JPS5811121A - Manufacture for piled plate such as shutter - Google Patents

Abstract

PURPOSE:To produce a piled plate such as shutter having reinforced connecting portion as one body and good heat-insulation properties by carrying out full connection between metal parts of surface members and foamed material of inner insulation members with foaming of foam-raw material simultaneously. CONSTITUTION:Many foaming particles (a) composed of thermoplastic resin containing main by styrene-absolute maleic acid (absolute maleic acid 2-25wt% is desirable) Co-polymer have been inserted between the surface plate 10, 10' made of metal. A pear of opposite sids of piled plates is covered with metal profile 70 into which steam may be injected. Two surface plates are heated and simultaneously steam is injected into the foam particles. Said foaming particles (a) are expanded by heating, and thermally welded one another, thereby producing foamed material. Simultaneously foamed material is caused to adhere to the surface member 10, 10' and the metal propile 70 as one body, and thus objective piled plate is obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing laminates for rain shutters, etc., and more specifically, a metal part such as a surface material and a foam material serving as an internal heat insulating material are integrally joined together at the same time as molding the foam material. This is a manufacturing method that greatly strengthens the integrity of the joint and provides excellent heat insulation.

Conventionally, for laminates such as shutters that have a surface material using metal plates made of aluminum or other materials, we provide a product with an insulation board interposed between the two surface materials for the purpose of heat insulation etc. However, once the insulation material has been formed on the board, it is difficult to adhere sufficiently to the metal surface material, and the bonding process is troublesome, so recently manufacturing methods have been developed that involve injecting foamed polyurethane between the surface materials. A method is proposed. However, in the case of foamed polyurethane injection, the skin layer of the foamed polyurethane is seamlessly bonded to the surface material, and the manufacturing method tends to create large voids due to air pockets during filling.In addition, it is brittle after curing, which causes vibrations when opening and closing the shutters. It is easy for the metal surface material to be partially chipped and fall off, creating a large void in that part, which reduces the insulation effect and weakens it. However, there was a drawback that the large warp easily caused trouble in closing the shutters.

Further, in the case of the foamed polyurethane injection described above, a sufficient degree of bonding between the surface material and the heat insulating material was not achieved because the surface material was made of metal.

Therefore, in the present invention, we have invented a manufacturing method that can eliminate the drawbacks of the above-mentioned prior art, and in the first invention method, at least the side to be joined is made of two surface materials made of metal plates. A large number of foamed particles made of styrene-maleic anhydride copolymer or a blend of this and other thermoplastic resins are interposed between them, and the two surface materials are heated and steam is injected into the foamed particles. The foamed particles are heated to expand the foamed particles to form a foamed body that is heat-sealed to each other, and at the same time, the foamed body is integrally joined with a facing material to obtain a laminate. In the method of manufacturing a laminate, the foamed particles are interposed between the facing materials, and at least one pair of opposing sides of the peripheral portion of the portion can be injected with steam. In this manufacturing method, the foam is covered with a metal profile, and when the foam is integrally joined to the surface material, this metal profile is also bonded at the same time.

Next, embodiments of the first invention method will be illustrated below with reference to the drawings.

First, in the case shown in Fig. 1, one surface material (10) made of aluminum, steel plate, or other metal is placed on a mold having a steam chamber (31), and a steam chamber (41) is placed around it. and a steam injection hole (42), surrounded by an enclosed mold (41).

Next, on the surface material (10), 2 to 2
A large number of styrene-maleic anhydride copolymers composed of 5% by weight and 98 to 75% by weight of styrene, or blends of maleic anhydride copolymers and other thermoplastic resins (e.g. polybutadiene, etc.) as above. After that, the other surface material (10) is placed on the foamed particles (a), and a mold opening having a steam chamber (51) is placed on the mold to close the mold. (10) [0]
'The foamed particles (a) are sandwiched between the two. Next, the steam chamber (31) of the mold (30) (50)
) (Surface material (IQI) that breaks metal by supplying steam to 5υ
indirect heating through heating of no.
The foamed particles (a) are heated by direct steam heating from the steam injection hole (c) of ci, and the foamed particles (a) are heated and expanded to form a foamed product ( company)
At the same time as forming the foam (support)), the surface material (lot
(The laminated plate fl as shown in Figure 2 is integrally joined with tof)
will be provided. After molding, cooling and mold release are performed in the same manner as in normal foam molding.

In addition, in the case shown in Fig. 6, the surface material +101 (101') consisting of two metal plates is made in advance with an appropriate interval between them suitable for the thickness of the foam to be molded, and the mold (30 ) +40) Next, as in the case of FIG. 1, the expanded particles (a) are placed on the surface material 110)
)' and direct steam heating from the steam injection hole α force to thermally expand the foamed particles (a) and thermally fuse them together.
At the same time as forming the foam, the surface material (lot (lot
It is sufficient if it is integrally joined with t.

In addition, regarding the above manufacturing, the surface material Qol (molding mold used to sandwich 101 + 30) (50),
Although the case where the steam chamber H (5υ) is shown as an example, the surface material (l
Any device having a heating means other than steam, such as one equipped with a heater, can be used as long as it can heat ot (+o).

By the way, in practice, the surface material made of metal plate (101 (10)
In addition to using a metal veneer, there may also be a laminated surface material that has a metal plate on the side to be bonded to the foam and a synthetic resin on the other side. In addition, as for its specific shape, in addition to being flat, one or both of the surface materials (lO) (lO) may be corrugated (as illustrated in Figure 4), or it may be easy to fit the metal profile +61. In the case of a ribbed shape (as illustrated in FIG. 5), various implementations are possible. And the overall shape is 90X for shutters etc.
180 (=-) and the thickness of the foam example is approximately 26R, but the application is not limited to square, and may be of other shapes, and may be of various sizes; in the case of rain shutters. For this purpose, a frame-shaped metal profile such as aluminum sash may be attached to the above-produced laminate using screws or other means to complete the shutter.

In carrying out the first invention method described above, when the steam chamber f41) of the mold as shown in FIG. 3 is divided into four independent chambers (411X41□X413X414) as schematically shown in FIG. As an example of surface material (lot (
The tof is made of vinyl chloride laminated type steel plate, and the space between the upper and lower surface materials +101 ++of' is filled with pre-foamed 25 f/l foamed particles made of styrene-maleic anhydride copolymer. do. Then, steam was introduced into four independent steam chambers (41□) to (414) of the mold and blown for 10 seconds. At this time, each steam room (
41□) The drain valve (not shown) of the machine 414) is open. Next, steam was introduced into the steam chambers (41□) (413), and the introduction of steam into the steam chambers (412) (414) was stopped. Regarding the drain valve at this time, the steam chamber (41□X413) is closed and the steam chamber (41□X413) is closed.
4) was opened and heated for about 20 seconds at a steam chamber pressure of 0.5 Kg/cd. Next, steam was introduced into the steam chamber ■ρ■4), and conversely, the introduction of steam into the steam chamber (41,) (413) was stopped. At this time, regarding the drain valve, check the steam chamber (
41□X414) is closed and the steam room (4],) (41
3) was opened and heated for about 20 seconds at a steam chamber pressure of 0.5 Kg/m. Finally, all the steam rooms (41,) to (4
14) Introduce steam to 0.0 and close all drain valves.
Main heating was performed for about 60 seconds at a steam chamber pressure of 7 Kg/cd.

In addition, during the period from the start of blowing to the end of main heating, steam was also introduced into the steam chamber (5o) that performs indirect heating on the upper and lower sides.
The steam pressure is maintained at 0.8 Kg/m. At night when the main heating is completed, the upper and lower steam chambers (1 paulownia) are heated, and the cooling water is introduced for about 2 hours.
After cooling for a minute, each mold was opened and the product was taken out, and the foam (-) was bonded between the upper and lower PVC steel plate surface materials (UO+UCII) to provide a laminate that became an integrated heat insulating panel. Ta.

In addition to the above-mentioned embodiments, the steam chamber (40) may be divided into two parts or various other methods may be possible.

Next, an embodiment of the second invention method will be illustrated with reference to FIG. 7 and subsequent figures.

First, a surface material 101 made of two metal plates is prepared in advance.
i is the thickness of the foam to be molded between them, j: 'j L, and the mold is set with an appropriate spacing between the molds (with a width of 1η), and the four circumferences are placed in a mold with a steam injection hole q2. A mold (8o) is set in a surrounding manner so that a steam chamber ff11 is formed between the outer periphery of the metal mold material V and the surface of the metal mold material. put.

And between the surface material (lot tlof there is a filling port (!10
) is filled with a large number of expanded particles (a) made of a styrene-maleic anhydride copolymer or a blend of this and other thermoplastic resins, and then molded into a mold (30). Steam chamber (3+1 (511 to indirect heating through metal surface material (+of)
The foamed particles (a) are heated and expanded by direct steam heating from the steam injection hole of the metal mold material ffO+ to form a foamed body (b) which is thermally fused to each other.
20) to the surface material (lot (+of) and metal shape material Q (
2) and are integrally joined to form a laminate plate as shown in Fig. 8.
will be provided.

Regarding the filling port (90) for filling the foamed particles (a), there are cases in which it is removed after filling, and cases in which the filling port 0 (2) is embedded in the foam 120). In the latter case, if it is connected to the metal profile (7o), it will be difficult to remove, and as shown in FIG. 9, the shape can further strengthen the sense of unity with the foam 120).

In addition, regarding the steam chamber 1) on the side of the metal mold material (to) around the part where the foamed particles (a) are interposed between the surface materials uo+t+of, the mold (4) in the first invention method was used.
If the steam chamber Kl) of 0) is divided into an appropriate number of throats, steam can be introduced in the same way as in the previous embodiment, and compared to the method of the first invention, it is possible to provide a laminate fi+ with the metal profile (3) added. .

Furthermore, when using only one set of side parts facing each other, the other set of side parts are molded with the steam chamber (41) and steam injection hole (42) shown in the embodiment of the first invention method. Type (40
) can be used, and the manufactured laminate plate is one in which only one set of opposing sides is covered with metal profile (see FIG. 10). In this case, after manufacturing the laminate (1), arbitrary metal shapes may be attached to the side portions of other sets by screwing, adhering, or other means.

In addition, as for the shape of the laminate according to the second invention method, the surface material (101 (ldl) made of aluminum or other appropriate metal as in the first invention method may be flat, or one or both surface materials + 101 nor may be wavy). Alternatively, various methods are possible, such as a metal shape (a ribbed shape that makes it easy to fit around the top).

According to the first invention method among the above manufacturing methods of the present invention,
Foamed particles are interposed between two surface materials whose surfaces are at least made of metal plates, and the two surface materials are heated and the heating is performed by injecting steam into the foamed particles. The foamed particles are heated by the indirect heating and the direct heating by the steam injection, and the heated expanded particles are made of styrene-maleic anhydride copolymer or other thermoplastic material. Because it is a blended product with resin and contains maleic acid, which has polarity, it has very high bonding properties with the surface material made of metal plates, and the foamed particles can be bonded to each other by heating and expanding without using an adhesive. The surface material is bonded together at the same time as the heat fusion, and the bond is strong and easy to manufacture. Therefore, the foam - may peel off from the surface material t101 +101',
This eliminates the drawbacks of conventional products, such as partial rosette chips falling off due to vibrations caused by opening and closing during use as a rain door, etc.

In addition, the laminate manufactured as described above includes a surface material LIOI (+o)' and a foam (2) made of the above-mentioned specific material.
Even after secondary foaming, there are small gaps between the particles between the bonded parts with 0), and the surface material is not bonded to the surface material over the entire surface. The expansion due to the thermal influence of the surface material (lot 1101') made of a plate can be released only in the surface material portion in the gap where the foam is not joined, and the overall effect is due to the difference in thermal expansion coefficient with the foam (3). This has the effect of preventing warping.

Furthermore, foams made of styrene-maleic anhydride copolymer or blends of this and other thermoplastic resins are very suitable for increasing heat resistance, and when the laminate is used as a shutter, it can be used in the summer or during heating. Even when the heat is transferred, thermal deformation does not occur and a good heat insulating effect is achieved. Therefore, even if you are in the middle of summer, the indoor cooling effect will not be lost, and in the middle of winter,
Even in this case, it is possible to provide a laminate for storm doors that has excellent heat retention without escaping the indoor heating effect.

Furthermore, among the manufacturing methods of the present invention described above, according to the second invention method 1, foamed particles are interposed between two surface materials, and at least one set of opposing sides of the surrounding area of the portion is made of metal. Because of the method of joining this metal mold material (70) with the surface material +10+ (+of) and the foam material (-) by adding several molds, it is possible to strongly join the metal mold material (70) with the foam material (-). This has the effect of omitting (in the case of integrating the entire periphery) or reducing (in the case of partially integrating the periphery) the need for retrofitting metal molds, making it easier to manufacture laminated panels such as rain shutters. This can further contribute to improving efficiency.

In addition to the above-mentioned shutters, the objects obtained by the methods of the first and second inventions include ceiling materials and wall materials for unit baths, face plates for tables and home kotara,
It is widely used in a variety of applications such as signboards, advertising boards, blackboards, doors, and partitions, and is highly effective.

[Brief explanation of the drawing]

The figures illustrate an embodiment according to the present invention, in which Figure 1 is a cross-sectional view showing the manufacturing process of the first invention method, Figure 2 is a perspective view of the manufactured laminate, and Figure 6 is a modified example. cross-sectional view, 4th
5 and 5 are cross-sectional views of laminates manufactured in several modified examples, FIG. 6 is a schematic plan view for explaining an example of steam injection during manufacturing, and FIG. 7 is a second method of the invention. FIG. 8 is a perspective view of the manufactured laminate, and FIG. 9 is a cross-sectional view showing the manufacturing process.
The figure is a partial sectional view of a modified example, and FIG. 10 is a perspective view of a J-shaped plate manufactured in a further modified example. fl) I+)'t+f'-=entire laminate, ill
(fi11'''・Surface material, (a)--foamed particles, (
20)...Foam, (engraved (40) (fill)...
・Molding mold, (311f4J) (511... steam chamber,
(42)...Steam injection hole, 4...Metal mold 1, (71
)...Steam room, ff2...Steam injection hole, (80)・
・Molding mold. Patent applicant Sekisui Plastics Co., Ltd. Figure 1' Figure 2 Figure 3 Figure 4 Figure 10' Figure 7 8 Figure 1' Figure 9 Figure 10

Claims (1)

[Claims] 1. A large number of foamed particles made of a styrene-maleic anhydride copolymer or a blend of this and other thermoplastic resin are placed between two surface materials whose surfaces are made of metal plates at least on the side to be joined. The two surface materials are heated, and the foamed particles are heated by injecting steam to heat and expand the foamed particles to form a foamed body that is thermally fused to each other. A method for producing a laminate for storm shutters, etc., characterized in that the laminate is obtained by integrally bonding the laminate with a surface material. 2. The two surface materials are sandwiched and heated in a mold having a steam chamber or other heating means, and the area around the area where the foamed particles are interposed between the two surface materials is heated by steam injection into the foamed particles. A lamination of a rain shutter or the like according to claim 1, wherein the foamed particles are heated by indirect heating through the surface material and direct heating by steam injection from the surroundings. Method of manufacturing the board. 6. Foamed particles of styrene-maleic anhydride copolymer containing 2 to 25% by weight of maleic anhydride and styrene 98
A method for producing a laminate for a rain door or the like according to claim 1, using a laminate formed with a content of 75% by weight. 4. The shutter according to claim 1, comprising foamed particles containing 2 to 25% by weight of maleic anhydride as a blend product of styrene-maleic anhydride copolymer and other thermoplastic resin. A method of manufacturing a laminate such as 5. A method for manufacturing a laminated board for a rain door or the like according to claim 1, wherein a corrugated plate is used as one of the two surface materials made of metal plates. 6. A large number of foamed particles made of a styrene-maleic anhydride copolymer or a blend of this and other thermoplastic resin are interposed between two surface materials whose surfaces are made of metal plates at least on the side to be joined, In addition, at least one set of opposing sides of the peripheral portion is covered with a metal shape material into which steam can be injected, and the two surface materials are heated and the foamed particles are heated by steam injection, and the foamed particles are heated. Manufacture of a laminate for rain shutters, etc., characterized by heating and expanding particles to form a foam that is heat-sealed to each other, and simultaneously bonding the foam to a surface material and a metal shape to obtain a laminate. Method. 7. The two surface materials are sandwiched and heated in a mold having a steam chamber or other heating means, and the area where the foamed particles are interposed between the two surface materials is surrounded by only the metal mold material or The foamed particles are surrounded by a mold that can be injected with steam, and the foamed particles are heated by indirect heating through the surface material and direct heating by steam injection from the surroundings.
Method for manufacturing laminates for shutters, etc., as described in Section 1.