JPS6179652A - Manufacture of sandwich board - 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 provides a sandwich board, in which a foamable reaction mixture having self-adhesive properties is interposed between two base materials, and at least one of the two base materials is embossed. The present invention relates to a method for continuously manufacturing a sandwich board that has a base material and does not have a decorative surface that is uneven.

Recently, as interior and exterior materials for buildings, insulation and weight reduction,
Sandwich plates using a metal plate that has both rigidity and rigidity as one base material are being mass-produced. However, most of the sandwich plates are products that have improved coldness and smoothness of the metal, so-called products that have a rich design and three-dimensional effect (embossed pattern), and that have suppressed the physical properties of the material (flexibility). do not have. Furthermore, even if they existed, they only had a limited number of colors, thicknesses, and patterns, and in reality they were no more than mere metal composite plates.

Furthermore, when a foamable reaction mixture, for example a synthetic resin raw material such as polyurethane resin, is used as a core material, the formation of the foam involves a chemical reaction that is greatly affected by various factors such as temperature. There has been a desire for a manufacturing method that can respond to temperature changes. In addition, sandwich boards produced using conventional manufacturing methods have the disadvantage that the decorative surface becomes shabby. Furthermore, since this kind of method that has been used in the past is a simple straight line process, the plastic foam raw material is supplied from the back side of the front material or the back material, and the spreading of the raw material,
It was not easy to disperse.

In order to eliminate such drawbacks, the present invention is designed to eliminate cracks, peeling, cracks, and scratches that occur in the coating film during embossing by heating a thin metal plate wound into a coil as necessary and then embossing it. In order to prevent
Next, the metal thin plate is formed into a predetermined shape, and this is approximately 50 to 9
After heating to 0℃, the plastic foam raw material is discharged, a face material is laminated, and this is sent to a kair oven to continuously and economically manufacture sandwich plates with a predetermined cross-sectional structure. In addition, the present invention proposes a method for manufacturing a sandwich board in which the decorative surface of the sandwich board is bent so as to form a concave V-shape, thereby preventing the decorative surface from becoming curved.

EMBODIMENT OF THE INVENTION Below, the manufacturing method of the sandwich board based on this invention is demonstrated in detail using drawings. FIG. 1 is a schematic configuration diagram showing an example of an apparatus used for carrying out the above method. (hereinafter simply referred to as a coil) is 0
It is configured to move along a trajectory that draws a character. To explain further, 2 is an uncoiler to which a coil A having a makeup tray membrane wound into a coil is attached and fed to the first bin roller 3. The first pinch roller 3 is driven by a motor (not shown) and feeds the coil A to the loop portion 4 at a predetermined speed. The loop portion 4 controls the supply state of the coil A when embossing the coil A, and also functions as a relief portion to prevent a large force from being suddenly applied to the coil.

Kei is the coil A fed from the loop section 4 using the guide roller.
When the coil A is guided and fed to the heater 6 and the coil A is pinched by the second pinch roller 7, the upper roller 5a separates from the coil A, and the driven lower roller 5b functions as a guide. In addition, the heater 6 is provided as necessary, and mainly covers the decorative coating of the coil A and the steel plate.
It softens the baked decorative film by heating it to 0°C, and prevents the decorative film from peeling off from the steel plate or cracking during embossing.
This prevents scratches and cracks from occurring. The heating method is one of hot air method, direct flame method, and hot wire method. A third pinch roller 7 feeds the coil A at a predetermined speed to the embossing roll (2) and functions as a brake against the movement of the coil A during embossing. The main embossing roll has a pattern consisting of male and female uneven parts formed on its outer circumferential surface, and an arbitrary pattern is applied to the coil A by meshing the upper and lower rolls 8a and 8b, and the upper and lower rolls 8a
, 8b is determined by the height of the uneven portion and the thickness of the coil A. The main purpose is to correct the residual strain existing in the coil A embossed by the leveler, and as shown in Figure 2, the upper and lower rollers 9a+, 9a
2.9a31. ,,． 9an (shown up to 9aa in the figure), lower roller 9b+, 9b2.9bq 1. ,,．
The upper roller group 9a +
1. ,,． 9an and lower roller group 9b+ 1. ,,,Qb
The gap G between n can be adjusted between groups or between each roller.

10 is the fourth pinch roller, which rotates faster than the main embossing roll, and with the coil A pulled, the embossing roll 8,
It is designed to pass through the Levelae process.

Of course, the fourth pinch roller IO can be replaced with a roller that simply functions as a guide if the next step has a tensioning function. (2) is a reversing machine that feeds the coil A from the second floor to each process on the first floor, and also turns the front side of the coil A into the back side, and the guide roller group 12.12a,
12b and a curved guide plate 13.13a,
The guide roller 12 can be brought into contact with or separated from the coil A by means of a switch (not shown). Moreover, the curved guide plate 13.13a curves the flat plate,
Guide pieces are provided on both sides, and numeral 14 is a sensor provided as necessary to speed up the coil feeding when the coil A reaches a certain height.
The zone between a and the molding machine 15 also functions as a loop.

The molding machine 15 is used to mold the coil A into a single or double width (not shown), for example, as shown in FIGS. 3(a) to 3(i). 16 is a preheater and coil A is 30
17 is a guide roller, and 18 is a conveyance roller. Reference numeral 19 denotes a discharge section, in which a foamable reaction mixture P (hereinafter simply referred to as a mixture) such as self-adhesive polyurethane foam, polyisocyanurate foam, phenol foam, etc. is applied to the back side (single side) of the coil A using, for example, a rotating blade. It is intended to be supplied by any of the following methods: a discharge method with a body, a spray gun method (air, airless), or an injection method. Note that as the mixture P, a thermosetting foamable synthetic resin is used.

Reference numeral 20 denotes a backing material supply unit in which backing material B, such as one or more of metal foil, asbestos paper, kraft paper, aluminum foil, plastic sheet, asphalt felt, etc., is laminated on mixture P. It is composed of, for example, an uncoiler (not shown), a guide 21, and a detector 22 provided as necessary.

To explain further, the guide 21 guides the backing material B onto the coil A, and determines the timing for bringing the backing material B into contact with the mixture P depending on the state of the mixture P (so-called self-adhesiveness of the mixture). more effectively) and mixture P
It has the function of averaging the dispersion unevenness. Its structure includes one roller or the structure shown in FIGS.
1a1.21a21. , , are arranged in parallel at the same height. Figures (b) and (C) show rollers 21a+1. .

, 21an arranged at a certain angle θ with respect to the traveling direction of the coil A, (d) is a guide shown in (a) in which rollers 21a + 1. ,,,21an
A guide in which a candy-like spreading plate 23 is interposed between the rollers 21 and a gap regulating plate/spreading plate 24 and a roller group 24a as shown in FIG. Further, the detector 22 detects cutting, damage, etc. of the back material B, and accordingly generates a signal to stop the operation of the discharge section 19. The principle behind this is a detector that uses electricity, magnetism, heat, and tension differences. 25 is a mold that transports the mixture P with it interposed between the coil A and the back material B, reacts and foams the mixture P in a good environment, and forms it into a sandwich plate S of a predetermined thickness. . Specifically, for example, either a steel belt or a caterpillar is engaged between the driving wheel 26.27 and the driven wheel 28.29, and a reinforcing roller 32 (in the case of a steel belt) is attached to the back of the upper and lower mold members 30.31. heating devices 33 and 34 are provided on the back side of the reinforcing roller 32, and a space containing all of these shapes is sealed with a cover 35. To explain further, the reinforcing roller 32 prevents the upper and lower mold members 30.31 from deforming due to the foaming pressure of the mixture P.
The heating devices 33 and 34 keep the inside of the mold at a temperature of 30 to 110°C.
This is to complete the reaction of the mixture P within a predetermined time and to exhibit predetermined physical properties. Also, cover 3
5 is more effective because it keeps the inside of the mold warm and does not release trichloromonofluoromethane released during the reaction of mixture P, or carbon dioxide gas, -carbon oxide, etc. released from the heating device into the working environment for safety and hygiene reasons. This is to obtain a heat retention effect.

In addition, for the type 25 person, only the exit parts 25a and 25b are type 2.
The structure is designed to prevent the leakage of gas within 5 to the maximum extent possible.

36 is a traveling cutter, 37 is a secondary forming machine, and 38 is a straightening machine. That is, the secondary forming machine 37 forms the side edges and seams of the sandwich plate S, and the straightening machine 38 forms the sandwich plate S into a V-shaped concave shape as shown in FIGS. The sandwich plate S
This prevents the decorative face of the person from becoming a Yamabushi.

Next, the method for manufacturing a sandwich board according to the present invention will be explained in detail. That is, the coil A is attached to the uncoiler 2 and fed to the loop section 4 via the first pinch roller 3. Next, the coil A is guided through the loop portion 4 to the second pinch row 95, and is fed to the heater 6. Note that the second pinch roller functions as a pinch roller only when the coil A first reaches the third pinch roller 7, and after that, the upper roller 5a moves up and the lower roller 5b acts as a mere guide roller. Next, the coil A sent to the heater 6 provided as necessary is heated to approximately 20 to 80°C, softens the decorative coating to a predetermined hardness, and
The embossing roll is mainly fed through the pinch roller 7. To explain further, if embossing is performed when the coil A is heated to 20° C. or below, or when the temperature is too high, peeling, cracking, flaws, cracks, shrinkage, etc. will occur in the decorative coating. In other words, if the decorative coating film of coil A is not heated, the above-mentioned phenomenon will occur due to deformation (processing) that exceeds the elasticity of the decorative coating film. As the resin content of the decorative coating approaches its softening point and the adhesive strength between the coil A and the decorative coating decreases, the cosmetic coating may peel off from the coil A, shrink, or lack scratch resistance. Because there is. Furthermore, if the heating temperature is lower than about 20° C., the resin component of the decorative coating loses its softness and increases its hardness, which may cause cracking of the decorative coating or greatly reduce its scratch resistance.

Next, the coil A that has left the heater 6 is mainly fed to the embossing roll by the rotation of the third pinch roller 7, and the embossing roll 1 has a concave part α and a convex part with respect to the coil A, for example, as shown in FIG. An embossed pattern consisting of β is continuously formed. The coil A that has left the main embossing roll is corrected by a leveler to remove any residual strain during embossing while being stretched by the fourth pinch roller 10, and then sent to the reversing machine (2). The coil Δ that has passed through the reversing machine U is sent to the molding machine 15 through the space where the level sensor 14 is located, and this coil A is passed through the space where the level sensor 14 is located.
11, etc., and then fed to the preheater 16. In preheater 16, coil A is approximately 3
The mold 25 is heated to 0 to 90°C and passed through the guide roller 17.
feed to the entrance of the Further, from the discharge part 19, the mixture P which is undergoing reaction and foaming is discharged onto the back surface of the coil A, and the back material B is guided and laminated thereon via the guide 21. Note that the discharged mixture P is spread by the guide 21 and is regulated to a certain thickness. Next, the mixture P reacts and foams in the mold 25, changing into, for example, cream time, gel time, and rise time, and from the outlet 25b, a sandwich panel S having a shape as shown in FIG. 7(a) is continuously formed. Sent out. Next, the sandwich panel S is cut into a predetermined length by a traveling cutter 36, and fed to a secondary forming machine 37 to be formed as shown in FIG. The product is bent as shown in Figure (al).

What has been described above is only one embodiment of the method for manufacturing a sandwich board according to the present invention, and it can also be manufactured by forming as shown in FIGS. 8(a), (b), and 9. .

That is, FIG. 8 (al) is a case where the upper and lower die members 30 and 31 are formed by a group of rollers formed corresponding to the cross-sectional shape of the sandwich plate to manufacture a sandwich plate;
The bl diagram shows the case where a sandwich plate is manufactured by discharging the mixture P onto the backing material B.

Moreover, FIGS. 9(a) to (e) show the shape of coil A,
It is also possible to manufacture a sandwich plate using the coil A, which has a simple plate shape as shown in FIG.

As described above, according to the method for manufacturing a sandwich board according to the present invention, since a coil having a decorative coating film on its surface is heated, an arbitrary uneven pattern can be formed on the decorative coating film without causing cracks, scratches, peeling, cracking, or shrinkage. Can be embossed without creating any embossments. ■During embossing, a constant tension is applied to the coil, so the uneven pattern does not shift during embossing, and a beautiful uneven pattern can be formed.

■Residual distortion during embossing can be removed by passing the material through a leveler under tension, so it will not bend or twist. ■The decorative coating does not crack or peel during embossing, so it has excellent weather resistance, scratch resistance, and chemical resistance. ■Since the coil is reversed along a U-shaped trajectory from embossing to molding, there is no unreasonable bending of the coil and smooth communication between each process. (2) Since the coil is heated and the mixture is discharged into it, the mixture can be reacted and foamed in a good condition, and a uniform foam structure can be formed between the coil and the backing material. ■Since the inside of the mold is sealed, heat retention is improved, and leakage of harmful gases and combustion gases into the working environment is reduced, greatly improving worker safety and hygiene. ■Since the timing of contact between the back material and the mixture can be easily and freely selected, the upper base material can be reliably bonded, greatly improving the strength of the sandwich board. ■Since the sandwich board is bent into a V-shape and concave shape in the final process, the decorative surface does not become uneven after construction, making it possible to form a wall with a beautiful appearance. It has the following characteristics.

[Brief explanation of the drawing]

Fig. 1 is a schematic diagram showing the configuration of an example of an apparatus for carrying out the method for manufacturing a sandwich plate according to the present invention, Fig. 2 is a perspective view showing a leveler, and Figs. 3(a) to ti+ show examples of forming a thin metal plate. 4 (al to (e) are explanatory diagrams showing an example of the guide, and FIGS. 5 (a) and (1)) are cross sections showing an example of a sandwich plate manufactured by the method according to the present invention. 6 is a perspective view showing an example of an uneven pattern formed by embossing, FIG.
, (b), and FIGS. 9(a) to (C1 are explanatory diagrams showing other embodiments. 1-... Frame, 6... Heater, Work... Embossing roll, 9... Leveler, ■... On the other hand - IM, 15...
- Molding machine, 16... preheater, 19... discharge section,
25... Mold, 35... Cover, 37... Secondary forming machine, 38... Straightening machine. Patent applicant: IG Technical Research Institute '2' (i), A stem 4 not shown, S difficult name 8 ward<b>

Claims (1)

[Claims] (1) Emboss is applied to a thin metal plate wound into a coil, then the distortion of the metal thin plate is corrected with a leveler, the metal plate is greatly curved inward and then turned over, and then fed to a forming machine to form a gutter. A plastic foam raw material that is in the process of reacting and foaming is discharged onto the back side of the thin metal plate, a backing material is placed on top of this, and the material is heated to 30 to 110°C while being regulated to a certain shape. Then, a sandwich plate filled with plastic foam between the thin metal plate and the backing material was fed in a continuous band, and this was cut into a predetermined length with a traveling cutter, and the ends of the sandwich plate were formed with a secondary forming machine. A method for manufacturing a sandwich board, characterized in that the decorative surface of the sandwich board is later formed into a concave shape using a straightening roller.