JPH0657434B2 - Method for manufacturing long laminated plate - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial field of application> The present invention relates to a method for manufacturing a long laminated plate, and more specifically, while conveying two surface materials having a considerable length in the longitudinal direction. The present invention relates to a method for producing a long laminated plate, which comprises producing a continuous long laminated plate by performing thermoforming of expanded particles filled between surface materials and subsequent cooling.

<Prior Art> Conventionally, a laminated plate in which a surface material made of a metal plate such as aluminum is laminated on the surface of a foam has been used. Since this laminated plate has a foam inside, it has excellent heat insulation,
Also, it is lightweight and has excellent rigidity because it is laminated with metal plates, it is not easily deformed, and it is also non-water absorbent, so it is suitable for wall materials, ceiling materials, roof materials, shutters, partitions, door panels, etc. Has been.

As a method for manufacturing the above-mentioned laminated plate, there is a method in which an adhesive is applied to both sides of a foam once formed into a board shape, and metal plates are superposed and bonded and integrated, but the application of the adhesive is troublesome. In addition, it is difficult, and a gap is likely to be formed on the bonding surface, so that sufficient bonding strength cannot be obtained.

Therefore, recently, foamed particles containing a styrene-maleic anhydride copolymer excellent in heat fusion property with a metal are used, and the particles are interposed between two surface materials and heated to form foamed particles. A method has been proposed in which the particles are expanded and heat-sealed between the expanded particles and between the expanded particles and the surface material.
62-10173 publication).

When manufacturing a laminated plate by this method, the surface material made of two metal plates is set in advance in a mold with an appropriate gap, and then the expanded particles are injected from the filling port of the mold. Fill within the above interval. Next, the expanded particles are heated to expand the expanded particles to form foams that are heat-sealed to each other, and at the same time, the foams are integrally joined with the surface material, and after cooling, the mold is opened and the laminated plate is taken out. Is.

This makes it possible to obtain a strong and uniform joining force with the metal plate.

<Problems to be Solved by the Invention> In the above-described method for manufacturing a laminated plate, the surface material preliminarily cut and formed into a predetermined size is set in the mold to manufacture the laminated plates one by one, and thus the laminated plates are manufactured one by one. The plate manufacturing time is relatively long,
In addition, there is a drawback that a standard size cannot be obtained.

Further, it is necessary to cool the mold in order to solidify the foam after the surface material is set in the mold and the expanded particles are filled, and the expanded particles are heated and expanded to be bonded to the surface material. For this reason, it is necessary to perform heating and cooling with the same mold, and the heating and cooling cycle of this mold requires extra energy and time, so there is the problem that production efficiency does not increase and manufacturing costs are high. It was

A transfer molding method may also be considered in which the heating mold and cooling mold are separated, the molded product that has been heat-molded in the heating mold is transferred to the cooling mold, and the mold is cooled in the cooling mold. The problem is that the structure of the manufacturing apparatus becomes complicated as a whole because it requires a transfer means to eject and transfer the product to the transfer mold, transfer it to a certain position in the cooling mold, and set it in the cooling mold. There is.

<Purpose> The present invention has been made in view of the above problems, and a method for manufacturing a long-sized laminated plate capable of realizing a simple structure of a manufacturing apparatus, saving energy required for molding, and shortening manufacturing time. Is intended to provide.

<Means for Solving Problems> In order to achieve the above-mentioned object, the method for manufacturing a long laminate of the present invention is one in which two facing long surface materials are conveyed in the longitudinal direction. Fill with thermoplastic foamed resin particles in between,
In the method of performing subsequent heat molding and cooling of the molded body, a side surface parallel to the conveying direction and a side surface on the surface material feeding side in the space between the two surface materials fed into the heating section of the expanded resin particles Is sealed with a side material, and the side surface opposite to the surface material feeding side is sealed with a rear end surface of the foam that has been already cooled and solidified, and foam resin particles are filled between the surface materials, and the filled foam resin particles Heat-expanding to form a heat-sealed foam, and at the same time obtaining a molded body by integrally joining the foam and the surface material, to the cooling section located on the downstream side of the heating section, the heating The surface material after molding is intermittently conveyed, and the space formed after the molding is filled with the expanded resin particles and the subsequent heat molding is performed in parallel with the cooling of the previously conveyed molded body at the adjacent position. Characterized by .

<Operation> In the method for manufacturing a long laminated plate described above, two long surface materials are conveyed in the longitudinal direction, and in one section of the conveyance line,
A method is employed in which a large number of expanded particles filled between both surface materials are heated and expanded to perform molding, and then the molded body is cooled in a section on the downstream side of the section. Therefore, unlike the conventional molding method that uses a surface material cut into a constant size in both width and length, heating and cooling are performed in different places of one conveyance line, and heat molding is performed on the upstream side. Since the part is conveyed and sent to the downstream side and cooled as it is, a long laminated plate can be continuously manufactured.

In addition, unlike the conventional manufacturing method in which molding and cooling are repeated by heating in the same mold, heating and cooling cycles are performed with dedicated molds respectively, so wasteful consumption of energy required for molding is saved and manufacturing time is shortened. Can be achieved.

Furthermore, since long lengths of surface material are being conveyed, it suffices to provide a section for cooling on the downstream side of the section for heat forming, and the heat formed part will be automatically conveyed to the cooling section. go. Therefore, unlike the conventional transfer molding, it is not necessary to particularly provide a transfer means for transferring the heat-molded molded product from the heating mold to the cooling mold, and the structure of the manufacturing apparatus is simplified.

In addition, the space between the two surface materials fed in is the side surface parallel to the transport direction and the side surface on the surface material feeding side, which is sealed by the side material, and at the rear end surface of the molded body which has already been cooled and solidified. It is surrounded on all sides. Thereby, the space between the two surface materials is filled with the expanded resin particles so as to be filled therewith.

Further, the surface material after the heat molding is intermittently conveyed to the cooling section, and the space formed after the molding is filled with the foamed resin particles and the subsequent heat molding, the molded article at the adjacent position previously conveyed. This is done in parallel with the cooling of. Thereby, a continuous long laminated plate can be manufactured at high speed, and the heating section and the cooling section of the molded body can be shortened.

<Example> Next, an example of the present invention will be described below with reference to the drawings.

1 and 2 show an embodiment of a manufacturing apparatus for carrying out the method for manufacturing a long laminated plate according to the present invention. An apparatus for producing a long laminated plate comprises a surface material delivery roll (3) for pulling out and carrying the surface material (1) wound around two winding rolls (2) in an opposed state, and one transfer section (I). In, a mold (4) for pressing both surfaces of the surface material (1) from above and below, and the surface material (1) conveyed through the mold (4) is mainly composed of a pulling roll (5). There is.

(6) is a guide plate interposed between the facing surface materials (1), and the surface material delivery roll (3) is located above and below the guide plate (6) and ), The surface material (1) is sandwiched, and the surface material (1) is conveyed by a frictional force by rotating the surface material (1) while applying pressure.

The mold (4) is a heating die (41) which is on the feeding side of the surface material and filled with foamed particles between the surface materials and heat-molded, and the surface material (1) which has passed through the heating mold (41). Cooling type (42) for cooling,
It is composed of a heat insulating part (43) interposed between both molds. Further, the heating mold (41) includes a hollow upper mold (41U) that presses the upper surface material (1) from above, and a hollow lower mold (41D) that presses the lower surface material (1) from below. Hollow side material (41R) (41L) (see Fig. 2) that seals the space between the two surface materials from the side surface parallel to the transport direction, and the hollow side material that seals the space from the side surface on the surface material feeding side. It is composed of side members (41C). The above space is made up of these three side members (41R) (41L) (41
C) and the rear end surface (E) of the molded body that has been cooled and solidified by the cooling mold (42) are surrounded on all sides, and the foam is filled in this space. Upper mold (41U), lower mold
(41D) and each side member (41R) (41L) (41C) in the hollow part of the steam chamber (46U) (46D) (46R) to introduce the steam for heating the expanded particles, respectively
(46L) and (46C) (hereinafter collectively referred to as reference numeral (46)) are formed. Further, the particle filler (47) for filling the expanded particles between the two surface materials is passed through the side material (41R) (second
In the side material (41C), a steam outlet hole (48) for sending steam from the steam chamber (46C) is formed between the two surface materials.

The cooling mold (42) is composed of an upper mold (42U) for pressing the heat-foamed molded body from above via the surface material (1) and a lower mold (42D) for pressing through the surface material (1). The cooling chambers (45U) (45D) for circulating cooling water are provided inside each mold. Cooling water can be circulated through the cooling chambers (45U) (45D) to cool the molded body. In addition, an air chamber (49) that fills air as a heat insulating material is formed in the heat insulating part (43).

Surface material delivery roll (3) and surface material tension roll (5)
The surface material (1) is intermittently fed by a predetermined distance D at a constant feed cycle T by rotating a fixed angle every fixed time. In this case, the feeding cycle T is set to a time sufficient for filling the expanded particles, heating and foaming, and cooling the molded body. The delivery distance D is a distance corresponding to the heating section (a section in which the surface material (1) can be heated, and the heating die (41) is measured along the conveyance direction.
A distance equal to or less than L) (corresponding to the length of). If the delivery distance D is longer than the distance L corresponding to the heating section, the surface material (1) is excessively fed beyond the heating section in one feeding, and after foaming the foam, An unheated portion is generated during the next heat molding, and it becomes impossible to obtain a continuous molded body. If the feeding distance D is shorter than the distance L corresponding to the heating section, both ends, which are apt to be insufficiently heated, are sufficiently heated, and even if the feeding is intermittent, the obtained laminated plate can be obtained. Are continuously fused and integrated.

The surface material (1) is preferably one in which at least the opposing surface is made of a metal plate, and in this embodiment, the surface material is
(1) The entire aluminum plate is used.
In addition to the aluminum plate, a metal plate such as a stainless plate or a zinc plate, a non-foamed styrene-maleic anhydride copolymer sheet, or the like may be used as the plastic sheet. Further, as the surface material (1), in addition to those having the same quality on both sides, for example, a heterogeneous combination in which one surface is a stainless steel plate and the other surface is an aluminum plate may be used. Further, the foamed particles are preferably a styrene-maleic anhydride copolymer or a blended product of this and other thermoplastic resin, according to which the surface material (1 ) Can be kept high and a very strong joining force can be obtained.

Next, explaining a method for manufacturing a long laminated plate by the above manufacturing apparatus, first, by the surface material delivery roll (3), the surface material tension roll (5), intermittently pull out the surface material (1), It is transferred into the heating mold (41). While pressurizing the heating mold (41) during this transportation pause, using the particle filler (47), both surface materials (1), measuring materials (41R) (41L) (41C) and already in the cooling process. The space surrounded by the rear end surface (E) is filled with the expanded particles, and subsequently, steam is passed through the steam chamber (46) to heat and expand the expanded particles. The heating at this time is performed not only indirectly through the surface material (1), but also by directly sending steam to the foamed particles through the upper steam outlet (48). By this heating, the foams are heat-sealed to each other, and at the same time, the foam and the surface material (1)
And are joined together.

After this, the space between the upper mold (41U) and the lower mold (41D) is slightly widened, and the surface material (1) is sent out by a distance D to cool the mold.
The molded body can be indirectly cooled by transporting it to the position of (42) and cooling the surface material (1) by the cooling mold (42). Then, during this cooling, in the heating mold (41), filling of the foamed particles between the subsequent surface materials and subsequent steam heating are performed.

In this way, the surface material (1) is delivered by the delivery distance D at regular time intervals, and during the rest period of the transportation operation, the cooling of the compact by the cooling die (42) and the heating die (41). Since the filling and the heating of the foamed particles in the subsequent portion can be concurrently performed in parallel, a continuous long laminated plate can be manufactured at a relatively high speed. In addition, in this embodiment, the mold (4) is divided by the heat insulation section (43) to separate the heating mold (4
Since the cooling mold (42) is formed with 1), the mold can be integrally formed. Therefore, it is possible to reduce the size of the mold, facilitate the manufacture, and reduce the manufacturing cost.

After that, in order to obtain a laminated plate having a desired size, the laminated plate after the cooling process may be cut into an appropriate length at an appropriate position during the transportation process.

Specific values of the steam manufacturing apparatus and the manufacturing method are as follows: the width of the surface material (1) is 600 mm, the distance between the surface materials is 25 mm, the feeding distance D of the surface material (1) in one feed is 250 mm, and the above heating zone. The distance L corresponding to is 300 mm, and the heating overlap length is 50 mm. The feed cycle T is 40se
c, of which the time required to fill the expanded particles is 6 seconds
After filling, the upper mold (41U) and the lower mold (41D) should be separated by a predetermined distance (2-3m).
(m) The time required to spread is 4 seconds, the time required to send the surface material (1) by the above-mentioned sending distance D is 1 second.
In the remaining 29 seconds, steam heating and cooling will be performed. In addition,
The vapor pressure sent to the expanded particles through the vapor outlet (48) is 1
~ 1.5 kg / cm ² .

Incidentally, the method for manufacturing a long laminate of the present invention is not limited to the above-mentioned embodiment, for example, the heat insulating part (4) of the mold (4).
3) may be filled with a heat insulating material such as asbestos instead of air, and in heating the foamed particles, without sending steam between the surface materials through the steam outlet hole (48), Upper mold (41U), lower mold (41D) and each side material (41R) (41L) (41
It may be performed only by heating from C). Furthermore, it is not necessary to heat using all of the upper mold (41U), the lower mold (41D) and each side material (41R) (41L) (41C), for example, the upper mold (41U) and the lower mold (41D). It may be heated by using either the upper mold (41U) or the lower mold (41D). For heating, a means such as an electric heater may be used instead of steam. Further, as the material of the expanded beads, other than a product made of a styrene-maleic anhydride copolymer or a blended product thereof with another thermoplastic resin, other styrene-based foams as long as they can be foam-fused, Alternatively, a urethane foam or the like may be used. Other various modifications can be made without departing from the scope of the invention.

<Effects of the Invention> As described above, according to the method for manufacturing a long laminated plate of the present invention, the surface material preliminarily cut and formed into a predetermined size is set in the mold to manufacture the laminated plates one by one. Different from the conventional method, the two facing long surface materials are used, and the foamed particles filled between the surface materials are molded by heating, and then the facing state is maintained. Since a long continuous laminated plate can be manufactured by transporting it to the downstream side as it is and cooling it, energy consumption required for heating can be reduced compared to the case where heating and cooling are repeated with one mold. Besides, the structure of the manufacturing apparatus is simplified. In addition, the space between the two surface materials fed in is the side surface parallel to the transport direction and the side surface on the surface material feeding side, which is sealed by the side material, and at the rear end surface of the molded body which has already been cooled and solidified. It is surrounded on all sides, and this space is filled so as to be filled with the expanded resin particles. This makes it possible to obtain a long laminated plate in which the entire molded body is uniformly foamed. Further, the conveyance of the surface material after the heat molding is intermittently performed to the cooling section, and the space formed after the conveyance is filled with the foamed resin particles and the heat molding is performed to cool the previously conveyed molded article at the adjacent position. Since the steps are performed in parallel, a continuous long laminated plate can be manufactured at a high speed, and the heating section and the cooling section of the molded body can be shortened. As a result, the manufacturing apparatus can be made compact. In addition, since it is possible to obtain laminated plates of various sizes by cutting it to a desired length and has the advantage of high productivity, it is possible to reduce manufacturing costs and improve workability. Produce an effect.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an embodiment of a manufacturing apparatus for carrying out the method for manufacturing a long laminated plate of the present invention, and FIG. 2 is a vertical sectional view taken along line II-II. (1) …… Surface material

Claims (4)

[Claims] 1. A method of transporting two facing long surface materials in the longitudinal direction, filling thermoplastic foamed resin particles between the surface materials, and subsequently performing heat molding and cooling of the molded body. At the heating section of the expanded resin particles
Of the space between the surface materials, the side surface parallel to the transport direction and the side surface on the surface material feeding side are sealed with side materials, and the side surface facing the surface material feeding side is the back side of the foam that has already been solidified by cooling. Sealed at the end face, filled the foamed resin particles between the surface materials, heat-expanded the filled foamed resin particles to form a heat-sealed foam, and simultaneously join the foam and the surface material together. Along with obtaining the molded body, to the cooling section located on the downstream side of the heating section, the surface material after the heat molding is intermittently conveyed, and the space formed after the conveyance is filled with the foamed resin particles and A method for producing a long-sized laminated plate, characterized in that the subsequent heat-molding is carried out concurrently with the cooling of the previously conveyed molded body at the adjacent position. 2. The method for producing a long laminate according to claim 1, wherein at least the facing surface of the surface material is a metal plate. 3. The production of a long laminate according to claim 1, wherein the foamed resin particles are a styrene-maleic anhydride copolymer or a blended product thereof with another thermoplastic resin. Method. 4. The method for manufacturing a long laminated plate according to claim 1, wherein the section for cooling is adjacent to the section for performing heat forming via a heat insulating portion.