JP2006181935A - Method of manufacturing hard polyurethane foam panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a hard polyurethane foam panel capable of manufacturing the hard polyurethane foam panel which has no difference in characteristics and has an intermediate frame material at its central part, or two hard polyurethane foam panels in two molding spaces by supplying a foamable raw liquid composition to two molding spaces using one mixer and one nozzle by a simple method. <P>SOLUTION: The method of manufacturing the hard polyurethane foam panel has an under surface material supply process, a frame installing process, a raw liquid supply process for supplying a foamable raw liquid composition from the nozzle 13 of a mixer 11, an upper surface material supply process, a foaming process for foaming and curing the foamable raw liquid composition to form a hard polyurethane foam having a predetermined shape and a demolding process. The intermediate frame material 31 which bisects the molding spaces is arranged to the central part of a frame 33. In the raw liquid supply process, the foamable raw liquid composition 26 is supplied to the divided molding spaces while divided by a dividing supply device 18 mounted on the nozzle 13. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for producing a rigid polyurethane foam panel.

  A square or rectangular rigid polyurethane foam panel, which is a heat insulating panel, having a face material on both sides and an intermediate frame material disposed in the length direction at the center in the width direction is known (Patent Document). 1, 2).

  As a method for producing a rigid polyurethane foam panel, a continuous production method and a batch production method are well known.

  In the continuous production method, the foaming stock solution composition is supplied and distributed from the mixer onto the lower surface material supplied after being unwound from the original fabric, and then the upper surface material is unwound and supplied from the original fabric, and the foamed stock solution composition is supplied to the upper surface by a nip roll. A rigid polyurethane foam panel in which a frame material is not integrated is manufactured by conforming to a material and a lower surface material, making the thickness uniform, then foaming and curing, and then cutting into a predetermined dimension. In the production of the rigid polyurethane foam panel having the intermediate frame member, the panel obtained by cutting and the intermediate frame member are bonded.

  In the batch production method, a frame material of a predetermined shape is formed between an upper surface material and a lower surface material to form a molding cavity, and one central part of this frame material, usually a short side of a rectangular frame A rigid polyurethane foam panel is manufactured by injecting a foamed stock solution composition into an injection molding machine from an injection port provided in the center portion and foaming and curing the composition, and by adhering a frame material to the periphery. Is.

  The continuous production method is characterized by the fact that rigid polyurethane foam panels of the same thickness can be manufactured easily and at low cost. However, if panels of the same thickness but different sizes are manufactured, a considerable amount of waste from cutting is produced. And cannot fully meet the demand for reduction of waste disposal.

  On the other hand, the batch production method described as a suitable manufacturing method in the above-mentioned Patent Documents 1 and 2 is foamed by injecting a predetermined amount of a foaming stock solution composition controlled by an injection molding machine into a molding cavity. Since it hardens, it has the feature that there is little waste generation amount. However, in the batch production method, the foamed stock solution composition is injected into the molding cavity formed by the upper surface material, the lower surface material, and the frame material disposed therebetween from the inlet provided in the frame material. Therefore, there is a limit to increase the uniformity of the distribution of the foaming stock solution composition in the molding cavity, and as a result, the molded rigid polyurethane foam panel has characteristics such as density and strength at the corners in the center. It was inferior to the part and lacked uniformity. In addition, since an intermediate frame member is provided in one panel, it is necessary to separately perform injection molding into two molding cavities defined by the intermediate frame member, and the manufacturing work is complicated.

As a technique for improving the uniformity of the characteristics of the rigid polyurethane foam panel, a molding space between the upper surface material fixed to the upper surface substrate and the lower surface material fixed to the lower surface substrate is formed on the lower surface material. A technique for manufacturing a rigid polyurethane foam panel with higher uniformity by closing the upper surface substrate and the lower surface substrate after supplying the foamed concentrate composition while moving the mixing head in one direction inside is known (Patent Document). 3).
JP 2000-220251 A JP 2000-257207 A JP 2003-145558 A

  However, when supplying the foaming stock solution composition into the molding space divided into two by the technique of Patent Document 3, the nozzle of the mixer is moved in the length direction of the first molding space while discharging the foaming stock solution composition. After the supply of the foaming stock solution composition is completed, the discharge is temporarily stopped, and then the nozzle is moved to the second molding space to start the foaming stock solution composition and the foaming is performed while moving in the length direction of the second forming space. It is necessary to supply the stock solution composition. However, according to the above method, since the reaction of the foaming stock solution composition is fast, the foaming stock solution composition supplied to the first molding space is already foamed when the supply of the foaming stock solution composition is finished in the second molding space. When the upper surface material is supplied and pressed, the foamed stock solution compositions having different reaction states are simultaneously pressed in the two molding spaces partitioned by the intermediate frame material, and as a result, the molded rigid polyurethane foam panel There is a problem that a difference occurs in characteristics.

  A rigid foam formed in the first molding space and the second molding space by supplying the foaming concentrate composition to the two molding spaces at the same time, supplying the top material in the same reaction and foaming state, and pressing to perform the foaming process. In order to prevent the difference in the characteristics of the polyurethane foam panel, a method using two mixers and a nozzle is possible, but this is preferable because the apparatus is expensive and contradicts the demand for cost reduction. It is not a thing.

  The present invention supplies a foaming stock solution composition to two molding spaces formed by a simple method using a single mixer and nozzle and defined by an intermediate frame material disposed in the center of a mold. A rigid polyurethane foam panel or two rigid polyurethanes having an intermediate frame material that has no difference in reaction based on the difference in foaming state, reaction when supplying and pressing the top material to the foam formed in each molding space A method for producing a rigid polyurethane foam panel capable of producing a foam panel is provided.

The present invention is a method of manufacturing a rectangular or square rigid polyurethane foam panel,
A lower surface material supply step of placing a lower surface material on the lower surface substrate, a mold frame installation step of placing a mold on the lower surface material to form a molding space, a polyol composition and a polyisocyanate component in the molding space; Under pressure in the molding space closed by the upper surface material, the raw material supply step for supplying the foamed stock solution composition mixed from the nozzle of the mixer, the upper surface material supply step for supplying the upper surface material to the upper surface of the mold A foaming step of foaming and curing the foamed stock composition to form a rigid polyurethane foam having a predetermined shape; and a demolding step of releasing the press and removing the mold to form a rigid polyurethane foam panel;
In the mold, an intermediate frame material that divides the molding space into two is disposed at the center, and the stock solution supplying step attaches the foamed stock solution composition to the nozzle in each of the divided molding spaces. It supplies by dividing | segmenting with the divided | segmented supply apparatus.

  By such a manufacturing method, the foamed stock solution composition is supplied to the two molding spaces using a single mixer and nozzle by a simple method, and the foam formed in each molding space has no difference in properties. A rigid polyurethane foam panel having two intermediate frames or two rigid polyurethane foam panels can be produced.

  In the manufacturing method of the above-mentioned rigid polyurethane foam panel, it is preferable that the divided supply device is a divided rod attached to the nozzle.

  The divided supply apparatus for the foamed stock composition having the above-described configuration is a particularly simple and low-cost divided supply apparatus.

The raw material used in the production of the rigid polyurethane foam panel of the present invention may be a known polyurethane foam, and may be a so-called isocyanurate foam. The density of the rigid polyurethane foam constituting the panel is 20 to 50 kg / m ³ , more preferably 25 to 45 kg / m ³ . Although the magnitude | size of the rigid polyurethane foam panel manufactured by this invention is not specifically limited, It is preferable that a width is 1500 mm or less and thickness is 10-200 mm. The invention is particularly advantageous in the production of long panels in length and in the production of thin panels in thickness.

  As the face material constituting the rigid polyurethane foam panel of the present invention, paper such as kraft paper, resin film, aluminum foil, etc. can be used, which is a laminated face material laminated with polyolefin film such as polyethylene film or aluminum foil. May be.

  The members constituting the mold need only be deformed by the foaming pressure at the time of foam hardening of the rigid polyurethane foam, and are not limited, but are preferably composed of aluminum or iron. The mold is preferably provided with at least a surface forming a molding cavity and a gas vent groove.

  The material constituting the intermediate frame material is preferably the same material as the above-mentioned frame when the two rigid polyurethane foam panels are manufactured using the intermediate frame material as one of the molds. When used as a component, a material suitable for the application of the panel, such as wood, is used.

  FIG. 1 is a perspective view illustrating a mixer and a nozzle including a split supply device. A split supply device 18 is attached to the nozzle 13 for discharging the foamed raw material composition of the mixer 11 equipped with the stirring motor 15. The divided supply device 18 includes a divided rod 25 that divides the foamed concentrate composition, a frame 23 that holds the divided rod, an arm 21 that attaches and fixes the frame 23 to the nozzle 13, and a fixing ring 19. The split rod 25 is fixed to the frame 23, and may be configured to be replaceable with the frame 23. Alternatively, the split rod 25 may be configured to be detachable from the frame 23 to facilitate replacement and cleaning. Good. The entire divided supply device 18 may be removed from the nozzle 13 and replaced. In addition, it is a preferable aspect that the distance between the nozzle 13 and the frame 23 can be arbitrarily adjusted.

  The mixer 11 can be used without particular limitation as long as the necessary foaming stock solution composition is formed by uniformly stirring and mixing the polyol component and the polyisocyanate component forming the rigid polyurethane foam. Although FIG. 1 illustrates the mixer 11 having a built-in stirring blade (not shown) that is rotated by the motor 15, a collision mixing type mixer may be used. The polyisocyanate component is supplied from each storage tank (not shown) to the mixer 11 through the pipe 17p, and the polyol component is supplied through the pipe 17r, mixed, and discharged from the nozzle 13. Further, the mixer 11 and the nozzle 13 may be connected by a flexible hose, and the mixer 11 may be fixed and only the nozzle 13 may be moved. However, from the viewpoint of ease of cleaning, FIG. The integral type shown is preferred.

  FIG. 2 is a perspective view showing a stock solution supplying process when a rigid polyurethane foam panel is manufactured using the mixer and nozzle provided with the divided supply device shown in FIG. A lower surface material 37 is laid on the lower surface substrate 35 by a lower surface material supply process. On the lower surface material 37, the mold frame 33 is disposed by a mold frame disposing process, and a molding space is formed. Further, an intermediate frame member 31 that divides the molding space substantially equally is disposed at the center of the molding space, and two molding spaces, a first molding space and a second molding space, are formed. Next, the mixer 11 and the nozzle 13 are positioned above the vicinity of one side of the mold 33 of the intermediate frame member 31, and the foamed stock solution composition is discharged from the nozzle 13 in the opposite mold direction (arrow X direction in the figure). Moving. The discharge start position of the foamed stock solution composition is indicated as A and the end point is indicated as B. The broken line P is an imaginary line showing the approximate shape of the foaming stock solution composition supplied up to the end point. The discharged foaming stock composition 26 collides with the dividing rod 25 disposed in front of the nozzle discharge hole in the flow direction to be divided into 26a and 26b, and contaminates the intermediate frame 31 with the foaming stock composition. Instead, they are supplied simultaneously to the first molding space and the second molding space, respectively. The discharge start position A and the end point B of the foamed stock solution composition are appropriately set according to the size of the panel to be manufactured, the discharge amount of the foamed stock solution composition, and the like. It is preferable that the foaming stock solution compositions 26a and 26b separately supplied are supplied to the central portions of the first molding space and the second molding space.

  FIG. 3 is a cross-sectional view showing a stock solution supplying step. In this example, an example is shown in which a split rod having a regular hexagonal cross section is used. The foaming stock composition discharged from the nozzle 13 collides with the dividing rod 25 and is divided into two, and is supplied to the first molding space and the second molding space formed by the mold frame 33 and the intermediate frame material 31 at the center. . The distance between the nozzle 13 and the dividing rod 25, the shape and size of the dividing rod 25, the distance from the tip of the nozzle, the distance from the dividing rod 25 to the molding space, and the like depend on the shape of the rigid polyurethane foam panel to be manufactured. Set as appropriate.

  FIG. 4 illustrates the foaming process in a cross-sectional view. That is, FIG. 4 shows a state in which the upper surface material is supplied after the stock solution supply process shown in FIGS. 2 to 3 is completed (upper surface material supply step), and the foamed stock solution composition is foam-cured by pressing with a press. It is. A mold frame 33 and an intermediate frame material 31 are disposed between a lower surface material 35 disposed on the lower surface substrate 35 and an upper surface material 38 mounted on the upper surface substrate 36 to support the upper surface material 38 and the upper surface material 38. Foamed stock solution compositions 26a and 26b are filled in the first molding space and the second molding space which are closed by the upper surface substrate 36 to form molding cavities having a predetermined shape. The upper substrate 36 and the lower substrate 35 are pressed between the press surface plates 51 and 53. The pressing may be performed directly using a press surface plate as the upper surface substrate and the lower surface substrate, or may be indirectly performed by the press surface plate through the upper surface substrate and the lower surface substrate as in this example. After the reaction of the foamed stock solution composition is completed, the pressure is released, the upper substrate 36 and the lower substrate 35 are removed, and the mold 33 is further removed to obtain a rigid polyurethane foam panel having an intermediate frame member 31 at the center ( Demolding process). Further, when the intermediate frame member 31 is provided with releasability in the same manner as the mold frame 33 and the upper and lower face members 37 and 38 are cut along the edge of the intermediate frame member 31, two rigid polyurethane foam panels can be obtained. it can.

  The cross-sectional shape of the dividing rod 25 is not particularly limited, and as illustrated in FIG. 5, in addition to the same hexagonal shape (a) used in FIG. 3, (b) a triangle, (c ) Ellipse, (d) quadrangle, etc. The split rods are arranged so that the foaming stock solution composition is supplied symmetrically. The regular hexagon of (a) may be arranged so that the apex is at the center position (position where the liquid is evenly supplied to the left and right), but as shown in FIG. It is a preferable aspect to arrange it horizontally at the center position of the object.

  FIG. 6 is a cross-sectional view illustrating another embodiment of the split supply device. The dividing device 40 is an adapter 41 having two discharge ports 42a and 42b fixed to the nozzle 13 with bolts.

The perspective view which illustrated the mixer and nozzle provided with the division | segmentation supply apparatus The perspective view which showed the stock solution supply process which manufactures the rigid polyurethane foam panel which has an intermediate frame material in the center part Sectional view showing the stock solution supply process Cross-sectional view illustrating the foaming process Sectional drawing which illustrated the shape of the split rod of the split supply apparatus of a foaming concentrate solution composition Sectional drawing which illustrated another Example of the division | segmentation supply apparatus of a foaming undiluted | stock solution composition

Explanation of symbols

DESCRIPTION OF SYMBOLS 11 Mixer 13 Nozzle 18 Division | segmentation supply apparatus 26 Foam stock solution composition 31 Intermediate frame material 33 Mold frame

Claims (2)

A method for producing a rectangular or square rigid polyurethane foam panel,
A lower surface material supply step of placing a lower surface material on the lower surface substrate, a mold frame installation step of placing a mold on the lower surface material to form a molding space, a polyol composition and a polyisocyanate component in the molding space; Under pressure in the molding space closed by the upper surface material, the raw material supply step for supplying the foamed stock solution composition mixed from the nozzle of the mixer, the upper surface material supply step for supplying the upper surface material to the upper surface of the mold A foaming step of foaming and curing the foamed stock composition to form a rigid polyurethane foam having a predetermined shape; and a demolding step of releasing the press and removing the mold to form a rigid polyurethane foam panel;
In the mold, an intermediate frame material that divides the molding space into two is disposed at the center, and the stock solution supplying step attaches the foamed stock solution composition to the nozzle in each of the divided molding spaces. A rigid polyurethane foam panel manufacturing method characterized by being divided and supplied by a divided supply device.   The method for manufacturing a rigid polyurethane foam panel according to claim 1, wherein the divided supply device is a divided rod attached to the nozzle.

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