JPH0255205B2 - - 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.

Hard surface material or lining material made of metal plate, hard synthetic resin board, asbestos board, etc. and soft flexible lining material or surface material made of kraft paper, synthetic resin film, metal foil, or laminates thereof, etc. A plate-shaped composite material using a flexible surface material and a lining material with a synthetic resin foam layer sandwiched between them can be used as an exterior wall material, lining material, or roofing material for buildings. Suitable for and widely used.

In manufacturing this composite material, two mold members 1 and 2 are arranged vertically facing each other as shown in Fig. 1, and the surface material F is placed on the lower mold member 2, and the liquid foam layer is placed on top of it. 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 out from a duct 5 to form a foam layer S, and then sent out from the mold 4.

The two mold members 1 and 2 are composed of endless bands and move at the same speed to the right in the figure in the mold 4 portion to continuously produce 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.

In the above-mentioned equipment, as can be seen from Fig. 1, the surface material F and the backing material R are supplied to the mold 4 from the feed end side along with the raw material M, and from this point they are fed into the heating chamber 6 in a high temperature atmosphere. The low-temperature surface material F and backing material R are introduced and immediately contact the mold members 1 and 2 and enter the mold 4, so when they enter the mold 4 and are sufficiently heated by receiving heat from the mold members 1 and 2, the raw materials This promotes foaming of M, and it cannot be said that heat is used efficiently.

In the present invention, the mold member along which the flexible surface material F or (and) the backing material R is placed is composed of an endless band, and by overlapping and moving them together over almost the entire length, the mold member is moved from the delivery end to the inlet end. The heat used for heating can be effectively utilized by utilizing the return process of the mold member.

2, 3, 4, and 5 show different embodiments of the present invention, in which 11 is an upper mold member, 12 is a lower mold member, 13 is a supply device for raw material M, and 14 is an upper and lower mold member. 15 is a mold;
6 is a heating chamber. The upper and lower mold members 11, 12 in FIGS. 2, 4, and 5 and the upper mold member 11 in FIG. Alternatively, it may be an endless band made of a cloth or the like and has a substantially seamless surface with a smooth surface, and is wound around the drum pulleys 17, 18, 19, and 20, respectively.

The lower mold member 12 in FIG. 3 is composed of a group of trochanters arranged in parallel on a horizontal plane. The lower mold member 12 also extends in front of the inlet end 15a of the mold 15, and the duct 14b also extends into this forward part; in the embodiment of FIGS. It consists of

In FIG. 2, the upper and lower mold members 11 and 12 are mold 1.
5 is built into the heating chamber 16, and the lower front portion of the mold member 12 protrudes from the heating chamber 16. The hard surface material F is placed on the lower mold member 12 and transferred toward the mold 15, while being preheated by heated air blown out from the preheating device 21. The flexible backing material R is superimposed on the inverted upper mold member 11 along the drum pulley 18 at the delivery end 15b of the mold 15, and together they pass through the heating chamber 16 to the inlet end 15a. The drum is transported to
While reversing along the pulley 17, the feeding device 13
A liquid raw material M is sprayed onto the backing material R. When the inversion is completed, it enters the mold 15 together with the surface material F from the inlet end 15a, foams therein while moving together with the mold members 11 and 12, forms a foam layer S, and is sent out from the delivery end 15b. Ru. The drum pulleys 18, 20 on the exit end side are driven by a prime mover (not shown), and the two mold members 11, 12
are moved at the same speed, and the drum pulleys 17, 19 on the feeding end side are movably supported to move the mold members 11,
Keep 12 tense.

In FIG. 3, the upper and lower mold members 11 and 12 are entirely housed in a heating chamber 16, and the hard surface material F is placed on the lower mold member 12, which is made up of a group of trochanters driven in one direction, and is placed in the mold 15. The flexible backing material R is heated by the heated air blown from the preheating device 21 while being transferred toward the inlet end. During the reversal at 15a, the raw material M is sprayed and deposited.

An example of a composite made by these two embodiments is shown in FIG. The surface material F of this composite material is made of a metal plate, and has rising portions f ₁ and f ₂ at both ends.
and an insertion edge f ₃ and an insertion groove f ₄ following these,
A foam layer S is filled in it, and an insertion edge _f3 and an insertion groove _f4 are formed.
It is integrated with the backing material R whose both side edges are joined.

In FIG. 4, the upper and lower mold members 11 and 12 are entirely housed in the heating chamber 16, and the flexible surface material F and backing material R are inverted at the delivery end 15b of the mold 15, and the lower mold member 12 and the upper mold member 12 are inverted. The drum pulley 19 is stacked on the mold member 11 and is preheated while being transferred to the entrance end 15a.
The raw material M is supplied to the surface material F which has been reversed along.

An example of a composite material manufactured by this embodiment is shown in FIG. 7, in which a flexible surface material F, a backing material R, and a foam layer S are integrally laminated to form a flat plate shape.

Figure 5 shows that by introducing the left and right covering materials C ₁ and C ₂ into the same structure as in Figure 4, the four surfaces of the foam layer S are coated with the surface material F and the lining material as shown in Figure 8. 1 shows an embodiment for manufacturing a composite material wrapped by material R and covering materials C ₁ and C ₂ . The coating 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 15b, and are fed from both sides of the mold 15 toward the feeding end 15a. While moving, it is preheated by the high-temperature atmosphere in the heating chamber 16, is reversed by reversing rolls 22, 22, and is fed into the mold 15.

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

As described above, in the present invention, when at least one of the surface material and the backing material has flexibility, the mold member in contact with the surface material and the backing material is constructed of an endless band, and the process of returning from the feeding end to the feeding end of the mold is used to Since the material and backing material are layered and moved together through the heating chamber, the surface material and backing material are The upholstery material is fed into the mold in a sufficiently heated state, and therefore, when the raw material comes into contact with these surface materials and back material, it is immediately heated to a temperature effective for promoting foaming, and the cream stage of the room temperature curing resin is reached. The foaming expansion phenomenon and reaction, which can be divided into a tack-free period, a rise period, and a set period, are completed in a short period of time. That is, according to the present invention, it is possible to preheat and form a foamed layer in a short time using heat that has not been used at all in the past, and thermal energy is effectively used, saving fuel, downsizing the device, and improving manufacturing efficiency. can be achieved all at once.

[Brief explanation of the drawing]

FIG. 1 is a schematic vertical cross-sectional view showing an example of a conventional device;
FIGS. 2, 3, and 4 are schematic vertical cross-sectional views showing different embodiments of the present invention, FIG. 5 is a schematic cross-sectional view showing further different embodiments, and FIGS. 6, 7,
FIG. 8 is a cross-sectional view of the composite material. 11, 12... Mold member, 13... Supply device, 1
4... Heating device, 15... Mold, 16... Heating chamber,
F... Surface material, R... Lining material, S... Foaming layer, M
……material.

Claims (1)

[Claims] 1. The raw material for the foam layer and the surface material and lining material, at least one of which is flexible, are fed into the mold formed by the parts sandwiched between the mold members arranged vertically, and the heating chamber surrounding the mold members is heated. When the raw material is foamed by passing through the inside and the surface material, foam layer, and backing material are laminated together and sent out from the mold, a mold member is used to fit the flexible surface material and backing material. In addition to being composed of an endless strip, a flexible surface material and backing material are supplied from the delivery end side of the mold, and the surface material and backing material are overlapped with the mold member at the inversion point on the delivery end side, and these are overlapped. 1. A method for producing a composite material having a synthetic resin foam layer, which comprises transporting the composite material in a heating chamber to the entrance end, inverting it as it is, and feeding it into a mold.