JPH023687B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a composite material in which a synthetic resin foam layer, a surface material sandwiching the foam layer, and a backing material are laminated integrally with each other.

A plate-shaped composite material in which a synthetic resin foam layer is sandwiched between a surface material and a lining material is widely used as an exterior wall material, interior lining material, and roof material of buildings.

In manufacturing this composite material, two mold members 1 and 2 are arranged vertically facing each other as shown in Fig. 1, and a surface material F is layered on the lower mold member 2, and a liquid foam layer is applied on top of the surface material F. The raw material M is sprayed and supplied from the supply device 3, and the backing material R is further layered on top of the raw material M, and the mold member 1,
There is a known technique in which foamed foam is introduced into a mold 4 sandwiched between molds 2 and 2, foamed in an atmosphere heated by heated air blown from a duct 5 to form a foam layer S, and the foamed layer S is sent out from the mold 4. The two mold members 1 and 2 are generally made up of endless bands and move at the same speed to the right in the figure in the mold 4 section to continuously produce a composite material, and are operated in a heating chamber 6.

The foam layer is generally made of epoxy resin, urethane resin,
It is made from cold-curing resins such as phenolic resins and isocyanurates, and is often heated in the mold to accelerate the reaction and foaming of the raw materials, thereby increasing the speed of movement of the mold 4. The efficiency can be improved or the length of the mold can be shortened to reduce the size of the entire device.

However, in the above-mentioned equipment,
As can be seen from FIG. 1, the surface material F and the backing material R are supplied together with the raw material M to the mold 4 from the feeding end side.
The surface material F and the backing material R, each having a lower temperature, are introduced into the heating chamber 6 in a high-temperature atmosphere and immediately contact the mold members 1 and 2 and enter the mold 4.
When heat is received from 2 and heated sufficiently, foaming of the raw material M is promoted, and it cannot be said that heat is utilized efficiently.

In the present invention, the mold member along which the surface material F and the backing material R, both of which are flexible, are made of an endless band, is built into a heating chamber, and the surface material F and the backing material R are placed at the delivery end of the mold. By supplying it from the side and moving it through the heating chamber toward the inlet end while separating it from the mold member that has been inverted at the delivery end, it is possible to preheat using the high temperature atmosphere of the heating chamber and use the heat effectively. This is how it was done.

Figures 2, 3 and 4 show different embodiments of the invention, in which 11 is an upper mold member;
12 is a lower mold member, 13 is a supply device for raw material M,
14 _is a duct 14 a having heated air outlets arranged along the upper and lower mold members 11 and 12, respectively;
The heating device consists of _14b , 15 is a mold, 16 is a heating chamber, and _24a and _24b are guide trochanters. The upper and lower mold members 11 and 12 are made of metal bands such as stainless steel or bands of rubber or cloth with reinforcing materials in the form of lines, plates, or nets added as necessary, and are substantially seamless and have smooth surfaces. Consists of an endless band, each with a drum
It is wrapped around pulleys 17, 18, 19, and 20. Further, the guide rollers 24 _a and 24 _b are provided at positions spaced apart from the upper and lower mold members 11 and 12, respectively.

In FIG. 2, the upper and lower mold members 11 and 12 are constructed with approximately the same length and are housed entirely in the heating chamber 16, and the flexible backing material R enters the heating chamber 16 from above the delivery end _15b . , guided by a guide roller 24 _a provided further above the upper mold member 11 and transferred toward the inlet end 15 _a , preheated by waste heat in the heating chamber, and stacked on the mold member 11. It turns around along the drum pulley 17 and enters the mold 15.
During this reversal, liquid raw material M is sprayed onto the backing material R from the supply device 13. On the other hand, the same flexible surface material F also enters the heating chamber 16 from below the delivery end _15b , and is guided to the guide trochanter _24b provided further below the lower mold member 12, and is guided to the inlet end _15a.
While being transferred towards the backing material R, it is preheated by the waste heat in the heating chamber, and is superimposed on the mold member 12 and reversed along the drum pulley 19 to the inlet end 15.
Enter type 15 from _a .

The raw material M foams while moving together with the mold members 11 and 12 in the mold 15 to form a foamed layer S, and is delivered from the delivery end _15b . The drum pulleys 18, 20 on the sending end side are driven by a prime mover (not shown) to move the two mold members 11, 12 at the same speed, and the drum pulleys 17, 19 on the feeding end side are movably supported. The mold members 11, 12 are kept under tension.

In FIG. 3, the lower mold member 12 is connected to the feed end 1.
5 _a is extended to the front part of duct 1
_4b is also extended to this front part, and this extended part constitutes a preheating device 21, and these upper mold members 11, 12 are entirely housed in the heating chamber 16.

As in FIG. 2, the flexible backing material R has a feeding end 15.
It enters the heating chamber 16 from above _b , is guided by a guide trochanter _24a , is preheated while being transferred toward the inlet end _15a , is stacked on the mold member 11, is turned over along the drum pulley 17, and is transferred to the mold 15. enter. The surface material F also enters the heating chamber 16 from below the delivery end _15b , is guided to the guide roller _24b while being preheated, is turned over along the drum pulley 19 in front of the inlet end _15a , and is overlapped on the mold member 12. It enters the mold 15 from the inlet end _15a . At this time, it is heated by the heated air blown out from the preheating device 21, and the raw material M is sprayed and deposited on the way. The surface material F and the backing material R are the guide trochanter 2
_4a and _24b , it is preheated by the high-temperature atmosphere in the heating chamber, as in FIG. 2.

An example of a composite material manufactured by the embodiment shown in FIGS. 2 and 3 is shown in FIG. 5, in which a flexible surface material F, a backing material R, and a foam layer S are integrally laminated. It is formed into a flat plate.

Figure 4 shows that by introducing left and right covering materials C ₁ and C ₂ into the same structure as in Figure 3, the four surfaces of the foam layer S are coated with the surface material F and the lining as shown in Figure 6. 1 shows an embodiment for producing a composite material wrapped by material R and covering materials C ₁ and C ₂ . The covering materials C ₁ and C ₂ are flexible, and like the surface material F and the backing material R, are fed into the heating chamber 16 from the side of the feeding end 15 _b , and both sides of the mold 15 are fed into the heating chamber 16 from the feeding end 15 _a . It is preheated by the high-temperature atmosphere of the heating chamber 16 while moving in the opposite direction, and is then reversed by reversing rolls 22, 22 and fed into the mold 15.

In each of the above embodiments, a flexible facing F,
The backing material R and the covering materials C ₁ and C ₂ are composed of kraft paper, asphalt felt paper, synthetic resin film, metal foil, or a laminate of an appropriate combination of these. In addition, borax is used as the liquid raw material M for forming the foam layer S.
Adding one or more types of heat-resistant and fire-resistant substances such as thermally foamable boron compounds such as sodium silicate and silicon compounds, or adding one or more reinforcing substances such as glass fibers that increase the mechanical strength of the foam layer. More than one seed may be added.

In addition, in order to promote foaming in the heating chamber 16, it is preferable to heat the raw material M to about 50 to 80°C, and at the same time as heating the mold members 11 and 12 to the above temperature, when the raw material M reaches the feeding end _15a . The inside of the heating chamber 16 is maintained in an atmosphere at the above temperature so that the surface material F and the backing material R are heated to the above temperature or a temperature close to this temperature. In addition to blowing heated air into the heating chamber 16, it goes without saying that the heating chamber 16 can be heated by any appropriate means, such as burning fuel inside or heating with electrical resistance heat.

As described above, in the present invention, when the surface material and the lining material have flexibility, the mold member in contact with the surface material and the lining material is constituted by an endless band, and the whole is housed in a heating chamber, and the surface material and the lining material are Since both are supplied from the delivery end of the mold and transferred through the heating chamber while being separated from the mold member that has been inverted at the delivery end, the radiant heat generated by the mold member heated by the heating device in the mold part is When the surface material and lining material are sufficiently heated by the high-temperature atmosphere consisting of the waste air in the heating chamber and then fed into the mold, the raw material comes into contact with such surface material and lining material. It is immediately heated to a temperature effective for promoting foaming, and the foaming expansion phenomenon and reaction, which can be divided into the cream stage, tack-free stage, rise stage, and set stage, of the room-temperature curing resin are completed in a short time.
That is, according to the present invention, the surface material and the lining material are preheated using waste heat, which has not been used at all in the past.
A foam layer can be formed in a mold in a short time, thermal energy is used effectively, and fuel savings, equipment downsizing, and manufacturing efficiency can all be achieved at once.

[Brief explanation of drawings]

FIG. 1 is a schematic vertical cross-sectional view showing an example of a conventional device;
FIGS. 2 and 3 are schematic vertical cross-sectional views showing different embodiments of the present invention, FIG. 4 is a schematic cross-sectional view showing further different embodiments, and FIGS. 5 and 6 are cross-sectional views of a composite material. . 11, 12... Mold member, 13... Supply device, 1
4... Heating device, 15... Mold, 16... Heating chamber,
24 _a , 24 _b ... Guide trochanter, F ... Surface material, R ...
...Backing material, S...Foam layer, M...Raw material.

Claims (1)

[Claims] 1. A raw material for the foam layer, as well as a flexible surface material and a lining material, are fed into a mold formed by a portion sandwiched between vertically opposed mold members, and the raw materials are foamed to form a surface material, a foamed layer, When laminating the backing material together and sending it out from the mold, the upper and lower mold members are each made up of endless bands, and these are built into a heating chamber,
The surface material and the backing material are supplied from the delivery end side of the mold, and are transported through the heating chamber toward the entrance end while being preheated while being separated from the mold member that has been inverted at the delivery end,
A method for producing a composite material having a synthetic resin foam layer, characterized in that the composite material is fed into a mold overlapping a mold member that is then reversed at the entrance end side.