JP3763939B2 - Insulating panel manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a heat insulating panel.
More specifically, the present invention relates to a method for manufacturing a heat insulating panel in which a synthetic resin foam is filled in a box made of a frame surrounding the periphery and face members attached to both sides of the frame.
[0002]
[Prior art]
A heat insulating panel in which a synthetic resin foam is filled in a box made up of a frame surrounding the frame and face materials attached to both sides of the frame is light and excellent in heat insulation. As described in Japanese Patent Publication (hereinafter referred to as Conventional Example 1), it is often used as a heat insulating panel for buildings such as a wall panel, a ceiling panel, a floor panel, and a roof panel.
[0003]
This thermal insulation panel is usually manufactured by attaching a face material to one side of the frame and producing a box with the other side open, and then placing synthetic resin foam into the box through the opening. By bonding the resin foam and the face material attached to one surface, and then covering the other open surface with the face material, and bonding the covered face material and the synthetic resin foam It was manufactured.
[0004]
As another method, a method described in JP-A-8-34027 (referred to as Conventional Example 2) is known.
In this method, a box made of a frame and face materials attached to both sides of the frame is manufactured, and a pre-foamed synthetic resin foam is put into the box from a through hole provided in the frame. Water vapor is supplied from another through-hole provided in the frame, the pre-foamed synthetic resin foam is further foamed, and this box is filled with the synthetic resin foam.
[0005]
[Problems to be solved by the invention]
However, in the method described in the conventional example 1, a synthetic resin foam is produced by foaming a foamable synthetic resin, and the synthetic resin foam is put in a box and bonded, and then covered with a lid. Thus, since many processes are passed, manufacture is complicated.
Further, the method described in Conventional Example 2 is extremely convenient because a heat insulating panel can be manufactured simultaneously with the production of the synthetic resin foam.
[0006]
However, in this method, in order to supply water vapor from the through-holes provided in the frame surrounding the periphery, it is not possible to supply water vapor to every corner of a thin, large surface heat insulation panel. There is a problem that the pre-foamed synthetic resin foam is not sufficiently foamed.
In addition, in the method of manufacturing a heat insulating panel in which a crosspiece is provided in a box and a plurality of small boxes are provided, if there is a small box that is not in contact with the frame, water vapor is contained in the small box. There is a problem that cannot be supplied.
[0007]
Furthermore, there are various methods for producing a synthetic resin foam for foaming a foamable synthetic resin, but it is impossible to fill all the synthetic resin foams in the frame by the above method.
For example, in the case of a polystyrene foam or the like, a foamable synthetic resin or a pre-foamed synthetic resin is foamed with water vapor, whereas in a polyurethane resin foam, it is blown out from a nozzle while being foamed.
Accordingly, in the polystyrene resin foam, after pre-foaming, it can be put in a predetermined container and foamed with water vapor, and the above method can be applied, but the polyurethane resin foam is not foamed with water vapor, so There is a problem that the method cannot be applied.
[0008]
In addition, when foaming is performed in the box, there is a problem that due to the foaming pressure, the face materials on both sides warp outward and a good heat insulation panel with good dimensional accuracy cannot be manufactured.
It is conceivable to press from both sides with a press so that the face materials on both sides do not warp. However, if the insulation panels are pressed one by one until foaming is completed, it is long to produce one insulation panel. There is a problem that time is required and productivity is poor.
In addition, to improve productivity with multi-stage presses in order to improve productivity, while the heat insulation panels are stacked in multiple stages, foaming of the heat insulation panels first installed in the multi-stage press is completed, There is a problem that the foam is solidified while the material is warped and cannot be fixed even if it is pressed.
[0009]
Further, when there is a small box that is not filled with foam in the box, there is a problem that when the box is pressed, the portion of the small box is recessed and a good heat insulation panel with good dimensional accuracy is not obtained.
Therefore, an object of the present invention is to provide a method for manufacturing a heat insulating panel with high dimensional accuracy, which can be filled with a synthetic resin foam while foaming from the tip of a nozzle like a polyurethane resin foam in a box. Is to provide.
[0010]
[Means for Solving the Problems]
The present invention has been made to achieve the above-mentioned object, and the invention according to claim 1 is synthesized in a box made up of a frame surrounding the periphery and face members attached to both sides of the frame. A method of manufacturing a heat insulating panel filled with a resin foam , wherein the face material is previously cut out at the center and a glass plate is attached to form a skylight portion, and then attached to the frame, from a through hole. After the foamable synthetic resin is injected into the box while being foamed, it is passed through a pair of slat conveyors or roll conveyors held at a predetermined distance.
[0011]
The invention according to claim 2 is a method for manufacturing a heat insulating panel in which a synthetic resin foam is filled in a box composed of a frame surrounding the periphery and face members attached to both sides of the frame , The face material is cut out at the center to attach a glass plate to form a skylight portion, and then attached to the frame. The box is divided into a plurality of boxes by a crosspiece attached inside. A small box is formed, and one or more through holes that communicate with one or more of the plurality of small boxes are provided in the face material. When injecting into the small box while foaming synthetic resin from the through hole, it is injected into the small box around the notch of the skylight part, and then a pair of slats held at a predetermined distance It passes between conveyors or roll conveyors.
[0012]
According to a third aspect of the present invention, the synthetic resin foam used in the first or second aspect of the invention is a polyurethane resin foam.
[0013]
(Function)
In the first aspect of the invention, the foamable synthetic resin is injected into the box while foaming the foaming synthetic resin from the through-holes. By providing the holes, the foamable synthetic resin can be supplied to the corners while being foamed. Therefore, the foamed synthetic resin foam can be filled to the corners.
[0014]
In the invention of claim 1, since the foamable synthetic resin is injected into the box while foaming the foamable synthetic resin from the through hole, it is passed between a pair of slat conveyors or roll conveyors held at a predetermined distance. The foamable synthetic resin injected into the box foams and passes between the pair of roll conveyors held at a predetermined distance until the pressure on the foaming ends pressing the face materials on both sides. Accordingly, the face material is held at a predetermined distance by the paired slat conveyer or roll conveyer and cannot be warped, so that a heat insulating panel with good dimensional accuracy is obtained. And since it passes between slat conveyors or roll conveyors, it can manufacture continuously.
[0015]
In the invention according to claim 2, the box is formed with a small box in which the inside of the box is divided into a plurality of boxes by a crosspiece attached to the inside, and one or more of the plurality of small boxes are formed in the box. A through hole is provided in the face material, and the foamable synthetic resin is injected into the small box while foaming from the through hole provided in the face material. Even if there is a small box that does not communicate with the frame, it is possible to fill the synthetic resin foam by providing a through hole in the face material that communicates with the small box.
[0016]
In the invention according to claim 2, after injecting the foaming synthetic resin into the box while foaming the foaming synthetic resin from the through hole provided in the face material, the pair of slat conveyors or roll conveyors held at a predetermined distance is used. Since the foaming synthetic resin injected into the box foams and passes through the space, the paired slats are held at a predetermined distance until the foaming pressure completely presses the face materials on both sides. By passing between conveyors or roll conveyors, the pair of slat conveyors or roll conveyors cannot hold and warp the face material at a predetermined distance, and there are small boxes that do not inject foam. However, the slat conveyor or the roll conveyor does not press the face material attached to the predetermined distance that constitutes the small box body, and therefore does not dent so as to be pressed by the press. A good thermal insulation panel of. And since it passes between slat conveyors or roll conveyors, it can manufacture continuously.
[0017]
In the invention according to claim 3, since the synthetic resin foam is a polyurethane resin foam, the polyurethane resin is injected into the box or the small box while foaming, so that the inside of the box or the small space. Can be filled with a synthetic resin foam.
[0018]
In general, when a foamed synthetic resin comprising a polyester or polyether type polyhydric alcohol, a diisocyanate ester and a catalyst such as water is discharged from a nozzle, a polyurethane resin foam undergoes a polyaddition reaction, a foaming reaction, and a crosslinking reaction. The polyurethane resin foam comes out from the tip of the nozzle while foaming.
Therefore, by inserting the tip of the nozzle into a through hole provided on one side of the box or small box and injecting the foamable synthetic resin into the box while foaming from the tip of the nozzle, the box or small box is injected. The box can be filled with a synthetic resin foam.
Moreover, since this polyurethane resin foam has good heat insulation properties and good mechanical strength, a heat insulation panel with good heat insulation properties and good mechanical strength can be obtained when manufactured by the invention of claim 3.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
Examples of the present invention will be described below.
1 and 2 show an embodiment in which the present invention is applied to the manufacture of a roof unit. FIG. 1 (a) is an explanatory view showing a state in which a roof skeleton is assembled, and (b) is a box. (C) is an explanatory diagram showing a state where the box is heated by a high-frequency heating device, (d) is a through hole provided on one face material of the box, and Explanatory view showing a state where foaming synthetic resin is being injected from the hole, (e) is an explanatory view showing a state where the heat insulating panel is being pressed, and (f) is a state where the roof panel is being finished (G) is explanatory drawing which shows a roof unit, FIG. 2: is a front view of a heat insulation panel.
[0020]
1 is a roof unit. As shown in FIG. 1 (a), the roof unit 1 has a skeleton 12 in which a bundle 12 is erected on a land beam 11 and a palm 13 is provided thereon. The two trusses are connected by a beam 14, and a rafter 15 is mounted thereon.
[0021]
A is a box. As shown in FIG. 2, the box A has a frame member 4 attached to a frame 3 in which a vertical frame 31 and a horizontal frame 32 are substantially rectangularly framed. A box 5 (there is a box 5 having a skylight part 51, a small box 52 filled with a synthetic resin foam, and an eaves part 53 not filled with a synthetic resin foam) is formed at the center. The face material 6 is attached to the both side surfaces. The face material 6 is not attached to both side surfaces of the skylight portion 51 of the small box 5, and a glass plate 61 is attached to the skylight portion 51.
[0022]
The box A has various sizes and the maximum length is 7.2 m.
2 is a heat insulation panel, and this heat insulation panel 2 is a box A filled with a synthetic resin foam.
Reference numeral 55 denotes a through hole that communicates with the small box 52 provided on one face member 6.
7 is a foaming device, and 71 is a nozzle. A drill 72 is provided with a through hole 55.
[0023]
8 is a high-frequency heating device, 85 is a press device composed of endless conveying devices provided at the top and bottom, and consists of a pair of slat conveyors 86, 86 held at substantially the same distance as the thickness of the heat insulating panel 2, The length is 21 m.
Reference numeral 9 denotes a roof panel. The roof panel 9 has a waterproof sheet 91 made of roofing attached to the upper surface of the heat insulating panel 2 and a ceiling material 92 made of gypsum board attached to the lower surface.
And this roof unit 1 attaches the roof panel 9 on the rafter 15 as shown in FIG.
[0024]
Next, the manufacturing method of this roof unit 1 is demonstrated.
As shown in FIG. 1 (a), a bundle 12 is erected on the land beam 11, a palm 13 is provided on this to form a substantially triangular truss, and these two trusses are connected by a beam 14. Then, the rafter 15 is attached on this to manufacture the skeleton of the roof unit 1.
On the other hand, as shown in FIG. 1 (b), the vertical frame 31 and the horizontal frame 32 are assembled into a substantially rectangular shape to form a frame 3, and a crosspiece 4 is attached to the frame 3 so that a large number of small boxes 5 are formed. Form.
[0025]
Then, a glass plate is attached to the central skylight portion 51, and the box 6 is manufactured by attaching the face material 6 with the skylight portion 51 cut out to both sides of the frame 3 with an adhesive.
Next, this box A is heated to about 40 ° C. by passing between the high-frequency heating devices 8 as shown in FIG.
Next, as shown in FIG. 1 (d), the drill 72 is provided with a through hole 55 that communicates with the small box 52 in the one face member 6 of the box A, and the nozzle 71 is inserted into the through hole 55 so that the foaming device 7 The foaming polyurethane resin is injected while foaming.
[0026]
Then, the foaming polyurethane resin injected into the box A heated to 40 ° C. does not cool, and therefore, the polyurethane resin foam is filled into the small box 52 while foaming almost uniformly. Can do.
In this way, in the heat insulating panel 2 with a small thickness, the foamable synthetic resin is supplied while being foamed to every corner by providing many through holes 55.
Further, even in the heat insulating panel 2 provided with a large number of small boxes 5 by dividing the frame into a large number by crosspieces, the synthetic resin can be injected while foaming from the through holes 55 communicating with the small box 52. However, it is convenient because the synthetic resin foam may not be provided in a portion that does not require heat insulation, such as a small box 53 located on the outside (eave portion) from the wall of the roof panel 1.
[0027]
Thus, even if the synthetic resin foam is a polyurethane resin foam, the synthetic resin foam can be filled by pouring the polyurethane resin into the small box 52 while foaming.
The box A filled with the foam in this way has a speed of 2 m / min between the slat conveyors 86 and 86 held at substantially the same distance as the thickness of the box A as shown in FIG. Pass through. Therefore, it passes between the slat conveyors 86, 86 over 10 minutes. This time is sufficient for the polyurethane resin to finish foaming.
[0028]
Then, until the foamable synthetic resin injected into the box A finishes foaming, that is, until the both side face materials 6 are completely pressed by the foaming pressure, the insulation panel 2 is maintained at the same distance as the thickness. Pass between the paired slat conveyors 86, 86. Therefore, even if there is a small box 53 that does not inject foam, the face material 6 is held at approximately the same distance as the thickness of the heat insulating panel 2 by the paired slat conveyors 86 and 86 and cannot be warped. Since the slat conveyors 86 and 86 do not press the face material 6 constituting the small box 53 having substantially the same thickness as the box A, the slat conveyors 86 and 86 do not dent, so that the heat insulation panel 2 with high dimensional accuracy is obtained.
And since it passes between slat conveyors, it can manufacture continuously and productivity is good. If the length of box A is 7.2 m at maximum, it is 7.2 m ÷ 2 m / min = 3.6 minutes, so continuous production is possible at a pace of about 3.6 minutes.
[0029]
Since this polyurethane resin foam has good heat insulation and good mechanical strength, the heat insulation panel 2 manufactured in this way has good heat insulation and good mechanical strength.
[0030]
Next, the waterproof sheet 91 is attached to the upper surface of the heat insulation panel 2 or the ceiling material 92 is attached to the lower surface to produce the roof panel 9 shown in FIG. 1 (f). The roof unit 1 having good heat insulating properties could be manufactured by attaching it onto the rafter 15 of the skeleton of the roof unit 1 manufactured in (1).
[0031]
Although the slat conveyor which became a pair as a press apparatus was shown in the said Example, a roll conveyor may be used instead.
[0032]
【The invention's effect】
In the invention according to claim 1, the box is provided with a through hole in one of the face materials attached to both sides, and the foaming synthetic resin is formed from the through hole provided in the face material. Since it is injected into the box while foaming, it is convenient that even a heat insulating panel with a small thickness can be filled with a fully foamed synthetic resin foam to every corner.
[0033]
In the first aspect of the present invention, after injecting the foaming synthetic resin into the box while foaming the foaming synthetic resin from the through hole provided in the face material, the pair of slat conveyors or roll conveyors held at a predetermined distance is provided. Therefore, the surface material is held at a predetermined distance by the paired slat conveyor or roll conveyor and cannot be warped, and a heat insulating panel with high dimensional accuracy can be manufactured. And since it passes through a slat conveyor or a roll conveyor, it can manufacture continuously and productivity is good.
[0034]
In the invention according to claim 2, the box is formed with a small box in which the inside of the box is divided into a plurality of boxes by a crosspiece attached to the inside, and one or more of the plurality of small boxes are formed in the box. A through hole is provided in one face material, and foamable synthetic resin is injected into the small box while foaming from the through hole provided in this face material. Even if there is a small box whose body does not communicate with the frame, it is convenient to provide a through hole that communicates with the small box in the face material to fill the synthetic resin foam.
[0035]
In the second aspect of the invention, as in the first aspect of the invention, the foamable synthetic resin is injected into the box while foaming the foamable synthetic resin from the through-hole provided in the face material, and then for a predetermined distance for at least one minute. The pair of slat conveyors or roll conveyors that are held in a pair are passed through, so that the face material is held at a predetermined distance by the paired slat conveyors or roll conveyors and cannot be warped, and dimensional accuracy is good. Insulation panels can be manufactured. Moreover, since it passes through the roll conveyor, it can be manufactured continuously and the productivity is good. Even if there is a small box that does not inject the foam, the conveyor does not press the face material constituting the small box having the same thickness as the box, so that it does not dent.
[0036]
In the invention according to claim 3, since the synthetic resin foam is a polyurethane resin foam, the polyurethane resin is injected into the box or the small box while foaming, so that the inside of the box or the small space. Can be filled with a synthetic resin foam.
Moreover, since this polyurethane resin foam has good heat insulation properties and good mechanical strength, a heat insulation panel with good heat insulation properties and good mechanical strength can be obtained when manufactured by the invention of claim 3.
[Brief description of the drawings]
1A and 1B show an embodiment in which the present invention is applied to the manufacture of a roof unit. FIG. 1A is an explanatory view showing a state in which a roof skeleton is assembled, and FIG. An explanatory view showing the state, (C) is an explanatory view showing a state in which the box is heated by a high-frequency heating device, and (D) is a foaming hole formed in one face material of the box, from which the through hole is formed. An explanatory view showing a state in which a synthetic resin is being injected, (e) is an explanatory view showing a state in which a heat insulation panel is being pressed, and (f) is an explanatory view showing a state in which a roof panel is being finished (G) is explanatory drawing which shows a roof unit.
FIG. 2 is a front view of a heat insulation panel.
[Explanation of symbols]
A Box 1 Roof unit 2 Thermal insulation panel 3 Frame 4 Crosspiece 5 Small box 55 Through-hole 6 Face material 85 Press device 86, 86 Paired slat conveyor

Claims (3)

A method of manufacturing a heat insulating panel in which a synthetic resin foam is filled in a box made of a frame surrounding a frame and a face material attached to both sides of the frame , the After forming a skylight part by cutting and attaching a glass plate, it is attached to the frame and injected into the box while foaming synthetic resin is foamed from the through hole, and then a pair held at a predetermined distance. A method for manufacturing a heat insulating panel, characterized by passing between slat conveyors or roll conveyors. A method of manufacturing a heat insulating panel in which a synthetic resin foam is filled in a box made of a frame surrounding a frame and a face material attached to both sides of the frame , the After forming a skylight part by cutting and attaching a glass plate, it is attached to the frame, and the box is formed into a small box in which the inside of the box is divided into a plurality of pieces by a crosspiece attached inside. The face material is provided with one or more through holes communicating with one or more of the plurality of small boxes , and the foamable synthetic resin is removed from the through holes provided in the face material. When pouring into a small box while foaming, after pouring into the small box around the notch of the skylight part , it passes between a pair of slat conveyors or roll conveyors held at a predetermined distance The manufacturing method of the heat insulation panel characterized by making it do.   The method for producing a heat insulating panel according to claim 1 or 2, wherein the synthetic resin foam is a polyurethane resin foam.

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