type of safety glass by heat-pressing a glass plate and a laminated plastic film using a rubber bag method or the like and peeling off a cover glass plate is disclosed in JP-A-58-194533 and JP-A-58-194533. This was proposed in Publication No. 58-194534. According to this method, thermocompression bonding of thermoplastic laminating plastic films is possible, but with thermosetting laminating plastic films, dents may occur on the release surface due to the influence of dust existing at the interface. However, the drawback was that a highly dust-free chamber was required. Further, there was also a decrease in yield due to insufficient mold release force during mold release.

Furthermore, in Japanese Patent Application No. 59-255037, the present applicant has proposed a method for manufacturing the above-mentioned pie layer type safety glass using conventional laminated glass using a vacuum bag and a vacuum packaging machine. In this method, the laminate is placed in a heat-sealable vacuum bag, the vacuum chamber is evacuated, the opening of the vacuum bag is heat-sealed, and the entire vacuum bag is heated to a predetermined temperature. It is something to do. According to this method, if a glass plate or a hard plastic film for lamination is placed on the surface, a good product can be made, but if a soft and easily damaged plastic film for lamination is placed on the surface, a good product can be made. In some cases, the laminated plastic film was deformed and perspective distortion occurred.

Furthermore, as a manufacturing method for this kind of laminate, Japanese Patent Publication No. 58-1
No. 2140 is known. According to this method, when laminating a plastic film on the smooth surface of a plate-shaped body, the plastic film is placed on an inflatable membrane whose periphery is fixed in a vacuum chamber, and the plastic film is laminated on the plate-shaped body. Place the plate horizontally with the surface of the body facing the plastic film, and then control the pressure on both sides of the membrane to inflate the membrane and press the plastic film against the surface of the plate to remove the plastic. A method has been proposed in which a film is crimped onto a plate.

However, in this method, the plastic films to be laminated are cut in advance to fit the shape of the plate-shaped object, so
It is extremely difficult to accurately position and properly attach the cut plastic film to the plate-like body. In particular, it is difficult to accurately press the surface of a curved plate-like object.

Furthermore, since an expandable silicone rubber film, for example, is used to pressurize the plastic film, defects may occur on the surface of the plastic film due to the surface properties of the film or dust adhering to the surface. .

[Problems to be Solved by the Invention] In the production of a laminate in which a plastic film for lamination is laminated on at least one side of a plate-shaped body, the present invention particularly relates to a safety glass in which a plastic film for lamination is laminated on at least one side of a glass plate. An object of the present invention is to provide a manufacturing method for producing a laminate of good quality without causing various defects such as unevenness, wrinkles, scratches, deformation, and perspective distortion in the laminate phase plastic film in the production of the laminate. It is something.

[Structure of the Invention] The present invention was invented as a result of research based on the above-mentioned object, and the gist thereof is that at least one of the plate-shaped bodies
In manufacturing a laminate made of laminated plastic films, a plate-like body is placed between two laminated plastic films to be laminated or one laminated plastic film to be laminated and a backing plastic film. Then, by sealing the periphery of both films in a deaerated state in a vacuum chamber, the plate-like body is wrapped with these films, and the plate-like body and the plastic film for lamination are brought into close contact, and the plate-like body and the plastic film for lamination are sealed. The present invention relates to a method for producing a laminate, which comprises crimping the film and then cutting the periphery of the laminated plastic film laminated onto the plate to match the outline of the plate.

The present invention will be explained in more detail below.

1 to 5 schematically show some of the configurations of a laminate 1 manufactured according to the present invention, and FIG. 2 is a cross-sectional view of a processed laminate, and FIG. 2 is a cross-sectional view of a laminate obtained by laminating a plastic film 3 for lamination on one side of the plate-like body 2 via an adhesive layer 4. FIG. 3 is a cross-sectional view of the processed laminate. A cross-sectional view of a laminate l in which a plastic film 3 for lamination is laminated on one side via an adhesive intermediate layer 5, and FIG. FIG. 5 shows a cross-sectional view of a laminate 1 in which a plastic film 3 for lamination is laminated on both sides of a plate-shaped body 2 via an adhesive layer 4.

The plate-shaped body 2 in the present invention is a substrate on which a plastic film for lamination is laminated, and typical examples thereof include an inorganic glass plate, a plastic plate made of polycarbonate, acrylic resin, and other types of plastics, but of course, it is not limited to these. The shape of the plate-like body 2 is not particularly limited, and the laminating plastic film 3 to be laminated on the plate-like body may be a thermoplastic film or a thermosetting film depending on the purpose. A plastic film for lamination, a plastic film for lamination in which a plurality of layers of a thermoplastic plastic film and a thermosetting plastic film are laminated, a plastic film for lamination in which an adhesive layer 4 is formed on the surface side of the plate-shaped body 2,
Various laminated plastic films such as laminated plastic films subjected to various processing may be used. In this case, the thickness of the laminated plastic film is not particularly limited, but is usually 0.3 to 2.5 mm.

Typical examples of the laminate of the present invention include automobiles, railways, etc., in which the plate-like body is a transparent glass plate, and a plastic film for lamination is laminated on the glass plate to increase safety in the event of breakage of the glass plate. For ships, aircraft, and other types of transportation vehicles, or! ! Safety glass for construction and various equipment. In the case of such safety glass, a transparent grain layer plastic film, such as polyethylene, is used, which has functions such as reducing skin damage caused by glass plate breakage in the event of a collision, and also has functions such as penetration resistance and scratch resistance. Laminated plastic film of terephthalate film, nylon film, self-healing thermosetting polyurethane film, etc. with adhesive interlayer film such as polyvinyl butyral, ethylene-vinyl acetate copolymer, or adhesive on the laminated side with glass plate. A laminated plastic film such as polyethylene terephthalate film, nylon film, self-healing thermosetting urethane, or a polyurethane layer or multilayer film, such as a thermoplastic urethane layer on the side facing the glass plate and a thermoplastic urethane layer on the outside. Typical examples of plastic films to be laminated to glass plates include plastic films for lamination having a self-healing thermosetting urethane layer, and plastic films made of surface-modified thermoplastic urethane.

The surface of such laminating plastic or Kufilm on which the plate is laminated should be sufficiently vented and the entire surface should be embossed to ensure preliminary crimping or crimping. The depth of such embossing is in the range of 0.1 to 5 μm, more preferably 1.0 to 2.5 μm. Further, since the laminated plastic film or each film constituting the laminated plastic film has adhesive properties, it can be subjected to various treatments such as corona discharge treatment.

The glass plate of the above-mentioned safety glass may be bent or strengthened, or it may be coated with a transparent surface coat such as a conductive coat, a heat ray reflective coat, a colored coat, a /\-de coat, a translucent coat, or an opaque coat. The thickness of the glass plate, which may be partially or entirely coated with a surface coating, is 1.0 to 20 mm, especially 2.0 mm for automobiles.
Approximately 0 to [i, Omm is appropriate.

In manufacturing a laminate according to the present invention, a surrounding member is prepared for enclosing the plate-shaped body in a vacuum chamber.

This surrounding member is composed of two laminated plastic films to be laminated to the plate-like body, or one laminated plastic film to be laminated and a backing plastic film.

That is, at least the side of each of the surrounding members on which the plastic film for lamination is to be laminated on the plate-shaped body is constituted by the plastic film for lamination constituting the body. Specifically, the entire bag to be finally formed may be made of a laminated plastic film that constitutes the body, or one side of the bag may be made of a laminated plastic film that is to be made into a plate-like body. , the other side may be made of a laminated plastic film made of another material or a flexible sheet (hereinafter referred to as a backing plastic film),
Further, the part to be laminated to the plate-like body of the bag may be made of the laminating plastic film constituting the laminate, and the other part may be made of the lining plastic film. Cover one side of the body. The parts of the final bag that are not made of the plastic film that makes up the laminate, such as the above-mentioned lining plastic film, are made of a film made of one or more layers of plastic film, or a flexible film. Plastic sheets etc. are used. Such materials include:
The plate-shaped body is non-adhesive, and after forming a bag containing the plate-shaped body in a vacuum chamber and pre-pressing it, the plate-shaped body is heated in a heating chamber or an autoclave without being removed from the vacuum bag. Alternatively, in the case of main compression bonding by heating and pressurizing, it is preferable to use a material that has thermal properties corresponding to the heating so that it does not melt or soften even at the heating temperature, for example, 50 to 150°C.

In particular, the material of the backing plastic film is heat-sealed to the laminated plastic film constituting the laminate.
It is preferable that a vacuum bag with good airtightness can be created by adhesion etc. For example, when sealing is performed by heat fusion to create a vacuum bag, polyethylene, polypropylene,
A single-layer thermoplastic laminated plastic film made of vinyl chloride resin, ethylene-vinyl acetate copolymer, polyurethane, unstretched nylon, etc., or a heat-sealed inner layer of these laminated plastic films, and nylon as the outer surface. Representative examples include, but are not limited to, two-layer type bags made by bonding films and polyester films.When sealing is performed by heat fusion, a vacuum bag is constructed. It is suitable that the entire vacuum bag, or at least the sealing part of the opening, has heat-sealing or hot-melting properties.

Figures 6 to 8 show embodiments of the present invention. In the present invention, the periphery of the surrounding member is sealed in a vacuum chamber with a plate-shaped body placed between the surrounding members marked 'A#. , the plate-like body is covered with a deaerated IE with a surrounding member, and v
The plastic film for lamination to be formed into the L layer is brought into close contact with the plate-shaped body.

These figures show an example of laminating the plastic film 22 for lamination on the glass plate 12 using a surrounding member consisting of the plastic film 22 for lamination and the plastic film 23 for lining.

The laminating plastic film 22 and the glass plate 12 are placed on the support stand 27 of the lower vacuum chamber 25, and the lining plastic film 23 is placed between the -E section vacuum chamber 24 and the lower vacuum chamber 2.
It is installed as a partition wall that separates 5.

Here, both the upper vacuum chamber 24 and the lower vacuum chamber 25 are evacuated, and at least the backing plastic film 23 is heated by the heating plate 26. When the degree of vacuum and the heating of the plastic backing film 23 is sufficient and it becomes flexible, the support stand 27 is raised and the plastic film for lamination 22 is pressed against the heated plastic film for backing 23, thereby making both of these films flexible. By sealing the periphery and releasing the vacuum, the glass plate 12
can be covered in a deaerated state by the laminating plastic film 22 and the backing plastic film 23.

Moreover, when sealing the plastic film 22 for lamination and the plastic film 23 for lining, the vacuum in the upper vacuum chamber 24 may be released first to seal the plastic film 23 for lining to the plastic film 22 for lamination, This may be used in combination with raising the support base 27. Also, if the backing plastic film 23 is flexible and can be sealed at room temperature, heating is not necessarily necessary.

The temperature at which the inside of the vacuum bag is evacuated and pre-pressed is 40℃.
℃ or less is preferable, and 20 ℃ or less is more preferable.

In addition, if the plate-shaped body and the laminated plastic film are sufficiently bonded together by just vacuum degassing inside the vacuum bag, sealing the opening of the vacuum bag is not necessarily necessary, or if the vacuum bag inside the vacuum bag is Similarly, when the plate-shaped body and the laminated plastic film are sufficiently pressed together by heating the vacuum bag while continuing evacuation, the opening of the vacuum bag does not necessarily need to be sealed.

In this way, the degassed vacuum bag containing the plate-like material is placed in the heating chamber while still in the vacuum bag, or heated while passing through the heating zone, or heated inside the vacuum chamber, and then the plate is heated. The shaped body and the plastic film for laminating the vacuum bag laminate are pressed together. In addition, in some cases, after the heat treatment as described in E, the material is placed in an autoclave and then heated and pressurized, or alternatively, the sheet is placed in an autoclave and heated and pressurized without performing the heat treatment as described in H. The plastic film for lamination on the side that will become the plastic film for lamination of the laminate of the vacuum bag may be pressure-bonded.

The temperature conditions for normal pressure mandibular heat treatment in the heating chamber described above will vary depending on the type of laminated plastic film, adhesive interlayer film, or adhesive used, and appropriate conditions will be selected depending on the type, but in general Generally 60℃~180℃
For example, when the plastic film for lamination is thermosetting polyurethane with an adhesive layer, the above heat treatment temperature is 80°C to 150°C, and the laminated side is thermoplastic polyurethane and the outside is thermosetting urethane. In the case of plastic film, the above heat treatment temperature is 80°C.
-150°C, and in the case of an end layer plastic film made of adhesive intermediate film material polyethylene terephthalate, the above-mentioned heat treatment temperature is 80°C - 150°C.

The suitable time for the heat treatment in the heating chamber is about 3 to 60 minutes. For example, after the heat treatment, a heat compression bonding treatment may be performed in an autoclave as required. In this case, usually 80 to 1
15 at 80℃ under heat and pressure of about 2 to 10 kglc-2
Hold for minutes to 2 hours.

It should be noted that attaching the plastic film for laminating the vacuum bag to the plate-shaped object is troublesome, but if the entire surface is embossed, vacuum evacuation will be easier. Pressure bonding can be performed by heat treatment in a heating chamber without any treatment, and manufacturing costs can be reduced. Note that the above heat treatment is not necessary if the adhesion between the plate-shaped body and the laminated plastic film is sufficient only by evacuation treatment in a vacuum bag without heat treatment in a heating chamber or autoclave.

After heat treatment in a heating chamber or after heating and pressurizing in an autoclave, remove from the heating chamber or autoclave and cool to room temperature as necessary. The plastic film is cut according to the outline of the plate-like body to obtain a laminate in which the plate-like body and the laminated plastic film are bonded together. When cutting such a plastic film for lamination, it may be cut in accordance with the outline of the plate-like object, or the trimming of the plastic film for lamination may be formed at a predetermined width around the plate-like object or at a necessary location. It may be cut, or it may be cut so that a margin of the laminated plastic film is formed around the plate-shaped body or at a necessary location.

[Example] Examples of the present invention will be described below.

Example 1 Width 700mm as a plastic film for lamination.

A film with a length of 500 mm and a thickness of 0.8H consisting of self-healing thermosetting urethane and an adhesive layer of 0.03 mm was used as a backing plastic film with a thickness of 0.
．． A 0.5 mm roll of unstretched nylon film is used, and dust is thoroughly removed from the roll.

In addition, a glass with a length of 441 am, a width of 337 layers, a bending depth of 28 cm, and a thickness of 3.01 cm was prepared and thoroughly cleaned and dusted.

This laminated plastic film and glass are placed on a support stand installed in the lower vacuum chamber, while the lining plastic film is installed as a partition between the upper vacuum chamber and the lower vacuum chamber, and the lower vacuum chamber and the E part are placed. Both empty chambers are evacuated to 2 mmHg, and at the same time, a heating plate installed in the upper vacuum chamber that has been preheated to 180°C
Heat the backing plastic film.

After evacuation, the heating plate is raised and at the same time the support base of the lower vacuum chamber is raised to seal the periphery of the laminated plastic film with the heated backing plastic film, and the upper and lower vacuum chambers are separated. By releasing the vacuum, you can create a vacuum bag with glass inside.

The following operations were performed in an atmosphere with a cleanliness level of class 1000.

This vacuum bag was placed in a heating chamber with an atmosphere of 100°C, and after the temperature of the glass plate exceeded 97°C, it was maintained for 10 minutes, and then taken out from the heating chamber and cooled. After cooling, the part of the vacuum bag without the glass plate and the lining plastic film were removed to obtain a body with good transparency.

Comparative Example 1 The plastic film for lamination described in Example 1 and the glass plate (dimensions: 300 mm x 300 mm each) were placed in a vacuum bag made of a 2 mm thick silicone rubber sheet with a smooth surface.
A laminated assembly consisting of overlapping layers (mm) was inserted. At this time, as in Example 1, the film and glass were sufficiently cleaned and dust removed.

Dust was also removed from the vacuum bag.

The inside of the vacuum bag was evacuated, and the entire bag was heated to 100° C. and held for 10 minutes. When I cooled it down and took out the body inside the bag, I found dust between the silicone rubber sheet and the laminated plastic film attached to the glass plate.
The surface has become uneven.

Comparative Example 2 Same as Example 1, the thermosetting polyurethane side of the plastic film for shoes was coated with polymethylsiloxane at 330°C.
The mold release treated glass was baked and the low thermoplastic polyurethane side was cleaned glass plate in a class 1000 dust-free room. The size of the laminated plastic film and glass plate is 200 mm x 200 mm, respectively.

This was placed in a vacuum rubber bag, and after vacuum degassing, it was placed in an autoclave and heated at 130℃ in an atmosphere of LOkg/ca2 for 20 minutes.
The mixture was held for 1 minute, cooled, and depressurized.

When the mold release treatment of the crimped body caused the glass to peel off,
In some cases, dents were created due to dust mixed in at the interface between the release-treated glass and the film.

[Effects of the Invention] As described above, according to the present invention, when producing a laminate in which a plate-shaped body and a plastic film for lamination are bonded together, part or all of the vacuum bag used for crimping is The laminated body is made of v1 residential plastic film.The plate-shaped body is placed in a vacuum bag, evacuated, the plate-shaped body and the laminated plastic film are crimped, and then the plate-shaped body of the laminated plastic film is evacuated. The laminate can be manufactured by simply cutting around the body, and at least a portion of the vacuum bag also serves as a laminated plastic film to be attached to the plate-shaped body.

Material costs can also be reduced. Furthermore, compared to conventional pre-pressed rubber bags, the vacuum bag used in the present invention can be easily manufactured by using an I-laminated plastic film that is attached to a plate-like object, or by using such a laminated plastic film and a lining plastic film. This can be easily done by heat sealing or other means, and manufacturing costs can be reduced.

In addition, in the present invention, the plate-shaped body is placed in a vacuum bag, the inside of the vacuum bag is evacuated, and the opening of the vacuum bag is then sealed. The pre-press bonding can be carried out by heating the pre-press bonded laminate in a heating chamber under normal pressure, or by heating and pressurizing it in an autoclave. The advantage is that the crimping manufacturing process can be simplified and the manufacturing time can be further shortened. Also, since the vacuum bag is thin and light, it has an energy saving effect on heat. Furthermore, in the conventional pre-crimping method using a pre-crimped rubber bag or the pre-crimping method using nipper rolls, due to the structure of the pre-crimping equipment and nipper rolls, during pre-crimping of a laminate having a plastic film for lamination on the surface, the crimping process is difficult. Wrinkles on the bag,
Irregularities and scratches are transferred to the laminated plastic film,
However, in the present invention, there is no material that transfers such defects to the upper surface of the laminated plastic film side of the plate during thermocompression bonding, resulting in a laminated body with good surface quality. plastic film can be obtained. In particular, the present invention can significantly reduce wrinkles, unevenness, and optical distortion on the surface of the laminated plastic film as described above, compared to conventional methods. The interior side of the single glass pane or laminated glass pane has anti-tear and abrasion properties to prevent skin damage to passengers when the glass pane breaks.
Furthermore, in some cases, it is ideal for producing safety glass that requires a high-quality surface texture, to which a laminated plastic film with #penetration is attached.

According to the present invention, since a vacuum bag that can be applied to various shapes and configurations is used, it has the advantage that it can be applied to the production of laminates with complex curved shapes compared to conventional rubber crimping. It is something that will be done.

[Brief explanation of the drawing]

Figures 1-5 show cross-sectional views of various types of laminates produced according to the invention; Figures 6-8 are illustrations showing the lamination apparatus used to carry out the invention; It is a diagram. 1: Laminated body, 2,12: Plate body, 3.22+
Plastic film for lamination, 4: adhesive layer, 5: adhesive interlayer film, 17: intake and exhaust pipe. 23: Plastic film for lining, 24 K-E vacuum chamber, 25; Lower vacuum chamber, 26: Heating plate,
27: Support stand 211su 2G Spear 31fufu! rr) Spear CO Spear'7 () Fang? Q

Claims (8)

[Claims] (1) In manufacturing a laminate in which a plastic film is laminated on at least one side of a plate-shaped body, between two laminated plastic films to be laminated on the plate-shaped body, or between one laminate to be laminated. The plate-shaped body is placed between the plate-shaped body that covers one side of the plate-shaped body and the non-adhesive backing plastic film, and the surroundings of both films are degassed in a vacuum chamber. The plate-shaped body is covered with these films by sealing, the plate-shaped body and the plastic film for lamination are brought into close contact with each other, the plate-shaped body and the plastic film for lamination are crimped, and then the laminated body is laminated on the plate-shaped body. A method for manufacturing a laminate, which comprises cutting the periphery of a plastic film to match the outline of a plate-shaped body. (2) In one of the vacuum chambers divided into two by the plastic lining film, a plate-like body is placed between the plastic lining film and the laminated plastic film to be laminated, and the entire vacuum chamber is The lamination according to claim 1, characterized in that the plate-shaped body and the plastic film for lamination are brought into close proximity to each other while maintaining the vacuum in the vacuum chamber in which the plate-shaped body and the plastic film for lamination are located, and the periphery thereof is sealed. How the body is manufactured. (3) When sealing the periphery of the laminating plastic film and the backing plastic film, the vacuum in the vacuum chamber in which the plate-like body and the laminating plastic film are not present is released. A method for manufacturing a laminate. (4) The method for manufacturing a laminate according to claim 3, characterized in that the plastic backing film is sealed to the laminated plastic film by heating. (5) Place the plastic film for lamination and the plate-shaped body in this order on a support set in the vacuum chamber, and move the support base toward the plastic film for lining, so that the plastic film for lamination can be used for lining. 4. A method for manufacturing a laminate according to claim 3, characterized in that the laminate is brought close to plastic films and the periphery of these films is sealed. (6) The method for producing a laminate according to claim 1, wherein the plastic film for lamination to be laminated is made of polyurethane. (7) The lamination according to claim 1, characterized in that the plastic film for lamination to be laminated on the plate-like body has an embossment having a depth of 0.1 to 5 μm on the side of the plate-like body. How the body is manufactured. (8) The method for manufacturing a laminate according to claim 1, wherein the plate-like body is a glass plate.