JPH0449462B2 - - Google Patents

Description

Detailed Description of the Invention (Industrial Field of Application) The present invention involves forming irregularities in an arbitrary pattern on a thin metal plate having a decorative film or film.
The unfoamed synthetic resin foam raw material is discharged onto the back side of the face material formed into a gutter-like cross section, and the back face material is laminated on top of it, and the raw material is reacted and foamed in a cure oven to form the front and back faces. The present invention relates to a composite board manufacturing device that can bond the composite board together and continuously form a foam that serves as a core material and a heat insulating material. (Prior art) As shown in Japanese Utility Model Publication No. 59-24490, this type of equipment includes a metal plate feeder, an embossing machine, a molding machine, a foam raw material discharge section, a steel belt, and a caterpillar type. There is a composite board manufacturing device in which molds are arranged in series. (Problems to be Solved by the Invention) However, in this type of device, there is no leveler after embossing, which causes twisting, and since the molding is performed in this state, the distortion is further amplified, resulting in a decorative surface with many uneven spots. It was hot. Furthermore, when a steel belt is used as a shape material, there is a drawback that the composite plate cannot be stably conveyed in one direction unless the front and back surfaces of the composite plate are flat as a whole.A caterpillar-type device requires a large device and is difficult to transport. Speed is 10~
It had the disadvantage of being 10 to 30 m/min slower than the 30 to 40 m/min of a steel belt at 20 m/min. (Means for Solving the Problems) In order to solve these problems, the present invention heats the thin metal plate before embossing to give the coating film flexibility and prevent cracking and peeling of the coating film. In addition, after embossing, residual distortion caused by embossing is corrected under tension using a leveler.Furthermore, a roller-type conveyor that can handle the cross-sectional shape of surface materials that are not flat, and a cure oven are used to straighten the foam raw material. It is constructed so that all the constituent materials are integrally formed. (Function) According to this configuration, the coating film on the thin metal plate is heated by the heater section, the embossing machine embosses any pattern to any width, and the leveler further reduces distortion during embossing. Removed under tension, molded by a molding machine into a gutter-like shape with an inclined decorative surface and a step in the middle, and discharged foam raw material from a discharge machine onto the back side of this surface material,
A backing material is laminated on top of that, and this is formed into a predetermined shape in a cure oven, and the foam raw material is reacted and foamed to fix all the constituent materials together, and then cut to a regular length with a traveling cutter. It is. (Embodiment) An embodiment of the composite plate manufacturing apparatus according to the present invention will be described below with reference to the drawings. FIG. 1 is a side view showing the apparatus according to the above invention. In the figure, reference numeral 1 denotes a thin metal plate feeding section (hereinafter simply referred to as the feeding section), which consists of an uncoiler 2 and a pinch roller 3. (having a decorative film) A is attached and is constantly and easily fed to the loop portion 4. The loop section 4 controls the speed difference and deviation that occur when transferring the thin metal plate A (hereinafter simply referred to as a coil) after the heater section 5 in the next process by loosening the coil A, and also This functions to prevent a large impact from being applied to the coil A being fed. The heater section 5 is composed of a pinch roller 6 that also serves as a guide and a heater 7. The pinch roller 6 pinches the coil A with upper and lower rollers 6a and 6b only at the start of the line, and thereafter acts as a mere guide roller to transfer the coil to the heater 7. It is something that will be sent. In addition, the heater 7 heats the decorative coating of the coil A, essentially the coil A itself, to about 30 to 60°C to soften the decorative coating, and prevents the decorative coating from peeling off from the steel plate during embossing, cracking, and scratches. This is to prevent cracks from occurring. The heating method is one of a hot air method, an open flame method, and a hot wire method. A pin roller 8 feeds the coil A at a predetermined speed to the embossing roll 9, and also functions as a brake against the movement of the coil A during embossing. Note that the pinch roller 8 is installed as necessary, and can also be removed. The embossing roll 9 has a pattern consisting of male and female uneven parts formed on its outer circumferential surface as shown in FIG. The gap between the upper and lower rolls 9a and 9b is determined by the height of the uneven portion and the coil A.
It is determined by the plate thickness. 10 is a leveler for correcting residual strain existing in the embossed coil A, and upper rollers 10a ₁ , 10
a ₂ , 10a ₃ , ...10an (shown up to 10a ₃ in the figure),
Lower rollers 10b ₁ , 10b ₂ , 10b _{3 .} . . 10bn (shown up to 10b ₄ in the figure) are arranged in a zigzag pattern in this order, and an upper roller group 10a and a lower roller group 10b
This allows the gap between the two to be adjusted. Reference numeral 11 is a tensioning pinch roller that rotates faster than the embossing roll 9, and when the coil A is being stretched (under tension), the embossing roll 9 and the leveler 1 are rotated.
0 steps are passed through. 1
2 is a molding machine that molds the embossed coil A into a cross section as shown in FIGS. 4a to 4h, for example. Reference numeral 13 denotes a conveying machine, and the coil A formed by the forming machine 12 is used as the surface material A' and is transferred to the discharging machine 21.
through the guide roller 22 and the cure oven 23.
This is to guide you. That is, the conveyor 13 guides and conveys the surface material A' directly below the discharge machine 21 as shown in FIG .
Conveying rollers 14 and 15 for conveying the paper to the entrance of the main shaft 19 and shaft 20 are mounted on the main shaft 19 and the shaft 20, respectively. The conveying rollers 14, 15 are either driven or of free roller construction, with a sixth cylindrical roller having a diameter corresponding to each decorative surface A', A'' of the surface material A'.
Place the surface material A′ as shown in Figure a, and
As shown in FIG. 2, tapered or cylindrical regulating rollers 16, 17, and 18 are used to prevent the surface material A' from being displaced in the left-right direction while it is being advanced and from coming off the conveyance path. The conveying rollers 14, 15 and the regulating rollers 16, 17, 18 are arranged alternately or at appropriate positions with respect to the traveling direction of the surface material A'. The dispensing machine 21 also supplies, for example, resin for polyurethane foam, resin for polyisocyanurate foam, resin for resol type benzyl ether type phenol foam, and flame retardants and flame retardant aids (borax, sodium metaborate, calcium carbonate). , aluminum hydroxide, antimony trioxide, bentonite, pearlite grains, and shirasu balloons, etc., is discharged onto the back surface of the surface material A'.The guide roller 22 is Consisting of upper and lower rollers 22a and 22b, the upper roller 22a guides the back material D onto the concave portion of the surface material A',
By controlling the gap between the upper and lower rollers 22a and 22b, it also functions as a nip roll that spreads the foam raw material P in the middle of reaction and foaming. Further, the cure ovens 23 are arranged in series immediately after the exit of the conveyor 13 , and mainly sandwich the foam raw material P which is in the middle of reaction and foaming between the surface material A' and the back material D. At the same time, it is conveyed, molded, cured, and at the exit, the
It is sent out as a continuous composite band with a cross section as shown in ~c. Its composition is shown in Figures 1, 5, and 8.
As shown in figures a and b, the drive roller 25 is attached to the main shaft 24.
A lower roller 27 having a free roller 26 coaxially mounted thereon is arranged between a transport roller group 28 arranged in a ladder shape and a lower roller 27, and a regulating roller 29 that guides the left and right side edges and step portions of the surface material A'. 30,3
The front and back materials A',
An upper roller group in which upper rollers 34 having a drive roller structure are arranged in a ladder shape via a main shaft 35 to clamp and convey the composite plate E, regulate the thickness of the composite plate E, and horizontally guide the backing material D. 36 and Kyuua Oven 2
It is composed of a heater 37 that heats the inside of the heater 3 to about 30 to 150°C, and a cover 38 that surrounds the gas heated by the heater 37 so as not to leak to the outside. To explain further, the main shaft 24 is tilted so that the outer peripheries of the cylindrical drive roller 25 and free roller 26 contact the decorative surfaces A' and A'' of the surface material A' with no difference in circumferential speed, as shown in FIG. 8a. The lower roller 2 is supported on a stand (not shown).
As is clear from the figure, the reason we did not use all 7 as drive rollers is that there is a difference in diameter between the drive roller 25 and the free roller 26, and the decorative surface created by this difference
This is to eliminate the difference in frictional resistance on A', A'', to easily convey the surface material A' in one direction without being twisted, and to prevent damage to the decorative surfaces A', A''. Further, the upper roller 34 is fixed to a main shaft 35 as shown in FIG. . Furthermore, each main shaft 24 of the conveying roller group 28 and the upper roller group 36 ,
35 is a transmission shaft 39 that connects gears 40 to 45, respectively.
Alternatively, the motor 46 can be connected via a belt (not shown).
The motors are driven at the same speed. In addition, the backing material D functions as a member such as a noncombustible sheet, a waterproof membrane, a heat shielding sheet, a water absorption sheet, a soundproofing sheet, a release sheet, a packing material, a reinforcing sheet, etc., and is, for example, asbestos paper, kraft paper, asphalt felt. , metal foil (Al,
Pb, Fe), synthetic resin sheet, rubber sheet, cloth sheet, glass cloth, or a combination of one or more of these, or a sheet that has been treated with waterproofing, flame retardant, etc. Consists of things, etc. 47 is a running cutter for cutting the continuous band into regular lengths. Next, the operation will be explained. First, the coil A attached to the feeding section 1 is fed to the loop section 4 via the pinch roller 3. At this time, even when the coil A is pulled by the pinch roller 3, since a brake device (not shown) is attached to the uncoiler 2, the coil A is pulled to the loop portion 4 under a certain allowable tension. This is what will be sent. The coil A is then fed from the loop section 4 to the heater section 5 via the pinch roller 6 which also serves as a guide, and is fed to the heater 7 for approximately 30 to 30 minutes.
The cosmetic film is heated to 60°C to soften it and then fed to the pinch roller 8. Note that the pinch roller 6 that also serves as a guide functions as a pinch roller until it guides the coil A to the pinch roller 8, and thereafter functions as a mere guide roller. Next, the coil A sent out from the pinch roller 8 is fed to the embossing roll 9, which continuously forms an embossed pattern on the coil A consisting of concave portions B and convex portions C as shown in FIG. 3, for example. It is something that forms. At this time, the embossing is performed with tension being applied to the coil A. The coil A sent out from the embossing roll 9 is leveler 1.
0, the residual strain during embossing is corrected while being stretched by a tensioning pinch roller 11, and then sent to the next process (not shown). The embossed coil A is in the molding machine 12
The molded material is fed to a conveyor 13, molded as shown in FIG. 4b, and fed to a conveyor 13 . The discharge machine 2 is placed on the concave part of the back surface of the surface material A' being conveyed by the conveyor 13 .
1, the foam raw material P is supplied, and then the backing material D is guided to the back side of the facing material A' via the guide roller 22a, and the foamed raw material P is sent to the cure oven 23 in a sandwiched state with the facing material A'. be provided. Then, while passing through the cure oven 23 , the foam raw material P
reacts and foams, fixing the front and back materials A' and D together and forming the foam P. Next, the composite strip sent out from the outlet of the cure oven 23 is cut into regular lengths by a running cutter 47 to produce a composite plate E as shown in FIG. 7a. What has been described above is only one embodiment of the composite plate manufacturing apparatus according to the present invention, and although it is not shown, the regulating roller 3
0 may be removed, or the main shafts 24 and 35 may be rotated by separate transmission shafts, and the lower roller group 28 and the upper roller group 36 may be rotated by motors at the same speed. Further, the regulating roller 29 can also be formed in a cylindrical shape. (Effects of the Invention) As described above, according to the composite plate manufacturing apparatus according to the present invention, there is no change in the force applied to the coil in the embossing zone, and embossing can be performed under constant tension at all times, so that the embossed pattern can be easily formed during processing. A beautiful uneven pattern can be formed without shifting. Because the decorative film was heated to make it soft enough for embossing, the decorative film would peel off from the steel plate during embossing, or the decorative film would wrinkle.
No cracks, scratches, or cracks.
It can form beautiful decorative coatings with excellent weather resistance, scratch resistance, and chemical resistance. The residual strain caused by the distortion formed by embossing is easily and sufficiently removed by flattening under tension, and there is no unevenness.
It is possible to form uneven patterns with a three-dimensional effect. The lines are arranged in a straight line and the mechanism does not apply excessive force to the coil, allowing for smooth embossing. Since the coil is heated and embossed, it is not affected by the environment. The straight line allows for high-speed embossing. Since a composite plate having steps and an inclined decorative surface portion can be transported smoothly, the decorative surface can be manufactured at high speed without any damage. The horizontal back surface of the composite plate is held and conveyed between the upper roller group arranged on the same horizontal plane and the drive roller that comes into contact with a part of the decorative surface, so even if the foam raw material reacts and foams, it is regulated to a predetermined thickness. It can be transported stably. The foam raw material sufficiently reacts and foams between the front and back materials heated by the cure oven, and is processed by the conveyor roller group and upper roller group without leaking to the outside from between the front and back materials. Because the material is sandwiched, it is possible to produce a large amount of composite plates in which the raw material is effectively foamed with a homogeneous foam structure. It has the following characteristics.

[Brief explanation of drawings]

FIG. 1 is a side view showing an embodiment of a composite plate manufacturing apparatus according to the present invention, FIG. 2 is an explanatory view showing an embossing machine of the above device, and FIG. 4A to 4H are explanatory diagrams showing examples of molding of the surface material, FIG.
6a and 6b are cross-sectional views taken along lines E-A and Ro-Ro in FIG. Figures 8a and 8b are cross-sectional views taken along the line Ha-ha and Ni-ni line in Figure 5. 1 ...Metal thin plate delivery section, 5...Heater section, 9...
...Embossing roll, 10...Revering, 12...Forming machine, 21...Discharge machine, 23 ...Cure oven, 28 ...Lower roller group, A...Metal thin plate, D...
... Back material, E... Composite board.

Claims (1)

[Claims] 1. A thin metal sheet feeding section consisting of an uncoiler and a pinch roller for feeding the thin metal sheet, and a loop section that accommodates the thin metal sheet fed from the feeding section in a slack state and adjusts between the front and rear processes. , metal sheet approx.
A heater unit that heats the temperature to 30 to 60°C, a pinch roller that also serves as a guide and is placed after the heater unit, an embossing roll that applies an arbitrary uneven pattern to the thin metal plate sent out from the roller, and a A leveler disposed at the rear, a tensioning pinch roller disposed at the outlet of the leveler, and a forming machine that forms a thin metal plate into a surface material with a gutter-like cross section with a stepped portion parallel to the longitudinal direction between the inclined decorative surfaces. and a conveyor for conveying the surface material from the outlet of the molding machine to the inlet of the cure oven;
A discharge machine that is located above the conveyance machine and discharges unfoamed foam raw material, a guide roller that guides the back material so as to cover the laminated foam raw material, and a cure oven that is arranged in series with the conveyance machine. The cure oven is equipped with a cylindrical drive roller in contact with one of the decorative surfaces and a cylindrical free roller in contact with the other decorative surface, which are mounted on a main shaft supported at an angle corresponding to the inclination of the decorative surface. A large number of rollers are arranged in a ladder shape, and correspond to a group of lower rollers with the above-mentioned regulating roller interposed between the lower rollers and the lower rollers,
A composite plate manufacturing apparatus comprising an upper roller group consisting of drive rollers that horizontally guide the backing material, a heater that heats the inside of the cure oven, and a cover that suppresses leakage of heated gas to the outside. .