JPS6011338A - Method of laminating of synthetic resin decorative sheet - Google Patents

Abstract

PURPOSE:To laminate a decorative sheet free from blisters, by perforating a synthetic resin decorative sheet to have approximately uniformly distributed fine pores with a pore diameter of 0.01-0.1mm. with 10-1,000 pores per cm<2>, and attaching the synthetic resin decorative sheet on the outer surface of a substrate with an adhesive between them. CONSTITUTION:A synthetic resin decorative sheet S is fed between rollers 1, 1 with needles, where the synthetic resin decorative sheet S is perforated to have uniformly distributed fine pores H with a pore diameter of 0.01-0.1mm. with 10-1,000 pores per cm<2>. Then the decorative sheet S is introduced into an adhesive applying apparatus 3 where it is coated with an adhesive uniformly, and is then fed into an air heating furnace 4 where the solvent in the adhesive layer is evaporated appropriately. Then the decorative sheet S is delivered by guide rollers 5, 6 and is turned to direct the adhesive-coated surface down and is led to the undersurfaces of the pressing rollers 7, where it is combined with an extrudate F and is pressed progressively by the pressing rollers 7 so that the it is joined to the outer surface of the extrudate F, and thereafter it is discharged outside of the apparatus by discharging rollers 9.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for laminating a decorative sheet made of synthetic resin such as polyvinyl chloride on the outer surface of extruded aluminum, various steel materials, plastic materials, etc.

In general, materials such as aluminum, steel, and plastic are often used in their raw form or with treatments such as anodizing, coloring, or painting, but recently, these materials have been improved in their design effects. Products laminated with synthetic resin decorative sheets such as polyvinyl chloride printed with woodgrain patterns and various patterns and colors have started to attract attention, and various laminates are available depending on the material and shape of the base material. A machine is being developed.

For example, when laminating a decorative sheet made of polyvinyl chloride to an extruded aluminum section, the adhesive is applied to the back side of the decorative sheet F using a knife coater method, and then heated with hot air to evaporate the solvent contained in the adhesive. After passing through a furnace, a lamination method is used in which a decorative sheet is applied in stages to the outer surface of an extruded aluminum shape as a base material while being partially pressed with a pressure roller. In this case, the decorative sheet adhered to the base material is usually laminated in a semi-dry smoke state, depending on the type of adhesive, so the amount of solvent contained in the adhesive layer at that point greatly affects the finished appearance and adhesion strength. That is, when the amount of solvent remaining in the adhesive layer is small, the initial adhesive force between the aluminum extruded shape and the adhesive is small, so that spaces are likely to be formed where the extruded shape is not completely laminated, especially in the case of an extruded shape with a complicated shape. On the other hand, if there is too much residual solvent, the adhesive will harden slowly, creating spaces in the recesses, and even on flat surfaces, small bubbles of solvent with no escape will easily form on the surface of the decorative sheet. The appearance is unfavorable as it appears as blisters.

On the other hand, the types of adhesives used for this type of application are generally thermosetting resin adhesives (e.g. epoxy resin,
polyurethane resin, polyester resin, melamine resin,
A urea resin adhesive (urea resin adhesive) is often used and is applied to a thickness of about 200 μm, of which about 40% to 80% is solvent. Therefore, in order to maintain an appropriate amount of solvent in the adhesive layer during lamination, the adhesive is passed through a hot air drying oven after being applied, and the solvent is volatilized with hot air at a temperature of about 30 to 50°C. It is extremely difficult to maintain a constant amount of solvent in the adhesive layer, even if the conditions of the hot air oven are controlled at a constant level, as it is greatly affected by variations in coating amount, lamination speed, temperature, humidity, etc. .

As a result of extensive research into this point over many years, the inventor of the present invention has determined how to apply the adhesive to the decorative sheet, dry it, and then apply the roller to the base material. Even if we strictly manage the material, it has its own limits and is far from solving the problem.In fact, the obstacle is that the decorative sheet made of synthetic resin such as polyvinyl chloride has poor total heat breathability, and the adhesive layer applied to the back side is difficult to solve. This is due to the fact that the solvent in the layer 11 does not evaporate smoothly and the air bubbles cannot be degassed smoothly, so it is difficult to impart excellent air permeability to the decorative sheet without losing its design effect by some means. If possible, the decorative sheet should be properly laminated without making any special improvements to the processes of applying and drying the adhesive to the decorative sheet and roller pressing the decorative sheet to the base material. This is what I discovered.

The method for laminating decorative sheets according to the present invention was developed based on the above-mentioned novel idea, in which fine pores with a diameter of 0.01 to 0.1 mm are formed in advance in a synthetic resin decorative sheet for 1 d. At a density of 10 to 1000 per hole, the perforations are formed in a uniformly distributed state and then adhered to the outer surface of the base material via an adhesive.

Hereinafter, embodiments of the method of the present invention will be explained in detail with reference to the drawings. Fig. 1 is a front view showing the structure of a laminating machine used for carrying out the present invention and its operation procedure, and Fig. 2 is a A cross-sectional view of an extruded aluminum profile V) to which a decorative sheet is attached using the method of this invention, and Figure 3 is an enlarged view of the main part showing the adhesion state between the extruded profile that will become the base material (FJ) and the decorative sheet ◎. It is a perspective view, and in the case of this example, the processing machine is an automatic profile laminating machine RK manufactured by West German FBI.
M 400 was used, and the synthetic resin decorative sheet (S) was a polyvinyl chloride resin sheet with a width of 150 mm and a thickness of 0.16 ffff printed with an Akita cedar grain pattern. An extruded aluminum material with a cross-sectional shape as shown in Figure 2, 4,000mm long, coated with an anodized film of 6mm thick, is used, and the lamination process is carried out by machine in the following order. It is carried out continuously.

That is, a long decorative sheet 6) is installed in a supply section in a low-yv spring state, and is pulled out at a constant speed in the direction shown by the arrow, using a nail roller (with a large number of needles implanted on its outer circumferential surface). 1
) (1) In this way, fine holes [phase] with a hole diameter of 0.01 MM are perforated in the decorative sheet 8) at a density of 25 holes per ld in a uniformly distributed state. At that time, the size of the micropore U) is 0. It is desirable to keep it within the range of O1 to 0.1M,
If the diameter of the pores is less than 0.01ff, adequate air permeability cannot be obtained, and if the diameter of the pores exceeds 0.01 ff, the presence of the pores will become noticeable, causing problems with the design effect, and the decorative sheet will not be used in subsequent processes. 6) When applying adhesive (2) to the back side, the adhesive (2)
) may appear on the surface. Regarding the distribution density of micropores, if the density is 10 or more per 1 d, a sufficient ventilation effect can be observed, but if the distribution density is 1000 or more, processing becomes extremely difficult. Regarding the perforation means, the method using the needle roller (1) described above is the simplest and easiest to process, and if the tip of the needle is formed into a conical shape, the decorative sheet 6)
The diameter of the fine holes (F()) can be adjusted freely by simply adjusting the pressing force of the needle roller (1) against the needle roller (1).Also, the drilling process of the fine holes (F() is a cosmetic process).
3) It may be performed before or after the step of printing the surface pattern.

Next, the decorative sheet 6) was introduced into an adhesive applicator (3) using a knife coater, and the adhesive (2) was prepared using 100 parts of Pondmaster RL906 (trade name) (base agent) and 6 parts of solvent.
5% and 5 parts of RL287-6948 (curing agent) were thoroughly mixed and applied uniformly to a thickness of about 100 μm, and then fed into a hot air oven (4), and the temperature inside the oven was 4Q'C.

Heating is carried out under the conditions of a passage speed of 20''/+, an air temperature of 25°C, and a humidity of 76% to appropriately volatilize the solvent in the adhesive layer.

The decorative sheet 6) that has undergone the above processing is guided to the lower surface of the pressure roller (7) as shown by the arrow, with the adhesive coated surface turned upside down through the guide rollers (5) and (6).
Here, it is combined with the extruded shape (F) that is carried on the feed rollers (8) arranged below, and is pressed step by step by the pressure roller (7) to form an extruded shape ω゛) After being affixed to the outer surface of the machine, it is discharged to the outside of the machine by a discharge roller (9).

Extruded shape C) with the decorative sheet 6) attached in this way
The volatilization of the adhesive (2) is carried out extremely smoothly and accurately due to the presence of the fine holes drilled in the decorative sheet 6), and when the decorative sheet is pressed, the degassing effect of the fine holes (81) Since the internal air bubbles are reliably eliminated, decorative sheets such as the extruded shape shown in Figure 4, which was laminated using the conventional method, do not have any floats (61) or blisters (2).
There is no fear that this will occur, and a product that always has a beautiful appearance can be obtained.

Table 1 shows that in order to confirm the above fact, the amount of adhesive (2) applied was adjusted to 60 μm by adjusting the gap of the knife coater.
The decorative sheet 6 of the example in which fine holes f (l) were adjusted in four ways, 00 μm, 140 μm, and 180 μm, and the decorative sheet 6 of the comparative example in which fine holes [phase]) were not formed.
The results of attaching Lsi to extruded shapes (Flml) are shown.

Table 1 As is clear from this table, in the case of the example, no abnormality occurred in the appearance, whereas in the comparative example, the concave groove portion (Fl
) on the decorative sheet 6υ, and on the flat part (F2) there is a bulge 6
2) occurs, and it can be confirmed that the occurrence of blisters increases as the amount of adhesive (2) applied, that is, the absolute amount of the solvent increases.

[Brief explanation of drawings]

Fig. 1 is a front view showing the structure and operating procedure of a laminating machine used in carrying out the present invention, Fig. 2 is a cross-sectional view showing an extruded aluminum profile with a decorative sheet pasted by the method of this invention, and Fig. Figure 3 is an enlarged perspective view of the main part showing the adhesion state between the extruded shape material that will become the base material and the decorative sheet, and Figure 4 is a cross-sectional view showing the extruded shape material after pasting the decorative sheet F using the conventional method. . 6) (F) Decorative sheet, ■Secondary... Aluminum extrusion profile, C1) Concave groove, C2) Planar part, C1) Decorative sheet floating I, (S2) Decorative sheet blistering ,
(1) Needle roller, (2) Adhesive, old) Fine pores, (3) Adhesive applicator, (4) Hot air stove,
(5) (6)... Guide roller, (7)... Pressure roller, (8)... Feed roller, (9)... Discharge port.
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Claims (1)

[Claims] Hole diameter 0.01-0.1ff in advance on synthetic resin decorative sheet
A method for laminating a decorative sheet made of synthetic resin, which comprises forming fine pores in a uniform distribution at a density of 10 to 1,000 per 1 d, and then attaching the pores to the outer surface of a base material with an adhesive. .