JPS5910906B2 - Foam-filled composite board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a composite board in which an elastic panel is filled with a foam.

Generally, when a base material having elasticity such as a metal plate is molded, oil circles as shown in FIG. 1 often appear on a wide flat decorative surface due to its physical properties.

Note that it may appear that there is none visually. However, theoretically, this always exists due to the molding process. That is, when a metal plate is bent, residual stress accumulates due to local elongation or contraction, which causes the bending. Therefore, the more severe the bending process, the more cracks will occur in such places, which has the disadvantage of seriously damaging the appearance of the decorative surface of the composite board. Moreover, this Pekotsuki phenomenon is
If the width of the decorative surface of the panel is narrow, for example about 150 mm or less, it will be suppressed by the rigidity of the base material and will not be very noticeable, but if it is about 180 mm or more, for example, the protrusions of the pekotsuki will appear greatly enlarged. For example, in a composite board with a decorative surface of 400 mm, the problem may appear as shown in FIG. As a countermeasure against this, filling the panel with a core material of a molded body is carried out.
However, when the molded body is filled, the core material is not tightly filled in all the recesses of the panel, so it is still difficult to visually eliminate the cracks. In particular, core materials such as synthetic resin foams have the disadvantage of lacking rigidity. In order to eliminate these drawbacks, the present invention provides structural improvements to the wide panel, and also prevents the formation of voids in the recesses of the panel, especially on the back side of the decorative surface, so that the cracks do not appear on the decorative surface. In addition, the present invention proposes a foam-containing composite board in which the foam raw material is supplied so as to be closely integrated with the surface of the material, so that it appears as if the pekotsuki has been visually removed from the decorative surface. Note that structurally speaking, 20 involves forming a panel by extremely bending (plastic deforming) an elastic base material;
Elongation and residual stress are concentrated in the bent portion. As a result of this elongation and residual stress escaping, the material is distorted radially from that point as a starting point, and a so-called "pekotsuki" extends in the direction of unstable internal stress to form a convex portion at the extreme end. However, on the sides and bent parts of the panel 25, the plastic deformation of the base material is complete, and work hardening and short span elements are added, so no distortion appears to the extent that it is visible, and it appears that there is no distortion from the outside. . However, since the decorative surface has no work hardening and no residual stress, and the 30 span is long, strain will immediately occur in this direction. Therefore, in consideration of this, we formed a rigid and short convex part in the area where large distortion appears, and made the starting point area of Pekotsuki flat.As a result, the terminal part of Pekotsuki is on the decorative surface, and The present invention provides a foam-containing composite board that eliminates this by the foaming pressure of the foam. DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a foam-containing composite plate according to the present invention will be described in detail below with reference to the drawings.

Figure 2 shows a longitudinal cross-sectional view of a foam-filled composite board (hereinafter simply referred to as a composite board), in which 1 is a panel formed from an elastic base material, such as a metal plate, into a concave shape, and 2 is a decorative surface. That is, it is the flat back surface (outer surface) of the concave bottom surface, and at least one end (both ends in the figure) thereof is formed with band-like protrusions 3 and 4 parallel to the panel edge. The convex portions 3 and 4 serve as fixed ends (fulcrums) of the decorative surface 2a, which is elastically deformed by a slight external force such as the foaming pressure of a foam, which will be described later, only during the manufacture of the composite board. Further, the convex portions 3 and 4 are formed to have a width and a height that are rigid enough not to deform much even when the decorative surface 2a is deformed. To give a specific example, in a surface-treated steel plate with a thickness of 0.3, the width (L) - 360 m
In the case of m, l = 60 degrees, thickness T = 15 degrees, t = 0.
It is about 5 to 2 degrees. In this case, the ends of the convex parts 3 and 4 and the decorative surface 2
The boundary a can be shaped into a letter, an L-shape, or any variation thereof during panel formation. 5 is an insertion piece that protrudes outward from the other side edge, and 6 is a female type connecting part formed by bending the other side edge once inward and then bending it outward again. It is formed from an engaging groove 7 having a U-shaped cross section and a protruding piece 8 whose end edge protrudes outward.

Reference numeral 9 fills the recess with a foam/insulating material (hereinafter simply referred to as foam), which is made of, for example, one of synthetic resin foam and inorganic foam. Examples of the synthetic resin foam include polyurethane foam and polyisocyanurate. These foams include foam, phenol foam, epoxy foam, area foam, polystyrene foam, and foams in which one or more of these foam raw materials are appropriately blended.

．． Inorganic foams include foamed gypsum, foamed glass, etc., and modified foams in which inorganic substances, inorganic fibers, aggregates, minerals, etc. are mixed into the foam structure of synthetic resin foams or inorganic foams. It is a distribution of one or more types of. To specifically illustrate these, inorganic substances include borates, silicates, carbonates, calcium salts, and aluminum hydroxide, and inorganic fibers include glass fibers, rock wool fibers,
These include asbestos fibers and carbon fibers. In addition, as aggregates, pearlite grains, whitebait balloons, microballoons,
glass balloon, anti-firestone, styrene beads, clay minerals,
These include granular materials (kaolin, bentonite), etc., and foams containing flame retardants, flame retardants, etc. Note that the aggregate also includes aggregate impregnated or coated with one or more of the above-mentioned borates. Furthermore, it is desirable that the foam 9 has a foaming pressure sufficient to elastically deform a portion 2a of the decorative surface of the panel. Note that the maximum value of the foaming pressure is on the bottom side of the deposited foam 9. In addition, in the case of polyurethane foam, the foaming pressure is approximately 0.1 to 0.21 Kg/Crii, which is approximately 1 m77 in the span of the above-mentioned surface-treated steel plate, which covers the decorative surface 2a! It is assumed that the foaming pressure can be varied within the following range. Reference numeral 10 has the function of covering the back surface of the foam 9 with a sheet-like material and making it into a sandwich panel shape to improve the mechanical strength of the composite board.

Note that this sheet-like material 10 may be stretched only between the insertion piece 5 and the base of the protrusion 8, or may be extended to the back surface of the insertion piece 5 etc. as shown in the figure. Examples of the sheet material 10 include kraft paper, asbestos paper, plastic sheet, asphalt loop ink, nonwoven fabric, glass cloth,
It is made of Japanese paper, thin metal plates, etc., a laminate of one or more of these, or one or more sheet-like materials laminated with metal foil. Next, to briefly explain the manufacturing method, it is assumed that a composite plate is manufactured using an apparatus as shown in FIG. 3, for example.

Galvanized steel plate (thickness: 0.3 mm) was used as the elastic base material.
), and the width and height are set to one of the dimensions described above. In addition, a two-component reaction polyurethane foam raw material was used as the foam 9, and a material made of kraft paper laminated with aluminum foil was used as the sheet-like material 10.Therefore, a bobbin A on which the above-mentioned steel plate was wound into a roll was used. From then on, it is continuously fed to a molding machine C via a pinch roller B. The molding machine C molds the elastic base material into the shape shown in FIG. 4 and sends it to the next process as a so-called panel. When the panel 1 reaches the entrance of the molding device where the endless belts D and E move while facing each other at a certain interval, each component of the polyurethane resin is mixed and discharged into the concave part of the panel 1 from the exit of the mixer in a so-called cream state. be done. Then, the above-mentioned raw material changes from gel to rice over time due to a polymerization reaction. Of course, the sheet-like material 10 is laminated on this raw material via the guide F when the cream is in the initial state of gel. Then, with the foam raw material sandwiched between the panel 1 and the sheet material 10, the gap between the end and rest belts (thickness T of the composite plate
). Then, the composite plate sent out in such a state is heated for about 3 minutes, with only the decorative surface 2 and the 10 sheet-like surfaces being regulated by an endless belt with a flat surface as shown in FIG. ~30m/- in an atmosphere of ~70℃
The composite plate as shown in FIG. 6 is obtained from the exit. In addition, in the mold where the side wall of the panel 1 is open, the horizontal direction is regulated by the mold material, and the side wall surface is regulated by the side wall of the panel 1, and the foam raw material is creamed in this sealed gap. The state changes from gel to rice, and the foaming pressure increases rapidly from the beginning of the rice time to the end of the rice time. The foaming pressure of this uniformly distributed load is (approximately 0.1 to 2
kg/Cd) acts as an external force to curve the decorative surface 2a (elastic deformation), expand the length of the so-called decorative surface 2, and stand still in a state where the elasticity of the base material and the foaming pressure are balanced, suppressing distortion. Visually,
This is to make it appear as if it has been deleted. It is also possible to provide a device for supplying additives at the position indicated by the dashed line in FIG. 3 to strengthen the hardness of the foam 9.
What has been described above is one embodiment of the foam-filled composite board according to the present invention, and the composite board is filled with a foam that contains a flame retardant and a flame retardant in the foam 9. Alternatively, the shape of the panel 1 may be formed, for example, as shown in FIG. 7, or a composite board may be formed in which the side walls of the panel 1 are inclined in shape, although not shown.

As described above, according to the foam-containing composite board of the present invention, the cracking that occurs during molding of wide panels, etc. can be controlled by the foaming pressure of the raw material during foam formation and the volume increase when the foam becomes a molded product. Because the base material is elastically deformed and the decorative surface is fixed under tension at all times, the pekotsuki becomes visually invisible and the beauty of the decorative surface of the composite board is significantly improved.

In addition, in terms of mechanical strength, since the foam was supplied as a fluid raw material, there were no voids unlike when a molded body is used as a core material, and the foam and base material are integrated into one body through the adhesive force of the foam. Because it is fixed, it has the advantage of greatly strengthening mechanical properties such as bending and tensile properties.

[Brief explanation of the drawing]

FIG. 1 is a perspective view showing an example of a conventional foam-filled composite board;
FIG. 2 is a longitudinal sectional view showing an embodiment of the foam-filled composite board according to the present invention, FIG. 3 is a schematic diagram showing the configuration of an apparatus for producing the foam-filled composite board according to the present invention, and FIG. A vertical sectional view showing an example of the panel, FIG. 5 is an explanatory view showing only the essential parts of the above device at appropriate locations, and FIG. 6 is a perspective view showing an embodiment of the foam-filled composite plate according to the present invention. 7 are explanatory diagrams diagrammatically showing other examples of shapes of the above-mentioned panel. 1... Panel, 2... Decorative surface, 3, 4
... Convex portion, 9 ... Foam and heat insulating material.

Claims (1)

[Claims] 1. An elastic base material is formed to have a concave cross section, and at least one end of the plane serving as the concave decorative surface has a band-shaped convex portion parallel to the side end of the concave shape and a cosmetic that can be elastically deformed by a slight external force. 1. A foam-containing composite board, characterized in that a panel having a surface and a foam body that applies pressure or the like to visually eliminate unnecessary distortion in a concave part of the panel is integrally provided.