JPS5896551A - Manufacture of composite board with flap - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for continuously manufacturing a composite plate with a flap formed by laminating and bonding a base material and a skin material. More specifically, the continuously supplied base material is cut leaving a part of the desired shape, and the skin material is pressed and bonded so that it matches only the desired shape of the base material, and then the skin material is pressed and bonded so that it matches only the desired shape of the base material. The present invention relates to a method for manufacturing a composite plate with a flap, which comprises cutting the base material into a larger size than the peripheral edge, and then cutting off a desired shape portion of the base material.

Traditionally, automotive interior materials, architectural panels, and furniture.

As a composite board for interior and exterior boards for ships, ceiling materials, etc.

Paper cardboard, plastic membrane poles, fiberboard,
Composite boards are used in which a skin material such as a foam sheet, nonwoven fabric, or polyvinyl chloride sheet is bonded to a base material such as a resin board or metal plate.

These composite plates are manufactured by continuously running a fixed-length seed or plate-like base material and skin material, and applying adhesive between nip rolls.
A commonly used method is to bond them together using an adhesive film or a binder such as a hot melt agent to form a composite board.

However, in the composite board manufactured by the above method, the base material and the skin material are bonded on the entire surface, so when the composite board is cut into the desired shape, no flap is formed and the cut part is directly exposed.
Not only does this impair the cosmetic properties, but it is also quite dangerous.

The present inventors have studied the production of a composite board that solves the above problems, and have provided a flap part on the skin material that is adhered to the base material to provide a safe and cosmetically-friendly product that can cover the cut surface of the composite board. We have succeeded in providing a method for continuously manufacturing composite plates with flaps.

In other words, the present invention cuts a continuously supplied base material leaving a part of the desired shape, press-bonds the skin material so that it matches only the desired shape part of the base material, and then cuts the base material into the desired shape part of the base material. A method for producing a composite plate with a flap, which comprises cutting the base material larger than the peripheral edge thereof, and then cutting off a desired shaped portion of the base material.

The base material used in the present invention may be a typical sheet-shaped body, plate-shaped body, etc., and includes, for example, polyolefin resins such as high-, medium- and low-density polyethylene, polypropylene, and polybutene-1, polyamide-based resins, Sheets or ports made of synthetic resins such as polyester resins, polyvinyl alcohol resins, and polystyrene resins, and the above resins include glass fiber, calcium carbonate, and talc.

Examples include sheets or boards made of composite materials containing fillers such as carbon fibers, sheets or boards made of natural rubber or synthetic rubber, metal plates made of aluminum or steel, fiberboards, press plates, etc. Furthermore,
Examples of other structural members include paper or plastic corrugated boards, hollow structures, non-uniform structures, synthetic resin foams, fibrous mats, and sponge bodies.

On the other hand, the skin materials used in the present invention include polyethylene foam, polypropylene foam, polyurethane foam, synthetic resin foam sheets such as ethylene-vinyl acetate copolymers, soft vinyl chloride sheets, leather, and natural fibers. Examples include conventional skin materials such as woven fabrics made of synthetic resin or synthetic resins, nonwoven fabrics, felt, and embossed sheets made of synthetic resins, and there are no particular limitations.

In the present invention, thermal welding is generally used to bond the base material and the skin material, but adhesives can also be used if desired. selected.

For example, hot melts such as ethylene-vinyl acetate copolymers, polyolefin resins, polyester resins, and carboxylic acid-modified polyolefins.

Ethylene-carboxylic acid copolymer, ionomer resin, etc. are applied by brushing, rolling, or in the form of a film.

Next, the present invention will be explained in detail based on the drawings.

In FIG. 1, which shows an example of a process diagram of the present invention, a continuously supplied base material 1 is cut into a desired shape by a rotary cutter 7.7'. At this time, a part of the desired shape is left uncut, as shown at position 10 in FIG. 2, which shows the cut surface of the base material. The base material 1, which has been cut into a desired shape leaving an uncut portion 10, is preheated by a preheating heater 8.8' if necessary, and then supplied to the next skin material bonding step.

In the bonding process, the molding with convex and recessed parts formed to match the desired shape is carried out between the rolls 5 and the molding with the concave and convex portions formed in completely opposite directions is carried out between the rolls 40 and 1. Moves in close contact with the uneven surface of the roll. Next, this skin material 2
is press-bonded between the convex part of the molding roll 5 and the nip roll 6 to the pre-cut portion of the base material 1 into a desired shape through the adhesive film 3 retracted between both rolls. Only the desired shape of the material 1 is continuously sent out as a composite board with the skin material 2 bonded. In this process,
Depending on the thickness of the skin material 2 to be laminated, it is necessary to form an appropriate clearance at the meshing part of the rolls 4 and 5, and if the adhesion of the molded roll 5 to the skin material 2 is not sufficient. is preferably sucked from inside the roll.

To prepare the above-mentioned composite plate in which only the desired shape of the base material 1 is bonded to the skin material 2, first manually cut the skin material 2 larger than the peripheral edge of the desired shape of the base material 1. Further, by removing unnecessary portions of the base material 1 from the uncut portions 10 formed in the cut portions of the base material 1, the flap-equipped composite plate of the present invention is obtained.

A continuous method is also possible as an alternative to the above-mentioned manual method for finishing composite plates with flaps. In this case, the process of bonding the desired shape of the base material 1 and the skin material 2 is performed using a rotary cutter 7.7'.
The molding roll 5 is synchronized so that the desired shape of the substrate 1 cut by the synchronous drive device and the protrusion of the molding roll 5 coincide, and at the same time, the molding is performed on the composite plate fed out from the roll 5. The intermediate product is cut larger than the peripheral edge of the desired shape of the base material using another rotary cutter, and is separated from the unnecessary base material original plate to obtain a predetermined composite plate. Preferably, all these operations are efficiently performed in an in-line system.

Furthermore, if you wish to manufacture composite plates with multiple shapes, use rotary cutter 7.7' and roll 5 for molding.
It is possible to simultaneously and continuously manufacture the convex portions by giving corresponding shapes to the respective convex portions.

The composite plate with flaps of the present invention is shown in cross-sectional view in Fig. 3(a).
The bottom view is shown in b), in which the adhesive film 3 is applied to the substrate 1.
It is clear that the skin material 2 to which the flap 11 is attached is adhered via the flap 11.

As described above, since the flap-equipped composite board of the present invention can cover the cut surface with a flap, it has excellent safety and cosmetic properties, as well as good heat insulation and soundproofing properties, and can be used as interior materials for automobiles, furniture, and construction panels. .

It is useful as interior and exterior materials for ships, ceiling materials, etc.

Hereinafter, the present invention will be specifically explained with reference to Examples.

Examples: Polypropylene cardboard with independent air chambers (thickness: 5 mm, basis weight: 1,000 g) was used as the base material, and polypropylene nonwoven fabric (thickness: 3 mm, basis weight: 3 mm/cm) was used as the skin material.
mF), polypropylene melt-extruded film with a thickness of 1 to 200 μm (Melt 70-index 1.5
．． Using a 900 extruder (using a 900 extruder) and the equipment shown in the attached Figure 1, the base material was cut into trapezoids with a rotary cutter while running at a line speed of 8 m/m, and then cut into a trapezoid with a preheating heater (100 kW, sheathed heater). Preheated to ℃.

On the other hand, the skin material is molded using rolls (difference in unevenness: 10 m,
Rubber processing) is used to form a mold, and in synchronization with the rotary cutter mentioned above, the base material cut into a trapezoid through a 200μ thick polypropylene melt extrusion film is matched with the convex part of the mold roll and crimped. They are laminated, and then the trapezoid part of the base material is cut larger than the local edge using a rotary cutter, and the product size is 800 m at the base. Upper side 500I11. Height 600mm 1 tsubo weight is approximately 1300
A trapezoidal composite plate with strong adhesion of the flap portion 30I11 was obtained.

[Brief explanation of the drawing]

Figure 1 shows an example of a process diagram for manufacturing a composite board according to the present invention. Figure 2 shows an example of the cutting process diagram of the base material used in the present invention, Figure 3 (al is a cross-sectional view of a composite board manufactured by the method of the present invention, and Figure (b) is a bottom view of the same). 1...Base material 2...Skin material 3.
...Adhesive film 4.5...Modeled 1tj o-lua, 7'...
...Rotary cutter 8.8' ...Preheater 10 ...Uncut section 11 ...Flap section Patent applicant Japan Petrochemical Co., Ltd. Agent Fig. 2 Animal 3

Claims (1)

[Claims] (1) In a method of continuously manufacturing a composite board with a flap formed by laminating and bonding a base material and a skin material, a continuously supplied base material is cut leaving a part of the desired shape, and one skin material is cut. A composite board with a flap, which is obtained by pressing and adhering the base material so that it matches only the desired shape part of the base material, and then cutting the base material larger than the peripheral edge of the desired shape part, and separating the desired shape part. Production method. (2+) The method for manufacturing a composite plate with a flag according to claim 1, wherein the base material is made of a polyolefin resin, and the skin material is made of a nonwoven fabric made of a polyolefin resin.