A machine for producing plastic laminates

Abstract: A machine for producing plastic laminates having a feed roller means consisting of a pair of feed rollers for feeding a material to be laminated, a facing type preheater means which allows the material to be laminated which is being fed, to be preheated, while it slides along the preheater means, and a heating and pressing roller means which has both the heating function and the pressing function in one body, for heating and pressing the material to be laminated which has been preheated, resultantly being simple in the structure, small in the external dimension, less expensive in the production cost and capable of producing plastic laminates without discontinuous adhesion to have a beautiful laminated surface appearance.

Description: This invention relates to an improvement applicable to a machine for producing plastic laminates. More specifically, this invention relates to an improvement developed for simplifying the structure of and for decreasing the external dimension of the machine for producing plastic laminates and for improving the quality of the finished surface of the plastic laminates produced employing the machine for producing plastic laminates. A card of a paper sheet on which literal information, such as characters, symbols or the like, is printed and/or pictorial information, such as photographs, seals or the like, is pasted and of which the top surface or the both surfaces is or are covered by transparent plastic sheet or sheets, is widely employed as an ID card, a page of a passport book or the like. A method for producing this type of a plastic laminate is to place a transparent plastic sheet whose back surface is coated with an adhesive on a paper sheet or the like on which literal information is printed and/or pictorial information is pasted, or to put a paper sheet or the like on which literal information is printed and/or pictorial information is pasted between transparent sheets, the inside surface of each of which is coated with an adhesive, to melt the adhesive by heating the assemblage of the transparent plastic sheet or sheets and the paper sheet or the like, and to stick the transparent plastic sheet or sheets to the paper sheet or the like by pressing the assemblage of the transparent plastic sheet or sheets and the paper sheet or the like. A machine for producing plastic laminates is employed for conducting the foregoing method for producing a plastic laminate. Fig. 1 is a side view of a machine for producing plastic laminates available in the prior art. Referring to Fig. 1, the machine for producing plastic laminates available in the prior art consists of a pair of preheating rollers 7 each of which is heated by a fourth heater 72 through a second heat transmitter 71, a pair of heating rollers 8 each of which is heated by a fifth heater 82 through a third heat tranmitter 81, and a pair of pressing rollers 9. In other words, the preheating function, the heating function and the pressing function are individually realised by means for preheating, heating and pressing, and a roller type preheating means is employed. When producing a plastic laminate, an assemblage of the transparent plastic sheet or sheets and the paper sheet or the like (hereinafter referred to as a material to be laminated) 6 is preheated by the pair of preheating rollers 7, while it is rolled by the pair of preheating rollers 7. Then, the material to be laminated 6 which has been preheated is heated by the pair of heating rollers 8. During this heating process, the adhesive coated on the back surface of the transparent plastic sheet or on the both surfaces of the transparent plastic sheets is melted. Then, the heated material to be laminated 6 of which the adhesive has been melted is pressed by the pair of pressing rollers 9. During this pressing process, the transparent plastic sheet or sheets is or are stuck on the paper sheet or the like or to the paper sheets or the like. Finally, the finished plastic laminate is cooled by a cooling means which is not shown in Fig. 1. Since the machine for producing plastic laminates available in the prior art has a pair of heating rollers and a pair of pressing rollers individually, it is involved with a drawback in which the structure is comlicated, the external dimension is large and the production cost is considerably expensive. On the other hand, when the preheating rollers 7 preheat the material to be laminated 6, the surface of the preheating rollers 7 is cooled by the material to be laminated 6 whose temperature equals to the room temperature. Therefore, the preheating process causes discontinuous temperature distribution on the surface of the preheating rollers 7. If the length of the material to be laminated 6 is shorter than the length of the circumference of the preheating roller 7, and/or if the preheating processes are conducted, leaving intervals therebetween, the foregoing discontinuous temperature distribution does not cause any particular problem. However, if the length of the material to be laminated 6 is longer than the length of the circumference of the preheating roller 7, and/or if the preheating actions are conducted continuously, the foregoing discontinuous temperature distribution along the circumference of the preheating roller 7 causes discontinuous preheating effect along the circumference of the preheating roller 7, because the cooled surfaces overlap each other. As a result, the discontinuous preheating effect causes discontinuous adhesion of the transparent plastic sheet or sheets and the paper sheet or the like and an ugly surface appearance of the finished plastic laminate. This is the other one of the drawbacks which the machine for producing plastic laminates available in the prior art can not avoid. US-A-5445700 discloses a plastics laminator in which two opposed heating plates are fixedly mounted within a heat conductor, each having a roller channel for receiving and substantially surrounding a silicon rubber roller with minimal clearance. Accordingly, the object of this invention is to provide a machine for producing plastic laminates which is simple in the structure, small in the external dimension, less expensive in the production cost and capable of producing plastic laminates of which the surface is uniformly adhered and which has a beautiful surface appearance. The present invention consists in a machine for producing plastic laminates, the machine comprising upper and lower heating means each consisting of a facing type preheater part which faces and is arranged to preheat the material to be laminated, a heat transmitter part which surrounds a respective one of a pair of heating and pressing rollers which are arranged to heat and press the preheated material, a heater for heating the preheater part; a heater for heating the heat transmitter part; and feeding means for feeding the material between the upper and lower heating means; characterised in that the feeding means are a pair of feed rollers; and in that the heat transmitter part, the heating and pressing roller and the heat transmitter part heater of one of the heating means are fabricated in one body which is elastically supported to allow it to move towards and away from the other heating means. Accordingly, the heating and pressing rollers have both the heating function and the pressing function in one element. As a result, the machine for producing plastic laminates in accordance with this invention is simple in the structure, small in the external dimension and less expensive in the production cost. Further, the machine for producing plastic laminates in accordance with this invention has facing type preheated means or a facing type preheater part rather than a roller type preheated. As a result, the machine for producing plastic laminates in accordance with this invention is free from discontinuous temperature distribution along the surface of the preheater, resulting in capability of realising uniform adhesion and of producing plastic laminates having a beautiful surface appearance. Since the machine for producing plastic laminates in accordance with a first embodiment of this invention has the facing type preheater means which allows the material to be laminated to be preheated, while the material to be laminated slides along the facing type preheated means, it is free from discontinuous temperature distribution, resultantly allowing it to produce a beautiful laminated surface appearance. The facing type preheater and heat transmitter means can be readily produced by an aluminum molding process. Therefore, the rather complicated structure of the facing type preheater and heat transmitter means does not cause any technical and/or economic problems. A cooling means for cooling the material to be laminated which has been heated and pressed may also be added. Preferably, the preheater heater and the heat transmitter part heater comprise a single heater. Preferably, each single heater is arranged in a recess provided in the facing type preheater and heat transmitter parts at a position to face the cylindrical surface of the respective heating and pressing roller to improve the heating efficiency. Preferably, the end surfaces of the preheater and heat transmitter parts are covered by cover plates. The heating and pressing rollers are allowed to move together with the facing type preheater and heat transmitter means due to the elastic support. Preferably, at least one of the heating and pressing rollers is covered by an elastic tube. This invention, together with its various features and advantages, can be readily understood from the following more detailed description presented in conjunction with the following drawings, in which:- Fig. 1 is a side view of a machine for producing plastic laminates available in the prior art, Fig. 2 is a side view of a machine for producing plastic laminates in accordance with the first embodiment of this invention, Fig. 3 is a side view of a machine for producing plastic laminates in accordance with the second embodiment of this invention, Fig. 4 is a cross-sectional view of a machine for producing plastic laminates in accordance with the second embodiment of this invention, and Fig. 5 is a cross-sectional view of a heating and pressing roller employable for a machine for producing plastic laminates in accordance with this invention. Referring to the drawings, a detailed description will be presented below for machines for producing plastic laminates in accordance with six embodiments of this invention. FIRST EMBODIMENT Referring to Fig. 2, a machine for producing plastic laminates in accordance with the first embodiment of this invention includes a feed roller means 1 consisting of a pair of feed rollers 11 for feeding a material to be laminated 6, the upper one or the lower one or both of facing type preheater means 2 for preheating the material to be laminated 6, while the material to be laminated 6 slides along the surface of the facing type preheater means 2, which is arranged to face the surface of the material to be laminated 6 and which is heated by a first heater means 21, and a heating and pressing roller means 3 consisting of a pair of heating and pressing rollers 31 for heating and pressing the material to be laminated 6 which has been preheated by the facing type preheater means 2, the heating and pressing roller 31 being heated by a second heater means 33 through a first heat transmitter means 32. When a plastic laminate is produced, a material to be laminated 6 is fed by the feed roller means 1 toward the facing type preheater means 2. The facing type preheater means 2 is actually a heating block along which the material to be laminated 6 slides and which is heated by the first heater means 21, and it preheats the material to be laminated 6 which is being fed by the feed roller means 1. In this embodiment, two sets of the facing type preheater means 2, the upper one and the lower one, are employed to heat both the top surface and the bottom surface of the material to be laminated 6 which slides in a gap between the upper and lower facing type preheater means 2. Although the facing type preheater means 2 is cooled by the material to be laminated 6, there is no possibility in which a discontinuous temperature distribution occurs. Although a temperature incline occurs along the surface of the facing type preheater means 2 along which the material to be laminated 6 passes, this temperature incline does not cause any problem for the quality of the surface of the finished plastic laminate. After being preheated, the material to be laminated 6 is heated and pressed in one action by the heating and pressing roller means 3 consisting of a pair of heating and pressing rollers 31. The heating and pressing rollers 31 are elastically supported by springs (not shown) to be allowed to part from each other or to come close to each other. Since the heating and pressing roller means 3 has both the heating function and the pressing function in one body, it is effective to decrease the external dimension of the machine for producing plastic laminates. A cooling means 5 consists of an upper cooling plate 51, a lower cooling plate 42 and a mechanism for pulling them to each other. After being heated and pressed, the material to be laminated 6 is cooled by the cooling means 5. Since the preheater means employed for this embodiment is not a roller type but a facing type, it does not cause a discontinuous temperature distribution along the heating surface. As a result, the machine for producing plastic laminates in accordance with this embodiment is allowed to produce a plastic laminate which has been uniformly adhered and has a beautiful surface appearance. Since the machine for producing plastic laminates in accordance with this embodiment has a heating and pressing roller means having both the heating function and the pressing function, the external dimension thereof is decreased. SECOND EMBODIMENT Referring to Fig. 3, a machine for producing plastic laminates in accordance with the second embodiment of this invention includes a feed roller means 1 consisting of a pair of feed rollers 11 for feeding a material to be laminated 6, and the upper one or the lower one or both of facing type preheater and heat transmitter means 4 consisting of a facing type preheater part 41 which is arranged to face the surface of the material to be laminated 6 which is being fed b.y the feed roller means 1, for preheating the material to be laminated 6 which is being fed by the feed roller means 1 and a heat transmitter part 42 which is connected to the facing type preheater part 41 and is arranged to surround a heating and pressing roller 31 which is a component of a heating and pressing roller means 3 which heats and presses the material to be laminated 6 which has been preheated, the facing type preheater and heat transmitter means 4 being heated by a third heater means 43. When a plastic laminate is produced, a material to be laminated 6 is fed by the feed roller means 1 to the facing type preheater and heat transmitter means 4. The facing type preheater and heat transmitter means 4 consists of a facing type preheater part 41 and a heat transmitter part 42. The facing type preheater part 41 and the heat transmitter part 42 are heated by the third heater means 43. The facing type preheater part 41 is actually a heating block along which the material to be laminated 6 slides. Since the preheater part 41 is not a roller type but a facing type, it does not cause discontinuous temperature distribution along the heating surface of the preheater part 41, resultantly allowing the machine for producing plastic laminates in accordance with the second embodiment to produce a plastic laminate which is uniformly adhered and has a beautiful finished surface appearance. The heat transmitter part 42 is a half cylinder arranged to partly surround a heating and pressing roller 31, which is a component of a heating and pressing roller means 3, which heats and presses the material to be laminated 6 which has been preheated by the facing type preheater part 41. Since the facing type preheater and heat transmitter means 4 is compact, it is effective to decrease the external dimension of the machine for producing plastic laminates in accordance with the second embodiment of this invention. In the drawing, the third heater means 43 is arranged in a recess produced in the heat transmitter part 42 to face the cylindrical surface of the heating and pressing roller 31. This arrangement is effective to heat the cylindrical surface of the heating and pressing roller 31 more efficiently. Further, in the drawing, the third heater means 43 is arranged in the neighborhood of the facing type preheater part 42. This is effective to heat the facing type preheater part 41 efficiently. Although the facing type preheater and heat transmitter means 4 has a rather complicated structure, it can be readily produced by using an aluminum molding process. Therefore, the shape of the facing type preheater and heat transmitter means 4 does not cause any technical and/or economical problems. A cooling means 5 consists of an upper cooling plate 51 and a lower cooling plate 52 and a mechanism for pulling them to each other. After being heated and pressed, the material to be laminated 6 is cooled by the cooling means 5. Referring to Fig. 4, the end surface of the heat transmitter part 42 is covered by cover plates 44. The cover plates 44 are effective to keep the internal space of the heat transmitter part 42 warm, resultantly improving the efficiency for using heat. Referring to Fig. 4, the bearings 34 of the shaft which supports one of the heating and pressing rollers 31 are elastically supported by springs 35, resultantly allowing one of the heating and pressing rollers 31 to part from or to come close to the other of the heating and pressing rollers 31. This causes the heating and pressing rollers 31 to press the material to be laminated 6 therebetween. Referring to Fig. 4, the heat transmitter part 42 is fixed to the bearings 34 of the shaft which supports the heating and pressing roller 31, resultantly allowing the heat transmitter part 42 to move together with the heating and pressing roller 31. This allows the gap between the heat transmitter part 42 and the heating and pressing roller 31 to be made minimum. As a result, the heat transmission efficiency is remarkably improved. Referring to Fig. 5, one or both of the heating and pressing rollers 31 can be covered by an elastic tube 36. This is effective to increase the area in which the elastic tube 36 contacts the material to be laminated 6, resultantly increasing the heating efficiency. The above description has clarified that a machine for producing plastic laminates which is simple in the structure, small in the external dimension, less expensive in the production cost, and capable of producing a plastic laminate which is uniformly adhered and has a beautiful laminated surface appearance, has been successfully provided.

Claims: A machine for producing plastic laminates, the machine comprising upper and lower heating means (4) each consisting of a facing type preheater part (2;41) which faces and is arranged to preheat the material (6) to be laminated, a heat transmitter part (32;42) which surrounds a respective one of a pair of heating and pressing rollers (31) which are arranged to heat and press the preheated material, a heater (21;43) for heating the preheater part (2;41); a heater (33;43) for heating the heat transmitter part (32;42); and feeding means (11) for feeding the material between the upper and lower heating means; characterised in that the feeding means are a pair of feed rollers (11); and in that the heat transmitter part (32;42), the heating and pressing roller (31) and the heat transmitter part heater (33;43) of one of the heating means (4) are fabricated in one body which is elastically supported to allow it to move towards and away from the other heating means. A machine according to claim 1, wherein the preheater heater and the heat transmitter part heater comprise a single heater (43). A machine according to claim 2, wherein each single heater (43) is arranged in a recess provided in the respective preheater (41) and heat transmitter (42) parts (4) at a position to face the cylindrical surface of the respective heating and pressing roller (31). A machine according to claim 2 or claim 3, wherein the heat transmitter part (42) is integral with the facing type preheater part (41) and wherein the preheater (41) and heat transmitter parts (42), the heating and pressing roller (31) and the single heater (43) of one of the heating means (4) are fabricated in said one body. A machine according to any one of the preceding claims, further comprising a cooling means (5) for cooling a laminate which has been heated and pressed. A machine according to any one of the preceding claims, wherein the end surfaces of the preheater (41) and heat transmitter (42) parts are covered by cover plates (44). A machine according to any one of the preceding claims, wherein at least one of the heating and pressing rollers (31) is covered by an elastic tube (36).

Inventors: ENDO TAKAAKI, TAKEDA HIDEYUKI, ENDO, TAKAAKI, TAKEDA, HIDEYUKI
Applicants: FUJIPLA INC, FUJIPLA INC.
Application year: 1996
Main classification: B32B31