JP3043611B2 - Compression molding method of plate-like mat material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for compression-molding a plate-like mat material into a predetermined uneven shape.

[0002]

2. Description of the Related Art In recent years, many roofs of warehouses, factories and the like use a metal folded plate roof material having a shape in which a plurality of peaks and valleys extend in parallel. Further, the roof material is made of glass wool or rock wool. Insulation is performed by attaching mat materials such as Since these mats are provided in a plate-like or roll-like form, see FIG. 1, in order to fit the roof 1 exactly, the mats are formed in a predetermined shape in advance or shown in FIG. 9. Thus, it is necessary to provide a groove 31 having a V-shaped cross section in the plate-like mat member 30 and to perform bending.

[0003]

However, since it is difficult to maintain the air layer of the fibrous mat material at a predetermined bulk density without crushing it, see FIG.
Adhesion of the heat insulating member 20 to the roofing material 1 is poor, and a large gap S remains at the corner of the roofing material 1 on the pushing side. In addition, the mat material usually has the nonwoven fabric 21 on both sides, but a portion corresponding to the corner 1a is easily broken especially at the time of molding. These have significantly reduced the condensation prevention performance. It is to be noted that cutting the plate-like mat member 30 into a V-shaped cross section to form a fold has a problem that it takes too many steps and costs. Therefore, an object of the present invention is to compression-mold a plate-like mat material into an accurate uneven shape, for example, following a folded-plate roof material.

[0004]

To solve the above problems, the following compression molding method was created. That is, the invention according to claim 1 is a method for compression-molding a plate-like mat material into an uneven shape having a plurality of peaks and valleys, wherein the plate-like mat material is placed on a lower mold of a vertical pressing type. The corresponding portion of the plate-shaped mat member is pressed against one of the plurality of valley portions of the lower mold by a pressing member, and then the corresponding portion of the plate-shaped mat member is sequentially pressed against the adjacent valley portion. The upper and lower pressing molds are closed and the plate-like mat member is compression-molded into a predetermined shape.

In the above-described compression molding method, before closing the upper and lower pressing molds, first, a corresponding portion of the plate-like mat member is pressed against one of the plurality of valleys of the lower mold, and then successively adjacent valleys. Pressing on the part is added. In other words, the plate-like mat member has a shape in which the side edge portion is drawn in advance and follows the mold surface without being excessively pulled, so that the formability during compression molding is good.

A second aspect of the present invention is a method of compression-molding a plate-like mat material obtained by mixing a thermosetting resin into a material mainly composed of a fibrous material into an uneven shape having a plurality of peaks and valleys. Then, the plate-like mat member is placed on the lower mold of the upper and lower pressing molds, and the pressing member presses a corresponding portion of the plate-like mat member against one of the plurality of valleys of the lower mold by a pressing member. The corresponding portions of the plate-shaped mat member are sequentially pressed against the adjacent valley portions, and the corresponding portions of the plate-shaped mat member are pressed against the plurality of valley portions of the lower die by the pressing member against the heated lower die. When the portion of the plate-shaped mat member near the contact surface with the lower mold is substantially hardened, the pressing member is retracted, and then the upper and lower pressing molds are closed to heat the plate-shaped mat member into a predetermined shape. It is characterized by pressing.

[0007] In the above compression molding method, the contact surface with the lower mold is heated while the plate-like mat member is pressed against the valley of the lower mold by the pressing member, and the surface hardened layer having an accurate shape following the mold surface. Is formed. When the pressing member is removed, the elasticity of the uncured portion on the back side of the plate-shaped mat member is restored, so that the upper and lower pressing molds can be closed and the entire plate-shaped mat member can be hot-pressed into a predetermined shape.

According to a third aspect of the present invention, in the compression molding method of the plate-like mat member according to the second aspect, a thermosetting resin layer is previously formed on a surface of the plate-like mat member in contact with the lower mold. It is characterized by having been done.

Therefore, by setting the above-mentioned thermosetting resin layer, the thickness and the curing time of the surface hardened layer formed on the plate-like mat member when heated by the lower mold can be appropriately selected. In this way, since the surface hardened layer is first formed in a shape following the lower die, it is easy to hot-press the entire plate-like mat material into a shape having a predetermined bulk density by closing the upper and lower pressing dies. it can.

[0010]

Embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view showing an example of a folded roof material. In the figure, a roofing material 1 is made of metal such as a steel plate,
It is bent in a substantially wave shape (for example, the height of the mountain is 100 mm), and the heat insulating member 2 is attached to the back surface of the roofing material 1 when performing heat insulating construction. As shown in FIG. 2, the material of the heat insulating member 2 is obtained by bonding a nonwoven fabric 3b to both surfaces of a material 3a in which a phenol resin which is a thermosetting resin is mixed in a fibrous material such as glass wool or rock wool. It is a plate-like mat member (hereinafter, simply referred to as "mat member") 3, and in this example, the thickness of the mat member 3 is about 50 mm. Note that the mat member 3 is generally distributed in a roll-shaped package.

Next, a method of hot-pressing the mat member 3 into an uneven shape following the roof member 1 will be described. FIG. 3 is a sectional view showing an outline of the hot-press forming apparatus, and FIG. 4 is a perspective view of a pressing apparatus. As shown in FIG.
Is provided with a vertical pressing mold having heating means and a pressing device 6,
The vertical pressing mold has an upper mold 7 and a lower mold 8 formed corresponding to the shape of the roof material 1. When the upper die 7 and the lower die 8 are separated from each other, the pressing device 6 is disposed at an intermediate position between the upper and lower pressing dies so as to move forward and backward. The pressing device 6, as shown in FIG. 4, it is vertically a plurality of cylinders 6b (6b ₁ ~6b ₄₎ to the movable frame 6a, the pressing member via a connector 6c of the rod knuckle of each cylinder 6b supporting the vicinity of both ends 6d (6d ₁ ~6d _4).
Then, the movable frame 6a can be moved laterally from an intermediate position between the upper mold 7 and the lower mold 8 via a moving means (not shown) and can be retracted from the vertical pressing mold.
Each cylinder 6b is connected to an air pump via an electromagnetic valve (not shown), and is configured to operate at a predetermined timing.

When manufacturing the heat insulating member 2, the thick plate-like mat member 3 is placed on the lower die 8 of the hot-press forming apparatus 5,
Causing the pressing device 6 in the retracted position activates the cylinder 6b ₁ ~6b ₄ in a state of being positioned by moving upward of the lower die 8 in a predetermined order. That is, as shown in FIG. 5 (a), first, lowering the pressing member 6d ₁ with respect to the valley portion 8a ₁ located substantially center out of the plurality of valley portions 8a of the lower die 8, the valleys 8a ₁ Then, the corresponding portion of the mat member 3 is pushed. Next, referring to FIG. 2B, a valley 8a ₂ adjacent to the valley 8a ₁ is formed.
The corresponding portion of the mat member 3 is pushed into the valley portion 8a, and the valley portions 8a are alternately sequentially arranged so as to be divided into right and left.
_3, press the corresponding portion of the mat material 3 to 8a _4. The state in which all the pressing members 6d are lowered is shown in FIG. 3C. In FIG.

As described above, the mat member 3 is arranged such that the left and right side edges are dragged toward the center and follows the surface of the lower die 8, so that after a certain pressing time has elapsed, the pressing device 6 is pressed. And lower mold 8 and upper mold 7 as shown in FIG.
And the mat member 3 is heated to cure the phenol resin at about 200 ° C. That is, in this example, the pressing force and the pressing time of the pressing member 6 d can be set arbitrarily separately from the mold clamping pressure and the heating time, and the mat member 3 is directed to the center of the lower die 8 in advance. And can be kept along the drag-type surface. Therefore, even if the upper and lower pressing molds are closed at a stretch, it is possible to prevent molding defects such as the conventional nonwoven fabric 3b being pulled at the corners of the mold surface and causing cracks, and the heat insulating member 2 is made of the material 3a. The air layer can be formed at a predetermined bulk density without damaging the air layer, and can be formed into an accurate uneven shape following the roofing material 1.

It is also possible to change the pressing order indicated by in FIG. For example, the working time can be shortened by simultaneously operating and the pressing member 6d in the order of →→→ or vice versa.
Can be lowered to facilitate positioning of the pressing start end of the mat member 3.

Next, another embodiment different from the above will be described. In this embodiment, a step of once heating one surface of the mat member 3 with only the lower mold 8 before closing the upper and lower pressing molds is added to the above-mentioned hot pressing of the heat insulating member.
That is, in the state of FIG. 5C in which the mat member 3 is pressed against the lower mold 8 by the pressing device 6, the lower mold 8 is heated, and the phenol resin near the contact surface of the mat material 3 with the lower mold 8. Is cured to form a surface hardened layer 3c (see FIG. 7). At this time, the heating / pressing time is set to a relatively short time (10 to 15 seconds in this example) so that the mat material as a whole can maintain a semi-cure state in which the mat member does not lose its elasticity. Note that the lower mold 8 is usually one that has been preheated by heating means.

Therefore, in this example, the mat member 3 is heated by the pressing member 6d with a sufficient pressing force against the valley portion of the lower die, and the contact surface with the lower die 8 is heated to accurately follow the die surface. The surface hardened layer 3c having a simple shape is formed. Thereafter, when the pressing member 6d is removed, the mat member 3 expands because the elasticity on the back side is restored, and as shown in FIG. 6, the upper and lower pressing molds can be closed and the whole can be easily hot-pressed into a predetermined shape. . In some cases, it is conceivable that the final hot-press forming by the upper and lower pressing molds is omitted and the forming of the mat member 3 is completed only by the hot-press forming using the pressing device 6. In that case, the upper mold 7 becomes unnecessary, so that the hot-press forming apparatus and the process can be simplified.

In the above example, the thermosetting material (phenolic resin) mixed in the material 3a is hardened in two stages (substantially two layers of a surface hardened layer and a remaining portion). As shown in FIG. 8, a thermosetting resin layer 3d may be formed in advance on one surface (the lower mold contact surface) of the mat member 3 '. That is, by appropriately forming the thermosetting resin layer 3d, the thickness and the curing time of the surface cured layer formed when heated by the lower mold 8 can be easily and reliably set.

In the above-described example, it is conceivable that the final hot-press forming by the upper and lower pressing molds is omitted and the forming of the mat member 3 is completed only by the hot-press forming using the pressing device 6.
In that case, the upper mold 7 becomes unnecessary, so that the hot-press forming apparatus and the process can be simplified. The material 3a to be subjected to hot pressing may be mainly made of felt or synthetic fiber in addition to glass wool and rock wool.

[0019]

As described above, according to the present invention,
Since the plate-like mat member can be compression-molded into an accurate uneven shape following, for example, a folded-plate roof member, the effect of preventing dew condensation on the roof to which the mat member is attached is enhanced.

According to the first aspect of the present invention, the plate-like mat material placed on the lower mold is sequentially dragged by the pressing member and closed along the mold surface before closing the upper and lower pressing dies. Good nature.

According to the second aspect of the present invention, the plate-shaped mat member is pressed to form a surface hardened layer having an accurate shape following the lower mold surface. By closing the pressing mold, the entire plate-like mat member can be easily hot-pressed into a predetermined shape.

According to the third aspect of the present invention, by setting the thermosetting resin layer, the thickness and the hardening time of the surface hardened layer formed on the plate-like mat member when heated by the lower mold are appropriately selected. Thereafter, the upper and lower pressing molds are closed, and the entire plate-shaped mat member can be easily hot-pressed into a shape having a predetermined bulk density.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a folded roof material.

FIG. 2 is a cross-sectional view showing a plate-like mat member.

FIG. 3 is a diagram illustrating a pressing device according to the embodiment.

FIG. 4 is a perspective view showing a main part of the pressing device.

FIG. 5 is a diagram illustrating a step of pressing a plate-like mat member against a lower mold.

FIG. 6 is a diagram illustrating a state in which a heat insulating member is hot-pressed.

FIG. 7 is a cross-sectional view illustrating a state in which a surface hardened layer is formed on a plate-like mat member.

FIG. 8 is a cross-sectional view illustrating a plate-like mat member according to another embodiment.

FIG. 9 is a cross-sectional view illustrating groove processing of a heat insulating material of a conventional example.

FIG. 10 is a diagram illustrating a state in which a conventional heat insulating material is attached to a folded-plate roof material.

[Explanation of symbols]

1 roofing material 2 heat insulating member 3 mat member (plate-shaped mat member) 3a material 3b nonwoven 5 thermal molding device 6 pushing device 6b (6b ₁ ~6b ₄₎ cylinder 6d (6d ₁ ~6d ₄₎ pressing member 7 upper die 8a (8a ₁ ~8a ₄₎ troughs 8 lower mold

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B29C 51/00-51/46 B29C 53/00-53/84

Claims (3)

(57) [Claims] 1. A method for compression-molding a plate-like mat material into an uneven shape having a plurality of peaks and valleys, wherein said plate-like mat material is placed on a lower mold of an up-and-down pressing type and pressed by a pressing member. The corresponding portion of the plate-shaped mat member was pressed against one of the plurality of valley portions of the lower die, and then the corresponding portion of the plate-shaped mat member was sequentially pressed against the adjacent valley portion, and then the pressing member was retracted. A compression molding method for the plate-like mat member, comprising closing the upper and lower pressing molds and compression-molding the plate-like mat member into a predetermined shape. 2. A method of compression-molding a plate-like mat material obtained by mixing a thermosetting resin into a material mainly composed of a fibrous material into an uneven shape having a plurality of peaks and valleys. The material is placed on the lower mold of the upper and lower pressing molds, and the corresponding portion of the plate-like mat member is pressed against one of the plurality of valleys of the lower mold by a pressing member, and then the valleys are sequentially pressed to the adjacent valleys. The corresponding portion of the plate-shaped mat member is pressed, and the corresponding member of the plate-shaped mat member is pressed against the heated lower die by the pressing member against the plurality of valleys of the lower die. When the portion near the contact surface of the plate-shaped mat member with the lower mold is substantially hardened, the pressing member is retracted, and then the upper and lower pressing molds are closed and the plate-shaped mat member is hot-pressed into a predetermined shape. Compression molding method of a plate-like mat material to be formed. 3. The compression molding method for a plate-like mat member according to claim 2, wherein a thermosetting resin layer is previously formed on a surface of the plate-like mat member that contacts the lower mold.