JP3257148B2 - Forming method of composite material of paper and metal plate - 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 forming a composite material in which paper and a metal plate are bonded. More specifically, by increasing the flexibility of the paper at the time of forming processing, it is possible to eliminate poor forming of the paper, and further by maintaining the lubricating property of the metal plate at the time of forming processing, to improve the forming technology of ordinary metal plates. The present invention relates to a method of forming and processing a composite material of paper and a metal plate, which is applicable.

[0002]

2. Description of the Related Art At present, metal plates made of aluminum, iron, galvanized iron, stainless steel, copper, tin and the like are used for various applications by performing various forming processes. Among metal plate forming processes, “bending process” and “caulking process” have been known for a long time, and are still widely used as a general metal plate forming method even today. The bending process is typically a simple bending process in which a metal plate is bent at 90 degrees or 180 degrees, and a continuous bending process (such as corrugated plate manufacturing) by a machine using a die. In addition, about the caulking, from the caulking which is launched by hand,
Various methods have been used up to continuous caulking technology by a machine.

[0003] On the other hand, paper is a material that can be imparted with characteristics such as flame retardancy, nonflammability, soundproofing, and moldproofing by devising its raw material formulation in addition to the characteristics of water absorption, dehydration, light weight, and the like. The thickness, width and weight can be freely adjusted. By forming a composite made by laminating these characteristic papers on various metal plates, it is possible to obtain products with various functions that cannot be obtained with conventional metal-plate-formed products. Can be

[0004] For example, the present inventors have disclosed in Japanese Patent Application No. Hei 4-1202.
As proposed in No. 93, by using a duct molding device, a composite material obtained by laminating non-combustible paper making use of water absorption and dehydration properties to an aluminum foil or a hot-dip galvanized iron plate is formed using a duct molding device to prevent dew condensation. Can be manufactured. Further, as proposed by the present inventors in Japanese Patent Application No. 4-240552, the dew condensation preventing ability can be improved by forming a composite material made of noncombustible paper and a metal plate into, for example, a corrugated plate or a folded plate. Roofing materials and wall materials can be manufactured.

[0005] The above-described dew condensation preventing duct can be manufactured using a duct forming apparatus as shown in FIG. 1, for example. The illustrated device is a device for forming a flexible spiral duct, and a composite material 1 in which paper and a metal sheet are bonded is passed through a guide roller 2 and then a corrugating die 3.
Corrugated. Next, by winding the duct and adjusting the angle of the engaging die 4, it is spirally bent at various outer diameters, and after being wound one round, is engaged with the edge of the already-wound portion to be fitted. Thus, the flexible spiral duct 5 is completed. In the case of manufacturing a spiral duct that is not subjected to corrugating, a similar duct forming apparatus provided with a goby processing die is used instead of the corrugating die 3 in FIG.

[0006]

In the case where the duct is continuously formed only from a metal plate to which paper is not bonded by using the above-described duct forming apparatus, cooling of the die and metal plate are required. Also, a solution in which a higher fatty acid such as stearic acid or butyl stearate or an ester thereof is dissolved in a solvent such as isopropyl alcohol (IPA) is used as a lubricant. Such a lubricant enters between the die and the metal plate when the metal plate passes through the die, cools the die, and acts to reduce the friction between the die and the metal plate. As a result, the life of the die can be maintained long, and troubles such as elongation and cracking of the metal plate due to friction can be prevented.

However, when a duct is formed by a similar method using a lubricant by using a composite material in which paper is bonded to a metal plate, the solvent in the lubricant is absorbed and the paper loses flexibility. Also, a peeling phenomenon occurs between the paper layers. For this reason, the swaged portion of the completed duct is opened, causing a problem that the swaging effect is insufficient. In addition, when corrugating is performed, another problem occurs in that the paper loses its flexibility and cracks occur in the uneven portions.
In addition, the odor of the solvent absorbed in the paper and safety problems are caused.

In order to eliminate these inconveniences, if molding is performed without using a lubricant, the friction between the metal plate and the die of the composite material becomes abnormally large, and the metal plate itself cracks, and paper is also damaged. The horn-like projections are generated and the commercial value is significantly reduced.

Accordingly, the present invention solves these problems, and even when a composite material obtained by laminating a paper and a metal plate is continuously formed by using a forming apparatus equipped with a die, the cracking of the paper is prevented. An object of the present invention is to provide a forming method capable of preventing generation of cracks in a metal plate due to increased friction with a die without generation.

[0010]

That is, the present invention is characterized in that when forming a composite material obtained by laminating paper and a metal plate, the paper is impregnated with water by 5% by weight or more and then formed. This is a forming method.

By impregnating the paper with water at the time of forming, the flexibility and flexibility of the paper are improved, and the occurrence of cracks in the paper or metal plate during bending or caulking is reliably prevented. In addition, even when forming is performed using a forming apparatus equipped with a die, a cooling effect of the die and a lubricating effect between the die and the metal plate can be provided, and continuous forming processability can be maintained. .

It is well known that various physical properties of paper greatly change under the influence of water content. This is considered to be due to the properties of cellulose, which is the main raw material of paper.For example, under high humidity conditions, the tensile strength of the paper tends to decrease, and the tear strength, folding strength, and elongation tend to increase. The growth rate is large. This is because the tensile strength of the paper does not depend on the strength of the fibers themselves, but is thought to be mainly due to inter-fiber bonds.It is considered that the bonds were loosened because water molecules entered between the fibers. Can be Therefore,
It was found that the paper cracking phenomenon, which is a problem when forming a composite material of paper and a metal plate, has an important relationship with the elongation of the paper, and the moisture content of the paper has a significant effect.

An air conditioning duct as proposed in the aforementioned Japanese Patent Application Nos. 4-120293 and 4-240552,
As a paper used for a composite material of a paper and a metal plate used for a roof material, a wall material, or the like, a paper provided with flame retardancy or nonflammability can be preferably used. Such a flame-retardant paper or a non-combustible paper has a large content of inorganic powder and a small content of an organic substance such as cellulose, so that the paper itself is hard and brittle. In the case of forming using such a composite material of flame-retardant paper or non-combustible paper and a metal plate, cracking of the paper is particularly noticeable. In the present invention, the paper is impregnated with at least 5% by weight, preferably 10% by weight or more of water in order to reliably prevent the occurrence of such cracking of the paper. As a result, even when flame-retardant paper or non-combustible paper containing a large amount of inorganic powder is used, the flexibility and flexibility of the paper can be exhibited.

On the other hand, the upper limit of the amount of water impregnated in the paper is preferably less than 30% by weight. Even if water is impregnated by 30% by weight or more, the elongation of the paper becomes constant and does not increase any more.
On the contrary, since the physical strength of the paper decreases, the paper tends to be easily torn during the forming process of the composite material.

Further, when a composite material of paper and a metal plate is continuously formed by a forming apparatus equipped with a die, if the processing speed, that is, the speed at which the composite material passes through the die increases, the paper is simply impregnated with water. In this case, insufficient lubrication occurs between the die and the metal plate, and the metal plate tends to be chattered or cracked. In addition, insufficient cooling of the dies causes poor gap adjustment between the dies and the metal plate, and the width of the swaged portion is not constant at the time of swaging, resulting in a ripple phenomenon, which tends to cause forming defects. In the present invention, in such a case, the paper is impregnated with an impregnating liquid obtained by adding a water-dispersible lubricant to water. Thus, a lubricating film can be formed between the die and the metal plate at the same time as replenishing the paper with water, and the problems caused by insufficient lubrication and insufficient cooling of the die can be solved.

Examples of the water-dispersible lubricant include a lubricating oil emulsion in which a synthetic lubricating oil such as a petroleum-based lubricating oil containing a high-molecular-weight hydrocarbon component or a silicone oil, a fatty oil, or the like is dispersed in water together with a surfactant. And an aqueous dispersion of ethylenebisamide, an aqueous dispersion of calcium stearate, and the like.

In the case where various lubricants as described above are added to water to form an impregnating liquid, the amount of the lubricant added to water is as follows:
The following general amounts can be used depending on the type of the lubricant. That is, for 100 parts by weight of water, 0.5 to 5 parts by weight in the case of a petroleum-based lubricating oil emulsion,
0.05 to 1 for silicone lubricating oil emulsion
Parts by weight, 0.1 in the case of an aqueous dispersion of ethylenebisamide.
5 to 10 parts by weight, and 0.5 to 10 parts by weight (all in terms of solid content) in the case of an aqueous dispersion of calcium stearate.

Among the above-mentioned lubricants, a particularly effective one is a lubricating oil emulsion. Even when the conditions such as the processing speed change, it can be dealt with by changing the addition amount widely. This is presumably because a lubricating oil thin film is formed between the die and the metal plate during the forming process, while the paper is moderately braked to prevent meandering.

Some types of metal plates have a surface property that is not easily compatible with water. For example, a hot-dip galvanized iron plate is well-adapted to water, but an aluminum foil is poorly-adapted, and a water film or a lubricating film on the surface is easily repelled. For this reason, in the case of continuously forming a composite material using a metal plate that is not familiar with water, if the processing speed is increased, the water film or the lubricating film may be cut off, causing poor lubrication. In such a case, the impregnating liquid consisting of only water, or the impregnating liquid obtained by adding a lubricant to water,
A water soluble thickener is added. Thus, even when a composite material using a metal plate having a surface property that is not easily compatible with water is formed, a water film or a lubricating film can be held on the surface.

As the water-soluble thickener, use may be made of water-soluble cellulose derivatives such as carboxymethyl cellulose, methyl cellulose and ethyl cellulose, and water-soluble polymers such as polyvinyl alcohol, polyacrylamide and starch. Is usually added in the range of 0.3 to 10 parts by weight (in terms of solid content) with respect to 100 parts by weight of water as the impregnating liquid. Among the above-mentioned thickeners, those having a particularly large effect are water-soluble cellulose derivatives. This is because they exhibit a thickening effect with a relatively small amount of addition, and have little effect on the performance of desorbing and adsorbing moisture to the paper layer after forming a molded product.

FIG. 2 is a sectional view showing an example of an apparatus for impregnating paper with an impregnating liquid consisting of water only or an impregnating liquid obtained by adding a lubricant and / or a thickener to water. This device is usually installed immediately after the guide roller 2 of the duct forming device shown in FIG. The composite material 10 obtained by laminating the paper and the metal sheet passes through the guide roller 11, is immersed in the vat 14 containing the impregnating liquid 13 by the sinking roller 12, and impregnated with the impregnating liquid. Next, after the excess impregnating liquid is squeezed by the squeezing roller 15, it is sent to the molding die 3 of FIG. The driving of the composite material 10 is performed by rotation of a die, and the composite material 10 is automatically pulled. An overflow pipe 16 is attached to the side wall of the bat 14 to keep the water level in the bat constant. When the level of the impregnating liquid in the vat 14 falls below a predetermined value, the impregnating liquid is automatically replenished into the vat 14 from the impregnating liquid tank 17 through the pump 18.

The moisture absorbed by the paper has the effect of swelling the cellulose fibers in the paper to soften the paper and prevent the paper from cracking during the molding process, as described above. The water absorbed by the paper evaporates into air after molding. When a lubricant and a thickener are added to water, the lubricant and the thickener remain in the paper after the water evaporates, but there is no danger of adversely affecting the remaining amount of the lubricant and the thickener.

When adding a lubricant or a thickener to water, an appropriate amount of a rat or cockroach repellent or the like is added as necessary, thereby preventing the attack of the rat or cockroach on the composite material product. You can have.

[0024]

The present invention will be described below in detail with reference to examples. All “parts by weight” in the examples mean solid content conversion. Example 1 80 parts by weight of aluminum hydroxide (trade name "B-153", manufactured by Nippon Light Metal Co., Ltd.) was added to 20 parts by weight of wood pulp (NBKP: LBKP = 7: 3, freeness: 530 ml CSF). The slurry thus obtained is subjected to papermaking using a fourdrinier paper machine, and impregnated with a flame retardant containing guanidine sulfamate as a main component at 25% per weight of the base paper by a size press in the middle of the paper machine. m ²
(Dry weight, hereinafter the same) flame-retardant base paper was obtained.

On the back side of the base paper, a pigment coating layer for further imparting flame retardancy was formed. 90 parts by weight of aluminum hydroxide (trade name "B-703", manufactured by Nippon Light Metal Co., Ltd.), vinylidene chloride latex (trade name "Saran L-
106 ", 7 parts by weight manufactured by Asahi Kasei Kogyo Co., Ltd.) and 3 parts by weight of PVA (trade name" PVA-117 "manufactured by Kuraray Co., Ltd.), and this is used with an air knife coating machine. Then, the back side of the base paper was coated at a coating amount of 20 g / m ² to form a pigment coating layer.

Next, an adhesive barrier layer for preventing the adhesive applied to the base paper in a later step from being absorbed into the base paper was formed on the base paper surface opposite to the pigment coating layer. 15 parts by weight of titanium oxide (trade name "R-820", manufactured by Ishihara Sangyo Co., Ltd.), 82 parts by weight of vinylidene chloride latex (trade name "Saran L-106"), and PVA
(Product name "PVA-117") A coating solution consisting of 3 parts by weight was prepared, and this was coated on the base paper surface using an air knife coating machine at a coating amount of 15 g / m ² , and an adhesive was used. It was a barrier layer.

Next, a urethane-based adhesive (trade name "Takenate A-975" manufactured by Takeda Pharmaceutical Co., Ltd.) to which a curing agent was added was 5 g / m on the adhesive barrier layer.
A coating amount of ² was applied, and an 80 μm thick electrogalvanized iron foil was dry-laminated on the adhesive-coated surface to produce a composite material.

This composite material is continuously formed using a duct forming apparatus (manufactured by PRD) as shown in FIG.
The diameter of the cylinder is 160 mm, the interval between the corrugated ribs is 7 mm,
A flexible spiral duct with a rib height of 3 mm was formed.

At the time of the molding process, an impregnating liquid was prepared consisting of 100 parts by weight of water and 3 parts by weight of a lubricating oil emulsion stock solution (trade name "Milk phosphorus", manufactured by Idemitsu Petrochemical Co., Ltd.) as a lubricant. The paper was placed in the impregnating liquid vat shown and impregnated with the composite by passing the composite through the impregnating liquid, and the water content of the paper was adjusted to 8 to 12% by weight. The duct product after the forming process did not have any cracks on the paper surface, and there was no chattering or poor forming of the galvanized iron foil.

Example 2 The electrogalvanized iron foil of Example 1 was applied to a thickness of 150 μm.
A flexible spiral duct was formed in the same manner as in Example 1 except that a composite material prepared in place of the soft aluminum foil was used. During the molding process, 100 parts by weight of water and methylcellulose as a thickener (trade name “MARPOROS M-4000”, manufactured by Matsumoto Yushi Seiyaku Co., Ltd.)
An impregnating liquid consisting of 3 parts by weight of a lubricating oil emulsion stock solution (trade name “Milk phosphorus”) as a lubricant was prepared,
This was put in an impregnating liquid vat in the same manner as in Example 1, and the impregnating liquid was impregnated into the paper by passing the composite through the impregnating liquid to adjust the water content of the paper to 8 to 12% by weight. The duct product after the forming process did not have any cracks on the paper surface, and there was no chattering of the aluminum foil and no defective forming.

Example 3 Using the same composite material as in Example 2, a flexible spiral duct was formed in the same manner as in Example 2. During this molding process, 100 parts by weight of water, 0.5 part by weight of carboxymethyl cellulose (trade name "CMC-1120", manufactured by Daicel Corporation) as a thickener, and an aqueous dispersion of ethylene bisamide as a lubricant (trade name "HI Micron G-11
0 ", manufactured by Chukyo Yushi Co., Ltd.) An impregnating liquid consisting of 2 parts by weight was prepared, put into an impregnating liquid vat in the same manner as in Example 1, and the impregnating liquid was impregnated with paper by passing the composite through the impregnating liquid. The water content of the paper was adjusted to 8 to 12% by weight. The duct product after the forming process did not have any cracks on the paper surface, and there was no chattering of the aluminum foil and no defective forming.

Example 4 The electrogalvanized iron foil of Example 1 was replaced with a 0.5 m thick
A spiral duct was formed using a duct forming apparatus (manufactured by Sanko Machine Co., Ltd.) using a composite material prepared in place of the hot-dip galvanized iron plate. During the forming process, the paper was impregnated with an impregnating liquid consisting of only water, and the water content of the paper was adjusted to 8 to 12% by weight. The duct product after the forming process did not have any cracks on the paper surface. However, when the processing speed of the duct forming apparatus was increased, there was a tendency that chattering and forming defects occurred in the galvanized iron plate.

Example 5 Using the same composite material as in Example 4, a spiral duct was formed in the same manner as in Example 4. During this molding process, water 10
An impregnating solution comprising 0 parts by weight and 0.3 part by weight of methylcellulose (trade name "MARPOROS M-4000") as a thickener was prepared, put into an impregnating solution vat as in Example 1, and compounded with the impregnating solution. The paper was impregnated with the impregnating liquid by passing the material through, and the water content of the paper was adjusted to 8 to 12% by weight. The duct product after the forming process did not have any cracks on the paper surface. However, when the processing speed of the duct forming apparatus was increased, chattering and molding failure tended to occur on the galvanized iron plate, but the tendency was less than in Example 4.

[0034]

According to the present invention, when a composite material in which paper is bonded to a metal plate is bent or swaged, only the metal plate is formed because there is a difference in elongation during the forming process between the paper and the metal plate. If it is attempted to form by the same method as described above, there have been problems such as cracking of the paper or metal plate, delamination of the paper, and occurrence of square projections on the paper. However, according to the present invention, the paper in the composite material is impregnated with moisture, thereby increasing the elongation of the paper at the time of forming, and solving problems such as generation of cracks, occurrence of delamination, and occurrence of square projections. can do.

Further, by using the impregnating liquid obtained by adding a lubricant to water, the lubricating effect between the die of the forming apparatus and the metal plate can be further improved, and the processing speed of the forming apparatus can be relatively increased. However, it is possible to effectively prevent the metal plate from chattering and cracking.

Further, by adding a thickening agent to an impregnating liquid composed of water or an impregnating liquid composed of water and a lubricant, the water film or the lubricant film formed on the surface of the metal plate can be reliably removed. It is possible to effectively prevent the metal plate from chattering, cracking, and the like, and to relatively increase the processing speed.

[Brief description of the drawings]

FIG. 1 is a plan view showing an example of an apparatus for forming a flexible spiral duct.

FIG. 2 is a cross-sectional view showing an example of a moisture impregnating device that can be used when carrying out the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Composite material 3 ... Die for corrugation processing 5 ... Flexible spiral duct 10 ... Composite material 11 ... Guide roller 12 ... Sinking roller 13 ... Impregnation liquid 14 ... Bat 15 ... Squeeze roller.

──────────────────────────────────────────────────続 き Continuation of front page (56) References JP-A-6-91806 (JP, A) JP-A-7-256822 (JP, A) JP-A-5-246199 (JP, A) JP-A-60-1985 131203 (JP, A) JP-A-5-177748 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 15/12

Claims (5)

(57) [Claims] 1. A method of forming a composite material in which paper and a metal plate are bonded to each other, wherein the paper is impregnated with water in an amount of 5% by weight or more and then formed. Molding processing method. 2. The method according to claim 1, wherein the paper is impregnated with water in an amount of 10% by weight or more and less than 30% by weight, and then formed. 3. The forming method according to claim 1, wherein the forming is carried out after impregnating with water to which a water-dispersible lubricant and / or a water-soluble thickener has been added. . 4. The molding method according to claim 3, wherein the lubricant is a lubricating oil emulsion. 5. The method according to claim 3, wherein the thickener is a water-soluble cellulose derivative.