JPH0399834A - Method and apparatus for preparing foamed sheet having uneven surface using rubber - Google Patents

Abstract

PURPOSE:To obtain a foamed sheet by pressing and heating a retaining mold composed of a metal net by moving a foamed and expanded raw plate under pressure by a retaining mold belt arranged in a rotatable manner so as to provide a predetermined gap from a belt to mold the same. CONSTITUTION:Butadiene rubber, natural rubber, tube reclaimed rubber, NaHCO3, (NH4)2CO3, CaCO3, MgCO3, BaSO4, chalk and ZnO are compounded and mixed in a predetermined mixing ratio and aged to prepare a stock. A base material composed of a nonwoven fabric is supplied to a metal belt 11 from a base material apparatus 10 and a raw plate 11 having thickness of about 1mm is sent out to the base material 9 from a supply apparatus 8 to which the stock 1 is supplied. The raw plate 1 enters a heating oven 3 along with the base material 9 by a conveyor apparatus 5 to be softened, foamed and expanded under heating and pressed by a retaining mold belt 6 to be expand ed upwardly through the meshes of the retaining mold belt 6 while the rear thereof is bonded to the base material 9 and molded into a foamed sheet 12 having a required uneven surface in the vicinity of the outlet of the heating oven 3.

Description

[Detailed Description of the Invention] (Industrial Field of Application) The present invention can be used to improve the feeling of foot pressure by placing it under carpets, etc., or to reduce floor impact noise by placing it under flooring in apartment complexes. The present invention relates to a method for manufacturing a foam sheet made of rubber or the like and having an uneven surface, which is used for various purposes, and an apparatus therefor.

(Prior art) Conventionally, it has been widely used as an underlay to improve the feeling of pressure under foot, such as as an underlay for flooring in apartment complexes, and to completely reduce floor impact noise by underlaying flooring in apartment complexes. A few proposals have been made regarding methods and apparatus for producing foam sheets having uneven surfaces using any of natural rubber, synthetic rubber, and synthetic resins such as vinyl chloride resin.

Among these proposals, the basic ones are
No. 639 (Patent No. 240422). This patent uses a formwork consisting of a metal frame with an appropriate outline, in which straight or curved wires are stretched in various conditions, and the upper surface of the wires is covered with rubber or other general materials to be used as bonges. By placing a raw material plate made of elastic resin and heating it, the raw material plate will be softened and curved and hang down between the wires while the negative part is caught on the wire and will not interfere with contact with other objects. Manufacture of a concave and convex plate made of a material similar to sponge rubber, which is characterized in that it expands completely freely without sagging and forms a concave and concave plate having uniform thickness at each part. method”.

(Problems to be Solved by the Invention) In the above invention, a raw material plate is placed on a mold made of gilt copper and heated, so that a part of it is caught on the wire.
Since it is made by foaming and expanding in a completely free state while the other parts soften and hang curved between the wires, the selection of raw materials and temperature are necessary to maintain the appropriate viscosity when the raw material plate is softened. It is very difficult to control and manage the structure, and it is also difficult to create something that forms a large, low-height convex part in the back space, and the range of selection for the uneven surface shape to be formed is limited. Moreover, since it is a batch system, it has drawbacks such as poor productivity.

(Means for Solving the Problems) The present invention has been made in view of these conventional problems, and aims to change the way of thinking about manufacturing by appropriately applying The aim is to solve the problems of conventional methods by creating a foamed sheet by heating and pressing a formwork made of gilt bronze.

In the present invention, a blank sheet formed to a required thickness from a material made of rubber as a main material mixed with a required foaming material, etc., is placed directly or The base plate is placed through a base material and heated and softened, and the blank plate, which has foamed and expanded, is pressed against the belt using a form belt rotatably installed at a predetermined distance from the belt. This invention is a method for manufacturing a foamed sheet having an uneven surface using rubber or the like, which is characterized by being moved and shaped. A conveyor device that rotates a belt capable of forming a shape at a required speed, and a formwork device that rotates a formwork belt with a predetermined gap from the belt in the same direction and speed as the belt. This is a manufacturing device for foam sheets with uneven surfaces made of rubber or the like.

(Function) The manufacturing method of the present invention is placed on a blank metal belt and heated, and is foamed and expanded while being pressed by a formwork belt, so the adjustment range for viscosity etc. when the blank sheet softens is smaller than that of the conventional method. Since the width is wider than that of the conventional one, it is easier to control the heating temperature during manufacturing, and it is also easier to select materials, resulting in a wider selection range.

Furthermore, in the conventional manufacturing method, there are certain restrictions on the selection range of the convex and concave shapes to be formed, but in the present invention, there are almost no such restrictions and various shapes can be easily manufactured.

In addition, since the manufacturing equipment of the present invention uses the entire heating furnace to heat the blank, temperature control is easy, and since a flow production system is adopted, productivity can be significantly increased. .

(Example) The present invention will be described in detail below based on an example shown in FIGS. 1 to 3. The materials shown in Table 1 are mixed according to the mixing ratio (weight ratio), mixed in a conventional manner, and then aged for an appropriate period of time to produce material 1.

No. 1 table Material name butadiene rubber natural rubber tube recycled rubber ZnO aCOs gCOs Na HCO5 (NHa)zcOs asO4 stearic acid gofun sulfur Bengara Nuka mobile oil Mixing ratio [weight] 3.7 11.4 14.5 7.3 9.2 2.3 15.3 7.6 2.3 0.6 7.6 2.4 0.5 6.4 8.9 ioo,.

In addition, butadiene rubber, natural rubber, and recycled tube rubber in the materials are the main materials of the foam sheet, and NaHCOs,
(NHd2COs is foam material, CJICO3, MgCO
3. BaSO4, chalk, ZnO, etc. are filling materials.

The manufacturing device 2 includes a heating furnace 3 that maintains the inside at a required temperature;
A conveyor device 5 rotates a metal plate belt 4 in the direction of the arrow at a required speed within the heating furnace 3, and a form belt 6 made of gold or copper placed between a predetermined distance from the metal plate belt 4 within the heating furnace 3. , a formwork device 7 that rotates in the same direction and speed as the metal plate belt 4, a supply device 8 that feeds the material 1 to a predetermined thickness using a calender device, and a base material 9 such as a thin nonwoven fabric. It is composed of a base material device 10 for supplying the base material.

After maintaining the temperature in the heating furnace 3 at 200±5°C and operating the conveyor device 5 and formwork device 7 to rotate the metal plate belt 4 and formwork belt 6 at a predetermined speed, the base material device l
A base material 9 made of a non-woven fabric with a thickness of about 0.3 ff is supplied from O onto the metal plate belt 4, and a raw plate 11 with a thickness of about 1 ff is placed on the base material 9 from the supply device 8 that was supplied with the material 1. Send.

The base plate 11 placed on the base material 9 enters the heating furnace 3 along with the base material 9 by the conveyor device 5, and while moving, the temperature gradually rises and softens, and further expands. Since the blank plate 11 to be used is pressed by the formwork belt 6, the blank plate 11 expands and bulges upward through the mesh of the formwork belt 6, and the back side of the roughly meshed part touches the base material 9. Glue it to
The foam sheet 1 has the desired uneven surface when it leaves the heating furnace 3.
Formed into 2. Foam sheet 12 coming out of heating furnace 3
is rolled up or cut into appropriate lengths.

In the above material 1, the base plate 11 with a thickness of about 1 tir becomes a foam sheet 12 with a thickness of 7 to 9 H. This thickness is determined at the installation position of the formwork belt 6 (
It varies depending on the gap between the metal plate belt 4), the shape of the mesh used, the area of the first mesh, etc.

Further, when the blank plate 11 is foamed and formed into a foamed sheet 12, the temperature of the blank plate 11 is 125 to 155°C, and it takes about 7 minutes.

The formwork belt 6 has a rectangular mesh and a large area (second
FIG. 3 shows a foam sheet 13 formed using a foam sheet 13 with a gap of about 2H from the metal plate belt 4. In the figure, 14 is the nonwoven fabric of the base material 9, 15 is a convex part, 16 is a concave part,
17 is a space formed on the back side of the convex portion 15. The thickness of each portion of the foamed sheet 13 is relatively average.

When this foamed sheet) 13'i carpet is placed under a carpet, the convex part 15 with the space 17 formed on the back side exhibits elasticity, making the carpet feel very good underfoot and extending the useful life of the carpet. be able to.

In this case, the manufacturing method according to the present invention differs from conventional manufacturing methods in that the blank sheet 11 is placed on the metal plate belt 4 and heated and softened, and is foamed and expanded while being pressed by the formwork belt 6. Since the plate 11 is softened and the adjustment range for the next viscosity etc. is widened, it becomes easy to control the heating temperature during manufacturing, and furthermore, the selection of materials becomes easy and the selection range becomes wide.

For example, when using rubber as the main material of the foam sheet 13, in the present invention, the compounding materials include 3.7% butadiene, 11.4% natural rubber (or better quality), and recycled tube rubber 14%.
．． 5% (low quality) is mixed (total 29.6
% rubber), but according to Japanese Patent Publication No. 32-8639, in the case of trouser cloth, smoke sheet is added to 50% of the compounded material.
(Listed in the 2nd to 15th lines of the right column of the first page of the bulletin)
In addition, in the case of using natural rubber, if the thickness of the substrate is 3FF or less, 40% or more of the rubber raw material is used (described in the fourth to second lines from the bottom of the right column on page 1 of the publication), and the present invention In this case, using low-quality rubber and in a small amount, foam sheets equivalent to conventional ones13? It is something that can be made.

Furthermore, since the manufacturing apparatus according to the present invention uses the tunnel type heating furnace 3 to heat the blank plate 11, it is easy to control and manage the temperature, and in addition, since a flow production method is adopted, productivity can be improved. can be significantly increased.

In addition, in the conventional manufacturing method, since the base plate is foamed and expanded while softening and hanging from the mesh, the top surface area of the convex portion 15 is large like the foam sheet 13 (the thickness 72 of the space 7 on the back side). It has been very difficult to manufacture products with relatively low height, but with the present invention, it can be easily formed, there is no restriction on the uneven surface shape of the product, and various shapes can be created. You can easily build things.

In the above embodiment, the metal plate heald 4 is used in the conveyor device 5, but instead of this metal plate, fine-grained steel, synthetic rubber, synthetic resin plate, etc. may be used. Any belt that forms a flat surface may be used.

Although a calender device is used as the feeding device 8 to completely feed the blank 11 of a predetermined thickness, other types of devices may be used as long as the same purpose can be achieved.

In addition, as the material 1, a mixture of synthetic rubber butadiene rubber, natural rubber, and tube recycled rubber was used as the main material of the foam sheet 12, but instead of this, synthetic rubber and natural rubber, each alone or a mixture of both, may be used. , synthetic resin such as vinyl chloride, etc. may be used.

Also, although the thickness of the base plate 11 is set to about IH, it is of course possible to change the thickness appropriately depending on the thickness of the foamed sheet 12 to be formed. Although the blank plate 11 is roughly continuous and sent out in the form of a fixed strip, it is also possible to cut the blank plate 11 into a predetermined length and send out continuously if necessary.

Further, although the base material 9 is layered on the back surface of the foam sheet 12, the base material 9 may be omitted depending on the purpose of use.

(Effect of the invention) Since the present invention has the above configuration, it has the following effects.

(1) The selection range of materials has become wider and manufacturing management has become easier, contributing to improved productivity.

(2) Since the foam sheet can be formed even if low-grade raw materials are used as the main material, product costs can be reduced.

(3) Since the uneven surface can be easily formed into various shapes, it is possible to reliably provide products that meet the intended use and customer requirements, contributing to increased sales.

(4) Manufacture management is easy, and since a flow production system is fully adopted, the number of manufacturing steps can be reduced, and in combination with the above items, it can be provided to customers at a low price.

[BRIEF DESCRIPTION OF THE DRAWINGS] The drawings show an embodiment of the present invention, in which FIG. 1 is a partially cutaway schematic side view of a manufacturing device, FIG. 2 is a partially cutaway plan view of a formwork belt, FIG. 3 shows a partially cut-out foam sheet, in which (a) is a plan view and (b) is a sectional view taken along line A-A. ■−・Material 2−・Manufacturing equipment 3・・・Heating furnace +
- Alloy 1f4 plate held...Conveyor device 6・Shaft formwork belt 7-・Formwork device 8...Supply device 9・
...Base material 11-Material plate 12.13...Foam sheet Figure 3 (A) (B) Figure 2

Claims (1)

[Scope of Claims] 1) A belt that rotates a blank plate formed to a desired thickness from a material mainly made of rubber or the like mixed with a necessary foaming material in a heating furnace maintained at a predetermined temperature. The base plate is heated and softened by being placed directly or through a base material, and the foamed and expanded base plate is transferred to the belt using a form belt rotatably installed with a predetermined gap between the belt and the base plate. A method for manufacturing a foam sheet having an uneven surface using rubber or the like, characterized in that the sheet is shaped by being moved under pressure. 2) A method for manufacturing a foamed sheet according to claim 1, characterized in that a material whose main material is natural rubber or synthetic rubber, either alone or a mixture of both, mixed with recycled rubber, is used. . 3) A method for manufacturing a foam sheet according to claim 1 or 2, characterized in that the blank sheet is placed on a belt via a base material and shaped. 4) A heating furnace that can maintain the required temperature, a conveyor device that rotates at the required speed a belt that can form a flat portion at the top within the heating furnace, and a formwork that is installed with a predetermined gap from the belt. 1. An apparatus for manufacturing a foam sheet having an uneven surface made of rubber or the like, comprising a formwork device that rotates a belt at the same direction and speed as the belt. 5) The foam sheet manufacturing apparatus according to claim 4, further comprising a form belt made of wire mesh having an appropriate shape and mesh size.