JPS6371334A - Manufacture of laminate material and device for same - Google Patents

Abstract

PURPOSE:To prevent unevenness, crimps, scars, deformation and see-through distortion by providing a vacuum system consisting of a plastic film, a retaining device to mount the film and a support bed to mount a sheet-shaped material and fixing the same by pressure by means of vacuum operation with an upper chamber and introduction of atmosphere. CONSTITUTION:After dust is removed from a plastic film 11, which is fixed to a plastic film retaining device 14. Also after dust is removed from a sheet- shaped material 12, which is placed on a support bed 13. The plastic film retaining device 14, to which the plastic film 11 is fixed, is fixed on the support bed 13 to form a vacuum structure. After the whole of a vacuum chamber 10 is evacuated through outlets 16 and 18, vacuum is released through the air outlet 16 except the vacuum structure and the plastic film 11 is bonded with the sheet-shaped material 12. Then, the surrounding area of the sheet-shaped material 12 is heated by a heater 23 and the edges of the plastic film 11 and the sheet-shaped material 12 are sealed. After cooling down, the surrounding area of the sheet-shaped material is cut off and a laminate material is taken out.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for manufacturing a laminate and an apparatus therefor.

[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. A problem was discovered in that the film was transferred to the film, resulting in a serious drawback as a safety glass. In addition, as an improved manufacturing method for the above-mentioned safety glass, a cover glass plate having the same shape as the safety glass to be manufactured is stacked on a plastic film of a laminate of a glass plate and a plastic film, and a pre-pressing rubber bag method or the like is used. JP-A-58-194533 and JP-A-58-19453 disclose a method of obtaining the above-mentioned type of safety glass by thermocompressing a glass plate and a plastic film and peeling off a cover glass plate.
This is proposed in Publication No. 4. According to this method, thermocompression bonding of thermoplastic plastic films is done by rotation, but thermosetting plastic films have the disadvantage of being affected by dust present at the interface, causing dents on the mold release surface. Therefore, a highly dust-free room was required.

Further, there was also a decrease in yield due to insufficient mold release force during mold release.

In addition, the applicant of the present invention has proposed in Japanese Patent Application No. 130-51271 a method for producing pie layer type safety glass using a vacuum bag and rI air-filled glass. In this method, as shown in FIG. 8, a vacuum bag 40 is made by heat-sealing the periphery of a plastic film 41 to be pasted and another film 43, leaving an opening on one side.
2, the vacuum chamber 45 is evacuated from the exhaust port 49, the opening 48 of the vacuum bag is heat-sealed with a heat sealing member 47, and the entire vacuum bag 40 is heated to a predetermined temperature to be bonded by thermocompression. It is. According to this method, a good laminate can be manufactured, but there is a drawback that, for example, the film 3 is discarded without being used as a material constituting the laminate, resulting in wasted film and high costs. Ta.

[Problems to be Solved by the Invention] The present invention relates to the production of a laminate in which a plastic film is laminated on at least one side of a plate-shaped body, and particularly to the production of a safety glass laminate in which a plastic film is laminated on at least one side of a glass plate. , it is possible to obtain a laminate of good quality without causing various defects such as unevenness, wrinkles, scratches, deformation, and perspective distortion in the plastic film, and the production cost is low and the laminate is easy to mass-produce. The object of the present invention is to provide a manufacturing method and an apparatus therefor.

[Means for Solving the Problems] The present invention has been made to solve the above-mentioned problems, and the first invention is to place a plate-like body on a support base having an exhaust port on the outer periphery of the plate-like body. a, and the plastic film to be laminated on the plate-like body surface is placed on the plate-like body through a plastic film holding device provided near the outer circumferential frame outside the exhaust port of the support base. The plastic film is stretched and sealed to cover the entire circumference, and the upper chamber formed in the part including at least the upper part of the plastic film is evacuated to create a vacuum, and the air is also evacuated from the exhaust port of the support base. At least the space between the plastic film and the surface on which the plate-shaped body is placed on the support base is also evacuated, and then the atmosphere is introduced into the upper chamber to release the vacuum and the plastic film is pressed against the plate-shaped body surface. The second invention relates to a method for manufacturing a laminate, characterized in that the plastic film is compressed onto a plate-like body, and a second invention is a laminate-producing apparatus for laminating a plastic film on a plate-like body, comprising: The package has a vacuum chamber and a support stand provided in the vacuum chamber on which the plate-like object is placed, and the support stand includes a plastic film holding device that is laminated on the surface of the plate-like object over the outer periphery of the support stand. Inside the holding device, an exhaust port is provided for evacuating the space formed between the plastic film stretched by the plastic film holding device and the mounting surface of the plate-shaped body of the support base. When the film is stretched on the surface of the plate-shaped object, the upper space above the plastic film in the vacuum chamber and the space formed between the plastic film and the mounting surface of the plate-shaped object of the support stand are separated separately. The present invention relates to a laminate manufacturing apparatus characterized in that it is capable of vacuum operation.

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. A cross-sectional view of the laminate, FIG. 2 shows an adhesive layer 4 on one side of the plate-shaped body 2.
FIG. 3 is a cross-sectional view of a laminate in which a plastic film 3 is laminated with a plastic film 3 interposed therebetween.
FIG. 4 is a cross-sectional view of a laminate l in which a plastic film 3 is laminated on one side of a laminated type plate-like body 2. FIG.

The plate-like body 2 in the present invention is a base on which a plastic film is laminated, and representative examples include an inorganic glass plate, a plastic plate made of polycarbonate, acrylic resin, and other types of plastics, but of course it is limited to these. It is not something that will be done. The shape of the plate-like body 2 is not particularly limited, and the plastic film 3 may be a thermoplastic film, a thermosetting plastic film, or a combination of a thermoplastic film and a thermosetting plastic film, depending on the purpose. A plastic film with multiple layers of
Various plastic films can be used, such as a plastic film with an adhesive layer 4 formed on the laminated surface side of the plate-shaped body 2, and a plastic film subjected to various processing.

Typical examples of the laminate of the present invention include automobiles in which the plate-shaped body is a transparent glass plate and a plastic film is laminated on the glass plate to increase safety when the glass plate is broken;
Safety crows for railways, ships, aircraft, and other types of transportation vehicles, for construction, and for various types of equipment. In the case of such safety glass, a transparent plastic film that 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,
For example, polyethylene terephthalate film, nylon film.

A laminated plastic film consisting of a self-healing thermosetting polyurethane film and an adhesive interlayer such as polyvinyl butyral or ethylene-vinyl acetate copolymer, or a polyethylene terephthalate film with an adhesive layer on the side that is laminated with a glass plate. , a plastic film such as a nylon film, a self-healing thermosetting urethane, or a single-layer or multi-layer film of polyurethane, such as a thermoplastic urethane layer on the side laminated with a glass plate and a self-healing thermosetting urethane layer on the outside. Typical examples include a plastic film having a layer or a plastic film made of thermoplastic urethane with a modified surface.

The side of the plastic film that is laminated onto the plate-like body is
It is best to emboss the entire surface to ensure sufficient ventilation and pre-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, the plastic film or each film constituting the plastic film can be subjected to various treatments such as corona discharge treatment to improve adhesiveness.

The glass plate of the safety glass described above may be bent or strengthened, or may be coated with a transparent surface coat such as a conductive coat, a heat ray reflective coat, a colored coat, a hard coat, a translucent coat, or a translucent coat. The thickness of the glass plate, which may be partially or entirely coated with an opaque surface coating, is l, 0 to 20 mm, particularly 2.0 mm for automobiles.
~8.0m is appropriate.

FIG. 6 is an explanatory diagram schematically showing a specific example of the laminate of the present invention, in which 10 is a vacuum chamber, 11 is a plastic film to be laminated, and 12 is a plastic film 1.
1 is a plate-like body on which the plate-like bodies are laminated; 13 is a support base on which the plate-like bodies are placed for lamination; 14 is a plastic film holding device for stretching the plastic film 11 on the surface of the plate-like body 12; 15 1G is the outer peripheral frame of the support base 13 on which the plastic film holding device is installed; 1G is the exhaust port for evacuating the upper chamber 17 on the plastic film 11;
1 and 21 are exhaust ports for evacuating the lower space 20 formed between the lower surface of the plastic film 11 and the a-layer surface 19 of the plate-like body 12 of the support base 13.

In the above device, the plastic film holding device 14
is provided over the entire circumference of the outer peripheral frame portion 15 of the support stand 13 so that the entire surface of the mounting surface 19 on the upper surface of the support stand 13 is covered with the plastic film 11, and the plastic film 11 is stretched. When the plastic film 11
A sealed space is formed between the lower surface of the plastic film 11 and the mounting surface 18 of the support base 13 by the plastic film holding device 14, the support base 13, and the outer peripheral frame portion 15, and the upper chamber 17 of the plastic film Ill is Separate vacuum chambers are provided. Through the exhaust ports 16, 18, and 21, the J: chamber 17 and the lower space 20 can be operated to be evacuated or introduced into the atmosphere by a vacuum pump (not shown).

The exhaust port 18 is connected to the mounting surface 19 of the plate-shaped body 12 of the support base 13.
One or more or continuous exhaust passages 21 are connected to the outside of the plastic film holding device 14, but to the inside area of the plastic film holding device 14, forming a vacuum system independent of the upper chamber 17.

The support stand 13 is made of a wooden mold, a metal mold, a plastic mold, a ceramic mold, etc., and is a storage device that supports the plate-shaped body 12 at its periphery, on its entire surface, or at its periphery and a predetermined area. It has a surface 1B and a base. The mounting surface has a shape that matches the shape of the surface of the plate-like body 12, and a heater for heating the plate-like body 12 is provided to facilitate adhesion of the plastic film 11 to the surface of the plate-like body 12. Can be done. The example shown in Figure 5 is
This is an example in which a heater 23 is provided around the entire circumference of the mounting surface 19 of the plate-shaped body 12 of the support base 13, and the pressure bonding between the plate-shaped body 12 and the plastic film 11 is performed around the circumference by the heating of this heater. , it can be strengthened by %. In addition, for this heater 1, h″y of the plastic film 11
As the heater that may be installed in the 5i, an appropriate heater such as an electric heater or a hot air heater can be used.

The plates 12 are adjacent to each other so that the plates 12 are heated before being placed into such a laminating device! Two heating chambers may be provided.

Plastic film holding device 1 in the device of the present invention
4 is shown in FIGS. 6 and 7. In the example shown in FIG. 6, the plastic film 11 is sandwiched between the base 24 and the upper base 25 arranged on the upper surface of the outer peripheral frame 15 of the support base 13, and the bolts are 2111, and the example shown in FIG. 7 is an example in which a steel band 27 or the like is used to attach to the outer peripheral frame portion 15 via adhesive M92B, which is an example of a flexible structure.

It is best to have a flexible structure that allows the plastic film holding device to follow the curved surface of the plate so that it can be applied to plates of various shapes.

In manufacturing the laminate according to the present invention, a vacuum structure including a plastic film 11 and a support base 13 as shown in FIG. 6 is used. After thoroughly removing dust from the plastic film 11, the plastic film 11 is placed in the plastic film holding bag 2214.
Fixed. After the plate-shaped body 12 is also thoroughly dusted off in advance, it is placed on the support stand 13, and the plastic film holding bag 314 to which the plastic film 11 is fixed is fixed on the support stand 13 to form a vacuum structure. The plastic film is fixed using a fastener. After the entire vacuum chamber 10 is evacuated through the exhaust ports 16 and 18, the vacuum structure is removed and the vacuum is released through the exhaust ports 18, and the plastic film 11 is brought into close contact with the plate-shaped body 12. Here, the heater 23
The peripheral part of the plate-shaped body 12 is heated to edge-seal the plastic film 11 and the plate-shaped body 12, and after cooling, the periphery of the plate-shaped body is cut and the laminate is taken out.The plate-shaped body has been heated in advance, In addition to vacuum compression bonding, thermocompression bonding can also be used.

Then heat the laminate or if necessary 2-10k
Heat and pressurize in an autoclave under g/cmZ to sufficiently bond the plastic film and the plate. For example, when thermoplastic urethane is used, the bonding temperature is 60 to 1
f30°C, preferably 80 to 140°C is appropriate.

Before or after compressing the plastic film to the plate-like body, the plastic film, the plate-like body, or the laminate of the plastic and the plate-like body is heated to a temperature at which the plastic film can be bonded to the plate-like body. surely,
Moreover, the speed of crimping work can be increased. The temperature conditions for this heat treatment vary depending on the type of plastic film, adhesive interlayer, or adhesive used, and appropriate conditions are selected depending on the type, but generally it is 60°C to 160°C. 0 For example, when the plastic film is thermosetting polyurethane with an adhesive layer, the above heat treatment temperature is 80°C to 150°C, and 1
! In the case of a plastic film with thermoplastic polyurethane on the first layer side and thermosetting urethane on the outside, the above heat treatment temperature is 80 ° C to 150 °C, and in the case of a plastic film consisting of 80
℃~150℃. Appropriate time for the heat treatment in the heating chamber is about 3 to 60 minutes.

Such heat treatment may be performed within the crimping device, or may be performed in a heating chamber as the next step in the crimping device. In addition, when heating the plate-shaped object, the heat treatment may be performed before the plate-shaped object is placed in the crimping device. It may be heated in advance in a heating chamber.

After such heat treatment, a heat compression bonding treatment may be performed in an autoclave as required.
Hold under heat and pressure of about 2 degrees for 15 minutes to 2 hours.

In addition, when attaching a plastic film to a plate-shaped object, if the entire surface side is embossed, vacuum evacuation will be easier. In some cases, crimping may be possible by heat treatment. In this case, manufacturing costs can be reduced. It should be noted that if the adhesion between the plate-shaped body and the plastic film is sufficient only by evacuation treatment in a vacuum bag without heat treatment in a heating chamber or autoclave, the above-described heat treatment is not necessary.

Of course, the lamination and pressure bonding operation of a plurality of plate-like bodies and plastic films may be performed simultaneously or continuously in a vacuum chamber.

In the illustrated vacuum chamber, the upper lid 28 is removed from the lower plate 30 so that the plate-shaped object can be placed in the vacuum chamber, and then when the upper lid 21 is closed, the backing 31 allows the inside of the vacuum chamber to be removed. Although the vacuum chamber is designed to be kept airtight, various types of opening/closing mechanisms can be used to open and close the vacuum chamber or open/close the opening and closing mechanism for transporting plastic or plate-like objects into the vacuum chamber.

"Example" Example 1 The support stand has external dimensions of 85 x 500 x 700+sm,
Can support a glass plate of 340 x 440 mm thickness 3mi+, bending depth 30m, width 25+ at the glass edge part of the wooden mold
It is equipped with a rubber heater of m, 13Q V, OJW/cm2. As a plastic film holding device, a combination of brushed steel with a cross section of 1010×20 as shown in FIG. 7 is prepared and fixed to the support stand with bolts.

The plastic film consisted of a 0.8 mm thick thermoset polyurethane film with a 0.02 mm thick adhesive layer, cut into 500 x 70 hm rectangles and mounted on a plastic film holding device. After cleaning the glass plate with detergent, it was placed on L of the support stand. After thoroughly removing dust from the glass plate surface and the plastic film surface, the plastic film holding device was fixed onto the support stand with bolts. After thoroughly removing dust from the glass surface and the film surface, the formwork was fixed onto the plate support with bolts.

Then, as shown in FIG. 4, the lid of the vacuum chamber 20 is closed, and the vacuum chamber is evacuated through the exhaust port 16.18 to a pressure of 2 mmHg.
Evacuate to. Here, the outside of the vacuum structure is opened to the atmosphere using the exhaust port 18, the plastic film is pressure-bonded to the glass plate, the glass plate is heated to 140°C with the heater 23, and the glass plate and the plastic film are sealed.
The periphery of the glass plate is cut out to take out the laminate.The laminate is placed in an autoclave and heated and pressurized at 140°C and 5 kg/c for 2.30 minutes.

The laminate thus obtained had good transparency without any scratches or distortion in the plastic film.

Example 2 The support stand has external dimensions of 90 x 500 x 700 mm, and 3
It is a wooden mold that can support a glass plate of 40 x 520 m5 + 3 mm thickness and 50 mm bending depth. A plastic film holding device shown in FIG. 7 consisting of a 1.5×20 mm steel strip and a viscosity layer was prepared.

The plastic film consists of a thermosetting polyurethane film (thickness 0.2+sm) as the surface layer, a thermoplastic polyurethane film (thickness 0.5+sm) as the middle layer, and an adhesive layer (thickness 0.02mm), 500 x 700m.
It was cut into a long sword shape of 500 m in size and attached to a plastic film holding device. The glass plate was washed with a detergent, then dust removed, heated in a dust-free atmosphere at 160°C, and placed on a support stand. After thoroughly removing dust from the plastic film surface,
As shown in FIG. 5, the plastic film holding device was fixed onto a support base with a fastener.

Next, close the lid of the vacuum chamber 20, and open the exhaust port 1 of the vacuum chamber 20.
8. Evacuate through 18 and evacuate to 2 mmHg. Here, the outside of the vacuum structure is opened to the atmosphere using the exhaust port 16, the plastic film is crimped onto the glass, and the periphery of the glass plate is cut out to take out the laminate.The laminate is placed in an autoclave at 140°C for 5 minutes. kg/crs2
．． Heat and pressurize for 30 minutes.

The laminate thus obtained had good transparency without any scratches or distortion in the plastic film.

Example 3 The support stand is a resin type that can support a glass plate with external dimensions of 300 x 800 x 1880 mm, 720 x 1400 mm, thickness 3 mm, and bending depth of 100 mm.The edge of the glass plate has a width of 25 mm, 130 cm, 0.8W/cm
It is equipped with a rubber heater. A plastic film holding device shown in FIG. 7, which had the same dimensions as the resin mold and was made of a 1.5×20 mm steel strip and an adhesive layer, was prepared.

The same plastic film as in Example 1 was used at 80 (l)
It was cut into a rectangle with a size of 1800 mm x and attached to a plastic film holding device. After cleaning the glass plate with detergent, it was placed on a support stand. After thoroughly removing dust from the glass plate surface and the plastic film surface, the plastic film holding device was fixed onto a support stand with a fastener as shown in FIG.

Next, close the lid of the vacuum chamber 20, and open the exhaust port 1 of the vacuum chamber 20.
6, 18. Evacuate through 19 to 2 mmHg. Here, the outside of the vacuum structure is opened to the atmosphere using the exhaust port 1B, the plastic film is pressure-bonded to the glass plate, the glass plate is heated to 140°C with the heater 23, the glass plate and the plastic film are sealed, and the glass plate is heated to 140°C. Cut out the periphery of the plate and take out the laminate. Place the laminate in an autoclave at 140°C, 5 kg/cts2.3
Heat and pressurize for 0 minutes.

The laminate thus obtained had good transparency without any scratches or distortion in the plastic film.

"Effects of the Invention" As described above, according to the present invention, as a method for laminating and pressing a plastic film on a plate-like object such as a glass plate, a plastic film and a plastic film holding device for attaching the plastic film are used in a plate-like manner. A vacuum system is constructed with a support base on which the body is mounted, and the vacuum system and one upper chamber of the vacuum system are vacuum-operated and air is introduced into the vacuum system. Compared to the method of putting it on and putting it in a pre-crimping device and crimping it,
The crimping work can be simplified and manufacturing costs can be reduced. Furthermore, compared to Japanese Patent Application No. 60-51271, there is no need to use a base film, making it possible to reduce costs and save labor.

Furthermore, in the conventional pre-crimping method using a pre-crimped rubber bag or the pre-crimping method using a nipper roll, due to the structure of the pre-crimping device and the nipper roll, it is difficult to pre-press the VI layer having a plastic film on the surface. However, in the present invention, the wrinkles, irregularities, and scratches of the pressure-bonding bag are transferred to the plastic film, resulting in a laminate with many surface defects.However, in the present invention, during thermo-compression bonding, the upper surface of the plate-shaped body on the plastic film side is transferred as described above. Since there is no material to transfer defects, a plastic film with good surface quality can be obtained. In particular, as described above, the present invention can significantly reduce wrinkles, unevenness, and optical distortion on the plastic film surface compared to conventional methods, so it can be used for windows of automobiles, other types of transportation vehicles, aircraft, etc. A plastic film that is tear-resistant, scratch-resistant, and, in some cases, puncture-resistant, is attached to the interior side of a single glass plate or laminated glass plate to prevent skin damage to passengers when the glass plate breaks. It is ideal for manufacturing safety glass that requires a high quality surface finish.

[Brief explanation of the drawing]

■Figures 1 to 4 show cross-sectional views of various types of laminates manufactured according to the present invention, and Figures 5 to 7 are explanations showing the lamination apparatus used to carry out the present invention. 8 are explanatory diagrams showing a vI layer device of a prior example. 2, 12: plate-shaped body, 3.11 niblast film 4: adhesive layer, 5: adhesive intermediate layer, lO: vacuum chamber, 13: support base 14 niblast film holding device, 15: Outer frame 1B, 18: Exhaust port, 182 mounting surface

Claims (8)

[Claims] (1) A plate-shaped body is placed on a support base having an exhaust port on its outer periphery, and a plastic film holding device provided near the outer peripheral frame portion of the support base outside of the exhaust port is placed on the support base. A plastic film to be laminated on the surface of the plate-shaped body is stretched and sealed so as to cover the front surface of the plate-shaped body and the entire circumference of the outer peripheral frame, and an upper chamber formed in a portion including at least the upper part of the plastic film is sealed. At the same time as degassing and creating a vacuum, the air is also degassed from the exhaust port of the support base to create a vacuum at least in the space between the plastic film and the mounting surface of the plate-shaped body of the support base, and then air is introduced into the upper chamber. 1. A method for manufacturing a laminate, which comprises introducing the plastic film into the plate, releasing the vacuum, and pressing the plastic film against the plate-shaped body to press the plastic film onto the plate-shaped body. (2) The method for manufacturing a laminate according to claim 1, wherein the plate-like body is a glass plate. (3) Before the plastic film is pressure-bonded to the plate-like body, the plastic film or the plate-like body is heated to a temperature at which the plastic film can be bonded to the plate-like body. A method for manufacturing a laminate. (4) After the plastic film is pressure-bonded to the plate-shaped body, the plastic film can adhere to the plate-shaped body on the periphery or entire surface of the plate-shaped body, the plastic film, or the laminate of the plate-shaped body and the plastic film. 2. A method for manufacturing a laminate according to claim 1, wherein the laminate is heated to a certain temperature. (5) 0.1 to 5 on the plate-like surface side of the plastic film
2. The method for manufacturing a laminate according to claim 1, wherein the laminate is embossed with a depth of μm. (6) A laminate manufacturing apparatus for laminating a plastic film on a plate-shaped body, the apparatus having a vacuum chamber and a support table provided in the vacuum chamber on which the plate-shaped body is placed. death,
On the support stand, a plastic film holding device is laminated on the surface of the plate-like object over its outer periphery, and on the inside of the holding device, the plastic film stretched by the plastic film holding device and the plate-like object of the support stand are placed. Equipped with an exhaust port for evacuating the space formed between the surface and the surface of the plate, when the plastic film is stretched over the surface of the plate-shaped object, at least the upper space above the plastic film in the vacuum chamber and the plastic film 1. An apparatus for manufacturing a laminate, characterized in that a space formed between a support base and a mounting surface of a plate-shaped body can be vacuum-operated separately. (7) The laminate manufacturing apparatus according to claim 6, characterized in that a heater for heating the plate-like body is provided on the periphery or the entire surface of the support base. (8) The laminate manufacturing apparatus according to claim 6, wherein the plastic film holding device has a flexible structure that can be made to follow the curved surface of the plate-shaped body.