JPS604766B2 - Form composite panel manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of making improved foam composite panels with low warpage.

When integral molding is performed by injecting a foamed curable resin stock solution between two face materials, if the properties, particularly the rigidity, of the two face materials are different, warp deformation is likely to occur, and this tendency becomes more pronounced as the difference in rigidity increases. The reason for this is that the shrinkage stress of the foam layer of the panel after molding is applied to the face material, which has poor rigidity, causing it to shrink, thereby applying a bending moment to other face materials. In order to solve this drawback, we created a face material with poor rigidity (hereinafter tentatively called back material).
It is also possible to make a back-splitting cut on the side of the other surface material (tentatively called the surface material), but with this method, there will only be one smooth surface. The present invention seeks to provide a method for obtaining a foam composite panel in which no visible processing means are visible in the product and virtually no warping occurs. In one embodiment of the method of the present invention, a plate material is provided inside the back material, which is 4 mm thicker than the back material (at least around the foam layer appears) and has the same rigidity as the surface material, and this back material is Injection foam molding is performed between the layer made of wood and plate material and the layer of surface material.

In another embodiment, a layer made of a non-adhesive material is formed on the inside of the backing material, and the material is foam-molded. Although these two embodiments have somewhat different functions, they are the same in that an intermediate layer is interposed, and there is no difference in effect. FIG. 1 is an explanatory diagram of a first embodiment, and FIG. 2 is an explanatory diagram of another embodiment. 1b and 2b are cross-sectional side views of the product.

In each figure, the same reference numerals are used for the same or corresponding parts, A and B are the molds, 1 is the surface material, 2 is the back material, and 3 is the mold.
4 indicates an intervening plate material or a non-adhesive layer, and 4 indicates a foam layer. 1st
In the embodiment shown in the figure, a rigid plate 3 is interposed.

The plate material 3 may be made of any material, but since it does not appear on the surface of the product, only the rigidity needs to be comparable to the surface plate 1, so from an economical point of view it is desirable to use a material that is as inexpensive as possible. 1st
Although the plate material 3 is shown separated from the back surface material in FIG. In this case, the stress is absorbed as the thickness of the panel decreases, and is supported by the rigidity of the surface material and plate material, so that only a slight strain appears on the periphery, so there is almost no bending moment for the entire panel, so no warpage occurs. . In the embodiment shown in FIG. 2, a release layer 3 is utilized. The release layer is formed by adhering a polyolefin film or sheet or by applying a release agent such as silicone oil. In this embodiment, the interface between the foam layer and the release layer can not only be freely shifted from each other, but also separated from each other, so the stress within the foam layer does not affect the backing material, and therefore, as in the previous embodiment, the warpage of the panel is prevented. Does not occur.
In the above explanation, the terms "face material" and "back material" are used, but in reality, any ordinary material used for foam composite panels may be used, and the former includes steel plates, various metal plates, decorative laminates, etc. Examples of the latter include paper cloth such as cardboard or kraft paper.

Note that the injection and foaming means itself may be carried out in accordance with a well-known conventional method, so a description thereof will be omitted.

[Brief explanation of drawings]

FIG. 1 is an explanatory diagram of a first embodiment, and FIG. 2 is an explanatory diagram of another embodiment. Figure 1-b and Figure 2-b are cross-sectional views of the product. 1...Top plate, 2...Back plate, 3...
...Intervening board material or peeling layer, 4... Foaming layer, A,
B...Mold for molding. Ototomi-zu Figure 2

Claims (1)

[Claims] 1. When a foamed curable synthetic resin stock solution is injected between two face materials with different stiffness and foam-molded together, a foam and a non-adhesive material are placed inside the face material with poor rigidity. A method for manufacturing a foam composite panel characterized by forming a foam composite panel by forming a section or by inserting a plate-like member made of a material having the same degree of rigidity as the highly rigid face material and having a smaller area on the same inner side. . 2. The method of manufacturing a foam composite panel according to claim 1, wherein the non-adhesive portion is formed of a film or sheet made of a foam and a non-adhesive substance. 3. The method for manufacturing a foam composite panel according to claim 1, wherein the non-adhesive portion is formed by applying a release agent.