JPS6051434B2 - Molding method of laminated sheet - Google Patents

Description

[Detailed description of the invention] The present invention relates to a method for molding a laminated sheet.

Conventionally, various decorative materials, laminated materials, etc. have been mainly molded by flat plate presses, but these have had drawbacks such as poor production efficiency and the ability to mold only fixed dimensions.

Molding by roll pressure has also been considered as a continuous molding method, but roll pressure is repeatedly applied and removed, making it impossible to obtain a molded product with a uniform and smooth surface finish. It could not be used for molding materials, laminated materials, etc. The present invention relates to a method for forming a laminated sheet that solves such conventional problems, and involves inserting two or more sheets of laminating material between two running belts pressurized with air pressure, heat-treating them, and laminating them. The object of the present invention is to provide a method for molding a laminated sheet characterized by the following.

FIG. 1 is a perspective view of an embodiment employing the molding method of the present invention, in which drive rolls 2, 2 are rotatably attached to a frame 14 via bearings 15, and a frame 13 is provided with tension. Rolls 1, 1 are attached via bearings 15 and hydraulic cylinders 16.

The rotational motion of the drive roll 2 is transmitted to the tension rolls 1 through a stainless steel belt 3, and the tension state of the stainless steel belt 3 can be appropriately adjusted by a hydraulic cylinder 16. A stainless steel belt 3 runs in parallel between the drive roll 2 and the tension roll 1,
At an intermediate position, there is a pressurizing chamber 4 provided with a slit 9 through which the stainless steel belt 3 can go in and out, a compressed air inlet 6, and an automatic solenoid valve 6. An electric heating plate 5 for heating the back surface of the stainless steel belt 3 is attached inside the pressurizing chamber. A sealing material 10 made of felt material is attached inside the slit 9 to prevent air pressure from disappearing, and the end of the sealing material 10 is fixed to a fixing bar 11. The sealing material 10 is hung in a substantially U-shape, and the tip of the U-shape is partially in contact with the back surface of the stainless steel sheet 3. The introduction port 6
The compressed air supplied from
An automatic solenoid valve 6' that opens and closes at 9/d and interlocks with the compressor 8 has a mechanism that can maintain the air pressure at around 9/d. Moreover, sudden pressure increase can be avoided by the safety valve 7 which operates at 11 and 9/d. Next, regarding an example of molding a laminated sheet, melamine resin with a low degree of condensation weighs 70y.
Impregnated paper 17, which was impregnated with a cellulose printing paper of /wl at a weight ratio of 80% to the base material, and kraft paper with a weight of 150 g/w were impregnated with an epoxy acrylate resin containing 2% benzoyl peroxide as a hardening agent. Impregnated paper for back side 18
is inserted between stainless steel belts 3 running at a speed of 4 m/min, and heated at an air pressure of 9 to 10 kg/d1 in a pressurizing chamber 4.
A temperature of 60°C is applied to mold the melamine resin decorative sheet 19.

Maintaining air pressure in the pressurized chamber depends on the characteristics of the sealing mechanism, so various studies have been conducted, but as a sealing material, it has a low slippage coefficient with the belt, has good anti-slip properties, and has a small air pressure loss rate, so it can be used with air pressure. It is desirable to use a material that does not break and can change shape.

Specific examples include the felt material in the above embodiments (this may be a material made of cotton woven fabric, synthetic woven fabric, etc., or a material impregnated or coated with wax, oil, etc. to improve sliding properties) Soft rubber materials, synthetic resin materials such as natural rubber, NBRl urethane resin (rubber), epoxy resin, polyethylene, etc. Polypropylene, silicone rubber (
Composite materials impregnated or laminated with tetrafluoroethylene resin (resin) and tetrafluoroethylene resin are suitable. Even if the sealing material is solid, it may be attached to the slit 9 portion as shown in Fig. 4, if it is made of a material with extremely good sliding properties, such as carbon block or oil-impregnated carbon block, together with the spring 20 that presses against the belt. . Furthermore, in order to reduce the coefficient of friction between the back surface of the belt and the sealing material and improve the sealing performance, a means may be adopted in which oil is injected into the compressed air using an automatic oil feeder.

As heating means, in addition to the electric heating plate as in the above embodiments, heating medium (steam, oil, etc.) circulation, far-infrared lamps, induction heating (microwaves, high frequency, etc.), etc. can be used to obtain a molding temperature of 100 to 180'C. Heating method can be adopted.

Further, in order to heat the belt 3 in advance, an electric heater or a means such as circulating a heating medium (steam, oil, etc.) may be employed inside the tension roll 1 and the drive roll 2. The belt wound between the drive roll 2 and the tension roll 1 has a forming pressure of 8 to 15 kg/CTl, 1
00~180℃ molding heat and 1~10k9/Clt
The material must be able to withstand hydraulic tension, have good thermal conductivity, and be free from scratches, pinholes, etc. on the belt surface. is appropriate.

The belt tension is determined by the retention of the molded material inserted and sandwiched between the belts (
It is necessary to prevent slippage), to ensure the finish of the laminated sheet, or to make one rotation of the tension roll, and there is no need for it to be unnecessarily large. Further, the tension roll 1 itself may be directly driven as long as the rotation speed is the same. The running speed of the belt is 1 to 20 m depending on the rotation speed of the drive roll etc.
It can be adjusted within the range of /minute. The air pressure applying mechanism is maintained by a high-pressure compressor 8 having the necessary capacity to fill and replenish the air pressure of 8 to 15 k9/Clt required for molding and the air pressure lost from the gap between the sealing material and the belt.

It is desirable that the loss of air pressure in the sealing mechanism is 5% or less, and if it reaches 5% or more, the molding pressure will be 8 to 15k.
This is not preferable because it cannot be maintained at 9/Clt and also affects the molding cost. The molding conditions are largely influenced by the molding material, especially the resin material.For example, if it is a thermoplastic resin material or a thermoplastic resin treated material, it can be laminated simply by heating and pressurizing, and high-speed molding can be performed in a short time. .

On the other hand, when molding a laminated sheet that is laminated simultaneously with the curing of the resin material, for example, when molding a melamine resin sheet, diallyl phthalate resin sheet, unsaturated polyester resin sheet, urethane resin sheet, etc., the curing time and curing temperature of the resin material It can be determined by taking into consideration the relationship between the two, molding flow characteristics, etc. To increase the molding speed, a high-speed molding process can be adopted by using a resin material with a short curing time or by using high-temperature molding. In addition, the molding method uses thermoplastic resin material,
Thermoplastic resin treated material (e.g. impregnated paper Etc), thermoplastic resin material or thermosetting resin treated material (e.g. impregnated paper Etc)
c) used only on the front side or only on the back side, processed paper, unprocessed paper, non-woven fabric, cloth, plywood, particle board, asbestos slate, or sheets laminated with metal sheets (e.g. copper foil, aluminum foil), or resin materials, resins It can be used for sheets etc. in which treated materials etc. are laminated, and it can also be applied to multi-laminated sheets with two or more layers. Furthermore, if the adhesion between the laminated layers is incomplete, an adhesion aid (primer) or adhesive may be present at the laminated interface. Also, an uneven embossment that can withstand pressure and heat is applied between the two belts. If the sheet is inserted in contact with the surface of a laminated material such as resin-impregnated paper, or if a belt whose surface is provided with uneven embossing is used, various embossing such as wood grain can be applied to the surface of the laminated sheet.

The method for molding a laminated sheet according to the present invention differs from the conventional molding method using a flat plate press because it can be molded continuously, making it possible to mold long objects. No steps or uneven shapes are formed on the molded material,
It can be molded into a smooth surface, making it ideal for decorative materials and laminated materials where surface finish is an important product characteristic.

Furthermore, since there is no moving wear when the belt runs, there is no energy loss and the molding work can be carried out smoothly. In addition, it can be used to mold multi-purpose laminated sheets, laminated materials, etc., as it can be freely adapted to changes in the number of laminated materials and materials.

[Brief explanation of drawings]

Fig. 1 is a perspective view of one embodiment of a molding device used in the molding method of the present invention, Fig. 2 is a perspective view of a pressurizing chamber, and Fig. 3 is a sectional view of the mounting structure of the sealing material in the slit portion of the pressurizing chamber. , FIG. 4 is a sectional view of another mounting structure for the sealing material. 10. ．． ．． ．． Tensionro, Ru, 2. ．． ．． ．． ．． ．． Drive roll, 3... Stainless steel belt, 4...
・Pressure chamber, 5... Electric heating plate, 6... Compressed air inlet, 8... High pressure compressor, 9...
Slit, 10, 12...Seal material, 13, 14
...Frame, 20...Spring.

Claims (1)

[Claims] 1. A method for forming a laminated sheet, which comprises inserting two or more laminated materials between two running belts pressurized with air pressure, heat-treating them, and laminating them.