GB2332875A - Producing a composite laminate - Google Patents
Producing a composite laminate Download PDFInfo
- Publication number
- GB2332875A GB2332875A GB9727476A GB9727476A GB2332875A GB 2332875 A GB2332875 A GB 2332875A GB 9727476 A GB9727476 A GB 9727476A GB 9727476 A GB9727476 A GB 9727476A GB 2332875 A GB2332875 A GB 2332875A
- Authority
- GB
- United Kingdom
- Prior art keywords
- press rollers
- synthetic resin
- core sheet
- laminate
- resin core
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 34
- 229920003002 synthetic resin Polymers 0.000 claims abstract description 37
- 239000000057 synthetic resin Substances 0.000 claims abstract description 37
- 239000011888 foil Substances 0.000 claims abstract description 24
- 239000002184 metal Substances 0.000 claims abstract description 24
- 229920001169 thermoplastic Polymers 0.000 claims abstract description 10
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract description 10
- 239000000853 adhesive Substances 0.000 claims abstract description 9
- 230000001070 adhesive effect Effects 0.000 claims abstract description 9
- 238000000034 method Methods 0.000 claims description 12
- 238000005520 cutting process Methods 0.000 claims description 7
- 238000007599 discharging Methods 0.000 claims description 2
- 238000003825 pressing Methods 0.000 claims description 2
- 239000000463 material Substances 0.000 description 6
- 229920005989 resin Polymers 0.000 description 4
- 239000011347 resin Substances 0.000 description 4
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 239000007767 bonding agent Substances 0.000 description 2
- 239000003063 flame retardant Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000000881 depressing effect Effects 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
- B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/18—Handling of layers or the laminate
- B32B38/1825—Handling of layers or the laminate characterised by the control or constructional features of devices for tensioning, stretching or registration
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/18—Handling of layers or the laminate
- B32B38/1875—Tensioning
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
- B32B2309/06—Angles
Landscapes
- Laminated Bodies (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
Abstract
A composite laminate (8) is continuously produced by extruding a thermoplastic synthetic resin (411) from an outlet (412) of an extruder (411) to form a synthetic resin core sheet (43) with the major surfaces thereof being adhesive surfaces; providing a pair of front press rollers (51) immediately downstream of the extruder (41), the front press rollers (51) defining a first clearance (511) therebetween for forming a pre-pressed laminate (43'); feeding first and second metal foil sheets (42) to the front press rollers (51) prior to forming the pre-pressed laminate (43'); providing a pair of rear press rollers (52) which define a second clearance (521) downstream of the front press rollers (51), the outlet (412) of the extruder (41) and the first and second clearances (511, 521) being located along a straight path; and providing a middle press roller (6) between the front and rear press rollers (51, 52) to laterally depress the pre-pressed laminate (43,) in a direction transverse to the straight path.
Description
METHOD AND APPARATUS FOR PRODUCING A COMPOSITE
LAMINATE
This invention relates to a method and apparatus for producing a composite laminate, more particularly to a method and apparatus for continuously producing a composite laminate.
Composite laminates that are manufactured by bonding manually a plurality of sheet materials with the use of adhesives are well known in the art. The sheet materials of the composite laminates are liable to separate from one another because of failure of the adhesives after the composite laminates have been in use for a period of time. To overcome this problem, another conventional method for producing a composite laminate involves depressing the composite laminate in a direction generally perpendicular to the opposite side faces of the composite laminate while the sheet materials are adhered to one another in order to improve the bonding strength of the sheet materials.
However, the bonding strength between the sheet materials is still not satisfactory.
The object of the present invention is to provide a method and apparatus for producing a composite laminate which has a plurality of sheet materials that are bonded to each other with an enhanced bonding strength.
According to one aspect of the present invention, a method for continuously producing a composite laminate having a thermoplastic synthetic resin core sheet and two metal foil sheets laminated respectively on two major surfaces of the synthetic resin core sheet, the major surfaces of the synthetic resin core sheet being adhesive surfaces, comprises the steps of:
extruding, from an outlet of an extruder, a thermoplastic synthetic resin that serves as the synthetic resin core sheet;
providing a pair of front press rollers immediately downstream of the extruder, the front press rollers defining a first clearance therebetween for forming a pre-pressed laminate;
feeding first and second metal foil sheets to the pair of front press rollers so as to sandwich the synthetic resin core sheet between the first and second metal foil sheets immediately prior to forming the pre-pressed laminate;
providing a pair of rear press rollers downstream of the front press rollers, the rear press rollers defining a second clearance therebetween for pressing and discharging the composite laminate, the outlet of the extruder, the first and second clearances being located along a straight path; and
providing a middle press roller between the front and rear press rollers to laterally depress the pre-pressed laminate in a direction transverse to the straight path so as to subject the pre-pressed laminate to a prescribed tension while the pre-pressed laminated is being pressed by the front and rear press rollers, thereby increasing the bonding strength between the major surfaces of the synthetic resin core sheet and the first and second metal foil sheets.
According to another aspect of the present invention, an apparatus for continuously producing a composite laminate having a thermoplastic synthetic resin core sheet and two metal foil sheets laminated respectively on two major surfaces of the synthetic resin core sheet, the major surfaces of the synthetic resin core sheet being adhesive surfaces, comprises:
an extruder having an outlet adapted for extruding a thermoplastic synthetic resin in molten state to form the synthetic resin core sheet;
a pair of front press rollers disposed immediately downstream of the extruder, the front press rollers defining a first clearance therebetween that is aligned with the outlet so that the front press rollers are adapted to draw the synthetic resin core sheet from the outlet therethrough;
means for feeding first and second metal foil sheets to the pair of front press rollers so as to sandwich the synthetic resin core sheet between the first and second metal foil sheets immediately prior to drawing of the synthetic resin core sheet through the first clearance so that a pre-pressed laminate is drawn out from the front press rollers away from the extruder;
a pair of rear press rollers disposed downstream of the front press rollers, the rear press rollers defining a second clearance therebetween so that the rear press rollers are adapted to press and continue drawing the pre-pressed laminate through the second clearance, the outlet of the extruder and the first and second clearances being located along a straight path; and
a middle press roller interposed between the front and rear press rollers and adapted to laterally depress the pre-pressed laminate in a direction transverse to the straight path so as to subject the pre-pressed laminate to a prescribed tension while the pre-pressed laminate is being pressed by the front and rear press rollers, thereby increasing the bonding strength between the major surfaces of the synthetic resin core sheet and the first and second metal foil sheets.
A preferred embodiment of the invention will now be described, by way of example only, and with reference to the accompanying drawing, in which
Figure 1 is a schematic view illustrating how a preferred embodiment of an apparatus for continuously producing a composite laminate operates according to a method for continuously producing the composite laminate of the present invention.
Referring to Figure 1, a preferred embodiment of an apparatus for producing a composite laminate 8 by means of a method for continuously producing the composite laminate 8 according to the present invention is shown to comprise an extruder 41, a pair of front press rollers 51, feeding means 3, a pair of rear press rollers 52, a middle press roller 6 and cutting means 7.
Thermoplastic synthetic resin 411 is fed into the extruder 41 and is heated to form a melt. The resin 411 in molten state is extruded from an outlet 412 of the extruder 41 to form a synthetic resin core sheet 43. A bonding agent is blended with the resin 411 in the extruder 41 so that the major surfaces of the core sheet 43 are adhesive surfaces when the core sheet 43 is extruded from the outlet 412. A foaming agent and a fire-retardant agent may be blended with the resin 411 in order to foam the core sheet 43 and provide the same with a fire-retardant characteristic. Instead of being blended with the resin 411, the bonding agent may be coated on the major surfaces of the core sheet 43 immediately after the core sheet 43 exits the outlet 412 of the extruder 41 in order to provide the major surfaces with adhesive qualities.
The front press rollers 51 are disposed immediately downstream of the extruder 41 and define a first clearance 511 therebetween which is aligned with the outlet 412 so as to draw synthetic resin core sheet 43 therethrough. The feeding means 3 feeds first and second metal foil sheets 42 to the front press rollers 51 in order to sandwich the core sheet 43 between the metal foil sheets 42 immediately prior to drawing of the core sheet 43 through the first clearance 511 to form a pre-pressed laminate 43'. Two vertical compression forces (F1) are exerted respectively onto the metal foil sheets 42 by the front press rollers 51 before the pre-pressed laminate 43' is drawn out from the front press rollers 51 away from the extruder 41 in order to ensure firm adhesion between the core sheet 43 and the metal foil sheets 42.
The rear press rollers 52 are disposed downstream of the front press rollers 51 and define a second clearance 521 therebetween. The rear press rollers 52 press and continue drawing the pre-pressed laminate 43' through the second clearance 521 in order to form the composite laminate 8. Two vertical compression forces (F1) are also exerted onto the pre-pressed laminate 43' in order to further ensure firm adhesion between the core sheet 43 and the metal foil sheets 42. The outlet 412 and the first and second clearances 511, 521 are located along a straight path.
The middle press roller 6 is interposed between the front and the rear press rollers 51, 52 to laterally depress the pre-pressed laminate 43' in a direction transverse to the straight path so as to subject the pre-pressed laminate 43' to a prescribed tension (F2) while the pre-pressed laminate 43' is being pressed by the front and rear press rollers 51, 52, thereby increasing the bonding strength between each of the major surfaces of the core sheet 43 and the corresponding one of the first and the second metal foil sheets 42.
Finally, the composite laminate 8 is cut into a plurality of composite laminate plates 9 of a predetermined length by the cutting means 7. In this embodiment, the cutting means is two opposed cutting knives 71.
It is noted that the composite laminate 8 can be produced continuously by the method of the present invention, thereby increasing the manufacturing speed and reducing the manufacturing cost. In addition, the front, rear and middle press rollers 51, 52, 6 can exert compression forces of different orientations, thereby enhancing the bonding strength between the core sheet 43 and the metal foil sheets 42.
Claims (6)
- CLAIMS: 1. A method for continuously producing a composite laminate having a thermoplastic synthetic resin core sheet and two metal foil sheets laminated respectively on two major surfaces of the synthetic resin core sheet, the major surfaces of the synthetic resin core sheet being adhesive surfaces, said method comprising the steps of: extruding, from an outlet of an extruder, a thermoplastic synthetic resin that serves as the synthetic resin core sheet; providing a pair of front press rollers immediately downstream of said extruder, said front press rollers defining a first clearance therebetween for forming a pre-pressed laminate; feeding first and second metal foil sheets to said pair of front press rollers so as to sandwich the synthetic resin core sheet between the first and second metal foil sheets immediately prior to forming the pre-pressed laminate; providing a pair of rear press rollers downstream of said front press rollers, said rear press rollers defining a second clearance therebetween for pressing and discharging the composite laminate, said outlet of said extruder and said first and second clearances being located along a straight path; and providing a middle press roller between the front and rear press rollers to laterally depress said pre-pressed laminate in a direction transverse to said straight path so as to subject the pre-pressed laminate to a prescribed tension while the pre-pressed laminate is being pressed by said front and rear press rollers, thereby increasing the bonding strength between the major surfaces of the synthetic resin core sheet and the first and second metal foil sheets.
- 2. The method for continuously producing a composite laminate as claimed in Claim 1, further comprising the step of cutting the composite laminate into a plurality of composite laminate plates of a predetermined length.
- 3. An apparatus for continuously producing a composite laminate having a thermoplastic synthetic resin core sheet and two metal foil sheets laminated respectively on two major surfaces of the synthetic resin core sheet, the major surfaces of the synthetic resin core sheet being adhesive surfaces, said apparatus comprising: an extruder having an outlet adapted for extruding out a thermoplastic synthetic resin in molten state to form the synthetic resin core sheet; a pair of front press rollers disposed immediately downstream of said extruder, said front press rollers defining a first clearance therebetween that is aligned with said outlet so that said front press rollers are adapted to draw the synthetic resin core sheet from said outlet therethrough; means for feeding first and second metal foil sheets to said pair of front press rollers so as to sandwich the synthetic resin core sheet between the first and second metal foil sheets immediately prior to drawing of the synthetic resin core sheet through said first clearance so that a pre-pressed laminate is drawn out from said front press rollers away from said extruder; a pair of rear press rollers disposed downstream of said front press rollers, said rear press rollers defining a second clearance therebetween so that said rear press rollers are adapted to press and continue drawing said pre-pressed laminate through said second clearance, said outlet of said extruder and said first and second clearances being located along a straight path; and a middle press roller interposed between said front and rear press rollers and adapted to laterally depress the pre-pressed laminate in a direction transverse to said straight path so as to subject the pre-pressed laminate to a prescribed tension while the pre-pressed laminate is being pressed by said front and rear press rollers, thereby increasing the bonding strength between the major surfaces of the synthetic resin core sheet and the first and said second metal foil sheets.
- 4. The apparatus for continuously producing a composite laminate as claimed in Claim 3, further comprising cutting means adapted for cutting the composite laminate into a plurality of composite laminate plates of a predetermined length.
- 5. A method for continuously producing a composite laminate substantially as hereinbefore described with reference to and as illustrated in the accompanying drawing.
- 6. An apparatus for continuously producing a composite laminate substantially as hereinbefore described with reference to and as illustrated in the accompanying drawing.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9727476A GB2332875A (en) | 1997-12-30 | 1997-12-30 | Producing a composite laminate |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9727476A GB2332875A (en) | 1997-12-30 | 1997-12-30 | Producing a composite laminate |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB9727476D0 GB9727476D0 (en) | 1998-02-25 |
| GB2332875A true GB2332875A (en) | 1999-07-07 |
Family
ID=10824316
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB9727476A Pending GB2332875A (en) | 1997-12-30 | 1997-12-30 | Producing a composite laminate |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2332875A (en) |
Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102007046226A1 (en) * | 2007-09-26 | 2009-04-09 | Thyssenkrupp Steel Ag | Method for producing a lightweight sheet |
| TWI401150B (en) * | 2010-07-30 | 2013-07-11 | ||
| US8540842B2 (en) | 2008-08-18 | 2013-09-24 | Productive Research Llc | Formable light weight composites |
| US8796580B2 (en) | 2009-12-28 | 2014-08-05 | Productive Research | Processes for welding composite materials and articles therefrom |
| US9005768B2 (en) | 2011-02-21 | 2015-04-14 | Productive Research | Composite materials including regions differing in properties and methods |
| US9115264B2 (en) | 2010-02-15 | 2015-08-25 | Productive Research Llc | Delamination resistant, weldable and formable light weight composites |
| US9233526B2 (en) | 2012-08-03 | 2016-01-12 | Productive Research Llc | Composites having improved interlayer adhesion and methods thereof |
| US11338552B2 (en) | 2019-02-15 | 2022-05-24 | Productive Research Llc | Composite materials, vehicle applications and methods thereof |
| ES2930061A1 (en) * | 2021-06-03 | 2022-12-05 | Ind Samart Sa | TENSIONING DEVICE FOR LICENSE PLATE LAMINATING MACHINE (Machine-translation by Google Translate, not legally binding) |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4521265A (en) * | 1981-11-20 | 1985-06-04 | Mitsubishi Light Metal Industries Limited | Process for preparing laminated plate |
-
1997
- 1997-12-30 GB GB9727476A patent/GB2332875A/en active Pending
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4521265A (en) * | 1981-11-20 | 1985-06-04 | Mitsubishi Light Metal Industries Limited | Process for preparing laminated plate |
Cited By (22)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US8470111B2 (en) | 2007-09-26 | 2013-06-25 | Thyssenkrupp Steel Europe Ag | Method for production of thin sheet metal |
| DE102007046226A1 (en) * | 2007-09-26 | 2009-04-09 | Thyssenkrupp Steel Ag | Method for producing a lightweight sheet |
| US8540842B2 (en) | 2008-08-18 | 2013-09-24 | Productive Research Llc | Formable light weight composites |
| US9889634B2 (en) | 2008-08-18 | 2018-02-13 | Productive Research Llc | Formable light weight composites |
| US9434134B2 (en) | 2008-08-18 | 2016-09-06 | Productive Research Llc | Formable light weight composites |
| US9239068B2 (en) | 2009-12-28 | 2016-01-19 | Productive Research Llc | Processes for welding composite materials and articles therefrom |
| US8796580B2 (en) | 2009-12-28 | 2014-08-05 | Productive Research | Processes for welding composite materials and articles therefrom |
| US10457019B2 (en) | 2010-02-15 | 2019-10-29 | Productive Research Llc | Light weight composite material systems, polymeric materials, and methods |
| US9981451B2 (en) | 2010-02-15 | 2018-05-29 | Productive Research Llc | Delamination resistant, weldable and formable light weight composites |
| US9415568B2 (en) | 2010-02-15 | 2016-08-16 | Productive Research Llc | Formable light weight composite material systems and methods |
| US9115264B2 (en) | 2010-02-15 | 2015-08-25 | Productive Research Llc | Delamination resistant, weldable and formable light weight composites |
| US9849651B2 (en) | 2010-02-15 | 2017-12-26 | Productive Research Llc | Formable light weight composite material systems and methods |
| US11331880B2 (en) | 2010-02-15 | 2022-05-17 | Productive Research Llc | Delamination resistant, weldable and formable light weight composites |
| US11084253B2 (en) | 2010-02-15 | 2021-08-10 | Productive Research Llc | Light weight composite material systems, polymeric materials, and methods |
| US10710338B2 (en) | 2010-02-15 | 2020-07-14 | Productive Research Llc | Delamination resistant, weldable and formable light weight composites |
| TWI401150B (en) * | 2010-07-30 | 2013-07-11 | ||
| US9962909B2 (en) | 2011-02-21 | 2018-05-08 | Productive Research Llc | Composite materials including regions differing properties, and methods |
| US9005768B2 (en) | 2011-02-21 | 2015-04-14 | Productive Research | Composite materials including regions differing in properties and methods |
| US9233526B2 (en) | 2012-08-03 | 2016-01-12 | Productive Research Llc | Composites having improved interlayer adhesion and methods thereof |
| US11338552B2 (en) | 2019-02-15 | 2022-05-24 | Productive Research Llc | Composite materials, vehicle applications and methods thereof |
| ES2930061A1 (en) * | 2021-06-03 | 2022-12-05 | Ind Samart Sa | TENSIONING DEVICE FOR LICENSE PLATE LAMINATING MACHINE (Machine-translation by Google Translate, not legally binding) |
| EP4098442A1 (en) * | 2021-06-03 | 2022-12-07 | Industrias Samar't, S.A. | Tensioning device for license plate laminating machine |
Also Published As
| Publication number | Publication date |
|---|---|
| GB9727476D0 (en) | 1998-02-25 |
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