JPS591255A - Continuous manufacture of sandwich 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: A method in which a coiled thin metal plate is rolled or formed into an uneven shape using a rolling roll, and a foamable synthetic resin such as polyurethane foam is discharged and foamed between the thin metal plates, and vinyl chloride After injecting the foamable polyurethane resin stock solution into the thin resin base material 2, before the foamable polyurethane resin stock solution is foamed by a roller through the back sheet, the central part of the urethane resin stock solution becomes thick on the entire surface of the base material. A method for producing a continuous foam insulation board (special method) in which the thickness of the urethane resin stock solution that has begun to foam is made uniform using a shaping roller, and then the foamed urethane resin is foam-molded into a flat layer using an upper and lower double conveyor. 144937/1983) is publicly known.

However, when the top and bottom panels are formed into an uneven shape, or when the edges of the top and bottom panels are bent so that they face each other at the sides and a sandwich panel is continuously formed, the top and bottom assemblies are Even if slight meandering occurs, it cannot be corrected after the synthetic resin foam has completed foaming and hardening, so preventing meandering of the bottom surface material is an extremely important technique from the standpoint of quality control.

In particular, when a synthetic resin foaming stock solution is foamed, the synthetic resin stock solution is still in a fluid state, and at the same time a force that tries to lift the top material due to the foaming pressure is exerted, there is also a force that tries to flow in the side direction. However, with the conventional method of simply pressurizing and clamping using upper and lower rolls or double conveyors, it was not possible to prevent the occurrence of subtle misalignment of the upper and lower surface materials, making it difficult to consistently obtain good quality products. Particularly recently, the use of heat insulating materials or soundproofing materials for general housing has increased, and the required dimensional tolerances have also become more sophisticated. However, in the conventional method, ±1.5m
+n'P1. The occurrence of variation in degree was unavoidable. As a countermeasure to this problem, we attempted to install a guide device on a part of the double conveyor to regulate the side position, but if the upper and lower surfaces are rigid bodies such as metal plates, the guide device may become abnormally worn, or in extreme cases, break. The problem could not be resolved by inviting

The inventors of this application have made various studies, but in a continuous production system using a highly rigid surface material like the one used in this application,
After the foamable synthetic resin stock solution has been discharged, the position and thickness of the upper and lower surfaces are gradually adjusted from the early stage of the reaction when it still has sufficient fluidity. As a result of reaching this conclusion and proceeding with intensive studies, we have completed the present invention.

The present invention will be explained in detail with reference to the drawings. (1) in Figure 1
and (1') are the upper surface material (
11) and a lower surface material (11'). Although the driving device is not shown, (11) and (11'
) is adjusted so that it can be sent out at the same speed. It is necessary to select the optimal speed for feeding the face material depending on the curing speed of the synthetic resin foam, but a range of (3 to] Om/min is appropriate. (21) and (21'') are -[ This is a guide roll that applies tension to each of the two lower facing materials and supplies the facing materials to the next process.

In addition to thin steel plates, the second lower surface materials (11) and (11') used in the present application may be stainless steel plates, aluminum or aluminum alloy plates, copper or copper alloy plates, or composite plates thereof. Its thickness is 0.1. -10m
It is preferable to have a width of 200 to 2000 mm, and it is also possible to use one that has been plated, painted, printed, laminated with a synthetic resin film, vacuum-deposited, or oxidized film-formed in advance.

(2) shows a cold-open forming device for thin-walled metal top and bottom materials;
Rolls for unevenness forming (22), (22'), (23),
A plurality of sets of (23') are provided. These forming rolls form the thin metal plate into a desired shape. Although only two sets of cold-open forming rolls are shown in FIG. 1, the number of sets may be increased or decreased as appropriate depending on the desired shape. still,
If it is not necessary to provide the surface material with an uneven shape, it is sufficient to simply roll the bottom surface material into sheets using a flat roll for IP.

(3) is a discharge port for the foamable synthetic resin stock solution. Although not shown, the stock solution supply tank is connected to equipment where the foamable synthetic resin stock solution is metered and piped to a desired company. A known mixing mechanism is selected depending on the type of synthetic resin. Only one outlet (3) may be used to horizontally traverse perpendicular to the advancing direction of the panel by the width of the panel, or multiple outlets may be installed in parallel to allow foaming in a stationary state. Alternatively, a synthetic resin stock solution may be sprayed. The foamable synthetic resin used in the present application is a thermosetting synthetic sesame foam whose raw material is liquid, such as polyurethane foam 11, phenol foam 11, polyimide foam, and urea foam. The thickness of the foam is not particularly limited, but is preferably in the range of 5 to 100 m/+n.

The roll (24) has a regulator device (5) for the upper surface material.
It is a guide roll for sending to. (4) is a guide roll for side edge position adjustment to prevent meandering of the upper and lower surface materials. Although it is provided at the inlet of the regulator device (5) in Fig. 1, it may be provided at the center or outlet of the regulator device, and it may be installed not only in one set but also in multiple sets as appropriate. .

In addition, if unevenness of a certain width is provided in the longitudinal direction on one or both of the upper and lower surface materials, a pair of upper and lower rolls is installed before entering the regulator device (5), and the uneven position of the surface material is adjusted. In the case of a concave shape, a convex guide ring that can be fitted into the concave shape is provided at a position corresponding to the concave shape, and in the case of a convex shape, a concave guide ring that can be fitted to the guide ring is provided to cooperate with the side end guide roll. You may choose to do so. In this case, the upper and lower guide rings are 0.0 mm from the uneven surface formed on the surface material. '5m/
It is desirable to have a margin of about +n.

The Shichiyater device (5) is designed to widen the gap between the upper and lower rolls in response to the gradual increase in thickness of the foamable synthetic resin stock solution discharged onto the lower surface material as the foaming reaction progresses. It consists of multiple pairs of rolls arranged. Although not shown, each of the plurality of pairs of roll gaps is equipped with an adjustment mechanism that can vary the gap. The gap between each of the plurality of pairs of rolls is determined by a foaming curve determined from the rise speed of the synthetic resin foam used and the conveyor speed, and is usually determined by the intermediate thickness between the thickest and thinnest regions of this foaming curve. It is desirable to set it nearby. Care must be taken because if the foamed material is pressurized too much at this initial stage of foaming, the foam formed will become flat, which will not give very good results to the properties such as pressure resistance of the final foamed molded product.

The length of the regulator unit is preferably from the initial stage of foaming of the foamable synthetic resin until the maximum height is reached after the foaming reaction is completed; in the case of rigid polyurethane foam, it is 2 m for fast reaction systems, and 2 m for slow reaction systems. It is about 10m. Although seven sets of regulator rolls are shown as an example in FIG. 1, the number of regulator rolls may be increased or decreased as appropriate depending on the reaction rate. Generally, it is desirable that the faster the reaction speed is, the smaller the distance between the front and rear rolls is, and usually a range of 30 to 300 mm is selected. There is no particular limit to the diameter of the regulator roll, but 2
A range of 5 to 250n+n+ψ is appropriate. While the foamable synthetic resin and the upper and lower surface materials pass between the regulator rolls, they are firmly adhered to each other.

(6) is a set of upper and lower conveyors that operate at a constant speed, and conveys the synthetic resin foam with face material that has undergone the foaming reaction to the heat curing chamber (7), and finally adjusts the thickness of the product. It has the role of pressurizing.

This upper and lower double conveyor is also equipped with an auxiliary device to appropriately adjust the upper and lower distances. As for the material of the conveyor (not shown), a steel conveyor is used, but a rubber or steel belt conveyor may be used as long as it has a function of pressurizing. In the case of steel conveyors, it is desirable to use a rubber or resin lining such as urethane to prevent noise and wear.

The synthetic resin foam with a face material whose thickness has been finally adjusted is
Heat curing chamber (7) installed near the double conveyor
). In this heat curing chamber, the synthetic resin foam molding is heated at 50 to 150°C, preferably 60 to 100°C, for 2 to 3 minutes to substantially complete the curing reaction of the synthetic resin foam. After curing, the long sandwich-shaped synthetic resin foam molded product is cut into a cutting machine (
8) is cut to a desired length to produce a final product, a sand inch panel (12).

Example: coiled, thickness 0.27mm, medium 1.000m
m steel plate is used as the top surface material, thickness 0.27 m/+n, I
ll A 930 m/m steel plate is used as the bottom surface material and is sent out from the upper and lower bending devices at a speed of 5 m/min, respectively.
As shown in the figure and Fig. 3, the upper surface material is formed by cold-open forming rolls so that the upper surface material can be formed with two recesses and the edges are bent, and the lower surface material is simply rolled into a flat plate and only the ends are formed. The upper and lower surfaces were processed by installing rolls for forming the lower surfaces so that they could be bent and formed. Next, a stock solution for rigid polyurethane foam having the formulation shown in Table 1 was mixed and stirred and simultaneously discharged onto the lower surface material at a discharge rate of 1.500 g/min. In this case, the discharge nozzle was made to reciprocate over a molding width of 900 mm. Further, the guide roll for adjusting the side end position is provided only at the inlet of the regulator device.

The rise time shown in Table 1 is 45 seconds, the final thickness of the sandwich panel is 18n+n+, and the conveyor speed is 5n1/
The conveyor will travel 3.75m from the start of foaming to the final thickness, calculated from 25 minutes.
The gap between the upper and lower rolls of the m/mψ steel regulator roll at the initial stage of foaming is set to 7 m/m, and the gap between the upper and lower rolls is increased to 18 m/u+ at the final stage of foaming. It was arranged as follows. The temperature of the heat curing chamber was adjusted to 60°C, and the sandwich-shaped foam molded product that had been substantially cured had a temperature of 1'380.
It was cut into lengths of mm using a cutting machine. The resulting sandwich panel has a thickness of 18. ] m/m, rll 9 ] 8
+n/m, length 1083m/m, there was only a slight step difference of ±0.2m/m at the edge of the upper and lower surface materials, which fully matched the target tolerance of ±0.5m/m. It was something to do.

As can be seen in the results of the examples, the present invention performs foaming from immediately after the start of foaming of the foamable synthetic resin stock solution until the completion of foaming based on the foaming curve obtained from the foaming rise speed, conveyor advancement speed, and final thickness. The thickness is adjusted by gradually increasing the gap between the rolls in small increments so that the thickness is approximately halfway between the maximum thickness and minimum thickness of the mixture, thereby applying a weak pressure relative to the foaming pressure. At the same time, a guide roll for side edge position adjustment is used in combination at the foaming stage, which is still in a fluid state.

Dimensions can be adjusted with an extremely simple device, and the difference in level caused by misalignment of the upper and lower surface materials at the side ends can be significantly reduced. If the side edge level difference becomes large, the product cannot be used other than being discarded as a defective product in applications that require dimensional accuracy with respect to the mounting partner, such as insulation and soundproofing materials for houses and factory buildings. However, the method of the present invention This is an extremely useful technique that can significantly improve dimensional accuracy and greatly improve yield.

[Brief explanation of the drawing]

Fig. 1 is a side view showing a series of steps in the manufacturing method of the present invention, Fig. 2 is a perspective view of an embodiment of the sandwich panel obtained by the present invention, and Fig. 3 is a cross-sectional view taken along line xx'. ,
FIG. 4 is a sectional view showing another embodiment of the present invention. (3) --- Monofoaming synthetic resin stock solution outlet (4) ---
One side end position adjustment guide roll (5)---Regulator roll (6)---Double conveyor (7)---One heating curing chamber (8)---One cutting machine (11), (11') --- Upper and lower surface materials・, (
12') ---- Sandwich panel (22), (22
'), (23), (23') --- Cold forming roll patent applicant Toyo Rubber Industries, Ltd.

Claims (1)

[Claims] The foaming property discharged in a method of continuously manufacturing sandwich panels by forming two sets of upper and lower cold-workable face materials into a desired shape while rolling, and discharging a foamable synthetic resin stock solution between the upper and lower face materials. The thickness and side edge dimensions are adjusted by using regulator rolls consisting of multiple upper and lower pairs and at least one set of side meandering prevention rolls from immediately after the foaming of the synthetic resin stock solution starts until the foaming reaction ends. A continuous manufacturing method for sand inch panels characterized by: