JPH06155484A - Manufacture of laminated panel using hard urethane foam - Google Patents

Abstract

PURPOSE:To furnish a product of a laminated panel of excellent quality inexpensively irrespective of the shape and dimensions of the laminated panel. CONSTITUTION:In a manufacturing method of a laminated panel wherein a flat frame is prepared by disposing separately two plate materials designed to form outer layers of a laminated panel and a stock solution of a hard urethane foam is injected into the frame and foamed, expanded and cured, a punching metal 23 is used for either one or both of the plate materials and the stock solution of the hard polyurethane foam is injected one or a plurality of times through one or a plurality of holes 28 out of a number of holes 28 provided in the punching metal 23.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention can greatly reduce the manufacturing cost by simplifying the manufacturing method of laminated panels used for outer walls of buildings, partitions, roofing boards and other general structures, especially manufacturing equipment. The present invention relates to a method for manufacturing a laminated panel using rigid urethane foam.

[0002]

2. Description of the Related Art Laminated panels using rigid urethane foam, which are widely used in buildings and general structures, are usually excellent in heat insulation and have high bending strength and light weight when laminated with plate materials. It is made by the following method.

This method, as shown in FIG. 9 and FIG.
A flat formwork 2 is created by arranging two plate materials 1a and 1b forming an outer layer of a laminated panel so as to be separated, and then the formwork 2 is sandwiched between upper and lower structures 3a and 3b which can be vertically divided. Then, two kinds of stock solutions inside the mold 2, for example, a stock solution of an isocineate component [a component having two or more isocineate groups (NCO)] and a polyol component [a polyol and a catalyst having two or more hydroxyl groups (OH)] , A mixture of foaming agents and the like] is simultaneously sprayed by using the sprayer 5 (arrow a), and the foaming and expanding action caused by the mixing of the two liquids is used to fill the inside of the mold 2 with urethane foam. Then, after the stock solution is cured in a foamed state, the mold 2 is taken out, and a three-layer laminated panel composed of the two plate materials 1a and 1b and a hard urethane foam is manufactured.

Incidentally, FIG. 12 shows an injection equipment for supplying the undiluted solution to the injector 5. In the figure, 6 and 7 are tanks for storing the undiluted solution, and 8 is an adjusting device for prescribing a mixing ratio and an injection amount of each undiluted solution. , 9 and 9 are the stock solutions sent from the adjusting device 8 to the injector 5
It is a hose that leads to.

[0005]

However, the above-mentioned manufacturing method has the following problems. (1) When the stock solution is cured, the plate materials 1a and 1b are indicated by arrows b and b.
Since it is strongly pressed from the inside as shown by (the pressing force is usually 1 ton to 5 ton / square meter), it is necessary to strongly construct the structures 3a and 3b that support the formwork 2, and therefore the equipment cost Becomes expensive.

(2) As a result of the above, if a small amount of various types of curved panel having different radii of curvature is to be produced, the profitability becomes large and it is difficult to commercialize the curved panel.

(3) In order to guarantee the quality of the product, that is, the heat insulating performance, the adhesive force between the rigid urethane foam and the plate material, the bending strength as a laminated panel, etc., the foaming action is uniformly generated. So that the central part 1 of the form 2
It is necessary to inject a predetermined amount of the stock solution at 0 (shown by hatching), and to expand the injected stock solution while foaming in the radial direction as shown by arrow c. However, if the injection range 1 (distance from the nozzle 12 of the injector to the central portion 10) becomes too large, it becomes difficult to cause uniform foaming / expansion action, and a large quality laminated panel is manufactured. I can't.

In view of the above problems, the present invention provides a method for manufacturing a laminated panel using a rigid urethane foam that can provide a good quality product at low cost regardless of the size and shape of the laminated panel. This is an issue.

[0009]

In order to solve the above problems, the present invention has the following means. (1) Two plate materials forming an outer layer of a laminated panel are arranged apart from each other to form a flat mold, and a stock solution of hard urethane foam is injected into the mold to foam, expand and cure. In the method for manufacturing a laminated panel, a plurality of holes is provided in either or both of the plate materials, and one or a plurality of the holes are penetrated to inject the stock solution once or a plurality of times. A method for manufacturing a laminated panel using a characteristic urethane foam. (2) The method for manufacturing a laminated panel using the rigid urethane foam according to claim 1, wherein the two plate materials form a curved curved surface. (3) The method for manufacturing a laminated panel using a rigid urethane foam according to claim 1 or 2, wherein the plate material provided with a large number of holes is a punching metal.

[0010]

[Action]

(1) When the undiluted liquid of the rigid urethane foam is foamed and cured, the excess undiluted undiluted liquid leaks out from the holes of the plate material, so that the pressing force on the plate material is significantly reduced. Therefore, it is not necessary to construct the support structure strongly, and the equipment cost is reduced. (2) By suppressing the amount of leakage from the holes of the plate material to a minimum, the injection amount of the stock solution is significantly reduced (to about 1/5) as compared with the conventional one. Therefore, the machine is small and the equipment cost of the injection equipment can be reduced. (3) As a result of the items (1) and (2), laminated panels having various shapes can be manufactured at low cost.

(4) Since the undiluted solution is injected through the holes provided in the plate material, it is possible to uniformly cause the foaming and expanding action over the entire panel. Therefore, a high-quality product can be provided regardless of the external dimensions of the laminated panel. (5) When punching metal is used as the plate material, it is possible to omit the punching step in the laminated panel manufacturing factory, and it is possible to further reduce the manufacturing cost in addition to the facility cost.

[0012]

Embodiments of the present invention will be described below with reference to the drawings. 1 to 6 show a first embodiment of the present invention, in which a large-sized laminated panel (each dimension of width × length × thickness is 2 m × 6 m × 50 mm) is shown in FIG. It is manufactured according to the following procedure. The thickness of the laminated panel in FIG. 1 is drawn with exaggerated proportions for the sake of clarity.

(1) First, a galvanized steel plate 22 and a metal punching metal 23 which form an outer layer of a laminated panel.
Are spaced apart from each other, and a slender plate member 26 is provided on the periphery thereof.
a and 26b are arranged to form a mold 27, and the mold 27
Is clamped between the upper and lower structures 24 and 25.

As shown in FIG. 4, the punching metal 23 has holes 28 having an inner diameter d of 30 mm and holes 28 having a pitch p of 300 mm. In addition,
The holes arranged and the hole diameters other than the above may be used.

On the other hand, the following equipment is prepared in advance as a stock solution injection facility. As shown in FIG. 6, the injection equipment has a required number (three in the figure) of injectors 29, 29, 29 and hoses 3.
The adjusting device 33 supplies two kinds of undiluted solution to each of the injectors 29, 29, 29 via 0, 30, and the storage tanks 31, 32 which supply undiluted solution to the adjusting device 33. As shown in FIG. 6, the nozzle 34 of each injector 29 preferably has a structure in which the stock solution is injected in a conical shape with the axis 36 of the injector as a center line and a solid angle α close to 180 degrees. .

(2) Next, an operator (not shown) holds the injector 29 in his hand and inserts the nozzle 34 of the injector 29 into the hole 28 of the punching metal 23. At this time, the hole diameter of the punching metal 23 is expanded if necessary so that the nozzle 34 can be inserted. The arrangement of the injector 29 is
The best position is selected by performing a test in advance so that the undiluted solution injected from each injector 29 uniformly foams and expands to share and fill the inside of the mold 27.

Since isocyanate, catalyst, foaming agent, etc. in the stock solution are harmful, workers wear necessary protective equipment (respiratory protective equipment, protective clothing, protective glasses, etc.). Since the preparation is completed as described above, the worker simultaneously operates all the injectors 29 to inject the undiluted solution simultaneously (arrow a). By this operation, the two types of stock solutions are jetted in a mixed state from the nozzles of each jet machine, and when the jet amount reaches a predetermined value, the adjusting device 3
3 operates to stop the supply of the stock solution.

On the other hand, as shown in FIG. 3, the injected stock solution expands while foaming in the radial direction around each injection position 35, 35, 35 (see arrow c) and fills the inside of the mold 27. To cure. And part of the foamed stock solution is shown in Figure 5.
As shown in FIG. 5, the punching metal 23 is projected outward from the hole 28 and hardened in a mountain-like swelling state. If the projecting portion 37 is inconvenient in construction, it is removed by using an appropriate cutter.

After the foaming / expansion / curing action is completed, if a void (not shown) where the material does not reach is found, the undiluted solution is passed through the hole 28 of the punching metal 23 again. And then fill with rigid urethane foam.

When the stock solution is hardened, a pressing force acts on the galvanized iron plate 22 and the punching metal 23 from the inside in the direction of arrow b, but this pressing force is significantly reduced as compared with the conventional pressing force. Therefore, the structure 2 supporting the form 27
It is possible to configure 4, 25 much simpler than the conventional one, and it is possible to significantly reduce the equipment cost.

Further, by adjusting the injection amount of the stock solution so that the leakage amount from the hole of the punching metal is minimized,
It is possible to reduce the injection amount of the stock solution.

In the above description, it is explained that the operator holds the injector 29 in his hand and manually operates it, but the injector 29 is mechanically supported by using a support tool (not shown) to perform the injection operation. You may make it operate remotely.

A second embodiment of the present invention is shown in FIG. In this embodiment, instead of the galvanized steel plate in the first embodiment, a plate material 2 in which a pattern of a roofing plate such as a single letter roof is embossed
2a is used, and other than that, there is no difference from the first embodiment. According to this method, it is possible to inexpensively manufacture a large-sized roofing panel that also serves as a base plate and has a good appearance.

A third embodiment of the present invention is shown in FIG. In this embodiment, instead of the flat galvanized steel plate and punching metal in the first embodiment, a curved steel plate 22b and a curved punching metal 23b are separately arranged to form the mold 2
7a is made, and this form 27a is used for the structures 24a, 25a.
After being held in between, the stock solution of rigid polyurethane foam is injected, and other than that, there is no difference from the first embodiment. According to this method, a laminated panel for an outer wall having a smooth primary curved surface can be manufactured at low cost.

It should be noted that the present invention is not limited to the above-mentioned embodiments, and the present invention is applied to, for example, a seamless large wall panel, a roof panel of a spherical roof, or a flat laminated panel of a normal size. Alternatively, two or three or more kinds of rigid urethane foam stock solutions having components other than those shown in the examples may be used. Further, instead of using a metal material for the plate material. In addition, it is possible to use other materials such as wooden plywood or synthetic resin boards. Furthermore, the plate material is movably supported via rollers, and the stock solution is poured while moving the plate material so that flow production is possible. It goes without saying that various modifications can be made within the range not departing from the gist of the present invention, such as a method of manufacturing a laminated panel.

[0026]

As described above, the present invention exhibits the following excellent effects. (1) Since a large number of holes are provided in the plate material forming the outer layer of the laminated panel, the pressing force when the undiluted solution of rigid urethane foam is cured is significantly reduced. Therefore, it is not necessary to firmly construct the structure that supports the mold, and the facility cost is reduced. (2) The amount of undiluted solution sprayed is greatly reduced compared to the conventional method by reducing the amount of leakage from the plate material hole to a minimum (about 1 /
5). Therefore, the machine is small and the equipment cost of the injection equipment can be reduced. (3) As a result of the items (1) and (2), laminated panels having various shapes can be manufactured at low cost.

(4) Since the undiluted solution is injected through the holes provided in the plate material, it is possible to uniformly cause the foaming action over the entire panel. Therefore, it is possible to provide a high-quality laminated panel regardless of the external dimensions of the laminated panel.

(5) If punching metal is used as the plate material, it is possible to omit the punching step in the laminated panel manufacturing factory, and it is possible to further reduce the manufacturing cost in addition to the reduction of the manufacturing equipment.

[Brief description of drawings]

FIG. 1 is a partially cut side view showing a method for manufacturing a flat laminated panel which is a first embodiment of the present invention (II in FIG. 2).
The enlarged view from the direction) is shown horizontally.

FIG. 2 is a horizontally elongated reduced arrow view from the II-II direction in FIG.

FIG. 3 is a horizontally long plan view for explaining the foaming / expansion action of a rigid urethane foam stock solution.

4 is a plan view of punching metal in FIG. 1. FIG.

5 is a cross-sectional view showing a portion of the laminated panel shown in FIG.

FIG. 6 is a block diagram of an injection facility.

FIG. 7 is a plan view of one plate member in the method for manufacturing a roof panel laminate panel according to the second embodiment of the present invention.

FIG. 8 is a partially cutaway elevational view showing a method of manufacturing a curved laminated panel according to a third embodiment of the present invention.

FIG. 9 is a laterally long cut side view showing a conventional method for manufacturing a laminated panel.

FIG. 10 is an enlarged arrow view from the XX direction in FIG.

FIG. 11 is a horizontally long plan view for explaining the foaming / expanding action of a conventional rigid urethane foam stock solution.

FIG. 12 is a block diagram of conventional injection equipment.

[Explanation of symbols]

 23 Punching Metal 27, 27a Form 28 Hole 29 Injector

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Claims (3)

[Claims] 1. A flat mold is formed by arranging two plate materials forming an outer layer of a laminated panel at a distance from each other, and a stock solution of hard urethane foam is injected into the mold to foam, expand and cure. In the method for manufacturing a laminated panel as described above, a large number of holes are provided in one or both of the plate materials, and the stock solution is injected once or a plurality of times through one or a plurality of the holes. A method for manufacturing a laminated panel using a rigid urethane foam, which is characterized by the above. 2. The method for manufacturing a laminated panel using a rigid urethane foam according to claim 1, wherein the two plate members form a curved curved surface. 3. The method for manufacturing a laminated panel using a rigid urethane foam according to claim 1, wherein the plate material provided with a large number of holes is a punching metal.