JPS5942633B2 - How to manufacture fittings - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention provides spaced-apart opposing front and back metal thin plates;
A filler filled between these thin metal plates by injection foaming,
The present invention relates to a method of manufacturing fittings such as doors, shutters, partitions, etc., which are formed by having frame members fitted and fixed to the peripheral edges thereof.

The fittings with the above structure have recently been put into practical use by the applicant, and instead of the so-called batch method, which has extremely low production efficiency, a filling material is used between the front and back metal sheets. The present applicant has developed a method for automatically filling the panel, cutting it to the required length to obtain a panel-like fittings body, and attaching a frame to the periphery of this body, and has already filed an application.

However, one of the issues that must be solved when implementing this method is the homogenization of foaming of the filler. In other words, factors that change the degree of foaming include the temperature of the thin metal sheet, the feeding speed, room temperature, the component ratio of the filler, and the heating temperature.If the degree of foaming of the filler changes due to these influences, it may result in overfilling or underfilling. This makes it difficult to ensure the strength of the fittings and the uniformity of the heat and sound insulation performance, and some of the filling material overflows, resulting in filling defects.
The present invention was developed based on the above-mentioned circumstances, and its purpose is to provide a method for manufacturing fittings that solves the above-mentioned problems and makes it possible to efficiently manufacture fittings having a predetermined performance. There is a particular thing.

That is, the present invention involves a bending process in which flanges are formed by roll forming on both side edges of two strip-shaped thin metal sheets fed out from two rolls, each having a hypotenuse portion that bends diagonally toward the inside, and a bending process in which flanges are formed by roll forming on both side edges of two strip-shaped thin metal sheets fed out from two rolls. a preheating process for preheating the formed plate; and a tape application process for attaching a sealing tape to the inner surface of the flange of the lower forming plate after preheating, with a part of it protruding from the flange. , a filler supply step in which a foamable filler stock solution is supplied onto the lower molded plate after preheating, and a process in which the upper and lower molded plates are superimposed on an endless rotary body arranged vertically apart. The upper and lower molded plates are held and conveyed, and the filling material is foamed by heating at a predetermined temperature? The foam filling process involves filling the space between the upper and lower molded plates, and the upper and lower molded plates, which are integrated with the adhesive force of the filler through this foam filling, are cut along the width direction to obtain the required length. a cutting process to obtain a panel-shaped fitting body;
and a framing step of fitting and fixing a frame material made of an aluminum alloy extruded material to the flange side edge of the fitting body and the cut end side edge, respectively, and the filler supplying step is performed in the direction of movement of the formed plate. The upper and lower formed plates are provided with a threaded rod disposed along the direction of movement of the formed plate and a threaded portion that engages with the threaded rod, or with a rack disposed along the moving direction of the formed plate and a pinion that meshes with the rack. A mechanical reciprocating linear movement mechanism in which the stock solution pouring member that pours out the filler stock solution from the overlapping position can approach and separate from the stacked position adjusts the supply position of the filler stock solution according to its fluctuation factors and lowers the filler stock solution. This is a method for manufacturing fittings, characterized by supplying a filler stock solution onto a molded board.

The present invention will be described below with reference to an embodiment shown in the drawings.

First, the structure of the fitting 1 will be explained with reference to Figs. 1 to 3. It consists of two thin metal plates 2, 3 on the front side and the back side that face each other apart, and foam injection foamed between these thin metal plates 2, 3. The upper, lower, left, and right sides made of extruded aluminum are fitted and fixed to the periphery of a chimney-like fitting main body 5 of the required length, which is made up of the two thin metal plates 2, 3 and the filler 4. It is formed by comprising frame members 6 to 9.

The metal thin plates 2 and 3 are colored steel plates, aluminum (including alloys) plates, or the like. This fitting 1 is manufactured through a bending process, a preheating process, a tape adhesion process, a filler supply process, a foam filling process, a cutting process, and a framing process.

That is, in the bending step, the oblique side portions 13b which are bent inward at least on both side edges of the strip metal thin plates 2A and 3A that are unwound from the two rolls 11 and 12 wound with the strip metal thin plates 2A and 3A are formed. This is a step of molding the flange 13 provided. This process is carried out by the roll forming device 1.
This roll forming device 14 performs other bending operations as necessary, for example, as shown in this embodiment, to further improve the strength of the fittings and to form grooves to serve as handle parts. The strips 1a, 1b, 1b are bent and formed. The preheating process is performed by using a preheating device 15 in which a heat source such as an electric heater or a heating lamp is housed in which a strip-shaped thin metal plate having a bent flange or the like, V-formed tab plates 2a and 3a are vertically spaced apart from each other, and heated to a predetermined temperature. This heating step is carried out to promote foaming of the filler stock solution.

For example, if the filler stock solution is a mixture of a polyol mixture containing Freon 11 and polyether and a polyisocyanate solution, the preheating temperature is 35 ± 1°C, but this temperature may vary depending on the type of stock solution and other factors. Of course, it can be determined as appropriate. In the tape pasting step, after preheating, a tape pasting device 36 attaches a sealing tape 16 made of paper or resin to the inner surface of the flange 13 of the lower molded plate 3a, with a portion of the pasting tape 16 extending from the flange 13. This is the process of attaching it so that it protrudes. The adhesion of the tape 16 to the inner surface of the flange 13 is carried out by guiding the adhesive tape 16 with a rotatable contact roller 17 that is driven to rotate in contact with the inner surface of the flange 13, as shown in FIG. There is. The filler supply step is a step in which a foamable filler stock solution is supplied onto the lower molded plate 3a after preheating, and may be performed before or after the tape adhesion step.

The filler stock solution contains a cellular synthetic resin material (preferable examples include self-adhesive polyurethane resin, polyisocyanurate resin, polyvinyl chloride resin, etc.) or a cellular rubber material, a crosslinking material, and a foaming material. This is a solution mixed in an appropriate ratio. In this supply process, the filler stock solution is supplied to a position P where the upper and lower molded plates 2a and 3a are overlapped, using a machine in which the stock solution pouring member 18 that pours out the filler stock solution can be moved toward and away from the position P. target linear motion mechanism 19
It is adjusted according to the fluctuation factors of the foaming of the stock solution.
The stock solution is supplied onto the lower molding plate 2b. As shown in FIGS. 6 and 7, the mechanical linear motion mechanism 19 includes a threaded rod 20 disposed along the moving direction of the molded plates 2a, 3a, and a threaded portion 21 that is threaded through the threaded rod 20. The adjustment table 22 supporting the stock solution pouring member 18 may be moved by automatic or manual relative rotation 1 drive, or as shown in FIGS. 8 and 9. A rack 23 disposed along the moving direction of the molded plates 2a, 3a, and a pinion 24 meshing with the rack 23,
The adjustment table 22 to which the low rack 23 is attached is moved by rotating the pinion 24 automatically or manually. In addition, 25 in Figure 7} and Figure 9
is a guide shaft that is provided along the moving direction of the molded plates 2a, 3a and guides the movement of the adjustment table 22. In the foam filling process, the upper and lower molded plates 2a and 3a are overlapped and sandwiched between the sections in which the upper and lower endless rotary bodies 26 and 27, such as belts or caterpillars, run in parallel and are spaced apart from each other. This is a step in which the filler is transported and heated at a predetermined temperature to foam the filler and fill it between the upper and lower molded plates 2a and 3a.

As a means for heating to a predetermined temperature, endless rotating bodies 26 and 27 are housed in an enclosure device 28 as shown in the figure, and dry hot air is circulated through the enclosure device 28.
, 27, various heating means can be employed, such as heating with a heat source such as an electric heater or a heat generating lamp provided close to . In addition, the heating temperature is (40 ± 5) 0C when the filler is polyurethane.
However, it goes without saying that this temperature is appropriately determined depending on the type of filler and other conditions. In this foam filling process, the adhesive tape 16 is attached to the filler material 4.
With the foam filling, the flange 13 of the upper molded plate 2a
It is attached to the inner surface, thereby preventing leakage from between the opposing flanges 13, 13 of the upper and lower molded plates 2a, 3a. In addition, 29 in Figure 4
, 30 indicate members for maintaining constant the opposing distance between the nipping and conveying portions held by the upper and lower endless rotating bodies 26 and 27, respectively. In the cutting process, the upper and lower molded plates 2a and 3a, which have been integrated by the adhesive force of the filler 4 through foam filling with the filler stock solution, are cut along the width direction using a cutting device 31. This is a process of obtaining a panel-shaped fitting main body 5 having a length.

It goes without saying that this cutting process includes not only the case where the panel-like fitting main body 5 of the required length is directly obtained by one cutting, but also the case where the panel-like fitting main body 5 of the necessary length is obtained by cutting multiple times. stomach. Further, the cutting device 31 disposed behind the endless rotary bodies 26, 27 is reciprocally movable, moves forward at the same speed as the moving speed of the upper and lower molded plates 2a, 3a, and performs cutting on the way. This prevents the conveyance of the upper and lower molded plates 2a and 3a by the upper and lower endless rotating bodies 26 and 27 from being stopped every time the cutting process is performed. The framing step is a step of fitting and fixing the frames 6 to 9 onto the flange 13 side edge and the cut surface side edge of the fitting main body 5, respectively, manually or by an automatic machine.

Each of the frame members 6 to 9 has fitting pieces 6a to 9a, and the upper and lower frame members 6 and 7 and the left and right frame members 8 and 9 are connected to each other via a fixture 32. . In the case of this embodiment, fixing devices 32 are inserted into and connected to the receivers 33 provided at both ends of the frame members 6 and 7, and the flanges 13
The frame members 8 and 9 that fit into the side edges are inserted through the adhesive tape 16 and have engaging protrusions 34 that engage the flanges 13 and 13.
This makes the attachment to the main body 5 of the fittings more robust. Further, numerals 35 in FIG. 3 indicate rivets for more firmly attaching the frame members 6 and 7 to the fitting main body 5, which are fitted on the cut end surface side. After the framing process, appropriate accessories are attached to the fittings as necessary. In addition, when carrying out the above manufacturing method, the type of filler, its component ratio, preheating temperature, conveyance speed of the metal sheet,
It goes without saying that the heating temperature, heating time, etc. in the foam filling process are appropriately set depending on the performance, manufacturing efficiency, etc. required of the fittings.

As explained above, the present invention is capable of automatically performing the bending process, preheating process, tape pasting process, filler supply process, and foam filling process within the range of the feeding length of the strip metal sheet. Therefore, there is no need to accumulate semi-finished products each time the process moves on, and each of the above steps can be carried out continuously.

Therefore, it has high manufacturing efficiency and is highly suitable for mass production. Since it is equipped with a preheating process, when the filler stock solution is supplied to the lower molded plate, foaming starts immediately, which can further improve manufacturing efficiency and shorten the time required for the foam filling process. I can do it.

Furthermore, in the filler supply process, the position of the filler stock solution can be adjusted using a mechanical reciprocating linear motion mechanism.
Depending on the variable factors such as the preheating temperature of the thin metal plate, the feeding speed, the room temperature, the type of filler, the component ratio, and the heating temperature during foam filling, the stock solution pouring member that pours out the filler stock solution is molded into upper and lower parts. It is possible to approach or move away from the position where the processed plates are overlapped.

Therefore, it is possible to prevent the filler stock solution from foaming too much and overflowing over the flange of the lower molding plate after the filler is supplied and before reaching the position where the upper and lower molded plates are overlapped. . Furthermore, this adjustment allows the foaming of the filler stock solution to be slightly lower than the flange at the time when the upper and lower molded plates are superimposed, so that the length of the foam filling process can be shortened. Therefore, since the filling material can be foamed according to the required performance of the fitting, it is possible to ensure uniformity of the strength and heat-insulating and sound-insulating performance of the fitting. Furthermore, since the mechanical reciprocating linear motion mechanism is configured with a threaded rod and a threaded portion, or a rack and a pinion, it is structurally simple and has a high accuracy in the movement position of the stock solution pouring member. It is easy to produce, and therefore the feasibility is extremely high.

[Brief explanation of drawings]

Fig. 1 is a cross-sectional view of a rain door manufactured by the method of the present invention, Fig. 2 is a vertical cross-sectional side view taken along the line - in Fig. 1, and Fig. 3 is an exploded perspective view of the same rain door with the filler omitted. 4 is a process diagram showing an outline of the apparatus system for implementing the method of the present invention, FIG. 5 is an explanatory diagram of measures to prevent filler leakage, and FIG.
The figure is a side view showing an example of the part from the preheating process to the foam filling process, Figure 7 is a sectional view taken along the line - in Figure 6, and Figure 8 is another part of the process from the preheating process to the foam filling process. A side view showing an example, and FIG. 9 is a sectional view taken along a line in FIG. 8. 2, 3... Metal thin plate, 2A, 3A... Band-shaped metal thin plate, 2a, 3a... Molded plate, 4... Filler, 5...
... Fittings body, 6, 7, 8, 9... Frame material, 6a, 7a
, 8a, 9a... fitting piece, 11, 12... roll,
13... flange, 13b... hypotenuse part, 14...
Roll forming device, 15... Preheating device, 16.
... Adhesive tape, 18... Stock solution pouring member, 19...
Mechanical linear motion mechanism, 20... Threaded rod, 21... Threaded portion, 23... Ratsuku 24... Pinion, 26,2
7... Endless rotating body, 31... Cutting device.

Claims (1)

[Claims] 1. A bending process in which flanges with oblique sides bent inward are formed on both sides of two strip-shaped thin metal plates fed out from two rolls by roll forming, and the upper and lower formed plates after bending are formed. a preheating step for preheating; a tape adhesion step for adhering a sealing tape to the inner surface of the flange of the lower molded plate after preheating with a part of it protruding from the flange; A filler supply process in which a foaming filler stock solution is supplied onto the side molded plates, and an endless rotary body arranged vertically apart is used to stack the upper and lower molded plates and sandwich and transport the upper and lower molded plates. At the same time, there is a foam filling process in which the filler is heated at a predetermined temperature to foam the filler and filled between the upper and lower molded plates, and the upper and lower molded plates, which are integrated by the adhesive force of the filler through this foam filling, are bonded along the width direction. A cutting process to obtain a panel-shaped fitting body of the required length by cutting the fitting body, and a framing process in which frame materials made of extruded aluminum alloy are fitted and fixed to the flange side edge and cut end side edge of the fitting body, respectively. The filling material supplying step includes a threaded rod disposed along the moving direction of the formed plate and a threaded portion that is threadedly engaged with the threaded rod, or a threaded rod disposed along the moving direction of the formed plate. Filling is carried out by a mechanical reciprocating linear motion mechanism that has a built-in rack and a pinion that meshes with the rack, and allows the stock solution pouring member, which pours out the filler stock solution to the position where the upper and lower molding plates are overlapped, to move toward and away from the rack. A method for manufacturing fittings, which comprises supplying a filler stock solution onto a lower molded plate by adjusting the supply position of the filler stock solution according to its variable factors.