JPH0449463B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention is a sandwich board, in which a foamable reaction mixture having self-adhesive properties is interposed between two base materials, and at least one of the two base materials is embossed. The present invention relates to an apparatus for continuously manufacturing a sandwich board having a base material. Recently, as interior and exterior materials for buildings, sanderch boards, which are made of a metal plate and have heat insulation, light weight, and rigidity, have been mass-produced. but,
All sandwich boards have a so-called design and three-dimensional feel (embossed pattern) that improves the coldness and smoothness of metal etc.
There are almost no products that are rich in material and have suppressed physical properties (flexibility) of the material. Furthermore, even if they existed, they only had a limited number of colors, thicknesses, and patterns, and in reality they were no more than mere metal composite plates. Furthermore, when a foamable reaction mixture, for example a synthetic resin raw material such as polyurethane resin, is used as a core material, the formation of the foam involves a chemical reaction that is greatly affected by various factors such as temperature. It was hoped that a device that could respond to temperature changes would emerge. In addition, some conventional manufacturing equipment simply has an embossing machine interposed between an uncoiler and a molding machine, but there are many cracks in the uneven pattern surface after processing, and the weather resistance and corrosion resistance are poor. , and had the disadvantage of poor appearance. Furthermore, since this kind of equipment that has been used in the past has a manufacturing process using a simple straight line, the plastic foam raw material is supplied from the back side of the front material or the back material, making it easy to spread and disperse the raw material. However, there was a drawback that the foamed structure was non-uniform, resulting in a low-foamed product. Furthermore, in the past, the control between the devices from the embossing process to the compositing process was not continuous, resulting in a disadvantage of poor productivity. Furthermore, there has been no apparatus for continuously manufacturing panels with stepped and inclined decorative surfaces. In order to eliminate these drawbacks, the present invention prevents cracks, peeling, cracks, and scratches that occur in the decorative coating during embossing by heating a thin metal plate wound into a coil and then embossing it. , and after releasing the residual strain during embossing, it is greatly curved inward and inverted, then the thin metal plate is formed into a predetermined shape, heated to about 50 to 90 degrees Celsius, and then plastic foam is formed. We propose a manufacturing device for sanderch boards that can smoothly, continuously, and economically produce sanderch boards with a predetermined cross-sectional structure by discharging raw materials, laminating face materials, and feeding them to a cure oven. It is something to do. DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the sandwich board manufacturing apparatus according to the present invention will be described in detail below with reference to the drawings. 1st
The figure is a schematic configuration diagram of the above device, where 1 is a pedestal and 2
Constructed into a storey structure, embossing line 2 on the second floor and compounding line 22 on the first floor are installed on almost the same center line as the above line 2, and reversed at one end between the second floor and the first floor. Rotating roller 5 forming part 15 and detecting the speed of the sanderch plate or mold
1 on the first floor, a control panel 52 on the second floor as required, and a secondary molding machine 53 after the compounding line. To explain further, the emboss line 2 is formed by a thin metal plate feeding section (hereinafter simply referred to as feeding section) 3.
, the first loop part 7, the heater 8 , the embossing roll 11, the leveler 12, the tensioning pinch roller 13,
The check portions 14 are arranged in a straight line. More specifically, the feeding section 3 consists of an uncoiler 4, a pinch roller 5, and a simple cutter 6 that may be installed as necessary.
This is for attaching a material (having a decorative film such as a decorative film) A and constantly feeding it to the first loop portion 7 without strain. Note that the simple cutter 6 is used to cut the thin metal plate A when necessary. The first loop section 7 controls speed differences and deviations that occur when transferring the thin metal plate A (hereinafter simply referred to as a coil) after the heater section 8 in the next process by loosening the coil A, and also controls the feeding section. This function is to prevent a large impact from being applied to the coil A fed from the coil A. The heater section 8 is composed of a pinch roller 9 that also serves as a guide and a heater 10. The pinch roller 9 pinches the coil A with upper and lower rollers 9a and 9b only at the start of the line, and thereafter acts as a mere guide roller to transfer the coil to the heater 10. It is something that will be sent. In addition, the heater 10 is a decorative coating of the coil A, which is essentially the coil A itself.
It softens the decorative coating by heating it to ℃ to prevent the decorative coating from peeling off from the steel plate or causing cracks, cracks, or cracks during embossing. The heating methods include hot air method, direct fire method,
Either the hot wire method. Embossing roll 11
In this method, an arbitrary pattern consisting of male and female uneven parts is formed on the outer peripheral surface, and the upper and lower rolls 11a and 11b are engaged to give the coil A an arbitrary pattern, and the gaps of the upper and lower rolls 11a and 11b are formed with uneven parts. It is determined by the height of the section and the thickness of the coil A.
Furthermore, the leveler 12 has an embossed coil.
This is to correct the residual strain existing in A', and as shown in _FIG .
12a ₂ , 12a ₃ , ... 12an (up to 12a ₃ is shown in the figure), lower rollers 12b ₁ , 12b ₂ , 12b ₃ , ...
12bn (shown up to _12b4 in the figure) in a zigzag manner, and the gap G between the upper roller group 12a and the lower roller group 12b can be adjusted. Further, the tensioning pinch roller 13 rotates faster than the embossing roll 11 , so that the coil A is passed through the steps of the embossing roll 11 and the leveler 12 while being stretched (under tension). Of course, it is provided as necessary. The check section 14 is a zone for checking whether the residual strain of the coil A' (coil after embossing) has been erased, cracks in the decorative coating film due to the embossing, etc. before proceeding to the next process. Next, the above-mentioned reversing section 15 is used to feed the coil A' from the second floor to the composite line 22 on the first floor, and also to turn the front surface of the coil A' into the back surface.
6, 17, a guide plate 18, and a curved guide plate 19, and the guide roller group 16 can be brought into contact with or separated from each other by a switch (not shown). Further, the guide plate 18 prevents the coil A' from penetrating, the curved guide 19 is a curved flat plate with guide pieces 19a provided on both sides, and 20 is a sensor that measures the height of the coil A'. When reaching the point, the coil feeding speed is increased, and the coil A' is looped in the zone between the curved guide plate 19 and the composite line 22 at the second loop part 21, and functions as a relief between the embossed lines 2 . It is something. In addition, the composite line 22 includes a forming machine 23 for forming the embossed coil A' into an arbitrary shape, a preheater 24, a group of guide/press rollers 25, a discharge section 31, and a back material B.
A guide 32, a mold 38, a cure oven 48 , a cutter 50, and a rotating roller 51 are arranged in a straight line. To explain in more detail, the molding machine 23 converts the coil A' into a single width or a double width (not shown).
For example, the preheater 24 is formed by forming the coil A' as shown in FIG.
It is heated to ℃. In addition, the guide/presser roller group 25 gradually twists the decorative surface of the coil A' sent out from the molding machine 23 with the decorative surface of the coil A' being a substantially horizontal surface until it reaches the entrance of the mold mechanism 37. It has an original inclined decorative surface, and is used for feeding with both longitudinal ends (male and female connecting portions) located on a horizontal surface. That is, the guide/presser row group 25 includes a plurality of rollers such that a conveyance roller 29 having a drive roller 27 and a free roller 28 attached to a main shaft 26 and a guide/correction roller 30 face each other, as shown in FIG. 4, for example. The coils A', which are arranged in the form of individual ladders and sent out from the molding machine 23, are conveyed to the mold 38 while gradually inclining the decorative surface so that it matches the inclination of the mold 38. Further, the discharge section 31 applies a self-adhesive foamable reaction mixture P (hereinafter simply referred to as a mixture) to the back surface (one side) of the coil A', for example, by a discharge method equipped with a rotating blade, by a spray gun method (air, It is intended to be supplied either by airless) or by injection method. In addition, mixture P
A thermosetting foamable synthetic resin is used as the material. Furthermore, the guide 32 is made of one or two types of backing material B wound around an uncoiler 33 mounted on the frame 1 on the second floor, such as coil, asbestos paper, kraft paper, aluminum foil, plastic sheet, asphalt felt, etc. This is for guiding the laminated product above onto the mixture P, spreading the mixture P, and laminating the mixture P. To explain further, the guide 32 guides the backing material B onto the coil A', and determines the timing for bringing the backing material B into contact with the mixture P depending on the state of the mixture P (so-called self-adhesion of the mixture). It has the function of making more effective use of the properties of the mixture) and evening out the uneven dispersion of the mixture P. Its configuration consists of one roller.
or the configuration shown in FIGS. 5a to 5e. That is, in figure a, the rollers 32a ₁ , 32
a ₂ ,... guide arranged in parallel at the same height, b
Figures and c diagrams show rollers 32a ₁ ,...32an as coils.
A guide in which rollers are arranged at a certain angle θ with respect to the traveling direction of A', and figure d is a guide in which a boat-shaped spreading plate 33 is interposed between the rollers 32a ₁ , . . . 32an in the guide shown in figure a. , E shows a guide in which the rollers 32 in FIG. Further, the detector 36 detects cutting, damage, etc. of the back material B, and accordingly generates a signal to stop the operation of the discharge section 31. The principle behind this is a detector that uses electricity, magnetism, heat, and tension differences. The above-mentioned mold mechanism 37 conveys the mixture P between the coil A' and the back material B, reacts and foams the mixture P in a favorable environment, and forms it into a sandwich plate S of a predetermined thickness. It is something. To explain more specifically, the mold mechanism 37 is composed of a mold 38, a cover 37a,
The mold 38 has, for example, a steel belt or a caterpillar interposed between the driving wheels 39, 40 and the driven wheels 41, 42, and reinforcing rollers 45 are arranged on the backs of the upper and lower mold members 43, 44, and heating is applied to the backs of the reinforcing rollers 45. Devices 46 and 47 are provided, and the space containing the entire shape is sealed with a cover 37a. To explain further, the reinforcing roller 45 prevents the upper and lower mold members 43 and 44 from deforming due to the foaming pressure of the mixture P, and
47 is for keeping the inside of the mold 38 at a temperature of 50 to 90°C to complete the reaction of the mixture P within a predetermined time and to exhibit predetermined physical properties. The cover 37a keeps the inside of the mold 38 warm, and also protects against trichloromonofluoromethane released during the reaction of the mixture P or carbon dioxide released from the heating device.
This is to prevent carbon monoxide and the like from being released into the working environment for safety and hygiene reasons, and to obtain a more effective heat retention effect. In addition, the entrance and exit portions 38a and 3 of the mold 38
Only the mold 8b has a structure that prevents leakage of gas within the mold 38 to the maximum extent possible. Note that the reinforcing roller 45 is not necessary in the case of a roller-pillar type mold member, and a rail is provided on which the roller rolls. In addition, the cure oven 48 completes the reaction and foaming of the apparent mixture P,
The composite plate strip S is conveyed by a group of rollers 49. The ambient temperature is 50-110°C. The cross section of the mold 38 and the cure oven 48 are as shown in FIG. Katsuta 50
This is to cut a composite belt S having a sanderch structure into a predetermined length while traveling. Furthermore, the rotating roller 5
1 detects the rotational speed of the lower mold member 44 or the moving speed of the continuous sandwich plate S, and the control panel 52 controls communication between the embossing line 2 and the composite line 22 .
On the second floor of the mount 1 , each factor is depicted in analog, digital, etc. using instruments, television cameras, etc. In addition, the secondary forming machine 53 forms a gap in the final stage in the cross-sectional shape of the coil A',
This method divides a double-width sandwich board S and also folds it in half. In addition, the control panel 5
2. The secondary molding machine 53 is installed as necessary. Next, the operation of the sandwich board manufacturing apparatus according to the present invention will be explained. First, the temperature of the heater section 8 is 50℃.
Emboss roll 11 , leveler 12,
The tensioning pinch roller 13 rotates at a speed of 20 m/min. On the other hand, the compounding line 22 is installed at a speed synchronized with the embossing line 2 , the preheater 24 is heated to 80°C, and the temperature inside the cure oven 48 is set to 90°C.
℃, the discharge part 31 is set by the control panel 52 to turn on and off depending on the presence or absence of the coil A, and the cutter 50 is controlled so as to cut to a fixed length while the sanderch board S is moving. has been done. Note that a roller or belt (not shown) faster than the composite line 22 is interposed between the secondary forming machine 53 and the cutter 50. Therefore, the coil A attached to the uncoiler 4 is sequentially fed to the loop section 6 via the pinch roller 5. Next, the coil A is guided by the guide/pinch roller 9 of the heater section 8 through the loop section 7, and is fed to the heater 10. Note that the pinch roller 9 functions as a pinch roller only when the coil A reaches the embossing roll 11 for the first time, and after that, the upper roller 9a functions as a pinch roller.
is raised, and the lower roller 9b acts simply as a guide roller. Next, the coil A fed to the heater 10 is heated to, for example, about 60° C. to soften the decorative coating to a predetermined hardness, and then fed to the embossing roll 11 . To explain further, if the embossing is performed without heating the coil A or when it is heated too much, the decorative coating will peel, crack, be damaged, crack, shrink, etc. In other words, if the decorative coating film of coil A is not heated, the above-mentioned phenomenon will occur due to deformation (processing) that exceeds the elasticity of the decorative coating film, and if the heating temperature is increased to 60°C or higher, the cosmetic coating film will deteriorate. As the resin content approaches its softening point and the adhesion between coil A and the decorative paint film decreases, the decorative paint film
This is because there is a risk that the material may peel off from the surface, shrink, or lack scratch resistance. Furthermore, if the heating temperature is lower than about 30° C., the resin component of the decorative coating loses its softness and increases hardness, causing the decorative coating to crack and significantly reduce its scratch resistance. Next, the coil A leaving the heater section 8 is subjected to an embossing roll 11 to continuously form an embossed pattern consisting of concave portions α and convex portions β as shown in FIG. 8, for example. The coil A' that has left the embossing roll 11 is then fed to the leveler 12. Next, the coil A' that has passed through the embossing roll 11 is corrected by a lever 12 to remove any residual strain during embossing while being stretched by a tensioning pinch roller 13, and then sent to a reversing machine 15. be. The coil A' that has passed through the reversing machine 15 is sent to the compounding line 22 on the first floor via the second loop section 21 where the level sensor 20 is present. Therefore, the coil A' is passed through the molding machine 23 in the state shown in FIG.
The preheater 24 is formed into a cross section as shown in h.
It will be sent to The preheater 24 heats the coil A' to about 80° C. and feeds it to the entrance 38a of the mold 38 via the guide/pinch roller 32. At this time, coil A' is connected to the molding machine 23.
The surface of the sanderch board that will become the decorative surface is supported in a horizontal state until it exits the outlet of the mold, and then the decorative surface is decorated by a group of guide and press rollers 25 between the preheater 24 and the mold entrance 38a. Gradually twist the mold 38 by the amount of inclination of the surface with respect to the horizontal plane.
It is intended to be sent to . Further, from the discharge part 31, the mixture P in the middle of reaction and foaming is discharged onto the back surface of the coil A', and the back material B is placed on the guide 32.
Guided through the stacks. Note that the discharged mixture P is spread by the guide 32 and is regulated to a certain thickness. Next, the mixture P reacts and foams in the mold 38, changing from cream time to gel time to rise time, for example, and a sandwich plate S having a shape as shown in FIG. 6 is continuously sent out from the outlet 38b. . Next type 3
Put the sandwich plate S from 8 in the Cure Oven 4
8, the mixture P is cured and fed to a cutter 50, cut into a predetermined length, and its both side edges etc. are molded via a secondary molding machine 53 to form a product. As described above, according to the sanderch board manufacturing apparatus according to the present invention, since the decorative coating film is heated to 30 to 60°C for the coil having a decorative coating film on the surface, an arbitrary uneven pattern can be formed on the decorative coating film. Can be embossed without cracking, flawing, peeling, cracking, or shrinking. During embossing, a constant tension is applied to the coil, so the uneven pattern does not shift during embossing, and a beautiful uneven pattern can be formed. Residual strain during embossing can be easily removed by passing it through a leveler, so there is no twisting or twisting. Loops are provided on each of the embossed line and composite line, allowing for smooth connections between lines. This is natural since the coil is reversed by drawing a U-shaped locus. The two-story structure allows the line to be made more compact. Since the coil was heated and the mixture was then discharged, the mixture could be reacted and foamed in a good condition, and a core material with a uniform foam structure could be formed between the coil and the back material. Since the inside of the mold is sealed, heat retention is improved, and leakage of harmful gases and combustion gases into the working environment is reduced, greatly improving worker safety and hygiene. Since the timing of contact between the back material and the mixture can be easily and freely selected, the upper base material can be reliably bonded and the strength of the sanderch board can be greatly improved. Yield is high because the embossing line and compounding line are controlled via a control panel. Since even complex shapes are secondary-formed in the final stage, it is possible to easily form double-width sanderch boards with molded mixtures. Even if the decorative surface of the sanderch board has a step and is inclined, it can be manufactured continuously. Because the cure oven was installed after the mold, the adhesion between the coil, backing material, and foam mixture was strengthened, and deformation of the foam was prevented as the reaction and foaming process was apparently completed. Even if the sandwich board is transported immediately after being manufactured, there will be no deformation or separation of the coil and foam as in the past. It has the following characteristics.

[Brief explanation of drawings]

Fig. 1 is a schematic diagram showing the construction of an embodiment of the sander plate manufacturing apparatus according to the present invention, Fig. 2 is a perspective view showing levels, Figs. The figure is a sectional view taken along line A--A in FIG. 1, FIGS.
FIG. 7 is a longitudinal sectional view of the molding machine, and FIG. 8 is a perspective view showing an example of an uneven pattern formed by embossing. 1 ... Frame, 2 ... Embossing line, 8 ... Heater section, 11 ... Embossing roll, 15 ... Reversing section, 22... Composite line, 23... Molding machine,
25... Guide/press roller group, 37 ... Mold mechanism, 38... Mold, 48 ... Cure oven.

Claims (1)

[Claims] 1. In an apparatus for manufacturing sanderch boards in which a core material made of synthetic resin foam is interposed between the front material and back material made of thin metal sheets, a device for feeding thin metal sheets to the second floor of a two-story frame is used. A thin metal plate feeding section consisting of an uncoiler and a pinch roller, and storing the thin metal plate fed from the feeding section in a slack state,
A first loop section that adjusts between the front and rear processes, a heater section that heats the thin metal sheet to 30 to 90 degrees Celsius, an embossing roll that applies an arbitrary uneven pattern to the thin metal sheet sent out from the heater section, and An embossing line arranged linearly in the order of levelers placed after the rolls, an inversion section that greatly curves inward and inverts the thin metal sheet sent out from the leveler, and a thin metal sheet fed from the inversion section. a second loop section that loops the thin metal sheet, a forming machine that horizontally forms the thin metal sheet into a predetermined shape, a preheater section that heats the formed thin metal sheet to 50 to 90 degrees Celsius, and a second loop section that twists the thin metal sheet to form a decorative surface. a group of guide/press rollers that feed out the plastic foam while tilted at a certain angle, and a discharge section that reacts with the thin metal plate or heated backing material that is sent out from the roller group and discharges the plastic foam raw material that is in the process of being foamed. , a guide roller that guides and places the backing material horizontally on a thin metal plate, a thin metal plate with an inclined decorative surface, and the backing material with the above-mentioned raw material interposed between them, and is conveyed, and the raw material is reacted and foamed. A mold mechanism for curing the sandwich board sent out from the mold mechanism into a predetermined shape, a curing oven for curing the sandwich board sent out from the curing oven, and a cutter for cutting the sandwich board sent out from the curing oven into a predetermined length are arranged in a straight line. A sandwich board manufacturing device characterized by comprising a first floor almost directly below the line and a compound line installed on an extension of the first floor.