JPH0688268B2 - Equipment for manufacturing phenol resin foam composite plates - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a composite plate manufacturing apparatus having a laminated structure in which a core material of a phenol resin foam is sandwiched between a lower surface material and an upper surface material.

<Conventional technology> Conventionally, resin foam such as urethane foam, polystyrene foam, and phenol foam has been used as a core material, and asbestos paper, glass paper, aluminum foil, gypsum board,
A composite plate having a laminated structure sandwiched between various face materials such as steel plates is known.

A general method for continuously manufacturing such a composite plate is to discharge the resin mixture onto the lower surface material that is continuously transferred,
An upper surface material is further continuously layered and supplied onto the resin mixed solution to form a layered continuous body. Next, the laminated continuous body is heated while being passed through a curing furnace while being pressed from the upper and lower surfaces thereof, whereby the layer of the resin mixed liquid is foamed and cured to a predetermined thickness, and the laminated continuous body coming out of the curing furnace is set to a predetermined size. A resin foam composite plate is obtained by cutting.

However, among the resin foams as the core material, the phenolic resin foams have excellent performances such as heat resistance, flame retardancy, and low smoke generation, but are extremely superior to other resin foams. It was brittle and difficult to use.

As a solution to the disadvantages of the phenol resin foam, a new foamable phenol resin mixture has been proposed by the same applicant as the present application (Japanese Patent Laid-Open No. 60-11520).
issue). This foamable phenol resin mixed liquid comprises a benzylic ether type phenol resin, a polyisocyanate compound, an aromatic sulfonic acid compound, water, a foaming agent and a foam stabilizer, and the mixture liquid is foamed and cured to obtain good mechanical properties. A phenol resin foam having physical properties is obtained.

<Problems to be Solved by the Invention> The present inventors manufactured a phenol resin foam composite plate using the above-mentioned foamable phenol resin mixture. In this manufacturing, the general method as described above was adopted and the temperature of the curing furnace was set to 60 to 80 ° C.

Examination of the composite plate thus obtained showed that the phenolic resin foam layer had good mechanical properties, but there was a portion where uniform foaming was not made in the foam, and the density uniformity Turned out to be a little problem. Further, although the above-mentioned foamable phenol resin mixed liquid has a good self-adhesive strength with various face materials, the face material may not always have a sufficient adhesive strength with the foam depending on the conditions.

Therefore, the inventors of the present invention have improved the conventional manufacturing apparatus and installed a conventional curing furnace for performing both foaming and curing of the resin mixed liquid layer,
Completely separates into two chambers, a foaming chamber for foaming the resin mixture layer and a curing chamber for curing the resulting foamed layer. Optimal conditions for foaming in the foaming chamber and optimal conditions for curing in the curing chamber. It was found that a phenol resin foam composite plate having uniform foaming of the foam layer, excellent in density uniformity, and having sufficient adhesiveness between the face material and the foam can be produced by giving Filed an application
60-200084).

However, in the improved device according to the above-mentioned prior application,
For example, regarding the temperature conditions, it is possible to maintain the optimum temperature in each of the foaming chamber and the curing chamber, but since the foaming chamber and the curing chamber are arranged side by side with a certain size, the foaming time and curing time in each chamber are It is uniquely determined by the line speed at which the laminated continuous body is conveyed through each chamber. As a result, there has been a disadvantage that the production control for surely performing the foaming in the foaming chamber to the vicinity of the rise time (the time required for the foam to reach the maximum height) becomes complicated. In particular, when there is a gap between the foaming chamber and the curing chamber, when foaming occurs in this gap, the foam itself may peel from the face material.

Therefore, the present invention further improves the apparatus according to the above-mentioned prior application, and can provide more appropriate conditions to the foaming chamber and the curing chamber, respectively, thereby providing a foam layer of uniform foaming and uniform density. At the same time, it is an object of the present invention to provide an apparatus capable of producing a phenol resin foam composite plate having good adhesion between the face material and the foam with even higher productivity.

<Means for Solving the Problems> The inventors of the present invention have completely configured the curing furnace for foaming and hardening the resin mixture layer of the continuous laminate, which is completely independent, separated and juxtaposed as in the above-mentioned prior application device. The present invention has been completed by finding out that the above object can be achieved by dividing the inside of the curing furnace into a foaming zone and a curing zone by a partition that can move in the horizontal direction without forming a curing chamber and a curing chamber. Is.

That is, the apparatus for producing a phenol resin foam composite plate according to the present invention comprises a continuous supply device for a lower surface material; an ejector for ejecting a foamable phenol resin mixture onto the lower surface material; An upper surface material laminating and supplying device for continuously laminating and supplying an upper surface material on the resin mixed liquid to form a continuous laminated body; and a pressing and conveying device vertically opposed to each other with a predetermined interval provided between them. A curing furnace for heating the layer of the resin mixed solution to foam and harden it to a predetermined thickness by continuously passing the laminated continuous body through a sheet; and a composite plate product obtained by cutting the foamed and hardened layered continuous body into a predetermined size. In a manufacturing apparatus of a phenol resin foam composite plate which is sequentially arranged with a cutting machine, in the curing furnace, the laminated continuous body is heated to a temperature of 20 to 80 ° C. by a partition that can be moved in the horizontal direction. Foam resin mixture layer It is characterized in that it is divided into a foaming zone for hardening and a hardening zone for hardening the foamed layer of the resin mixture by heating the laminated continuum emerging from the foaming zone to a temperature of 50 to 100 ° C.

<Function> Although the quality of the product of this type of composite plate is mainly affected by the quality of the foaming of the resin foam as the core material, according to the present invention, the inside of the cure furnace is partitioned into a foaming zone and a curing zone. Since it is divided, not only can the optimum temperature for foaming of the foamable phenol resin mixture and the optimum temperature for curing after foaming be given in each area, but the partition can be moved horizontally to expand and cure the foamed area. Since the length of the zone can be changed, the foaming time and the curing time can be adjusted without changing the line speed. Therefore, the temperature
At the optimum foaming temperature within the range of 20 to 80 ° C, it is possible to foam in the foaming zone for the optimum time up to just before the rise time, and thus the foamed phenolic resin foam layer,
It becomes possible to cure efficiently in a curing zone having an optimal curing temperature within the range of 50 to 100 ° C.

If the foaming temperature is lower than 20 ° C, the rise time becomes extremely long, and if it is higher than 80 ° C, the foaming rate cannot be controlled, uniform foaming is not performed, and the uniformity of density is deteriorated. On the other hand, if the curing temperature is lower than 50 ° C., the curing will be insufficient and the mechanical properties of the foam will be poor. If the temperature is higher than 100 ° C, the foam tends to crack.

<Examples> Hereinafter, the present invention will be described in more detail with reference to preferred examples. The attached drawings show an example of the composite plate manufacturing apparatus of the present invention, which comprises a lower surface material continuous supply device 1, a foamable phenol resin mixed liquid discharger 2, an upper surface material stacking supply device 3,
The curing furnace 4 and the cutting machine 5 are arranged in this order. The lower surface material supply device 1 includes an uncoiler 11 around which a lower surface material is wound and a pinch roller 12, whereby the lower surface material is continuously supplied from left to right in the drawing. The discharger 2 is a device that discharges a predetermined amount of the foamable phenol resin mixed liquid onto the lower surface material, and includes one or a plurality of discharge nozzles. The upper surface material stacking and feeding device 3 has an uncoiler 31 around which the upper surface material is wound and a guide roller 32, whereby the upper surface material is continuously stacked and supplied on the resin mixed liquid discharged onto the lower surface material. It is an apparatus for forming a laminated continuous body. The inside of the curing furnace 4 is formed by a partition 6 that can move in the horizontal direction.
It is divided into 41 and a curing area 42, and the length ratio of the foaming area 41 to the curing area 42 can be changed by moving the partition 6 in the horizontal direction. The foam area 41 is
It has a pressing and conveying device in which a plurality of rollers 43 and 44 are vertically opposed to each other with a predetermined gap. The pressing and conveying device composed of a plurality of rollers is extended to a part of the curing area 42, but in the vicinity of the outlet of the curing area 42, the belt conveyors 45 and 46 are vertically opposed to each other with a predetermined gap. It is a pressing and conveying device composed of a belt conveyor. In the illustrated example, a pre-heater 7 is installed in front of the discharger 2 to preheat the lower surface material. When using a steel plate etc. as the bottom surface material, if necessary, use a pinch roller.
An embossing roll and a molding machine can be installed between 12 and the preheater 7.

The operation of this apparatus will be described. The lower surface material continuously supplied from the lower surface material supply device 1 is preheated through the preheater 7 and then continuously fed into the line. Then, a predetermined amount of the foamable phenol resin mixed liquid is continuously discharged from the discharger 2 onto the lower surface material, and the upper surface material continuously supplied from the upper surface material supply device 3 onto the resin mixed solution. By covering, a layered continuous body in which the layer of the resin mixed liquid is sandwiched between the upper surface material and the lower surface material is formed. The layered continuous body is conveyed from inside the curing furnace 4 while being pressed from above and below by a pressing and conveying device to maintain a predetermined thickness. During this time, the resin mixed liquid of the laminated continuous body is uniformly spread between the lower surface material and the upper surface material, and the plurality of rollers 43 and
It is heated to 20 to 80 ° C. via 44 and reaches a predetermined thickness near the exit of the foaming zone 41 just before the rise time.
The foamed laminated continuum exiting the foaming zone 41 is then sent to a curing zone 42, where it is cured by heating it to 50-100 ° C via multiple rollers 43,44 and biaxial belt conveyors 45,46. Is completed. The foamed and cured laminated continuous body continuously sent out from the curing area 42 is cut into a predetermined size by the cutting machine 5 to form a composite board product.

Phenolic resins that can be preferably used in the present invention include benzylic ether type phenolic resins and resol type phenolic resins, and self-adhesion with a face material is possible without using these adhesives.

As the surface material, asbestos paper, glass paper, aluminum foil, various heat resistant and flame resistant laminated paper, gypsum board, metal surface material and the like can be appropriately used.

The present invention will be further described below with reference to usage examples of the apparatus of this embodiment.

Example of use Synthesis of benzylic ether type phenol resin: Phenol 357g, paraformaldehyde 174g, lead naphthenate 1.5g, zinc naphthenate 3.0g are mixed with stirring,
After reacting at 110 to 114 ° C. for 3 hours, it was immediately dehydrated under reduced pressure to obtain a benzylic ether type phenol resin having a viscosity of 30,000 cps (at 25 ° C.).

Preparation of Effervescent Phenolic Resin Mixture: Component A Benzylic ether type phenolic resin (synthesized above) 88.5 parts by weight Foaming agent "Freon R-11" (Mitsui Fluorochemicals) 8.8
Parts by weight Foam stabilizer "Tween-40" (manufactured by Kao Atlas) 2.7 parts by weight B component curing agent (70% aqueous solution of p-toluenesulfonic acid) 30 parts by weight C component crude diphenylmethane diisocyanate ("Millionate MR-200", Japan Polyurethane Co., Ltd.) 10 parts by weight The above components A, B and C were mixed with a mixer (P-306 manufactured by Toho Machinery Co., Ltd.) to prepare a foamable phenol resin mixture.

Manufacture of Composite Plates: Composite plates of various sizes were manufactured using a color steel plate as the lower surface material and aluminum foil-clad kraft paper as the upper surface material using a device such as the attached drawings. At this time, the charging amount of the foamable phenol resin mixed liquid was 39 kg / m ³ , and the line speed was 15 m.
/ min, the total length of the curing furnace was 35 m, and the pressing and conveying device in the curing furnace was a plurality of roller parts 31 m and a belt conveyor part 4 m. Also, by moving the partition in the curing furnace horizontally, the optimal foaming zone length according to the composite plate dimensions,
That is, the foaming was adjusted to give a predetermined time. The composite plate dimensions and manufacturing conditions are summarized in Table 1.

Each of the phenolic resin foam layers of the obtained composite plate had few skin layers, and the foam cross section did not have a layered portion,
It was uniformly foamed and had a density of 34 to 35 kg / m ³ . Also, the obtained composite board is cut with a jigsaw, a circular saw, etc.
It had sufficient adhesive strength to withstand the processing of the inside and outside corners.

<Effects of the Invention> As described above, according to the present invention, since the inside of the curing furnace is divided into the foaming zone and the curing zone by the movable partition, it is possible to provide the optimal foaming temperature and the optimal curing temperature in each zone. At the same time, it is possible to adjust the optimal foaming time and curing time according to the type of foam and product size by simply moving the partition without changing the line speed, producing a good quality composite board product. It can be manufactured with good properties.

[Brief description of drawings]

The attached drawings are explanatory views showing an embodiment of the apparatus of the present invention. 1 ... Lower surface material continuous supply device, 2 ... Discharging machine, 3 ... Upper surface material stacking supply device, 4 ... Cure furnace, 5 ... Cutting machine, 6 ...
… Partitions, 41… Foaming areas, 42… Curing areas.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification number Reference number within the agency FI Technical display location B29L 9:00 4F (72) Inventor Junichi Tomiuga 7-43 Daikokucho, Tsurumi-ku, Yokohama-shi, Kanagawa Hodogaya Chemical Co., Ltd. Central Research Laboratory Tsurumi Branch Office

Claims (1)

[Claims] 1. A continuous supply device for a lower surface material; a discharger for discharging a foamable phenol resin mixed liquid onto the lower surface material; a continuous upper surface material on the resin mixed liquid discharged onto the lower surface material. A stacking and feeding device for the upper surface material that stacks and feeds the film continuously to form a continuous stacked body; and a pressing and conveying device that is vertically opposed to each other at a predetermined interval, and continuously passes the continuous stacked body between them. A curing furnace for heating the layer of the resin mixed liquid to foam and harden it to a predetermined thickness, and a cutting machine for cutting the foamed and hardened laminated continuous body into a predetermined size to obtain a composite plate product are sequentially arranged. In the manufacturing apparatus of a phenol resin foam composite plate, in the curing furnace, a foaming zone for foaming the resin mixture layer by heating the laminated continuous body to a temperature of 20 to 80 ° C. by a partition that can move in the horizontal direction. , The laminated continuum from the foamed area An apparatus for producing a phenol resin foam composite plate, characterized in that it is divided into a hardening zone for heating the foamed layer of the resin mixture by heating at a temperature of 50 to 100 ° C.