JPS58173656A - Continuous manufacture of foamed body packed panel - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for continuously manufacturing panels filled with a foam that exhibits almost no volumetric expansion after being discharged from a foaming machine.

Conventionally, foam-filled panels have been made using synthetic resins such as urethane, isocyanurate, urea, phenol, etc., and liquid foaming agents that turn into gas and expand in volume when heated or under reduced pressure, typically freon or butane. The panels filled with the body have excellent heat insulation and soundproofing properties, so they have been widely used in buildings, refrigerators, etc.

Since these panels are made by injecting the foam raw material into the panel and then foaming it, it is difficult to use an open method, so a method is used in which the material is injected into a nearly sealed panel.

With this method, the expansion ratio varies depending on the panel temperature, which tends to cause unfilled areas, and since the panel is almost sealed, it is difficult to discover unfilled areas, and it is difficult to repair them later. , resulting in incomplete filling, ie, insulation panels being produced with unfilled areas. For example, a method of injecting foam into a panel with a structure in which the interior of the panel is divided into squares by an inner frame as shown in Figure 2 is to inject foam into a panel with upper and lower panels adhered to the outer frame. The foam raw material is injected through the injection port, and is foamed and solidified. Alternatively, even if either the upper or lower surface materials are not bonded, a presser cover may be installed in place of the surface material, and the injection can be made from the injection port provided on the outer frame or the presser cover, but the foaming pressure It is necessary to press the top and bottom of the panel to prevent the panel surface material from blistering. In addition, it is necessary to provide a hole for air vent to remove this foaming pressure, and to provide a jig to prevent the foam from leaking back through the injection port after injection is completed. In addition, there are drawbacks that lead to a decrease in productivity, such as the need to provide cutouts of appropriate size and arrangement in the inner frame so that the cells are sequentially filled with the injected foam. Furthermore, since the spatial volume of these squares varies from panel to panel and even within a single panel, it is very difficult to control the injection amount and density of the foam, and unfilled portions are likely to occur. Moreover, it is impossible to check the foam filling state during the filling process because of the upper and lower surface materials or the holding lid, and if an unfilled area occurs, it is impossible or difficult to repair it, which is impractical. Difficult to use in production.

The present inventor has intensively studied a method of filling panels with foam that hardly expands in volume after being discharged from a foaming machine as a way to overcome the drawbacks of the conventional method. It is not possible to completely eliminate the disadvantages of low productivity, generation of defective panels, etc. In addition, for foams that do not expand in volume after being discharged from a foaming machine, it takes time to stabilize the foaming and obtain a foam with a constant density, and with intermittent injection, management is complicated and quality control such as density is difficult. Therefore, it is possible to solve the drawbacks of the conventional method by continuously producing one side of the panel by filling it with foam while one side of the panel is open, before the panel is closed. He discovered what could be done and completed the present invention.

That is, the present invention is a method for continuous production of foam-filled panels with improved productivity and high quality, and can be applied to foams with almost no volumetric expansion after being discharged from a foaming machine. This type uses air as a foaming agent and is usually manufactured by a mixing machine called a mechanical floss foaming machine or an Oaks type continuous mixer (Japanese Patent Application No. 138604/1986, Japanese Patent Publication No. 4
No. 0-17143), the foam main agent, curing agent, and air are mixed, the air is uniformly dispersed in the resin to form a foamed state, and the foam is discharged through a mechanical cloth foaming machine. It is like being formed.

In addition to the urea resin raw material, the foam main agent includes dust from resin raw materials such as phenol resin, and the hardening agent varies depending on the type of resin, but in the case of the urea resin raw material, acidic aqueous solution,
Examples include aqueous solutions of hydrochloric acid, sulfuric acid, cynic acid, oxalic acid, para-toluenesulfonic acid, salts thereof, and acid anhydrides.

The foam base agent or curing agent may also contain commonly used additives such as surfactants, foam stabilizers, and viscosity modifiers.

An example of such a foam base agent is to add 35 parts by weight of water and 2 parts by weight of sodium alkyl diphenyl ether disulfonate to 100 parts by weight of a urea resin initial condensate having a viscosity of 550 centiboise and a non-volatile content of 68%. There is a resin liquid with a 50 centimeter void.

This resin liquid and curing liquid were injected into the mechanical floss foaming machine (for example, Toho TM-302 model manufactured by Toho Kikai Kogyo ■) at a flow rate of 100,738 by weight, and compressed air was injected from the injection port to reduce the internal pressure. It is maintained at 3.5 to 4.5 Kp/cm2, and the rotor of the foaming machine rotates at a rotation speed of 450 rpm. The obtained foam-containing mixture is filled into a panel through a foaming machine discharge nozzle.

The foam-filled panels of the present invention are produced by continuous manufacturing. This process is shown and explained in FIG.

First, the panels l are arranged on the belt conveyor 2,
It is transported in the direction of arrow A. A panel lu is a wooden frame shown in Figure 2 with a panel pasted on one side of the bottom with adhesive and temporarily fixed with a stacker, etc. In order to be used for filling,
aligned on the belt. The panel 1 is then filled with foam discharged from the injection nozzle 4 of the foam injection device 3.

The foam is manufactured by a mechanical floss foaming machine (not shown) and reaches the injection nozzle 4. The discharge nozzle 4 is movable up and down and back and forth using an air cylinder 5 so that the inside of the panel 1 is not filled with foam. The positions of the inner frame 8 and outer frame 9 are detected by a photoelectric sensor, a riminotoschi, or the like. To achieve more complete filling, the conveying speed of the belt conveyor 2 may be varied. By using such a discharge nozzle 4, accurate injection is possible even if the shape of the panel changes.

The panel 1 is then treated by a surface treatment device 13 comprising a foam leveling belt 11 and a surface treatment brush 12. The foam is over-injected into the panel by about 105-115%, and to remove this excess foam, the panel is heated with an endless steel or plastic foam leveling bell (11) at a relatively slow speed, e.g. 1-3 m/min. Up arrow C
Run in the direction of (clockwise rotation). Foam leveling belt 1
It is desirable that the positional relationship between the panel 1 and the panel 1 satisfies the following requirements. That is, θ□-50 to 8 in Fig. 3
00°, preferably 60 to 70°; if it exceeds 80°, the foam cannot be discharged out of the frame smoothly, and if it is less than 50°, the device becomes large, which is not preferable. Also, θ in FIG.

=40 to 80°, preferably 50 to 70°, and 50
If the angle is less than 0, excess foam will not be smoothly scraped off, and if it exceeds 80 degrees, the foam will adhere to the return side 7 of the belt, especially the inside, causing operational troubles such as meandering of the belt. In order to avoid leaving any foam on the foam leveling belt, the foam leveling belt is sandwiched between a pair of plastic removal brushes 14 that rotate at high speed.

Next, for surface treatment, a plastic treatment brush 12 that rotates at high speed removes 1% of the foam from the panel surface.
Scrape to a depth of m and remove foam adhered to the top surface of the frame. This treatment step also has the effect of preventing deterioration of adhesiveness due to foam mixed into the adhesive when the lid is closed. The preferred specifications for the treated brush 12 are a brush core diameter of 60 to 80 mm.
MLφ, the flocking material is made of nylon or polypropylene, the diameter is 4 to 0.7 mφ, the length of the flocking material is 30 to 40%, and the peripheral speed of the brush is in the range of 200 to 800 m 7 minutes. Prior to the scraping process using a brush, a surface hardening device 16, such as a far-infrared lamp, is used to harden the surface of the foam to a depth of about 3 to 10111 mm to ensure smooth scraping.
A hot air knife or microwave generator may be placed on and passed through the panel. Further, the panel presser roll 17 stops the panel from moving up and down, and keeps the distance between the processing brush 12 and the panel l constant.

Note that it is desirable to install an excess foam recovery device 20 below the foam injection device 3 and the foam leveling belt 11.

The foam removed by the recovery device 20Fi foam leveling belt 11 and when adjusting the foam before starting injection, when cleaning between the nozzles from the foaming machine after stopping, or when the panel is temporarily not supplied. To efficiently collect foam. A schematic diagram of the device is shown in FIG. 5, and the upper part includes a water supply pipe 22 for discharging the foam 21 together with water;
The lower bottom surface has a water discharge part 23 made of all steel, for example, for discharging the supplied water. The foamed body 21 from which the supplied water 24 has been removed can be destroyed, for example, by using a high-speed stirrer or by being pressed with a press. Next, when the panel 1 is to be closed, an adhesive is applied to the upper part of the panel 1, a top cover is pasted, a post process 30 such as temporary fixing, pressing, etc. is carried out, and then the cover is closed. Note that the top material may be omitted depending on the use of the panel.

By using the above method, the filling state of the foam can be visually confirmed during production, so there is no unfilled part.
Continuous production of foam-filled panels of good quality was achieved in an extremely smooth and efficient manner.

[Brief explanation of the drawing]

Figure 1 is a process diagram of the continuous manufacturing method for foam-filled panels, Figure 2
The figure is a perspective view of the panel, Figure 3 is a plan view of the foam leveling belt, Figure 4 is a sectional view taken along line B-B in Figure 3, Figure 5 is a front view of the excess foam recovery device, and Figure 6. is a left side view of the surplus foam recovery device. 1...Panel, 2...Belt conveyor, 3...
... Foam injection device, 4... Injection nozzle, 5...
・Air cylinder, 7... Belt return side, 8.
... Middle frame, 9 ... Outer frame, 11 ... Foam leveling belt, 12 ... Treatment brush, 13 ... Surface treatment device, 14 ... Removal blanket, 16 ... Surface solidification device, 17 ... Presser roll, 20 ... Recovery device, 21 ... Foam, 22 ... Water supply device, 23
...Golden steel, 24...Water. Patent applicant Mitsui Toatsu Chemical Co., Ltd. Agent Patent attorney Masaru Inoue Figure 3 Figure 4 Figure 6rXj

Claims (1)

[Claims] 1. In a continuous manufacturing method for producing a foam-filled panel by injecting a foam with almost no volumetric expansion after injection into a conveyed open-lid panel, (1) a foam injection step; (2) a surface treatment step; and (3) a surplus foam recovery step. 2. The method for continuously manufacturing a foam-filled panel according to claim 1, wherein the foam injection step includes injecting the foam with a movable injection nozzle. 3. Claim 1, wherein the surface treatment step comprises a step of performing surface treatment with a foam leveling belt and a surface treatment brush.
A method for continuously manufacturing a foam-filled panel as described in Section 1. 4. The surplus foam recovery step includes the use of a device having a water supply pipe for discharging the foam at the upper part and a discharge part for discharging the water supplied to the lower floor surface. Continuous manufacturing method for foam-filled panels. 5. The foam leveling belt is 60~
Has an angle of 7o0 and 50 to 70 degrees to the horizontal direction
Claim 3 is inclined at an angle of
A method for continuously manufacturing a foam-filled panel as described in Section 1. 6. The surface treatment brush has a core diameter of 60~SOWφ, the thickness of the flocked material is 0.4~0.7Wφ, and the length of the flocked material is 30~4.
0 m, and the brush has an outer peripheral speed of 200 to 80
The foam-filled panel according to claim 3, which rotates at 0 m/min to scrape the foam from the smoothed surface to a depth of 1 to 4 ft, and remove the foam from the panel frame surface. Continuous manufacturing method.