JPH041007A - Method and apparatus for manufacture of foam resin filled panel - Google Patents

Abstract

PURPOSE:To permit an efficient manufacture of foam resin-filled panels in a flow of operational structure by arranging inducting, foaming, carrying, take-away and cleaning and returning devices in that order. CONSTITUTION:The subject apparatus consists of an inducting device 1, a foaming device 2, a carrying device 3, a take-away device 4 and a cleaning and returning device 5. The inducting device 1 sets panel products 6a in a predetermined temporary form and sends the same into a thermostatic chamber 7. The foaming device 2 pours foaming liquid into the panel products 6a which have been carried therein to foam the same. A carrying device 3 carries to a separate position the uppermost one of stacked foamed panel products 6b which have undergone the foaming treatment. The take-away device 4 removes the foamed panel products 6b from a surface plate 9 being carried by a take-away conveyor 20 from the thermostatic chamber 7. The cleaning and returning device 5 cleans both sides of the unloaded surface plate 9 and sends the same back into a position in which the panel product 6a is placed on the surface plate. All of the aforesaid devices are operated by central processor according to the programmed flow of the surface plates 9 to effect a successive and automatic operation of inducting, foaming, carrying, take-away and cleaning and returning.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method and apparatus for manufacturing foamed resin filling panels used for architectural parts such as shutters and doors.

[Prior Art] There are continuous methods and batch methods for manufacturing foam resin-filled panels.

The continuous method involves rolling out a coiled panel material (thin metal plate) in a line, forming it into a roll, injecting foaming liquid, foaming,
Although operations such as cutting are performed consistently, the width and depth of the protrusions, grooves, etc. formed on one surface are not uniform due to continuous forming using forming rolls. This had the disadvantage that it was impossible to do so, and a line had to be dedicated to products with the same cross-section. In addition, the line equipment becomes very long and a heat insulating and pressurizing device is required over almost the entire length of the line, resulting in a large amount of space and equipment costs.

On the other hand, the punch type is a method in which a formed and temporarily assembled panel product is inserted into each stage of a multistage press, a foaming liquid is injected while maintaining a constant temperature and pressure, and this state is maintained for a certain period of time to foam. However, since it is separated from the molding process, it can be made with any cross-sectional shape, but on the other hand, it has the disadvantage of being inefficient because it requires two setup changes for each batch. In addition, since foam residue adheres to the surface plates (multi-stage press), this must be cleaned and removed when changing one setup, but the vertical spacing between each surface plate is approximately 80 to 120 cranes. It is narrow and difficult to insert cleaning tools etc.
Therefore, cleaning it takes a very long time. Furthermore, there was also the problem that there was idle time during the foaming operation.

[Problem to be solved by the invention]

By the way, many of the recent construction parts such as shutters and doors have extremely complex cross-sectional shapes that cannot be formed using a continuous process, so a batch process is often used for foaming. The biggest drawback of the hatch type is its inefficiency, as mentioned above.

- For example, in the case of stacking 10 sheets, the following time is required to complete foaming.

Inserting products into each stage of the surface plate - 1
Preheating the product for 1 minute---1------・--1------
------
---One-----0, 8 minutes (5 seconds for - sheets, 5X10=50 for 10 sheets) Cure (foaming) time--m----
−・−−〜−−−−−−5 minutes product removal 1−−−−−
--------------
−−−−−10 minutes total−−−−−−−−−−−1−−
-----------------------It takes about 20 minutes, that is, about 20÷1.degree.-2 minutes to foam each sheet.

Therefore, the present invention provides an efficient method and apparatus for manufacturing a foamed resin-filled panel by continuously performing each operation in a hatch type manner.

[Means for Solving the Problems] In order to solve the above problems, the present invention takes the following measures.

[1] A method for manufacturing a foamed resin-filled panel by sequentially performing the following operations a) to e) a) A hollow panel product is placed on a surface plate, and a surface plate is placed on which the panel product is placed. Carrying in a constant temperature room through a preheating room b) At a specified position in the constant temperature room, insert the surface plate carrying the panel products carried in to the bottom and stack them on the specified tier, and then Inject foaming liquid into the panel products of the tiers,
Foaming operation in which the foaming liquid inside the panel products is foamed while they are stacked in a fixed configuration C) Transport operation in which the surface plate on which the topmost foamed panel product is placed is transported to another position and lowered d) Lowered to the bottom Carrying out the surface plate with the foamed panel product placed on it from the constant temperature room and removing the foamed panel product from the top of the surface e) Cleaning the front and back surfaces of the empty surface plate and returning it to the original position on which the panel product will be placed. Cleaning and returning operation [2], manufacturing equipment for foamed resin-filled panels made by assembling the following devices a) to e) a) A surface plate carrying a hollow panel product is transported by a conveyor through a preheating chamber and heated to a constant temperature. Carrying device entrance for carrying into the room) At a predetermined position in the constant temperature room, use a lift to lift up the surface plate on which the panel products that have already been carried in are placed from below, or use a hook to lock the surface plate and carry it into the room below. A foaming device that repeats the operation of inserting a surface plate with panel products placed on it to stack them on a predetermined tier, and uses an injection machine to inject foaming liquid into the panel products on a specific tier so that foaming can occur while the panel products are stacked on a specific tier. c) A conveyor device that lifts the surface plate with the topmost foam panel product on it and transports it onto the carry-out conveyor exiting the temperature-controlled room and lowers it. 2) The foam panel product that has been sent out from the temperature-controlled room on the carry-out conveyor An unloading device that removes only the foam panel product from the top of the surface plate placed on it e) After passing the empty surface plate between the cleaning rollers installed above and below, the original panel product is removed by a forwarding conveyor that intersects with the carry-in conveyor. Cleaning/returning device for returning to the loading position [Function] By taking the above measures, that is, by sequentially arranging the loading, unloading, and cleaning/returning devices configured as described above. Each operation can be carried out on an assembly line, allowing efficient production of 9 foam resin-filled panels.

〔Example〕

Embodiments of the present invention will be described below with reference to the drawings.

Figure 1 is a perspective view showing the manufacturing process of a foam resin filled panel;
2 to 4 are a front view, a plan view, and a side view of the manufacturing device, which includes a loading device 1, a foaming device 2. Conveyance device 3. It consists of an unloading device 4, a cleaning return device 5, and the like.

The carry-in device 1 is a device for carrying a panel product 6a formed into a predetermined pre-assembled shape and with a space into which a foaming liquid can be injected into a constant temperature room 7 where foaming etc. A surface plate 9 is placed on which the panel product 6a is placed at a certain input position by the carrying-in conveyor 8.
is carried into constant temperature room 7.

A foaming device 2 is used to store panel products 6 brought into a constant temperature room 7.
This is a device for foaming by injecting foaming liquid into a. The structure is as follows: First, a thermostatic chamber 7 maintained at 40 to 60°C (a certain area on the entrance side is a preheating chamber 7a) is provided.
The fixed@9 carried in with the panel products 6a on it is stopped at a predetermined position inside the constant temperature room 7. At this position, the surface plate 9 on which the panel product 6a is placed is lifted from below by the lift 10, and this lifted object is locked with the hook 11 to create a space below this, and the surface plate carried into this space is Insert 9. By repeating this operation, the surface plates 9 with the panel products 6a placed thereon are stacked up in a predetermined tier.

In addition, at this time, in order to align the inserted surface plate 9 with the level of the surface plates 9 that have already been stacked, a shaping machine 12 may be provided in which a shaping plate comes out from around the surface plate 9.

Next, a foaming liquid is injected from the bottom into the panel products 6a in a certain level using the injection machine 13, and foaming is caused while the liquid is stacked up in the certain level. A certain pressurized condition is required to foam the injected foaming liquid.

It is necessary to maintain that state at a constant temperature for a certain period of time, and this is ensured by the number of stacking stages based on the temperature in the thermostatic chamber 7, the weight of the surface plate 9, and the transport tact. FIG. 5 is an explanatory diagram of the injection fi13.

The two foaming liquids P liquid and R liquid stored in tanks 14 and 15 are respectively sent to the injection head 18 by pumps 16 and 17, and the injection head 18 is inserted into the injection hole of the panel product 6a to inject the two liquids. It is injected while mixing.
The surface plate 9 used here has its surface directly connected to the panel product 6a.
Since it comes into contact with the surface, it requires considerable flatness and smoothness. Therefore, it is desirable to perform surface treatment such as hard chrome plating. In addition, such treatment also causes the release of particles that adhere to the surface/2! It also becomes easier to remove the liquid.

The conveyance device 3 is a device for conveying the foamed panel product 6b that has risen to the top of the stack after the foaming process is completed to another position, and is based on a conveyor 19 having a lifting function and a conveying function. That is, the uppermost foamed panel product 6b is lifted up along with the surface plate 9 by the transporter 19 and transported to a side position, and at this position is lowered onto the carry-out conveyor 20 that exits the thermostatic chamber 7.

The unloading device 4 is a device that removes the foamed panel products 6b shipped from the constant temperature room 7 by the unloading conveyor 20 from the top of the surface plate 9, and has a space for this operation, and has a suitable ejection device or unloading chute. (The ejection may be done manually).
The foamed panel product 6b carried out is sent to the next process such as wood assembly.

The cleaning return device 5 cleans the front and back surfaces of the empty surface plate 9,
This is a device that transports the panel product 6a to a position where it is placed. That is, since the surface plate 9 has leaked foaming liquid attached to it, it must be cleaned and removed. For this purpose, a cleaning roller 21 that is forcibly rotated is provided on the carry-out conveyor 20. Then, pass through this gap to clean the surface plate 9. The cleaned surface plate 9 is placed on a forwarding conveyor 22 whose starting and ending ends intersect with the carrying-out conveyor 20 and the carrying-in conveyor 8, and is sent to the original loading position. Since this forward conveyor 22 intersects with the carry-out and @in conveyors 20°8, an elevator 23 is provided at the takeover point of the fixed IM 9, and the elevator 23 takes over by raising and lowering. In addition, guide rollers 24 and the like for guiding the surface plate 9 are provided along the paths of the conveyors 820 and 22. Then, the panel product 6a is again placed on the surface plate 9 which has been returned to the initial loading position, and is carried into the constant temperature room 7 by the carry-in conveyor 8.

If each of the above-mentioned devices is operated according to a program following the flow of the surface plate 9, the foaming liquid is injected into the panel product 6a to form the foamed panel product 6b. Each operation is performed consecutively. The processing time is determined by the transport tact time of the surface plate 9, and this also determines the number of stages of the surface plate 9 stacked in the thermostatic chamber 7.

In other words, for the second foaming process, it is necessary to maintain an ambient temperature of 40 to 60°C, a curing time of 5 minutes, and a curing pressure of 0.2 kg/cd.
m x 25 m iron surface plate 9 (weighs 640 kg,
The surface pressure received by placing this on -stage is 0.02k
g/-) and set the takt time to 30 seconds (therefore, one sheet will be finished every 0.5 minutes), in order to obtain the required curing pressure of 0.2 kg/-. is 0.2÷0.02=10, at least.

If 10 layers are stacked on top of this, a special pressurizing device will not be required because only the weight of the surface plate 9 will be used. On the other hand, the required curing time 5
Since 5÷0.5 = 10, we need to stack 10 more rows below the previous 10 rows. Also, if the preheating time is 1.5 minutes, then 1.5÷0.5=3
Therefore, it is sufficient to add three more steps. Therefore, it is sufficient to stack at least 10+10+3=23 stages.

Note that when starting the operation of one or more devices, the FM manual conveyor 8
By attaching heating devices (not shown) above and below, it is possible to shorten the warming amplifier time before starting one work, and more efficient work becomes possible.

〔Effect of the invention〕

As described above, this invention has been able to combine the advantages of the conventional hatch type, which is not limited by the shape of the product, with the efficiency of the continuous type. in particular.

1) Each process including foaming process is performed on each conveyor 8, 21.
．． Although it is a continuous type with 22 operations, there is no idle time and it is efficient. That is, if the tact time is set to 30 seconds as described above, the efficiency is at least four times that of the hatch type.

11) The foaming process is carried out by stacking the surface plates 9,
Moreover, since each conveyor 8, 21, 22 makes two endless revolutions, the space occupied by the entire apparatus is small, and there is no need for a long-distance heating and pressurizing device unlike in a continuous type.

111) The cleaning of the empty surface plate 9, which conventionally took a lot of time using a batch method, can now be done automatically using an assembly line method, resulting in a significant time reduction. Became.

iv) If a sufficient number of stacking stages of the surface plate 9 is secured,
The takt time can also be changed, and as a result, the processing capacity can be adjusted accordingly.

(2) Each processing operation is performed on the surface plate 9 as a whole, and even if the shape of the panel product 6a placed thereon is changed, it is not affected by the change.

It is also possible to sandwich products of different shapes between flowing products.

[Brief explanation of drawings]

Figure 1 is a perspective view showing the manufacturing process of a foam resin filled panel;
2 to 4 are a front view, a plan view, and a side view showing the main parts of this panel manufacturing apparatus, and FIG. 5 is an explanatory view of the injection machine. (Symbol) 1. Carrying-in device 2.. Foaming device 3.. Conveying device 4. 8. Loading conveyor 9.. Surface plate 10.. Lift 11.. Hook 13.. Injector 19.. Conveying machine 20.. Carrying out conveyor 21.. Cleaning roller 22.. Outgoing conveyor. Agent: Yoshi Itano, patent attorney. Male figure 5 procedural amendment November 14, 1990

Claims (1)

[Claims] [1] A method for manufacturing a foamed resin-filled panel by sequentially and continuously performing the following operations a) to e).a) A hollow panel product (6a) is placed on a surface plate (9). ) and carrying the surface plate (9) with this panel product (6a) on it through the preheating chamber (7a) into the thermostatic chamber (7) at a constant temperature b) Predetermined position in the thermostatic chamber (7) At the same time, the surface plate (9) carrying the panel products (6a) that has been brought in is inserted at the bottom and stacked on the specified level, and a foaming liquid is injected into the panel products (6a) in a specific level, c) A foaming operation in which the foaming liquid in the panel product (6a) is foamed while the panel product (6a) is stacked on the surface plate (9) on which the top foam panel product (6b) is placed.
) to another position and lower it down d) The surface plate (9) on which the lowered foam panel product (6b) is placed is carried out from the constant temperature room (7) and the foam panel product (6
b) Carrying out operation of removing the surface plate (9) from above e) Cleaning and return operation of cleaning the front and back surfaces of the empty surface plate (9) and returning it to the original position on which the panel product (6a) is placed [2] A manufacturing device for foamed resin-filled panels made by assembling the following devices a) to e) A) A surface plate (9) on which a hollow panel product (6a) is placed is transferred to a preheating chamber (7a) by a conveyor (8). ) Carrying device (1) that carries the panel products into the temperature controlled room (7) through the temperature controlled room (7).
In addition to lifting the surface plate (9) on which the panel product (6a) was placed from below with the lift (10), the panel product (6a) that had been brought in was placed below the surface plate (6a) that was secured with the hook (11) and kept in that position. Repeat the operation of inserting the surface plate (9) to stack the product on a predetermined tier, and at the same time, insert the injection machine (1
3) The foaming device (2) c) injects the foaming liquid into the surface plate (9) on which the top foam panel product (6b) is placed
The unloading conveyor (9) lifts it up and leaves the constant temperature room (7).
20) Conveying device (3) that transports the foam panels upward and lowers them down. D) Foam panels are transported from above the surface plate (9) on which the foam panel products (6b) are placed, which have been sent out from the constant temperature room (7) by the conveyor (20). Unloading device (4) that removes only the product (6b) e) After passing the empty surface plate (9) between the cleaning rollers (21) installed above and below, the transport intersects with the loading conveyor (8). Original panel product (6a) on conveyor (22)
) to the position where it is placed (5)