JPS6036393B2 - Continuous production equipment for synthetic resin sheets or films - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention involves continuously applying a reactive synthetic resin mixture to a surface to be coated traveling at a predetermined speed, and pasting a coating thin film on the surface of the mixture coated with brackets. Synthetic Resin Sheet relates to continuous production equipment for film.

When manufacturing a sheet or film using a reactive synthetic resin mixture consisting of two or more components, such as a foamable viscous synthetic resin, or when laminating or impregnating it on a base fabric, the specified A method has been adopted in which the reactive mixture is continuously applied in the width and thickness of the coating onto a surface to be coated that is traveling at a high speed in the traveling direction.

The reactive mixture applied to the running surface to be coated reacts or foams during running, or is passed through a foaming chamber as necessary, until the running surface is finished. The largest synthetic resin sheet or film or laminated or impregnated layer having a predetermined width and thickness is produced by completing the reaction and foaming. In this continuous manufacturing method, products of a predetermined width and wall thickness are continuously made in a long shape, so the desired synthetic resin product can be obtained by cutting it to a predetermined length, making it suitable for mass production and easy to work with. It has advantages such as less man-hours. By the way, if the reactive mixture of synthetic resin that is continuously molded into a long shape is foamable, as the mixed solution applied to the surface to be coated reacts and foams, the air bubbles on the surface disappear. Since a thick skin is formed on the top surface, the finished product has a thick skin, resulting in a product that has lost its flexibility and is highly rigid.

Further, the density near the epidermis is high, and the farther from the epidermis, the lower the density, resulting in uneven density distribution in the thickness direction. In addition, gas escapes to the outside due to the air bubbles on the surface, which increases the density of the foam, making it impossible to obtain a product with a low density as a whole.

When the reactive mixture contains a polyisocyanate with a low boiling point such as tolylene di-isocyanate, the polyisocyanate is scattered from the surface of the applied reactive mixture, significantly deteriorating the working environment. The reaction is not completed due to a lack of Nato,
Adhesiveness is difficult to remove.

In particular, when the temperature of the foaming chamber or after-cure chamber is raised to promote reaction and increase productivity, the amount of scattering increases and this tendency becomes more pronounced. The reactive mixture applied from the supply die to the running surface to be coated can be controlled to a predetermined width and thickness by devising the supply die. 54-81367
It can be controlled using the coat hanger die disclosed in No. 1, etc. However, even if such a supply die is used to apply a mixed liquid of a constant width and a constant thickness, the mixture on the sides in the width direction will flow outward and spread over time, resulting in insufficient thickness on the sides. rate decreases. In order to solve these problems, a thin coating film is applied to the surface of the reactive mixture applied to the running surface.

When a coating thin film is pasted on the surface of the mixture, it prevents the formation of bubbles on the surface, eliminates the formation of a thick skin, makes foaming uniform, and evens out the density distribution. It also has the advantage of eliminating scattering and preventing it from spreading outward. Various materials can be used as the coating thin film, but a thin film sheet of aluminum or the like is also used if it remains with the product, and a release sheet that is peeled off after the reaction or foaming is completed may also be used. Therefore, when applying a coating sheet to the surface of a reactive mixture, it should be applied at a stage where the liquid mixture has not yet started to react or foam, or at an early or middle stage of the reaction when the reactive mixture does not develop elasticity. Of course, but
During this bonding, it is undesirable for air to remain at the bonding interface between the surface of the liquid mixture and the covering sheet. If air pockets exist locally, cavities will form in the product, causing reactions and
The foaming speed becomes uneven and the density distribution becomes uneven. Therefore, care must be taken to prevent air from entering between the surface of the mixed liquid and the coating sheet, but the reactive mixture applied from the V-feeding die onto the running surface to be coated,
It is applied almost uniformly in the width direction of the product when it is discharged from the die lip, but the lower surface to be coated during travel must not be completely flat, and the coating must be guided so that it sticks to the surface of the reactive mixture. The contact point of the guide member for contacting the thin film is not smooth, and furthermore, due to continuous operation for a long time, minute streaks occur along the running direction, and the surface condition is not necessarily smooth. For this reason, there was a problem in that it was impossible to prevent air from entering. The present invention was made based on the above circumstances, and it is possible to improve the quality of the product by preventing air from entering and remaining at the bonded surfaces when a thin coating film is attached to the surface of a reactive mixture. The present invention aims to provide a continuous manufacturing apparatus for synthetic resin sheets or films.

That is, the present invention guides the coating thin film into contact with the mixture surface at a position where the coating thin film starts contacting the reactive mixture, and also guides the coating thin film into contact with the mixture surface at a position where the coating thin film starts contacting the reactive mixture surface. A guide member is provided to slightly raise the mixture and retain a predetermined amount of the mixture.
In order to prevent air from entering the contact surface between the coating thin film and the mixture due to the mixture retention area just before the contact start point, and to regulate the amount of the mixture retention in the parentheses to a constant level, the amount of retention is detected by a detector. According to this detection, the displacement of the guide member is adjusted so as to approach or move away from the mixture.

The details of the present invention will be explained below based on an embodiment shown in FIGS. 1 to 7.

FIG. 1 schematically shows the overall structure of an apparatus for continuous production of foamed synthetic resin sheets.

Reference numeral 1 denotes a lower release sheet constituting the running surface to be coated, and is made of, for example, a transparent polyester sheet.

2 is a lower model sheet supply roll containing the lower acid type sheet 1; 3 is a carrier roll; 4 is a feeding bag roll; 5 is a guide back roll; 6 is a lower model sheet peeling roll; 7 is a carrier roll; Reference numeral 8 denotes a bottom scale-shaped sheet winding roll.

The lower release sheet 1 has a predetermined width and is run at a constant speed from the supply roll 2 to the take-up roll 8. This is a kokasha die for applying the reactive synthetic resin mixture 9 to the lower scale-shaped sheet 1 on the feeding back roll 4.

A mixture of two or more liquid synthetic resins is fed into this feeder die 10' from a mixer 11. Synthetic resin raw materials contained in pressurized tanks (not shown) are injected into the mixer 11 via pumps (not shown) and injection pipes 12a, 1b (not shown), and the synthetic resin raw materials are thoroughly mixed by the driving force of the motor 13. This Kagiazusa mixture is sent to the Tosonsha die 10. The general die 10 has a predetermined width and applies the reactive mixture 9 onto the lower release sheet 1 at a predetermined thickness. The structure of this joint die 10 will be described later. Reference numeral 14 denotes a top model sheet, which corresponds to the coating thin film of the present invention.

The upper release sheet 14 is also a transparent polyester sheet, for example. 15 is a supply roll for the top release sheet 14, and 16, 17 and 18 are carrier rolls.

Reference numeral 20 indicates a guide roll for adhering the upper release sheet 14 to the surface of the reactive mixture 9, 21 indicates an upper surface sheet peeling roll, 22 and 23 indicate carrier rolls, and 24 indicates an upper model sheet winding roll. .

Further, 25 indicates a foaming chamber, and 26 indicates an after-cure chamber.

The supply die 10 is, for example, a coat hanger die shown in FIGS. 2 to 4, in order to continuously apply the reactive mixture 9 with a predetermined width and a predetermined thickness onto the lower release sheet 1. are using. The reactive synthetic resin mixture composed of two or more components used in the present invention starts a reaction after being mixed in the mixer 11. In other words, the reaction time, that is, the pot life, is about several seconds to several tens of minutes after mixing. Conventionally, it is difficult to continuously apply a product with a uniform width and a uniform thickness onto the lower release sheet 1 for products with a short pot life.
The main reason for this is that because the pot life is short, the gel compound partially adheres in the internal passage of the die 10, inhibiting fluidity and making the width and thickness non-uniform. The coat hanger dies shown in FIGS. 2 to 4 are suitable for solving these problems. That is, the coat hanger die 10 is a front member 1 serving as a die block.
00a and a die rear surface member 100b are abutted against each other. An inlet 101 for a reactive mixture different from the discharge port of the mixer 11 is formed in the die rear member 100b, and this inlet 101 is formed in the matching surfaces of the die front member 100a and the die rear member 100b. flare part 1
Ren is suitable for 02. Note that the injection port 101 is located above the center line 0, 10 in the width direction of the die 10. A manifold 103 is formed on the abutting surface. Manifold 1
03 hangs over the flared portion 102 at the center, and extends through the die land 104 over the entire widthwise width of the lower portion. The die land 104 extends over a spout 105 closed at the lower end surface of the die 10. The spout 105 is constituted by a die lip 106. Each member 100a, 10
Jackets 108 and 108 are formed by plates 107a and 107b, respectively, on 0b, and the jacket 1
A temperature regulating liquid for regulating the temperature of the die 10 is circulated in 08, 108, and 109, 10
9 each indicate an inlet. The reactive mixture enters die 10 through inlet 101 , passes through manifold 103 and die land 104 , and is discharged through outlet 105 .

In this case, the reactive mixture discharged from the spout 105 is
It is necessary to make the amount uniform across the width as well as the residence time from the die inlet 101 to the outlet 105. For this reason, the width and cross-sectional area of the manifold 103 are made equal to or smaller than those at the center from the center to the ends. That is, as shown in FIG. 3, the width D of the manifold portion closer to the center is equal to or greater than the width D2 of the manifold portion farther from the center;
Alternatively, the cross-sectional area at D is equal to or larger than the cross-sectional area at D2. Further, the opening angle of the manifold 103 is preferably 140 degrees or more and less than 170 degrees. Here, the opening angle is 1'5 and 3/5 of half the width of the die in one direction from the widthwise center of the die (line 0, 10,), as shown in Figure 3.
The center of the manifold part at the position, that is, the point x (1/5
It means the angle 8 formed by two straight lines connecting Y (point 3'5) and Y (point 3'5). If this angle 8 is 170 degrees or more, the residence time will be particularly long at the ends in the width direction of the die 10, resulting in a large difference in discharge time compared to the center part, and this angle 0
When the temperature is less than 140 degrees, the discharge time, discharge amount, and residence time become longer, and a reaction of the mixture occurs within the die. Therefore, if the coat hanger die 10 having the configuration shown in FIGS. 2 to 4 is used, the residence time and discharge amount of the reactive mixture in the die can be made uniform across the width of the die. , it is possible to continuously supply and coat the lower release sheet 1 with a mixture having a predetermined width and a predetermined thickness.

Since the mixture applied on the lower release sheet 1 has the same residence time in the width direction in the die, the reaction time to start the reaction is as shown by the imaginary line A in FIG. It will be distributed as isochronous lines perpendicular to the direction. Next, apply the top release sheet 14 to the mixture 9.
The guide roll 201 for adhesion to the surface will be explained based on FIGS. 5 to 7. The guide roll 20 is opposed to the guide back roll 5, and the support shaft 2
It is rotatably supported with respect to 01. Note that the guide roll 20 does not necessarily need to rotate. Support shaft 201
As shown in FIG.
, 202b, and each of these arms 202a
, 202b have worm shafts 203a, 202b, for example.
03b is provided. Each worm shaft 203a, 20
3b is engaged with worm wheels 204a, 204b, and these worm wheels 204a, 204b are rotationally driven by, for example, /gus motors 205a, 205b. Therefore, the pulse motors 205a, 205b
When the worm wheels 204a, 204b are rotated, the arm 20 is rotated via the worm shafts 203a, 203b.
2a, 202b are moved in the vertical direction, and therefore the support shaft 2
01, the guide roll 20 is moved up and down as shown. In other words, the guide roll 20 is driven by the pulse motors 205a, 2
By the vertical position adjustment control device including 05b, the mixture 9
The contact depth with respect to the upper surface of is variable. The guide roll 2 guides the upper release sheet 14 sent via the carrier roll 18 so that it comes into contact with the upper surface of the coating mixture 9, and the upper template sheet 14
onto the top of mixture 9.

As a result of this pressing, the top surface of the mixture 9 is smoothed out between it and the top release sheet 14, and the top surface of the mixture 9 becomes a smooth surface. As shown in the figure, the mixture 30 accumulates in a bulge just before the contact start point of the upper template sheet 14. Since this accumulated mixture 30 is generated between the upper surface of the mixture and the lower surface of the upper mold release sheet 14, This stagnant mixture 30 prevents air from entering at the point of contact initiation.The amount of the stagnant mixture 30 is determined by the contact depth of the guide roll 30. That is, when the guide roll 30 approaches the guide back roll 5, the guide roll 30' Since it comes into deep contact with the coating mixture 9, the amount of the top surface scraped increases and the amount of the stagnant mixture 30 increases.On the other hand, if the amount of contact is made shallow, the amount of stagnant mixture 30 decreases. Air easily enters the contact interface with the mixture 9, and too much retention means that too much of the coating mixture 9 is scraped off.
0' causes a difference from the set thickness, making it impossible to manage the product thickness to the set value. Therefore, the amount of stagnant mixture 30 produced just before the point of contact initiation must be regulated with high precision. For this reason, a detector 31 is provided in front of the stagnant mixture 30.

The detector 31 is composed of a laser transmitter 32 and a laser receiver 33, as shown in FIG. 7, for example.
The laser beam emitted from the laser transmitter 32 is reflected from the retained mixture 3 and enters the laser receiver 33. First, determine the appropriate retention amount of the retention amount 30, set its standard value to 0, and then determine how far the reflected light returns from the zero position of the light receiver 33 due to increase or decrease in the retention mixture 30. Amounts can be measured. In addition,
The transmitter 32 and the light receiver 33 are attached to holders 34 and 35, respectively, and these holders 34 and 35 are guided by a guide rod 36 extending in the width direction of the coating mixture 9, and are moved in the width direction by a traveling drive means (not shown). It will be run on. Therefore, the amount of the staying mixture 30 can be scanned along the width direction. In this case transmitter 3
The relative positions of the light receiver 2 and the light receiver 33 are maintained at a constant distance. The detector 31 that has detected the amount of the retained mixture 30 in this way transmits the measured value to the electrical signal converter 4.
0 to convert it into an electrical signal.

The signal output from this electrical signal converter 40 is sent to a data processing device 41 such as a computer, and is compared with a set value signal inputted in advance. Based on this comparison, the data processing device 41 controls the left and right pulse motors 20.
The adjustment amounts for 5a and 205b are calculated and signals are sent to pulse counters 42 and 42, respectively. These pulse counters 42, 42 rotate the pulse motors 205a, 205b based on instructions from the data processing device 41, so that displacement adjustment of the guide roll 20 in the vertical and inclination directions shown in the figure is performed. The operation of such an embodiment will be explained.

The lower surface release sheet is fed out at a constant speed from a supply roll 2, and then transferred to a carrier roll 3 and a feeding back roll 4.
, a guide back roll 5, a peeling roll 6, and a carrier roll 7, and then wound around a winding roll 8. Note that the lower release sheet 1 may be run in an endless manner. A reactive synthetic resin mixture 9 from a supply die 10 is applied to the lower release sheet on the feeding back roll 4 .

In this case, since the supply die 1 is constituted by the coat hanger die as described above, the mixture 9 having a predetermined width and thickness is continuously supplied to the lower release sheet. That is, the coating amount of the coating mixture 9 is the same as that of the die 101.
Therefore, it is regulated and is supplied onto the upper release sheet 1 in a relatively even distribution amount, and the upper surface is also relatively smooth. Furthermore, since the reaction time distribution state is an isochronous line shown by the imaginary line A in FIG. 2, the difference in reaction speed along the running direction is small. The coating mixture 9 is transported together with the lower release sheet 1 and reaches the guide roll 20 .

The top template sheet 14 is fed into the guide roll 20 via the supply roll 15 and the carrier rolls 16, 17 and 18, so that the guide roll 20 guides the top template sheet 14 onto the top surface of the coating mixture 9. and touch it. During this contact, the upper surface-type sheet 14 is guided by the guide roll 20 so as to be slightly pressed against the upper surface of the coating mixture 9.

Then, on the upper surface of the coating mixture 9, the guide roll 20
A portion of the upper layer is scraped off by the upper surface scale-shaped sheet 14 being pressed. This scraping not only flattens the top surface of the coating mixture 9 but also
The mixture 30 that has become surplus due to this "pounding process" is deposited in a raised retention area 30 between the bottom surface of the sheet 14 and the top surface of the mixture 9 immediately before the contact start point P between the sheet 14 and the coating mixture 9. This stagnant mixture 30 acts as a partition wall that prevents air from entering the contact point P between the sheet 14 and the coating mixture 9.
Do not create air pockets at the contact interface. As a result, the sheet 14 adheres well to the mixture 9 over the entire surface. Further, the amount of the stagnant mixture 30 is detected by the detector 31, and if the amount of the stagnant mixture 30 is small, the pulse motor 206
The guide roll 20 is lowered by means of a and 205b.

Due to this downward movement, the amount of the coating mixture 9 scraped off in the upper layer increases, so that the amount of the staying mixture 30 increases. On the other hand, when the amount of accumulation is large, based on the measurement by the detector 31, the pulse motors 205a and 205b
Increase 0. This rise reduces the amount of coating mixture 9 that is scraped off, so that the amount of retained mixture 30 is reduced. If the amount of retention is proportionally uneven along the width direction, the amount of retention can be adjusted by tilting the guide roll 20 based on the operation of one of the pulse motors 205a, 205b based on the scanning of the detector 31. make it uniform.
Although the action of the guide roll 20 can smooth the upper surface of the coating mixture 9, the coating amount, coating width, and thickness of the coating mixture 9 are originally controlled by the supply stream. Since the mixture 9 is applied relatively evenly, it is not important to smooth the upper surface of the mixture 9 using the two guide rolls.

This guide roll 20 is used to roll the upper model sheet 14 into the mixture 9.
Its main function is to guide the mixture 30 so as to press it against the upper surface of the contact point P, and to build up a certain amount of the retained mixture 30 in front of the contact starting point P to prevent air from entering. When the upper release sheet 14 is pasted onto the coating mixture 9 in this manner, the coating mixture 9 has a sandwiched structure between the lower release sheet 1 and the upper template sheet 14.

Such a sandwich structure is passed through a foaming chamber 25 and an after-cure chamber 26 to promote foaming and reaction, thereby obtaining a foam of a predetermined maximum size. Incidentally, the upper model sheet 14 and the lower release sheet 1 are peeled off at the stage when foaming is completed and wound up on winding rolls 24 and 8, respectively. The upper release sheet 14 may also be an inorganic sheet. Although the predetermined elongated foam is not shown, it is wound onto a take-up roll. In addition, from the carrier roll 18 to the guide roll 2
The incident angle of the upper surface release sheet 14 guided in the opposite direction, that is, the angle Q formed with respect to the upper surface of the coating mixture 9, is preferably 30 degrees or less.

In other words, if the incident angle Q is large, the sliding part of the reactive mixture will not replace the surface part of the applied reactive mixture on the lower surface, so the reactive mixture in the pooled part will gel, or in the case of foamable raw materials. This is because foaming starts and a uniform surface becomes impossible, and the amount of the retained mixture 30 can be set small by reducing this incident angle Q, making it easier to measure. Furthermore, the present invention is not limited to the above embodiments.

For example, two guide rolls may be freely rotatable, but they may also be of a non-rotating type, and in the case of a non-rotating type, as shown in FIGS. 8A, B, and C, It is also possible to use a semicircular roll 81, a small-diameter rod-shaped body 82, a plate body 83, or the like. Further, the detector 31 may be a television camera 90 as shown in FIG. 9 when the upper release sheet 14 is made of a transparent material.

In this case, a coloring agent is added to the raw materials to color the reaction mixture, and the accumulated amount is detected as white and black, or in the case of a transparent reaction liquid, a television camera 90 is used as shown in FIG. The amount of accumulation may be detected by placing it diagonally and detecting the density of the reflected light. Further, if the upper model sheet 14 is made of a non-transparent material such as an aluminum thin film, FIGS.
As shown in the figure, a laser transmitter 100 is installed at one end in the width direction across the retained mixture 30, and a laser receiver 10 is installed at the end of the pond.
1 may be installed. Furthermore, as can be understood from the above explanation, the reactive mixture applied in the present invention is composed of at least two or more components, and includes all resin liquids that react and solidify with or without heating. It does not matter whether it is foaming or non-foaming.

Therefore, both reactive thermoplastic synthetic resins and thermosetting synthetic resins are included, and resins such as polyurethane, polyester, epoxy, and acrylic are most preferred, but polyurethane resins and foams thereof are most preferred. In the present invention, when the coating thin film is left on the upper and lower surfaces of the product, that is, when a release sheet is not used, the product remains with the thin film adhered to both sides of the product. As detailed above, the present invention uses a combined die that continuously applies a reactive synthetic resin mixture in a predetermined width and thickness to a running surface to be coated traveling at a predetermined speed. When attaching the thin coating film to the surface of the coating mixture on the running surface, a guide member guides the coating thin film into contact with the surface of the coating mixture, and the contact depth of the guide member with the coating mixture is adjusted to ensure that the thin film is adhered to the surface of the coating mixture on the running surface. The mixture is retained just before the contact point of the coating mixture and the retained mixture prevents air from entering toward the contact point.

Therefore, according to this method, the stagnant mixture just before the contact point prevents air from entering, so that no air remains at the contact interface between the thin film and the applied mixture, and the thin film is in close contact with the mixture surface over the entire surface, so that the mixture It uniformizes the reaction and foaming, prevents scattering, and also produces high-quality products without creating cavities within the product. Moreover, the amount of the above-mentioned staying mixture is measured by a detector, and based on this detection, the guide member is displaced via an adjustment control device to control the staying amount at a constant level, which has advantages such as good prevention of air intrusion. There is.

[Brief explanation of drawings]

1 to 7 show one embodiment of the present invention, FIG. 1 is a schematic diagram of the overall configuration, FIGS. 2 to 4 show the structure of the supply die, and FIG. 2 shows a part of the structure. Figure 3 is a cutaway perspective view, Figure 3 is a front view, Figure 4 is a sectional view taken along line W-W in Figure 3, Figure 5 is an enlarged side view showing the area around the guide roll, and Figure 6 is adjustment of the guide roll. 7 is a diagram showing the detector; FIGS. 8A, B, and C are diagrams each showing modified examples of the guide member; FIG. 9 is a diagram showing another example of the detector; FIG. The figure and FIG. 11 are diagrams showing further examples of other detectors. DESCRIPTION OF SYMBOLS 1... Bottom release sheet (coated running surface), 9... Reactive synthetic resin mixture, 10... Supply die, 14... Top release sheet (coating thin film), 20, 81, 82, 83...
- Guide member, 31...detector, 32...laser beam transmitter, 33...laser beam receiver, 41...data processing device (adjustment control device), 205a, 205b...
Pulse motor (adjustment control device), 30... Retention mixture, 90... Television camera. Figure 2 Figure 3 Figure 4 Figure 7 Figure 1 Figure 9 Figure 5 Figure 6 Figure 8 Figure 10 Figure 11

Claims (1)

[Scope of Claims] 1. A supply die that continuously applies a reactive synthetic resin mixture in a predetermined width and thickness to a coating surface traveling at a predetermined speed in the traveling direction; a thin film supplying device for supplying a coating thin film onto the surface of the reactive synthetic resin mixture; and a thin film supplying device provided at a position where the coating thin film starts contact with the surface of the reactive synthetic resin mixture, and the coating thin film should be attached to the surface of the reactive mixture. A guide member for guiding and retaining a predetermined amount of the mixture just before the contact point between the coating thin film and the mixture, a detector for measuring the amount of the mixture retained just before the contact point, and a detection signal from the detector. 1. A continuous production apparatus for synthetic resin sheets or films, comprising an adjustment control device for moving the guide member toward and away from the mixture to maintain a constant amount of the mixture retained. 2. The continuous production apparatus for synthetic resin sheets or films according to claim 1, characterized in that a laser beam transmitter and a light receiver are used as detectors for detecting the amount of the reactive mixture remaining. 3 Claim 1, characterized in that a television camera is used as a detector for detecting the amount of residence of the reactive mixture.
An apparatus for continuous production of synthetic resin sheets or films as described in 2.