JP3497599B2 - Method and apparatus for manufacturing foam panel - 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 and apparatus for manufacturing foam panels.

[0002]

2. Description of the Related Art For example, a foam panel used as an interior / exterior wall material is composed of a synthetic resin foam layer such as polyurethane resin and an outer surface material thereof. As a conventional method for manufacturing this kind of foamed panel, for example, a so-called double conveyor method shown in FIG. 7 of the accompanying drawings and a so-called multi-stage press method shown in FIG. 8 are well known.

The former double conveyor system is a double conveyor device 50 in which a lower belt conveyor device 51 and an upper belt conveyor device 52 are vertically arranged at predetermined intervals as shown in FIG. While the lower outer surface material 53 is being supplied to the foamed resin material 55, the foamed resin material 55 is continuously injected onto the lower outer surface material 53, and the upper outer surface material 54 covers the upper part of the resin material 55.
The foamed resin material 55 is foamed while being pressurized with a predetermined pressure to integrally form a foamed layer 56 between the lower outer surface material 53 and the upper outer surface material 54. In FIG. 7, reference numeral 61 is an uncoiler having a lower outer surface material, 62 is an uncoiler having an upper outer surface material, 63 and 64 are roll forming machines for shaping the lower and upper outer surface materials into predetermined shapes, and 65 is an injection of a foamed resin material. The machine (mixing head) 66 is a cutter, and P1 is a foam panel product.

The double conveyor system has an advantage that the same panel product can be continuously and mass-produced, as can be easily understood from the drawings. However,
At the same time, the equipment becomes large and many mechanical equipments are required before and after the injection, and above all, it is difficult to cope with the production of various kinds.

On the other hand, the multi-stage press system is as shown in FIG.
An outer surface material 7 having a cavity 73 inside is provided at each stage of a multi-stage press device 70 having a plurality of press plates 71, 71 in the vertical direction.
2 is set, the injection machine (mixing head) 74 is moved in the vertical direction, and the foaming resin material 76 is sequentially injected from the injection hole 75 of each outer surface material 72 to form the foaming layer 77 integrally with the outer surface material 72. To do. In FIG. 8, reference numeral 78
Is a hydraulic press device, 79 is a moving device for an injection machine, and P2 is a foam panel product.

[0006] This multi-stage press system can be downsized in terms of equipment as compared with the double conveyor system, and is suitable for multi-product production. However, this multi-stage press system has major problems that the down time as the equipment is long and that the setting of the outer surface material is complicated and the productivity cannot be improved.

[0007]

SUMMARY OF THE INVENTION In view of such circumstances, the present invention is applicable to a wide variety of products without requiring a large amount of equipment, and has a high productivity, and a novel method for producing a foamed panel, and The purpose is to provide a device.

[0008]

That is, first, in the method for manufacturing a foamed panel of the present invention, the outer surface of a panel having a cavity for forming a foamed layer therein and an injection hole for a foamed resin material at its rear end is first described. While feeding the material into the pressure conveyor device from its front part, while the panel outer surface material rear end is still outside the pressure conveyor device, the injection machine of the foamed resin material from the standby position to the panel outer surface. Move to the injection hole position at the rear end of the material, and inject the foamed resin material into the cavity from the injection hole while advancing in synchronism with the advance of the panel outer surface material by the pressure conveyor device, and wait after the injection is completed. The panel outer surface material which has been moved to a position and has been injected is moved forward while being pressurized in the pressure conveyor device for a predetermined time.

Further, according to the apparatus of the present invention, the panel outer surface material having the cavity for forming the foam layer therein and the injection hole of the foam resin material at the rear end thereof is moved forward while pressing for a predetermined time. A pressure conveyer device, a feeding device that intermittently feeds the panel outer surface material into the pressure conveyer device, and is arranged between the pressure conveyer device and the feeding device, and the front portion is provided by the feed device. In order to inject the foamed resin material into the cavity from the injection hole in the rear end portion of the panel outer surface material sent into the pressure conveyor device, the pressure conveyor device moves from the standby position to the injection position. It is characterized by comprising an injection device configured to inject the foamed resin material while advancing in synchronism with the advancing of the panel outer surface material and return to the standby position after completion of the injection.

Further, the apparatus of the present invention has a pallet for mounting a panel outer surface material having a cavity for forming a foamed layer therein and an injection hole for a foamed resin material at its rear end, and the pallet. A pressure conveyor device that moves forward while pressing the mounted panel outer surface material for a predetermined time, and a feeding device that intermittently feeds the pallet mounting the panel outer surface material into the pressure conveyor device, and From the injection hole at the rear end of the panel outer surface material, which is disposed between the pressure conveyor device and the feeding device, and the front portion is placed on the pallet fed into the pressure conveyor device by the feeding device. In order to inject the foamed resin material into the cavity, it moves from the standby position to the injection position and injects the foamed resin material while advancing in synchronism with the advance of the pallet by the pressure conveyor device, and waits after the injection is completed. Characterized by comprising the configured infusion device to return to location.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A manufacturing method of the present invention will be described below with an apparatus according to the accompanying drawings. 1 is a side view of a main part of a foam panel manufacturing apparatus showing an embodiment of the present invention, FIG. 2 is an enlarged sectional view of the same, FIG. 3 is a sectional view of a foam panel product, and FIG. 4 is a part of an outer surface material. 6 is a perspective view in which the panel outer surface material is placed on a pallet, and FIG.
[Fig. 6] is a plan view showing another example.

First, the method for manufacturing a foam panel according to the first aspect comprises the following steps. That is, the step of feeding the panel outer surface material into the pressure conveyor device, the step of feeding the panel outer surface material and the step of injecting the foamed resin material into the cavity inside the panel outer surface material, and the step of adding the completed panel outer surface material And moving forward while pressurizing in the pressure conveyor device.

As shown in FIG. 1, the foamed panel manufacturing apparatus comprises a pressure conveyor device 20, a feeding device 30, and an injection device 40, and presses the panel outer surface material 10 for a predetermined time to form a foamed panel. Form. The apparatus is used by being arranged in a known curing oven or the like which is adjusted to a predetermined curing temperature of the foamed resin raw material.

First, the panel outer surface material 1 used in the present invention.
0 will be described. As shown in FIGS. 3 and 4, the panel outer surface member 10 is made of metal, wood, synthetic resin or the like forming the outer surface of the foamed panel product P. In this example, the panel outer surface member 10 is a bottom member. 11 and an upper surface member 12. The lower surface member 11 is formed in a box shape having an upper surface opened by a lower surface portion 11a and a side surface portion 11b. The upper surface member 12 has an upper surface portion 12a.
And the side surface portion 12b, the lower surface member 11 is formed into a shape that can be fitted like a lid.

The side surface portions 11b and 12b are for determining the thickness of the panel, and the lower surface member 1 and the upper surface member 12 are arranged at a predetermined interval. Thereby,
A cavity 13 for forming the foam layer F is formed inside the panel outer surface material 10. Each side portion 11b, 1
2b, an injection hole 15 of a foamed resin material is formed in the rear end portion 10R of the panel outer surface material 10. Reference numeral 10F in FIG. 4 denotes a front end portion of the panel outer surface material 10.

The pressure conveyor device 20 includes a panel outer surface material 1
0 is moved forward while being pressurized with a predetermined pressure for a predetermined time, and a belt conveyor device conventionally used for manufacturing a foam panel of this kind can be used. The pressure applied to the panel outer surface material 10 by the pressure conveyor device 20 and the pressurizing time are appropriately determined depending on the material and thickness of the foamed layer F and the panel outer surface material 10 to be formed.
In the illustrated embodiment, the pressure conveyor device 20 is provided with an upper belt conveyor device 21 and a lower roller conveyor device 2.
However, as shown by the broken line in FIG. 1, a lower belt conveyor device 23 may be used in place of the lower roller conveyer device 22. In this pressure conveyor device 20,
While the one panel outer surface material 10 is being moved forward while being pressurized, the next panel outer surface material 10A is fed from the feeding device 30.

Next, the feeding device 30 will be described. The feeding device 30 is a device for intermittently feeding the panel outer surface material 10 into the pressure conveyor device 20, and in the embodiment, as shown in FIG. 1, a known accumulator is mounted on a suitable machine base 31. A rate type chain conveyor 32 is provided. The feeding device 30 is configured such that one panel outer surface material 10 is fed to the pressure conveyor device 20 and the filling device 40 is also provided.
While the foamed resin material is being injected into the cavity 13 of the panel outer surface material 10 by the following, the next panel outer surface material 10A
The feeding into the pressure conveyor device 20 is stopped.
Then, when the injection of the foaming resin raw material into the inside of the panel outer surface material 10 is completed, the above-mentioned accumulated type chain conveyor 32 operates promptly, and the next panel outer surface material 10
A is fed into the pressure conveyor device 20, and the panels are continuously fed out. Reference numeral S is a stopper for the panel outer surface material 10 provided in front of the machine base 31 and is released or set in conjunction with the accumulation type chain conveyor 32.

The injecting device 40 is for injecting the foamed resin material into the cavity 13 of the panel outer surface material 10 sent into the pressure conveyor device 20 by the injecting device 30. It is arranged between the device 20 and the feeding device 30. The injection device 40 includes an injection device 41 and a traverse device 42.

The injection machine 41 has a nozzle 43 which can be inserted into the injection hole 15 of the panel outer surface material 10, and injects the foamed resin raw material into the cavity 13 through the nozzle 43.
In addition, the traverse device 42 is the same as the traverse device 42 shown in FIG.
As shown by the chain line, while reciprocating from the standby position A to the pouring position B, it also reciprocates along the path of the panel outer surface material 10 from the feeding device 30 to the pressure conveyor device 20. be able to.

In the traverse device 42, the front portion of the panel outer surface material 10 is moved from the feeding device 30 to the pressure conveyor device 2.
0, while the rear end 10R is still outside the pressure conveyor device 20, the injection machine 41 is moved from the standby position A to the injection position B, that is, the injection nozzle 43 injects the rear end of the panel outer surface material 10. It is moved to a position where it can be inserted into the hole 15. Then, the injection nozzle 43 is inserted into the injection hole 15 to inject the foamed resin material into the hollow portion 13, and is advanced in synchronization with the advance of the panel outer surface material 10 by the pressure conveyor device 20. The injection machine 41 has a panel outer surface material 10
The rear end portion 10R is adjusted so as to inject a predetermined amount of the foamed resin raw material into the hollow portion 13 by the time the rear end portion 10R is fed into the pressure conveyor device 20. The nozzle 43 is retracted and pulled out from the injection hole 15, and is moved to the standby position A shown by the chain line in FIG.

According to this injecting device 40, the panel outer surface material 10 is sent to the pressure conveyor device 20, and at the same time, it moves from the standby position A to the injecting position B while moving in synchronization with the infeed of the panel outer surface material 10. The foamed resin material is injected, and after the injection is completed, it returns to the standby position A again. Therefore, the process from the injection process to the pressurization process can be performed continuously, which is extremely efficient.

As described above, when the injection of the foamed resin raw material by the injection machine 41 is completed and the injection machine 41 returns to the predetermined standby position A, at the same time, the feeding device 30 is operated again to perform the next operation. The panel outer surface material 10A is fed to the pressure conveyor device 20. Then, the injection process by the injection device 40 is repeated to continuously manufacture panels.

The panel outer surface material 10 into which the foamed resin raw material is injected is maintained in a pressurized state by the pressure conveyor device 20, and the foamed resin raw material is foamed and hardened in the hollow portion 13, so that FIG. As shown in, a foam layer F is formed in the cavity 13.

Next, an apparatus for manufacturing a foam panel according to a fourth aspect will be described. As indicated by the reference numerals in parentheses in FIG. 1, in this device, the pallet 33 is supplied before the panel outer surface material 10 is fed into the pressure conveyor device and is pressurized.
Placed on. The pallet 33 mounts the panel outer surface materials 10 one by one. As shown in FIG. 2, the pallet 33 is formed to have a size along the outer shape of the panel outer surface material 10 so that the panel outer surface material 10 can be easily mounted. The upper part is open so that you can place it.

According to this pallet 33, even if the panel outer surface material 10 is made of a material having a poor shape-retaining property such as paper or a thin plate of synthetic resin, not only the desired panel shape can be easily maintained, It is possible to reliably feed or pressurize the panel outer surface material 10.

The panel outer surface material 10 is the pallet 33.
And is fed into the pressure conveyor device 20 from the front end portion 10F by the feeding device 30. Reference numeral 24
Is a guide roller that comes into pressure contact with both side surfaces 39 of the pallet 33.

Further, a plurality of panel outer surface materials 34 can be placed on the pallet 33 to manufacture the panel. In this example, as shown in FIG. 5, two panel outer surface members 34, 34 are placed on the pallet 33. Reference numeral 35
Is the injection hole. At that time, as shown by the one-dot chain line in the figure, if an injection device having two nozzles 37, 37 is used in one injection device 36, two panels can be manufactured in one step, which is extremely efficient. Is.

Further, as shown in FIG. 6, even a panel outer surface member 38 having a shape such as a trapezoid or a triangle which is difficult to be fed by an ordinary conveyor device or the like is placed on the pallet 33 and the pallet 33 is placed. Panel outer surface material 3
Since 8 can be moved and pressed, it is also effective for manufacturing odd-shaped panels.

[0029]

As described above, according to the present invention, it is possible to surely cope with the production of a wide variety of products with simple and small equipment. In addition, since the panels are delivered intermittently and the foaming resin raw material is injected in synchronization with the delivery of the panels, there is almost no downtime of the equipment, continuous production of panels is possible, and productivity is significantly improved. be able to.

Further, when a pallet is used for placing the panel outer surface material, not only the panel outer surface material can be set easily and surely, but also a panel outer surface material or a deformed panel outer surface material having poor shape retention is used. However, the panel can be reliably manufactured.

[Brief description of drawings]

FIG. 1 is a side view of an essential part of a foam panel manufacturing apparatus showing an embodiment of the present invention.

FIG. 2 is an enlarged sectional view of the same.

FIG. 3 is a cross-sectional view of a foam panel product.

FIG. 4 is a perspective view in which a part of the outer surface material is omitted.

FIG. 5 is a plan view showing a state in which a panel outer surface material is placed on a pallet.

FIG. 6 is a plan view showing another example.

FIG. 7 shows a method for manufacturing a general foam panel,
It is a side view which shows an example of a double conveyor system.

FIG. 8 is a cross-sectional view showing another manufacturing method, showing an example of a multi-step pressing method.

[Explanation of symbols]

10 panel outer surface material 13 Cavity 15 injection holes 20 Pressure conveyor device 30 feeding device 33 pallets 40 injection device A standby position B injection position

Continuation of the front page (56) Reference JP-A-4-226717 (JP, A) JP-A-58-3838 (JP, A) JP-A-62-267111 (JP, A) JP-A 1-110110 (JP , A) (58) Fields investigated (Int.Cl. ⁷ , DB name) B29C 39/00-39/44

Claims (4)

(57) [Claims] 1. A panel outer surface material having a cavity for forming a foamed layer inside and a pouring resin material injection hole at its rear end is fed into the pressure conveyor device from its front part, and While the rear end of the panel outer surface material is still outside the pressure conveyor device, the injection machine for the foamed resin material is moved from its standby position to the injection hole position of the rear end portion of the panel outer surface material, and the While injecting the foamed resin material into the cavity, it moves forward in synchronism with the advance of the panel outer surface material by the pressure conveyor device, and moves to the standby position after completion of injection, and the panel outer surface material that has been injected is the pressure conveyor device. A method for manufacturing a foam panel, wherein the inside of the foam panel is moved forward while being pressurized for a predetermined time. 2. The injection molding process according to claim 1, wherein the next panel outer surface material is fed into the pressure conveyor device while the completed panel outer surface material moves forward in the pressure conveyor device. The manufacturing method of the foam panel which is repeated. 3. A pressure conveyer device for moving forward while pressurizing a panel outer surface material having a hollow portion for forming a foam layer inside and having an injection hole of a foamed resin material at its rear end for a predetermined time. A feeding device that intermittently feeds the panel outer surface material into the pressure conveyor device, and is disposed between the pressure conveyor device and the feeding device, and the front part is the pressure conveyor device by the feeding device. In order to inject the foamed resin material into the cavity from the injection hole at the rear end portion of the panel outer surface material that has been fed into, move from the standby position to the injection position and advance the panel outer surface material by the pressure conveyor device. An apparatus for manufacturing a foamed panel, comprising: an injection device configured to inject a foamed resin material while advancing in synchronization and return to a standby position after completion of injection. 4. A pallet on which a panel outer surface material having a cavity for forming a foam layer therein and having a foamed resin material injection hole at its rear end is mounted, and a panel outer surface mounted on the pallet. A pressure conveyor device that moves forward while pressing the material for a predetermined time, a feeding device that intermittently feeds the pallet on which the panel outer surface material is placed into the pressure conveyor device, and the pressure conveyor device and the feeding device. A foamed resin from the injection hole at the rear end of the panel outer surface material placed on the pallet, which is disposed between the feeding device and the front portion is fed into the pressure conveyor device by the feeding device, into the cavity. In order to inject the material, it is configured to move from the standby position to the injection position and inject the foamed resin material while advancing in synchronism with the advance of the pallet by the pressure conveyor device, and return to the standby position after the injection is completed. And a filling device.