JPH09277368A - Compression molding of matting sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To form a matting sheet mainly composed of fibrous materials into an accurate uneven shape copying a folded plate roof sheeting by hot-press molding. SOLUTION: A matting sheet 3 is placed on the lower mold 8 among upper and lower clamp molds and the corresponding region of the matting sheet 3 is pressed against the trough part 8a1 positioned at the almost central part of the lower mold 8 by the pressing member 6d1 of a press device 6 and subsequently pressed against the alternately and successively adjacent trough parts 8a2 -8a4 of the lower and mold 8 so as to be distributed left and right. Thereafter, the press device 6 is allowed to retreat and the upper and lower clamp molds are closed to subject the plate-shaped mat material 3 to hot-press molding so as to have a predetermined shape.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for compression-molding a plate-shaped mat material into a predetermined uneven shape.

[0002]

2. Description of the Related Art In recent years, there are many cases in which a folded metal roof material having a shape in which a plurality of peaks and valleys extend in parallel is used for a roof of a warehouse or a factory. Further, glass wool or rock wool is used as the roof material. A matte material such as this is attached for heat insulation. Since these mat materials are provided in the shape of a plate or a roll, refer to FIG. 1. In order to fit the roof material 1 exactly, the mat material is formed into a predetermined shape in advance or shown in FIG. As described above, it is necessary to provide the plate-like mat member 30 with the groove 31 having a V-shaped cross section and perform bending.

[0003]

However, since it is difficult to mold the air layer of the fibrous mat material while keeping it at a predetermined bulk density without crushing it, refer to FIG.
Adhesion of the heat insulating member 20 to the roof material 1 is poor, and a large gap S remains in the corner portion on the pushing side of the roof material 1. Further, the mat member is usually provided with the non-woven fabrics 21 on both sides, but the portion corresponding to the corner portion 1a is easily broken especially at the time of molding. These significantly reduced the dew condensation prevention performance. In addition, if the plate-shaped mat member 30 is cut into a V-shaped cross section to form a fold, there is a problem that the number of steps and the cost are too high. Therefore, an object of the present invention is to compression-mold a plate-shaped mat material into an accurate uneven shape, for example, following a folded-plate roof material.

[0004]

In order to solve the above problems, the following compression molding method was created. That is, the invention of claim 1 is a method of compression-molding a plate-shaped mat member into a concavo-convex shape having a plurality of peaks and troughs, wherein the plate-shaped mat member is placed on a lower die of a vertical pressing mold. The corresponding part of the plate-shaped mat material is pressed to one of the plurality of valleys of the lower mold by the pressing member, and then the corresponding part of the plate-shaped mat material is sequentially pressed to the adjacent valleys, and then the pressing member. And then the upper and lower pressing dies are closed to compression-mold the plate-shaped mat member into a predetermined shape.

In the above compression molding method, before closing the upper and lower pressing molds, first, the corresponding portion of the plate-shaped mat member is pressed against one of the plurality of valleys of the lower mold, and subsequently the adjacent valleys are successively pressed. Pressing against the part is added. That is, the plate-shaped mat member has a shape in which the side edge portions are pulled by hand in advance so that the plate-shaped mat member can freely follow the mold surface without being excessively pulled, and thus has good moldability during compression molding.

Further, the invention of claim 2 is a method of compression-molding a plate-like mat material, which is a material mainly composed of a fibrous material and a thermosetting resin, into an uneven shape having a plurality of peaks and valleys. Then, the plate-shaped mat material is placed on the lower mold of the vertical pressing mold, and the pressing member presses the corresponding portion of the plate-shaped mat material to one of the plurality of valley parts of the lower mold, Corresponding parts of the plate-shaped mat material are sequentially pressed to adjacent valley parts, and the corresponding parts of the plate-shaped mat material are pressed to the heated lower mold by the pressing member against a plurality of valley parts of the lower mold. The plate-like mat material is heated to a predetermined shape by retracting the pressing member when the portion of the plate-like mat material near the contact surface with the lower die is substantially cured. It is characterized by being pressure molded.

In the above compression molding method, the plate-shaped mat member is pressed against the valley of the lower mold by the pressing member and the contact surface with the lower mold is heated so that the surface hardened layer has an accurate shape following the mold surface. Is formed. Then, if the pressing member is removed, the elasticity of the uncured portion on the back side of the plate-shaped mat member is restored, so that the vertical pressing mold can be closed and the entire plate-shaped mat member can be thermocompressed into a predetermined shape.

According to a third aspect of the present invention, in the compression molding method for a plate-shaped mat member according to the second aspect, a thermosetting resin layer is formed in advance on the plate-shaped mat member on the surface in contact with the lower mold. It is characterized by being.

Therefore, by setting the above-mentioned thermosetting resin layer, it is possible to appropriately select the thickness and the curing time of the surface-cured layer formed on the plate-shaped mat member when heated by the lower mold. In this way, since the surface-hardened layer is first formed in a shape following the lower mold, thereafter, it is easy to thermoform the entire plate-shaped mat member into a shape having a predetermined bulk density by closing the upper and lower pressing molds. it can.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view showing an example of a folded plate roofing material. In the figure, the roof material 1 is made of metal such as steel plate,
The heat insulating member 2 is attached to the back surface of the roof material 1 when it is bent into a substantially wave shape (for example, the mountain height is 100 mm) and heat insulation is performed. As shown in FIG. 2, the material of the heat insulating member 2 is formed by adhering a nonwoven fabric 3b to both surfaces of a material 3a in which a phenol resin which is a thermosetting resin is mixed in an appropriate amount in a fibrous material such as glass wool or rock wool. It is a plate-shaped mat material (hereinafter, simply referred to as "mat material") 3, and in this example, the thickness of the mat material 3 is about 50 mm. The mat member 3 is generally distributed in the form of a roll.

Next, a method of thermocompressing the mat member 3 into an uneven shape following the roof member 1 will be described. FIG. 3 is a sectional view showing the outline of the thermocompression molding device, and FIG. 4 is a perspective view of the pressing device. As shown in FIG. 3, the thermocompression molding device 5
Comprises a vertical pressing mold having a heating means and a pressing device 6,
The vertical pressing mold has an upper mold 7 and a lower mold 8 which are formed to correspond to the shape of the roof material 1. Further, when the upper die 7 and the lower die 8 are in a separated state, the pressing device 6 is arranged at an intermediate position of the upper and lower pressing dies so as to be movable back and forth. The pressing device 6, as shown in FIG. 4, it is vertically a plurality of cylinders 6b (6b ₁ ~6b ₄₎ to the movable frame 6a, the pressing member via a connector 6c of the rod knuckle of each cylinder 6b supporting the vicinity of both ends 6d (6d ₁ ~6d _4).
Then, the movable frame 6a is moved laterally from an intermediate position between the upper die 7 and the lower die 8 via a moving means (not shown) so that it can be retracted from the vertical pressing die.
Each cylinder 6b is connected to an air pump via an electromagnetic valve (not shown) and is configured to operate at a predetermined timing.

When manufacturing the heat insulating member 2, the thick plate-shaped mat member 3 is placed on the lower mold 8 of the thermocompression molding apparatus 5,
Causing the pressing device 6 in the retracted position activates the cylinder 6b ₁ ~6b ₄ in a state of being positioned by moving upward of the lower die 8 in a predetermined order. That is, as shown in FIG. 5A, first, the pressing member 6d ₁ is lowered to the valley portion 8a ₁ located substantially at the center among the plurality of valley portions 8a of the lower die 8 and the valley portion 8a ₁ Then, the corresponding portion of the mat member 3 is pushed in. Next, see FIG. 8B, the valley 8a ₂ adjacent to the valley 8a _1.
The corresponding portion of the mat member 3 is pushed in with respect to each other, and thereafter, the valley portions 8a that are adjacent to each other are alternately arranged so as to be distributed right and left.
Press the corresponding part of the mat member 3 onto ₃ , 8a ₄ . The state in which all the pressing members 6d are lowered is shown in FIG. 11C, and in the same figure, ~ indicates the order of pressing.

As described above, the mat member 3 has a shape in which the left and right side edges are pulled toward the center and follows the mold surface of the lower mold 8, so that the pressing device 6 is pressed after a certain pressing time. The lower mold 8 and the upper mold 7 as shown in FIG.
And are closed and the mat member 3 is heated to cure the phenol resin at about 200 ° C. That is, in this example, the pressing force and the pressing time of the pressing member 6d can be arbitrarily set separately from the mold clamping pressure and the heating time, and moreover, the mat member 3 is directed to the central portion of the lower mold 8 in advance. It can be placed along the pulling surface. Therefore, even if the vertical pressing mold is closed at a stretch, it is possible to prevent a molding defect in which the nonwoven fabric 3b is pulled by the corner portion of the mold surface and cracks as in the conventional case, and the heat insulating member 2 is made of the material 3a. It is possible to form an accurate uneven shape following the roof material 1 with a predetermined bulk density without damaging the air layer.

It is also possible to change the pressing order indicated by-in FIG. For example, and can be operated simultaneously to shorten the working time, or the pressing member 6d in the order of →→→ or vice versa.
Can be lowered to facilitate the positioning of the pressing start end of the mat member 3.

Next, another embodiment different from the above will be described. In this embodiment, a step of heating one surface of the mat member 3 with only the lower mold 8 is added before the upper and lower pressing molds are closed in the thermocompression molding of the heat insulating member.
That is, in the state of FIG. 5C in which the mat member 3 is pressed against the lower mold 8 by the pressing device 6, the lower mold 8 is heated and the phenol resin in the vicinity of the contact surface with the lower mold 8 of the mat member 3 is heated. Is cured to form the surface-hardened layer 3c (see FIG. 7). At this time, the heating / pressing time is set to a relatively short time (10 to 15 seconds in this example) so that the semi-cured state in which the elasticity of the entire mat material is not lost can be maintained. The lower mold 8 is usually preheated by a heating means.

Therefore, in this example, the mat member 3 is pressed against the valley portion of the lower mold by the pressing member 6d with a sufficient pressing force, and the contact surface with the lower mold 8 is heated to accurately follow the mold surface. The surface hardened layer 3c having a different shape is formed. After that, if the pressing member 6d is removed, the elasticity of the mat member 3 is restored on the back side and the mat member 3 swells, and as shown in FIG. 6, the upper and lower pressing molds can be closed and the whole can be easily thermocompressed into a predetermined shape. . Depending on the case, it is possible to omit the final thermocompression molding by the vertical pressing mold and finish the molding of the mat member 3 only by thermocompression molding using the pressing device 6. In that case, since the upper mold 7 is not required, the thermocompression molding device and process can be simplified.

In the above example, the thermosetting material (phenol resin) mixed in the material 3a is divided into two stages (substantially two layers of the surface-hardened layer and the remaining portion) to be cured. As shown in FIG. 8, the thermosetting resin layer 3d may be previously formed on one surface (lower mold contact surface) of the mat member 3 '. That is, by appropriately forming the thermosetting resin layer 3d, the thickness and the curing time of the surface-cured layer formed when the lower mold 8 is heated can be set easily and reliably.

In the above-mentioned example, it is possible to omit the final thermocompression molding by the vertical pressing mold and finish the molding of the mat member 3 only by thermocompression molding using the pressing device 6.
In that case, since the upper mold 7 is not required, the thermocompression molding device and process can be simplified. Further, the material 3a to be subjected to thermocompression molding may be mainly composed of felt or synthetic fiber in addition to glass wool and rock wool.

[0019]

As described above, according to the present invention,
Since the plate-shaped mat material can be compression-molded into an accurate uneven shape, for example, following a folded-plate roof material, there is an effect that the effect of preventing dew condensation on the roof to which this is attached can be enhanced.

According to the first aspect of the present invention, the plate-shaped mat member placed on the lower mold is sequentially drawn by the pressing member along the mold surface before closing the upper and lower pressing molds. Good nature.

According to the second aspect of the present invention, since the plate-shaped mat member is pressed to form a surface-hardened layer having an accurate shape following the mold surface of the lower mold, after the pressing member is retracted, the upper and lower parts are moved up and down. The pressing die can be closed and the entire plate-shaped mat material can be easily thermoformed into a predetermined shape.

According to the third aspect of the invention, the thickness and the curing time of the surface-cured layer formed on the plate-shaped mat material when heated by the lower mold are appropriately selected by setting the thermosetting resin layer. After that, the upper and lower pressing dies are closed, and the entire plate-shaped mat member can be easily thermocompressed into a shape having a predetermined bulk density.

[Brief description of drawings]

FIG. 1 is a perspective view showing a folded plate roofing material.

FIG. 2 is a cross-sectional view showing a plate-shaped mat member.

FIG. 3 is a diagram illustrating a pressing device according to an embodiment.

FIG. 4 is a perspective view showing a main part of a pressing device.

FIG. 5 is a diagram illustrating a step of pressing a plate-shaped mat member against a lower mold.

FIG. 6 is a diagram illustrating a state in which a heat insulating member is thermocompression molded.

FIG. 7 is a cross-sectional view illustrating a state in which a surface hardened layer is formed on a plate-shaped mat member.

FIG. 8 is a cross-sectional view illustrating a plate-shaped mat member according to another embodiment.

FIG. 9 is a cross-sectional view illustrating groove processing of a conventional heat insulating material.

FIG. 10 is a diagram illustrating a state in which a conventional heat insulating material is attached to a folded plate roof material.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 roofing material 2 heat insulation member 3 mat material (plate-like mat material) 3a material 3b non-woven fabric 5 thermocompression molding device 6 pressing device 6b (6b _{1 to} 6b ₄ ) cylinder 6d (6d _{1 to} 6d ₄ ) pressing member 7 upper mold 8a (8a ₁ ~8a ₄₎ troughs 8 lower mold

Claims (3)

[Claims] 1. A method for compression-molding a plate-shaped mat member into a concavo-convex shape having a plurality of peaks and troughs, wherein the plate-shaped mat member is placed on a lower die of a vertical pressing mold and is pressed by a pressing member. The corresponding portion of the plate-shaped mat material was pressed to one of the plurality of valleys of the lower mold, and then the corresponding portion of the plate-shaped mat material was sequentially pressed to the adjacent valleys, and then the pressing member was retracted. A method for compression-molding a plate-shaped mat member, characterized in that the upper and lower pressing molds are closed and the plate-shaped mat member is compression-molded into a predetermined shape. 2. A method of compression-molding a plate-shaped mat material, which is a material mainly composed of a fibrous material, into which a thermosetting resin is mixed, into an uneven shape having a plurality of peaks and valleys, wherein the plate-shaped mat The material is placed on the lower mold of the vertical pressing mold, and the pressing member presses the corresponding portion of the plate-shaped mat material to one of the plurality of valleys of the lower mold, and subsequently to the adjacent valleys. The corresponding portion of the plate-shaped mat material is pressed, and the pressing member maintains each corresponding portion of the plate-shaped mat material pressed against the heated lower mold against the plurality of valleys of the lower mold. When the portion of the sheet-shaped mat member near the contact surface with the lower die is substantially hardened, the pressing member is retracted, and then the vertical pressing die is closed to thermoform the plate-shaped mat member into a predetermined shape. A method for compression-molding a plate-shaped mat material. 3. The compression molding method for a plate-shaped mat member according to claim 2, wherein a thermosetting resin layer is previously formed on a surface of the plate-shaped mat member that contacts the lower mold.