JPS6210174B2 - - Google Patents

Description

[Detailed Description of the Invention] This invention relates to a method for manufacturing a laminate plate for shutters, etc.
More specifically, by joining together the metal parts such as the surface material and the foam that serves as the internal heat insulating material at the same time as the foam is molded, the integrity of the joint is greatly strengthened and the heat insulating effect is excellent. This is a manufacturing method that can provide a wide variety of products.

Conventionally, for laminates such as shutters that have a surface material made of aluminum or other metal plates, we provide a product with an insulation board interposed between the two surface materials for the purpose of heat insulation, etc. However, once the insulation material has been formed on the board, it is difficult to adhere sufficiently to the metal surface material, and the bonding process is troublesome, so recently manufacturing methods have been developed that involve injecting foamed polyurethane between the surface materials. A method is proposed.
However, in the case of foamed polyurethane injection, the skin layer of the foamed polyurethane is seamlessly bonded to the surface material, and the manufacturing method tends to create large voids due to air pockets during filling.In addition, it is brittle after curing, which causes vibrations when opening and closing the shutters. It is easy for parts to chip and fall off, creating large voids in that part, which reduces the insulation effect and weakens the insulation, and also causes the joint surface material to warp greatly due to the above-mentioned continuous bonding. The disadvantage was that the large warp easily caused trouble in opening and closing the shutters.

In addition, when using the above foamed polyurethane injection,
As for the degree of bonding between the surface material and the insulation material, which are seamlessly bonded, since the surface material is made of metal,
A sufficient bonding degree could not be obtained.

Therefore, in the present invention, we have invented a manufacturing method that can eliminate the drawbacks of the above-mentioned prior art, and in the first invention method, at least the joining target side is between two surface materials made of metal plates. In this case, metal pipes that can be injected with steam are interposed at appropriate locations, and a large number of foamed particles made of a styrene-maleic anhydride copolymer or a blend of this and other thermoplastic resins are interposed, and two sheets are prepared. At the same time, heating is performed by injecting steam into the foamed particles from the surrounding area and steam injection from the metal tube to heat and expand the foamed particles to form a foamed body that is thermally fused to each other. The present invention resides in a method for manufacturing a laminate plate for a rain door or the like, characterized in that the foam is simultaneously bonded to a surface material and a metal pipe to obtain a laminate plate.

Further, in a second method of the invention, at least one set of opposing sides of the peripheral portion of the portion where the foamed particles are interposed between the surface materials is covered with a metal shape material into which steam can be injected, and the foamed particles are In this manufacturing method, when the surface material and the metal tube are joined together, the metal shape material is also joined at the same time.

Next, embodiments of the first invention method will be illustrated below with reference to the drawings.

First, in the case shown in FIG. 1, one surface material 10 made of aluminum, steel plate, or other metal is placed on a mold 40 having a steam chamber 41, and the inside is made into a steam chamber 31 and a steam injection hole is formed. A metal tube 30 having a diameter of 32 is also placed thereon, and the metal tube 30 is surrounded by a surrounding-framed mold 50 having a steam chamber 51 and a steam injection hole 52 so as to communicate with the metal tube 30. Next, 2 maleic anhydride is applied on the surface material 10.
-25% by weight, styrene-maleic anhydride copolymer composed of 98-75% by weight of styrene, or a blend product of maleic anhydride copolymer and other thermoplastic resin (e.g. polybutadiene, etc.) as above A large number of foamed particles a are laid down, and then the other surface material 1 is placed on the foamed particles a and the metal tube 30.
0' is placed and has a steam chamber 61.
The foamed particles a are placed between the surface materials 10 and 10' by closing the mold. Next, by supplying steam to the steam chambers 41, 61 of the molds 40, 60, indirect heating is achieved by heating the metal surface materials 10, 10', and the steam injection hole 52 of the mold 50 and the metal tube 30 are heated indirectly. The foamed particles a are heated by direct steam heating from the steam injection hole 32, and the foamed particles a are heated and expanded to form the foamed body 20 which is thermally fused to each other. 20 is integrally joined with the surface materials 10, 10' and the metal tube 30 to provide the laminate 1 as shown in FIG. After molding, cooling and mold release are performed in the same manner as in normal foam molding.

In addition, in the case shown in FIG. 3, the surface materials 10 and 10' made of two metal plates are placed in a mold with an appropriate distance between them that is suitable for the thickness of the foam. , 10' and the metal tube 30 are set, and then the foamed particles a are filled into the above-mentioned space from the filling port 53 of the mold 50 to fill the surface material 1.
The expanded particles a are left between 0 and 10'. Next, as in the case of FIG. 1 above, foamed particles a
Heating is performed indirectly through heating of the surface materials 10, 10' and by direct steam heating from the steam injection hole 52 of the mold 50 and the steam injection hole 32 of the metal tube 30, and foaming is performed. The particles a may be heated and expanded to form a foamed body 20 that is heat-sealed to each other, and at the same time, the foamed body 20 may be integrally joined to the surface materials 10, 10' and the metal tube 30.

In addition, in the above manufacturing process, the molds 40, 60 used to sandwich the surface materials 10, 10' are shown as having steam chambers 41, 61, but the molds 40, 60 used to sandwich the surface materials 10, 10' are shown as having steam chambers 41, 61; It is also possible to use a heating means other than steam, such as one equipped with a heater.

In addition, in practice, the surface material 10,1 made of a metal plate
0' may be a metal veneer or a laminated surface material having a metal plate on the side to be bonded to the foam and a synthetic resin on the other side. In addition, the specific shape thereof may be flat, one or both of the surface materials 10, 10' may be corrugated (as shown in FIG. 4), or it may be ribbed so that the metal profile 70 can be easily fitted. In the case of the shape (as illustrated in FIG. 5), various implementations are possible.
And the overall shape is 90 x 180 cm for shutters etc.
The thickness of the foam 20 is approximately 2 cm, but depending on the purpose, it is not limited to a rectangular shape and may have other shapes, and various sizes may be used. A frame-shaped metal profile such as aluminum sash may be attached to the laminated board using screws or other means to complete the shutter.

The metal tubes 30 mentioned above can be interposed in a criss-crossed state as shown in FIG. 1, or they can be interposed only in one direction in the vertical and horizontal directions of the surface material (see FIGS. 6 and 7). In addition to aluminum tubes, other materials can also be used.

Next, an embodiment of the second invention method will be illustrated with reference to FIG. 8 and subsequent figures.

First, a mold 40 having steam chambers 41 and 61,
60, a surface material 10, 10' consisting of two metal plates is placed in advance with a metal tube 30 interposed between the two,
The foam body 20 is set in a mold with an appropriate interval between the foam bodies 20 and the foam body 20, and the surrounding area is surrounded by a frame-shaped metal shape member 70 with a steam injection hole 72. A mold 80 is set around the outer periphery of the mold 80 so as to form a steam chamber 71 with the metal mold member 70. Then, between the surface materials 10 and 10', styrene is inserted from the filling port 90.
The mold 4 is filled with a large number of expanded particles a made of a maleic anhydride copolymer or a blend of this and other thermoplastic resins.
0,60 steam chambers 41,51 through the metal surface materials 10,10', and direct steam heating from the steam injection hole 72 of the metal profile 70 and the steam injection hole 32 of the metal tube 30. The foamed particles a are heated and expanded to form a foamed body 20 that is heat-sealed to each other, and at the same time, the foamed body 20 is integrally joined to the surface materials 10, 10', the metal tube 30, and the metal shape 70. In this way, a laminate 1' as shown in FIG. 8 is provided.

Regarding the filling port 90 for filling the foamed particles a, there are cases in which it is removed after filling, and there are cases in which the filling port 90 is embedded inside the foam 20, and especially in the latter case, it is not connected to the metal mold material 70. If the foam body 20 is provided in such a way, it will be difficult to remove it, and the shape as illustrated in FIG. 10 can further strengthen the sense of unity with the foam body 20.

Furthermore, when the metal profile 70 is used only on one set of opposing sides, the other set of sides has the steam chamber 51 and the steam injection hole 52 shown in the embodiment of the first invention method.
It is sufficient to use the attached mold 50, and the manufactured laminate 1'' is obtained in which only one pair of opposing sides are covered with the metal mold 70 (Fig. 11). In this case, after manufacturing the laminate 1'', arbitrary metal shapes may be attached to the side portions of the other sets by screws, adhesive, or other means.

Further, as for the shape of the laminate according to the second invention method, in addition to the case where the surface materials 10, 10' made of aluminum or other appropriate metal are flat as in the first invention method, one or both of the surface materials 10, 10' may be flat.
0' may have a wave shape, or may have a ribbed shape that makes it easy to fit around the metal shape 70, etc. Various implementations are possible.

Among the manufacturing methods of the present invention, according to the first method of the present invention, at least two bonding objects are made of metal plates.
Since foamed particles are interposed between the two surface materials and a metal pipe that can be injected with steam is interposed, indirect heating can be performed by heating the two surface materials, and direct heating can be performed from around the foamed particle layer. In addition, direct steam heating from the metal tube inside the foamed particle layer is possible, allowing even foaming to reach the inside of the foamed particle layer.Moreover, the heated foamed particles are made of styrene-maleic anhydride copolymer. Also, since it is made of this and other thermoplastic resins and contains polar maleic acid, it has very high bonding properties with the surface material made of metal plates, and the heating particles of foamed particles can be used without using adhesives. At the same time, they are joined together by mutual thermal fusion by heating and expansion, and the degree of joining is strong and manufacturing is easy. Therefore, the surface material 10,1
This eliminates the drawbacks of conventional products, such as peeling off from the 0' or chipping partially due to vibrations caused by opening and closing during use as a rain door.

In addition, in the laminate manufactured as described above, small gaps between particles remain even after secondary foaming between the bonded portions of the surface materials 10, 10' and the foamed body 20 made of the specified material. The foam is not bonded to the surface material over the entire surface, and the foam prevents the expansion due to thermal effects of the surface material 10, 10' made of metal plates when the laminate is used as a rain door etc. The surface material can escape only in the gap portion where the foam is not exposed, and has the effect of preventing warping of the entire body due to the difference in coefficient of thermal expansion from the foam 20.

Furthermore, foams made of styrene-maleic anhydride copolymers or blends of these with other thermoplastic resins are highly heat-resistant and suitable for use in summer or heating applications when the laminates are used as shutters. Even when the heat is transferred, thermal deformation does not occur and a good heat insulating effect is achieved. Therefore, the laminated board for shutters has excellent heat retention properties without escaping the indoor cooling effect even in midsummer, and without escaping the indoor heating effect even in midwinter.

Furthermore, by injecting steam into the foamed particle layer through the metal tube 30, the steam heating is made uniform as described above, and it is possible to provide a laminate with no defective fusion, and it also has a reinforcing effect as a framework within the laminate after manufacturing. It can also be increased.

Furthermore, according to the second method of the present invention among the above-described manufacturing methods of the present invention, a metal mold member 70 is attached to at least one pair of opposing sides of the periphery of the portion where the foamed particles are interposed between two surface materials. In addition, because of the method of joining and integrating the metal profile 70 with the foam 20 together with the surface materials 10, 10' and the metal tube 30, the metal profile 70 can also be strongly bonded to the foam 20. This has the effect of omitting (in the case of integrating the entire circumference) or reducing (in the case of partially integrating the periphery) the post-installation process of the metal profile 70 on the tube-filled laminate. It can contribute to increasing manufacturing efficiency.

Furthermore, in addition to the above-mentioned shutters, the products obtained by the first and second invention methods include ceiling materials and wall materials for unit baths, face plates for tables and home kotatsu, signboards, advertising boards, blackboards, doors, It can be widely used for various purposes such as partitioning, and can exhibit excellent effects.

[Brief explanation of the drawing]

The figure illustrates an embodiment according to the invention,
FIG. 1 is a cross-sectional view showing the manufacturing process of the first invention method;
FIG. 2 is a perspective view of the manufactured laminate, FIG. 3 is a sectional view of a modified example, FIGS. 4 and 5 are sectional views showing several types of laminates manufactured in the modified example, and FIG. 7 and 7 are perspective views showing several types of laminates manufactured in the modified example, FIG. 8 is a partially omitted sectional view showing the process of manufacturing by the second invention method, and FIG. 9 is a sectional view of the manufactured laminate. FIG. 10 is a partially cutaway perspective view of a laminate, FIG. 10 is a partial sectional view of a modified example, and FIG. 11 is a perspective view of a laminate manufactured in a further modified example. 1, 1', 1''...the entire laminate, 10, 10'...
Surface material, a... Foamed particles, 20... Foam, 30... Metal tube, 31... Steam chamber, 32... Steam injection hole, 40,
50, 60... Molding mold, 41, 51, 61... Steam chamber, 52... Steam injection hole, 70... Metal mold material, 71...
Steam chamber, 72... Steam injection hole, 80... Molding mold.

Claims (1)

[Scope of Claims] 1 Metal pipes capable of injecting steam are interposed at appropriate locations between two surface materials whose surfaces are made of metal plates at least on the side to be joined, and a styrene-maleic anhydride copolymer or a styrene-maleic anhydride copolymer or the like is interposed between the two surface materials. A large number of foamed particles made of a blended product with other thermoplastic resins are interposed, and while the two surface materials are heated, steam is injected into the foamed particles from the surrounding area and steam is injected from the metal tube. A storm door characterized in that a laminated plate is obtained by heating to expand the foamed particles to form a foamed body that is heat-sealed to each other and at the same time to integrally join the foamed body to a surface material and a metal pipe. A method of manufacturing a laminate such as 2 The two surface materials are sandwiched and heated in a mold having a steam chamber or other heating means, and steam can be injected into the foam particles around the area where the foam particles are interposed between the two surface materials. The foam particles are heated by indirect heating through the surface material and direct heating by steam injection from the surroundings and steam injection from a metal tube. A method for producing a laminate for shutters, etc., as described in item 1. 3. Lamination of shutters, etc. according to claim 1 above using foamed particles of styrene-maleic anhydride copolymer made of 2 to 25% by weight of maleic anhydride and 98 to 75% by weight of styrene. Method of manufacturing the board. 4. A shutter, etc. according to claim 1, comprising foamed particles containing 2 to 25% by weight of maleic anhydride as a blend product of styrene-maleic anhydride copolymer and other thermoplastic resin. A method for manufacturing laminates. 5. A method for manufacturing a laminate for a rain door or the like according to claim 1, wherein a corrugated plate is used as one of the two surface materials made of metal plates. 6. At least metal pipes capable of steam injection are interposed at appropriate locations between two surface materials whose surfaces are made of metal plates at least on the side to be joined, and styrene-maleic anhydride copolymer or this and other thermoplastic resin is interposed at appropriate locations. A large number of foamed particles made of a blend of the above are interposed, and at least one set of opposing sides of the periphery is covered with a metal mold material that can be injected with steam, and the two surface materials are heated. At the same time, heating is performed by injecting steam into the foamed particles, and the foamed particles are heated and expanded to form a foamed body that is heat-sealed to each other, and at the same time, the foamed body is joined to the surface material, the metal pipe, and the metal shape material. A method for producing a laminate for shutters, etc., characterized by obtaining a laminate. 7 The two surface materials are sandwiched and heated in a mold having a steam chamber or other heating means, and the area where the foamed particles are interposed between the two surface materials is surrounded by only the metal mold material or this. and surrounded by a steam-injectable mold, the foamed particles are heated by indirect heating through the surface material and direct heating by steam injection from the surroundings and steam injection from a metal tube. A method for manufacturing a laminate for shutters, etc., as described in item 7.