JPH0890742A - Production of flash panel - Google Patents

Abstract

PURPOSE: To uniformly and efficiently heat a core material. CONSTITUTION: A preheating furnace 20 equipped with a far infrared ceramic heater 36 is used in a flash panel manufacturing process and a core material 14 is heated by radiant heating in a non-contact state. Therefore, even when the surface of the core material 14 has unevenness or the difference in level of an assembled part (e.g. the difference in level between a frame part and a crosspiece), the entire surface thereof is uniformly heated and no partial overheating is generated and the generation of scorch is suppressed. Since the core material is heated by far infrared rays, the core material 14 is heated up to the interior thereof and continuously heated under a uniform condition regardless of the dimension thereof and the quality of a flash panel is stabilized.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flash panel manufacturing method, and more particularly to a heating method for heating a core material when bonding a decorative plate.

[0002]

2. Description of the Related Art There is known a flash panel in which a decorative plate is adhered to both surfaces or one surface of a core material assembled in a frame shape. The core material is, for example, particle board, plywood, or the like, and the decorative board is, for example, one surface of plywood or the like coated with a thermoplastic resin such as melamine resin. Therefore, the flash panel, which is lightweight and has an excellent appearance, can be manufactured at low cost and is widely used as a plate material for a hanging shelf or a desk of a system kitchen. Such a flash panel is prepared, for example, by heating at least one surface of a core material assembled in a frame shape, applying an adhesive such as vinyl acetate emulsion to the one surface, and separately preparing the adhesive-applied one surface. It is manufactured by pressing and adhering the decorative plate.

[0003]

The above heating of the core material is intended to shorten the pressing step by rapidly drying the adhesive to increase the adhesive strength, and conventionally, it has been heated to a predetermined temperature. It was performed by so-called hot plate heating in which pressure is applied from both sides by a hot plate made of iron. With such a heating method,
Since the core material is conductively heated from the surface that is in contact with the hot plate, if there are irregularities on the surface of the core material or steps in the assembly part, non-contact parts occur and the core material is not heated uniformly, resulting in uneven temperature. Will occur. In such a case, if an attempt is made to bring the entire surfaces to be bonded together to a sufficiently high temperature, the contacting parts may be excessively heated and the surface of the core material may be burnt.
Moreover, since the iron plate used for heating such a hot plate has a relatively large area equal to or larger than the area of the core material and has a large heat capacity, it is necessary when the dimensions of the core material fluctuate during continuous operation. Since the amount of heat is different, there is a problem that the heating is likely to vary and the quality is not stable.

The present invention has been made in view of the above circumstances, and an object thereof is to provide a method for manufacturing a flash panel capable of uniformly and efficiently heating a core material. .

[0005]

In order to achieve such an object, the gist of the present invention is to provide a heating step of heating at least one surface of a core material assembled in a frame shape, and the heated core material. In a method of manufacturing a flash panel, including a coating step of applying an adhesive on one surface and a pressure step of applying a pressure on a decorative plate to the one surface coated with the adhesive, the heating step of the core material, The core material is radiantly heated using far infrared rays.

[0006]

In this way, since the core material is heated by radiant heating, unlike the conventional conductive heating using a hot plate, the core material is heated in a non-contact manner. Even when there is a step in the assembly part or the like, the entire surface is heated uniformly, partial overheating does not occur, and the occurrence of charring etc. is suppressed. Moreover, since the far infrared rays are used for heating, the inside of the core material is heated and the core material can be continuously heated under uniform conditions regardless of the dimensions of the core material, and the quality of the flash panel is stabilized.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 is a diagram showing an outline of a flash panel 10 manufactured by a manufacturing method according to an embodiment of the present invention with a decorative plate 12 and a core material 14 separated from each other. Veneer 12
For example, one surface of plywood is coated with a thermoplastic resin such as melamine resin. On the other hand, the core material 14 is, for example, a rectangular bar made of so-called particle board that is thermocompression molded from a wood chip (chip) as a main raw material with an adhesive, and is assembled into, for example, a rectangular frame shape, and at the center in the longitudinal direction of the rectangle. Similarly, the crosspiece 16 made of particle board is provided. Both sides in the thickness direction of the square bar assembled in the frame shape and the core 14 of the crosspiece 16 are located on the same plane.

The flash panel 10 includes the decorative plate 12 described above.
Is bonded to one side of the core material 14 with a water-based adhesive such as a vinyl acetate emulsion resin, which realizes a relatively inexpensive plate material that is lightweight and has an excellent appearance. There is. In addition, in FIG. 1, a flash panel 1 in which a decorative plate 12 is adhered to only one surface is shown.
Although 0 is shown, the decorative plate 12 may be adhered to both surfaces of the core material 14.

The above-described water-based adhesive such as vinyl acetate emulsion resin produces adhesiveness due to polymerization caused by the decrease in the water content in the emulsion, and therefore the flash panel 10 is manufactured. In order to shorten the process, it is necessary to heat and dry the adhesive quickly. On the other hand, in order to obtain a strong adhesive force, it is necessary to hold the decorative plate 12 and the core material 14 in close contact with each other by sandwiching and pressing with a pressing plate at the time of bonding. Therefore, a manufacturing method in which an adhesive is applied to the core material 14 and the decorative plate 12 is attached and heated while applying pressure is also possible. However, in such a method, the pressing plate is heated to a high temperature and the decorative plate 12 is passed through the decorative plate 12. Since heating is performed by heat conduction, it takes a long time to apply pressure and heat. Therefore, generally, only the core material 14 is preheated to a predetermined temperature, and the residual heat reduces the water content to obtain an adhesive force. Therefore, in the manufacturing line of the flash panel 10, a heating means for heating only the core material 14 is provided in advance. The manufacturing line will be described below.

2A and 2B are diagrams showing a device configuration of a continuous flash bonding line for manufacturing the flash panel 10 described above. FIG. 2A is a state seen from above, and FIG.
3B is a cross-sectional view taken along line bb in FIG. The continuous flash bonding line has a decorative plate 12 on one side of the core material 14.
And a preheating furnace 20, an adhesive application device 22, a free conveyor 24, and a cold press device 26.

The core material charging belt conveyor 18 is for charging the core material 14 into the preheating furnace 20 from the inlet 28, and the core material 14 is preheated at a constant conveying speed of, for example, about 1 m / min. Move towards 20. The loading belt conveyor 18 is controlled by an inverter, which is common to the mesh conveyor 34 in the preheating furnace 20 described below, so that the conveyor belt 18 has a similar conveyance speed.

The preheating furnace 20 is, for example, a drying furnace main body 32 formed in the shape of a box with the inlet 28 and the outlet 30 at both ends in the longitudinal direction by a steel plate having a heat insulating material (not shown) provided on the inner surface, Belt conveyor for loading core material 1
8, a mesh conveyer 34 for passing the core material 14 from the inlet 28 to the outlet 30 at a constant conveying speed of about 1 m / min, passing through a substantially central portion in the height direction inside the drying furnace main body 32.
And a plurality of longitudinal far-infrared ceramic heaters 36 provided in the upper and lower inner wall surfaces of the drying furnace main body 32 such that the direction perpendicular to the longitudinal direction is the longitudinal direction. .

The far-infrared ceramic heater 36 is capable of providing an output of about 1.7 kW by applying a voltage of about 200 V, for example, and the output is controlled by a control panel (not shown) to be preset. The temperature inside the furnace is maintained at a constant value. The inlet 28 and the outlet 3
Exhaust ducts 38 and 40 are provided near 0, respectively, so that water vapor and the like generated in the process of heating the core material 14 are exhausted. The transport speed of the mesh conveyor 34 is always kept at the same value as that of the loading belt conveyor 18.

The adhesive coating device 22 includes a coating roller 42 which is rotated while being pressed against each other, an adjusting roller 44 arranged above the coating roller 42, and a pair of feed rollers which convey the core material 14 toward the free conveyor 24. 46,4
This is a so-called roll coater having 6 and the core material 14 is conveyed toward the free conveyor 24 at a speed of about 35 m / min while being sandwiched between the coating roller 42 and the feed rollers 46, 46. At this time, the adhesive is accumulated between the application roller 42 and the adjusting roller 44, and both rollers 4
By rotating 2, 44, the preheating furnace 2
One side of the core material 14 sent out from the outlet 30 (FIG. 2).
A predetermined amount of adhesive will be applied to the upper surface in (b). The application amount is appropriately set by changing the pressing force of the adjusting roller 44, for example.

The coating roller 42, the roller 46,
The vertical interval with respect to 46 is changed by, for example, driving the motor 50 to move the coating roller 42 in the vertical direction. Above the loading belt conveyor 18, the core material 1 loaded from the inlet 28 of the preheating furnace 20 is introduced.
4 is provided with a contact-type or non-contact-type thickness sensor 52 for measuring the thickness of the core 4, and the motor 50 has an appropriate interval according to the thickness of the core material 14 measured by the thickness sensor 52. The coating roller 42 and the like are moved so that the value becomes a value.

The free conveyor 24 also serves as a workbench for adhering the separately prepared decorative plate 12 to one surface of the core material 14 sent from the adhesive material application device 22, for example, by manual work. is there. This free conveyor 2
4 does not have any driving means, and the core material 14 is
The adhesive is applied to the cold pressing device 26 by rotating the feed roller 46 of the adhesive applying device 22 or manually.

The cold pressurizing device 26 is provided with a pair of pressurizing plates 54, 54, and the core material 14 to which the decorative plate 12 is attached is arranged between the pressurizing plates 54, 54.
The decorative plate 12 is firmly adhered to the core material 14 by applying a pressure of about gf / cm ² for a predetermined time (for example, about 30 seconds).

When the flash panel 10 is manufactured by the continuous flash bonding line constructed as described above, first, the core material 14 is attached to the charging belt conveyor 18.
When placed, the specified transport speed (for example, about 1 m / min)
Is sent to the preheat furnace 20 and is introduced into the inside through the inlet 28. In this process, the thickness sensor 52 detects the thickness of the core material 14, and the motor 50
Is driven to set the gap between the coating roller 42 and the roller 46 of the adhesive coating device 22 to a value according to the thickness of the core material 14.

The temperature inside the preheating furnace 20 is maintained at a constant temperature by the far infrared ceramic heater 36, and the core material 14 is sent from the inlet 28 to the outlet 30 in about 1 minute, for example. As a result, the surface of the core material 14 has a predetermined temperature (for example, 6
It is uniformly heated to about 0 to 120 ° C. The rising time of the preheating furnace 20 (time until the temperature inside the furnace reaches a predetermined temperature) is, for example, about 10 to 15 minutes. The core material 14 carried out from the outlet 30 is immediately applied with a predetermined amount of adhesive on one surface thereof by the adhesive application device 22. For this adhesive, for example, a vinyl acetate emulsion resin having a resin content of about 40 to 60% by weight, a viscosity of 10,000 to 60,000 cps, and a minimum film forming temperature of 15 ° C. or less is preferably used.

When the core material 14 is sent to the free conveyor 24 with the adhesive applied on one side, a separately prepared decorative plate 12 is attached on one side by, for example, manual operation, and further moved by manual operation. As a result, the core material 14 to which the decorative plate 12 is attached is placed between the pressure plates 54, 54 of the cold pressure device 26. Then, the adhesive is dried by the residual heat of the core material 14 while being pressed with the predetermined pressure force for, for example, about 30 seconds.
4 and the decorative plate 12 are firmly bonded to each other, and the flash panel 10 is manufactured. As is clear from the above description, in the present embodiment, the heating by the preheating furnace 20 is the heating step, the step of applying the adhesive by the adhesive applying device 22 is the applying step, and the decorative plate 12 is attached. The step of pressurizing the obtained core material 14 with the cold pressurizing device 26 corresponds to the pressurizing step, respectively.

Here, according to this embodiment, the preheating furnace 20 provided with the far infrared ceramic heater 36 is used in the flash production line, and the core material 14 is heated by radiant heating, so that the core material 14 is heated without contact. From being
Even if the surface of the core material 14 has irregularities or steps in the assembly portion (for example, the steps between the frame portion and the crosspiece 16), the entire surface is uniformly heated, and partial overheating does not occur, so that charring occurs. Suppressed. Moreover, the core material 14 is heated by far infrared rays.
The inside of the flash panel 10 is heated to the inside and continuously heated under uniform conditions regardless of the size of the core material 14, and the quality of the flash panel 10 is stabilized.

Further, since the far infrared ceramic heater 36 has a smaller heat capacity than the conventionally used hot plate,
As described above, the rise time is about 10 to 15 minutes, which is relatively short when the heating plate is used, and the manufacturing process is made efficient.

Further, in this embodiment, since a vinyl acetate emulsion resin having a relatively large resin content of 40 to 60% is used as the adhesive, the pressurizing time by the cold pressurizing device 26 is as described above. Thus, a relatively short time of about 30 seconds is sufficient. Therefore, coupled with the fact that the heating time is shortened to about 1 minute, the manufacturing process of the flash panel 10 is made more efficient.

On the other hand, in the conventional manufacturing process, an adhesive having a relatively small resin content of about 15 to 25% is used, and a pressurizing time of about 2 to 3 hours is required. Therefore, the manufacturing efficiency is improved by collectively pressing a plurality of flash panels 10. However, in order to collectively pressurize in this way, it is necessary to stack the flash panels 10 having the same shape, and in general, since the flash panels 10 are often produced in small quantities and in many types, high manufacturing efficiency can be obtained in the end. It was difficult.

Further, according to the present embodiment, the thickness sensor 52 is provided above the charging belt conveyor 18 so that the gap between the coating roller 42 and the roller 46 of the adhesive coating device 22 corresponds to the thickness of the core material 14. It is set to an appropriate value according to Therefore, the pressing force of the application roller 42 on the core material 14 is kept constant, and an appropriate adhesive application amount is always obtained.

Although one embodiment of the present invention has been described in detail with reference to the drawings, the present invention can be carried out in still another mode.

For example, in the above embodiment, the core material 1
Although the flash panel 10 in which the decorative plate 12 is bonded to only one surface of No. 4 has been described, the same manufacturing line can be used for the flash panel in which the decorative plate 12 is bonded to both surfaces. However, in the case of adhering the decorative plate 12 to both surfaces, after adhering to one surface, the decorative plate 12 is adhered to one surface on the opposite side by further passing the line of the above-mentioned embodiment, or an adhesive is applied. The coating roller 42 of the device 22 is used as the core material 1.
It is necessary to adopt a method in which it is provided on both sides of No. 4 and the adhesive is applied simultaneously on both sides to attach the decorative plate 12 and pressurize it. It should be noted that, except when the decorative plates 12 are bonded simultaneously on both sides, the far infrared ceramic heater 36 provided on the inner wall surface of the lower side of the preheating furnace 20 does not necessarily need to perform heating.

Further, in the embodiment, the far infrared ray ceramic heater 36 is used to perform the radiant heating by the far infrared ray in the heating step. However, as long as the far infrared ray is emitted and the radiant heating is possible, other Other heaters such as the far-infrared heater and the infrared heater may be used.

Further, in the embodiment, the thickness sensor 52
Although the thickness of the core material 14 is measured by the motor 50, and the distance between the coating roller 42 and the roller 46 of the adhesive coating device 22 is automatically maintained at an appropriate value by driving the motor 50, The motor 50 and the thickness sensor 52 may not be necessarily provided when only the core material 14 having a different thickness is used, or when the interval is manually adjusted.

Although vinyl acetate emulsion resin was used as the adhesive in the examples, urea resin, starch or the like may be appropriately mixed and used, or a copolymer emulsion resin or the like may be used. Other adhesives may be used.

In the pressurizing step, a hot pressurizing device for heating while pressurizing may be used instead of the cold pressurizing device 26. By doing so, the pressing time can be made relatively short even when an adhesive having a relatively small resin content is used.

Although not illustrated one by one, the present invention can be variously modified without departing from the spirit thereof.

[Brief description of drawings]

FIG. 1 is a view showing an example of a flash panel manufactured by a manufacturing method of the present invention with a core material and a decorative plate separated.

FIG. 2 is a diagram schematically showing a continuous flash bonding line for manufacturing the flash panel of FIG. 1, (a)
Is a view seen from above, and (b) is a view showing a bb section in (a).

[Explanation of symbols]

 10: Flash panel 12: Decorative board 14: Core material

Claims (1)

[Claims] 1. A heating step of heating at least one surface of a core material assembled in a frame shape, an applying step of applying an adhesive to one surface of the heated core material, and one surface to which the adhesive agent is applied. In a method of manufacturing a flash panel, which comprises a step of pressurizing and adhering a decorative plate, the step of heating the core material radiatively heats the core material using far infrared rays. Panel manufacturing method.