JPH01204739A - Production of composite panel - Google Patents

Abstract

PURPOSE:To obtain a flat composite panel having no density irregularity, by performing the ageing, after the emission of a core material in a liquid raw material state, in such a state that the composite panel is curved in a convex bow-shape as a whole. CONSTITUTION:An ageing machine 2 is constituted of a lower mold 3 and an upper mold 4 both of which are formed by arranging rolls, caterpillars or belts up and down each other and a core material B is reacted while a composite panel is fed between the mold materials of the lower and upper molds 3, 4 to be molded. The lower and upper molds 3, 4 are formed so that the intermediate gap therebetween is curved in a convex bow-shape as shown by figures (a), (b). That is, the figure (a) shows such a case that the upper and lower molds 4, 3 are formed of caterpillars, and the figure (b) shows such a case that said molds 4, 5 are formed of rolls and the composite panel is transferred along the gap between the molds 4, 3 in a curved state, and the reaction and foaming of the core material B are advanced. By this method, even when the core material B is emitted to the central part of the composite panel in a state showing flowability, said material B is dispersed toward both side edges as if it is emitted uniformly and the density irregularity at the time of the formation of the core material B can be eliminated.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to a method for manufacturing a composite board having a structure in which a synthetic resin foam is used as a core material and this core material is sandwiched between an upper base material and a lower base material. It is. More specifically, the present invention relates to a method for manufacturing a composite plate having flatness also by secondary foaming of a synthetic resin foam as a core material.

[Conventional technology]

Conventionally, in the manufacturing method of this type of composite board, the synthetic resin foam serving as the core material is discharged as a raw material, and after being laminated with the lower base material - core material - upper base material, the core material is reacted and foamed in a curing machine. let them do it;
A method of forming a composite plate of a predetermined shape has been used.

In addition, in the curing machine, caterpillars, steel belts, and rollers are placed vertically facing each other with a gap that matches the final shape of the composite plate, and the core material of the composite plate reacts and foams within this gap. The board was being formed.

[Problem to be solved by the invention]

However, in the past, in order to improve productivity, the synthetic resin foam was cured in a curing machine until the apparent reaction and foaming were completed. There was a risk of deformation. That is, as shown in FIG. 7, the lower base material A is formed into a substantially gutter-shaped cross section, the gutter-shaped portion of the lower base material A is filled with the core material B, and the exposed surface of the core material B is formed into the upper base material. In the case of the composite plate coated with material C, the wider the composite plate, the more the cross section tended to become concave as shown by the dotted line.

[Means to solve the problem]

In order to eliminate such drawbacks, the present invention obtains a flat composite board by curing the core material after discharging it in a liquid raw material state by curving the entire composite board into an upwardly convex arch shape. The present invention provides a method for manufacturing a composite plate that can be used.

〔Example〕

The method for manufacturing a composite plate according to the present invention will be described in detail below with reference to the drawings. FIG. 1 is an explanatory diagram showing an outline of an apparatus for carrying out the above method for manufacturing a composite plate, in which A is the lower base material, B is
1 is a core material, C is an upper base material, 1 is a discharge part, and 2 is a curing machine. To explain further, lower base material A and upper base material B are made of flexible materials, for example, lower base material A is made of metal such as colored steel plate, copper plate, aluminum plate, clad steel plate, vibration damping steel plate, etc. Materials (flat plate, embossed plate), upper base material C is asbestos paper, kraft paper, metal foil CAR1Fe,
Pb), plastic sheet, asphalt felt, etc., or two or more types are laminated together. In the composite board, the lower base material A serves as the decorative surface material and the connecting part forming material, and the upper base material C serves as the back surface material. This is the result. Note that, as shown in FIGS. 2A to 2, the lower base material C may be formed into a substantially gutter-like cross section before being transferred to the discharge portion 1.

In the discharge section 1, core material B is a synthetic resin foam such as polyurethane foam, polyurea foam, polyisocyanurate foam, phenol foam, polyimide foam, etc., and various flame retardants, flame retardant aids, and aggregates are mixed therein. Spray gun method (air,
(airless), a discharge method with rotating blades, an injection method, etc. To explain further, the discharge part 1 has a core material B as shown in FIGS. 3(a) to 3(d).
Raw materials can be discharged. That is, (a) as shown in the figure, it is discharged onto the lower base material A, and then the upper base material C is laminated, or (as shown in the figure bl), the lower base material A and the upper base material C are laminated.
As shown in figure fC1, after discharging onto the upper base material C, it may be laminated onto the lower base material A. After being discharged separately, they can be laminated. The curing machine 2 is made of one of a caterpillar, a roll conveyor, a belt conveyor (the caterpillar 2 is shown in Fig. 1), or a combination thereof, and depending on the type of core material B, it can be foamed and hardened at room temperature, or heated with warm air. The reaction of the synthetic resin foam that is the core material B can also be accelerated by hot air, steam, or the like. That is, the curing machine 2 has rolls, caterpillars, belts, etc. arranged above and below each other to form a lower mold 3 and an upper mold 4, and reacts the core material B while conveying the composite plate between the mold materials of the lower mold 3 and upper mold 4. The material is then molded. The lower mold 3 and upper mold 4 are shown in Fig. 4 fa), (bl
As shown in the figure, the gap in the middle is curved in an upwardly convex arc.

That is, figure (a) shows the case where the upper and lower molds 4.3 are formed by caterpillars, and figure fb1 shows the case where they are formed by rolls.The composite board is transferred along this gap while being curved, and the core material Reaction B and foaming progress. Due to this, core material B
When it has fluidity, even if it is discharged into the center of the composite plate, it will be dispersed toward both side edges, and it will be discharged uniformly, which can eliminate uneven density when forming the core material B. Furthermore, the degree of curvature of the gap formed by the lower die 3 and the upper die 4 varies depending on the width of the composite plate and the materials of the lower base material A, the upper base material C1, and the core material B. In belt type curing m2, belts 3a and 4a are wound around deformed rolls as shown by dotted lines in Fig. 4 (bl).In the composite plate formed in this way, as shown in Fig. 5, Although it is curved immediately after being sent out from the curing machine 2, due to the elasticity of the lower base material A and the secondary foaming of the core material B, it can finally become a flat composite board as shown by the dotted line. Furthermore, as shown in FIG. 6, the composite board is constructed so as to be fixed to the substrate at both side edges, so even if a curve remains, it can be flattened during construction.

What has been described above is only an example of the method for manufacturing a composite plate according to the present invention, and after discharging the raw material of the core material B as shown in FIG. Although not shown, it is also possible to curve the lower base material A in the discharge section 1.

〔Effect of the invention〕

As described above, according to the method for manufacturing a composite board according to the present invention, it is possible to obtain a flat composite board even if secondary foaming of the core material occurs. Furthermore, even if the composite board remains curved, it can be eliminated during construction. Moreover, due to the fluidity of the raw material for the synthetic resin foam forming the core material, a composite board with uniform density can be obtained. It has the following effects and characteristics.

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram showing an outline of an apparatus for carrying out the method for manufacturing a composite plate according to the present invention, FIGS. Figure 3(a)-(
d) is an explanatory diagram showing an example of the discharge part, FIGS. 4(a) and (b)
is an explanatory diagram showing the state of the composite plate between the upper mold and lower mold of the curing machine,
FIG. 5 is an explanatory diagram showing the state of a composite board formed by the manufacturing method according to the present invention, FIG. 6 is an explanatory diagram showing the construction state of the composite board, and FIG. 7 is an explanatory diagram showing the state of construction of the composite board manufactured by the conventional manufacturing method. It is an explanatory view showing the mode of a composite board. A: lower base material, B: core material, C: upper base material,
1...Discharge part, 2...Curing machine. Fig. 1 Juban Momme Fig. 1 "Illusion rA (bl f8(ri, A (ri, A) 5″ 1°)

Claims (1)

[Claims] (1) In a method for manufacturing a composite board in which a synthetic resin foam is used as a core material and the front and back surfaces of the core material are sandwiched between a flexible upper base material and a lower base material, the raw material for the core material is The material is discharged onto the back side of the material or the lower base material, or between the upper base material and the lower base material, and then laminated, and the whole is curved upward into a convex arch shape to be cured and integrated. A method for manufacturing composite boards.