WO2009057899A2

WO2009057899A2 - Panel for prefabricated water tank and method of manufacturing the same

Info

Publication number: WO2009057899A2
Application number: PCT/KR2008/005872
Authority: WO
Inventors: Ki Jin Kim; Jang Hee Ahn; Sang Ki Lee
Original assignee: Young Sung Ind. Co., Ltd.
Priority date: 2007-10-30
Filing date: 2008-10-07
Publication date: 2009-05-07
Also published as: WO2009057899A3; KR100847763B1

Abstract

The present invention provides a panel for a prefabricated water tank including a main body made of an SMC and formed in a plate shape and a protection layer formed of a metal layer and adhering to a side of the main body, in order to increase the life and improve the external appearance.

Description

PANEL FOR PREFABRICATED WATER TANK AND METHOD OF MANUFACTURING THE SAME

Technical Field

[1] The present invention relates to a panel for a prefabricated water tank and a method of manufacturing the same. More particularly, the present invention relates to a panel for a prefabricated water tank that can be simply manufactured by integrally forming a thin metal layer on the surface of the panel and has high durability and good appearance by effectively blocking sunlight, and a method of manufacturing the panel. Background Art

[2] In general, a prefabricated water tank, a kind of water tank assembled in a cylindrical shape from several panels in a site with an appropriate structure to store water, is widely used in various places, such as an apartment, school, building, and factory.

[3] Panels made of sheet molding compound (SMCs) have excellent characteristics in mechanical properties, corrosion resistance, and productivity, such that they are widely used in recent years for panels for a prefabricated water tank.

[4] The SMC used for the panel for a prefabricated water tank is made from mainly unsaturated polyester resin and glass fiber and is a kind of plastic material that is formed in a plate shape in a semisolid state.

[5] A panel made of the SMC is manufactured by putting the SMC between a cope and a drag and pressure-forming the mold while heating such that a bottom panel for the bottom, side panels for the sides, and a top panel for the top are manufactured for each usage.

[6] On the other hand, in the related art, as being frequently installed on rooftops of buildings, outdoors, and in the open air, water tanks are exposed to sunlight for a long time, as well as rain and snow, which are factors decreasing their life.

[7] In particular, for SMC panels, as the top panel and the side panels are exposed to sunlight (ultraviolet rays) for a long time, the unsaturated polyester resin evaporates and the glass fiber is correspondingly exposed, such that problems including considerably decreasing durability and spoiling the external appearance are caused. Therefore, it is required to consider appropriate measures against these problems.

[8] The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art. Disclosure of Invention Technical Problem

[9] The present invention has been made in an effort to provide a panel for a prefabricated water tank and a method of manufacturing a panel having advantages of having increased life and improved external appearance by integrally forming a protection layer, which is formed of a metal layer, with a main body formed of an SMC to protect the main body from sunlight.

[10] Further, the present invention has been made in an effort to provide a panel for a prefabricated water tank and a method of manufacturing the panel having advantages of being simply manufactured and having improved productivity by integrally forming the protection layer formed of a metal layer in a mold through a simple process. Technical Solution

[11] An exemplary embodiment of the present invention provides a panel for a prefabricated water tank including a main body made of an SMC in a plate shape and a protection layer formed of a metal layer and adhering to a side of the main body.

[12] The main body has a flat plate, which is a plane with edges, and flanges vertically bending from ends of the edges of the flat plate in the opposite direction to the protection layer.

[13] The protection layer is made of aluminum, copper, stainless steel, etc., having a thickness of about 50-120μm.

[14] A shock-absorbing layer is further disposed between the side of the flat plate and the protection layer.

[15] The shock-absorbing layer may be made of a glass fiber mat or a non- woven fabric.

[16] A sub-protection layer formed by coating a resin may be further disposed on the protection layer.

[17] Another exemplary embodiment of the present invention provides a method of manufacturing a panel for a prefabricated water tank that includes sequentially stacking an SMC, a shock-absorbing sheet, and a metal layer onto a drag, assembling a cope with the drag, and performing the forming by pressing the cope and the drag that are heated to a predetermined temperature.

[18] The shock-absorbing sheet may be made of a non- woven fabric or a glass fiber mat.

[19] The metal layer may be made of aluminum, copper, stainless steel, etc., having a thickness of about 50-120μm.

[20] The press-forming is applied for about 3 to 10 minutes between the cope and the drag, which are heated to about 120 to 15O⁰C.

[21] An adhesive primer may be applied on the side of the metal layer facing the SMC to improve adhesion.

[22] Further, a resin may be coated on the other side of the metal layer to form a sub- protection layer.

[23] Further, another exemplary embodiment of the present invention provides a prefabricated water tank that includes: a plurality of bottom panels that form a bottom by being connected with each other; a plurality of side panels that are disposed in connection with each other on planes perpendicular to the bottom panels and of which lower ends are connected to the outer edges of the bottom to form side walls; and a plurality of top panels that are disposed in connection with each other on planes perpendicular to the side panels and facing the bottom panels and of which the outer edges are connected with the upper ends of the side walls.

[24] The side panel has a flat plate, which is a plane with edges, flanges vertically bending in one direction from ends of the edges, a side protection layer made of urethane foam and disposed on a side of the flat plate, and a side cover formed of a thin metal plate and disposed on the side protection layer.

[25] The top panel includes a flat plate, which is a plane with edges, flanges vertically bending down from ends of the edges of the flat plate, a protection cover formed of a metal layer and adhering to the upper side of the top panel, and a shock-absorbing member made of a fiber and interposed between the upper side of the flat plate and the protection cover.

[26] The protection cover of the top panel may be formed of a material having about

50-120μm thickness, selected from aluminum, copper, and stainless steel, the shock- absorbing member of the top panel may be made of a glass fiber mat or a non- woven fabric, and a coating layer may be formed on the protection layer by coating a resin.

Advantageous Effects

[27] According to the prefabricated water tank having the above configurations and a method of manufacturing the water tank of the present invention, since the protection layer formed of a metal layer is provided on the main body formed of the SMC, weatherability and external appearance are improved.

[28] That is, the protection layer blocks sunlight (ultraviolet rays) and protects the SMC, such that the panel is not worn or damaged. Therefore, the life can be extended and the metal keeps the natural color and shine, thereby improving the external appearance.

[29] Further, according to the panel for a prefabricated water tank and a method of manufacturing the panel of the present invention, since the metal layer and the SMC are integrally formed in contact with each other through a simple process in one mold, manufacturing processes are reduced and productivity is considerably improved.

[30] Further, since the shock-absorbing layer is interposed between the metal layer and the SMC, wave patterns, breaking, and air bubbles that may be generated by fusion and flow of the SMC in the mold are prevented, thereby achieving a smooth and uniform protection layer.

[31] Further, according to the panel for a prefabricated water tank and a method of manufacturing the panel of the invention, the adhesive primer improves adhesion of the SMC and the metal layer, such that durability of the protection layer is improved.

[32] In addition, according to the panel for a prefabricated water tank and a method of manufacturing the panel of the invention, since the protection is formed by coating a resin, it is possible to more effectively block the ultraviolet rays and maintain the external appearance for a long time. Brief Description of the Drawings

[33] FIG. 1 is a perspective view showing an exemplary embodiment of a panel for a prefabricated water tank according to the present invention.

[34] FIG. 2 is a cross-sectional view showing an exemplary embodiment of the panel for a prefabricated water tank according to the present invention.

[35] FIG. 3 is a partial enlarged cross-sectional view showing the panel for a prefabricated water tank according to the present invention.

[36] FIG. 4 is a partial enlarged cross-sectional view showing another exemplary embodiment of the panel for a prefabricated water tank according to the present invention.

[37] FIG. 5 is a block diagram illustrating an exemplary embodiment of a method of manufacturing a panel for a prefabricated water tank according to the present invention.

[38] FIG. 6 is a cross-sectional view illustrating the method of manufacturing the panel for a prefabricated water tank according to the present invention.

[39] FIG. 7 is a cross-sectional view illustrating another exemplary embodiment of the method of manufacturing the panel for a prefabricated water tank according to the present invention.

[40] FIG. 8 is a perspective view showing an exemplary embodiment of a panel for a prefabricated water tank according to the present invention.

[41] FIG. 9 is a cross-sectional view showing an exemplary embodiment of the panel for a prefabricated water tank according to the present invention.

[42] FIG. 10 is a cross-sectional view showing the bottom panel of the exemplary embodiment of the panel for a prefabricated water tank according to the present invention.

[43] FIG. 11 is a cross-sectional view showing a side panel of the exemplary embodiment of the panel for a prefabricated water tank according to the present invention.

[44] FIG. 12 is a perspective view showing the top panel of the exemplary embodiment of the panel for a prefabricated water tank according to the present invention.

[45] FIG. 13 is a cross-sectional view showing the top panel of the exemplary embodiment of the panel for a prefabricated water tank according to the present invention.

[46] FIG. 14 is a partial enlarged cross-sectional view showing the top panel of the exemplary embodiment of the panel for a prefabricated water tank according to the present invention. [47] FIG. 15 is a partial enlarged cross-sectional view showing the top panel with a coating layer of an exemplary embodiment of the panel for a prefabricated water tank according to the present invention.

Best Mode for Carrying Out the Invention [48] A panel 10 for a prefabricated water tank according to an exemplary embodiment of the present invention, as shown in FIGS. 1 to 3, includes a main body 11, a protection layer 16 adhering to a side of the main body 11, and a shock- absorbing layer 14 interposed between the side of the main body 11 and the protection layer 16. [49] The main body 11 is made of a sheet molding compound (SMC) that is generally widely used as a material for panels for water tanks. [50] The main body 11 has a flat plate 12, which is a plane with edges, and flanges 13 vertically bending from the ends of the edges of the flat plate 12 in the opposite direction to the protection layer 16. [51] The protection layer 16 is formed of a thin metal layer having about 50-120 μm thickness.

[52] The metal layer is made of aluminum.

[53] The metal layer may be made of copper or stainless steel, not aluminum.

[54] The shock- absorbing layer 14 is made of a fiber and disposed between the flat plate

12 of the main body 11 and the protection layer 16. [55] The shock-absorbing layer 14 may be made of a fiber having good heat resistance, such as a glass fiber mat or a non- woven fabric. [56] Alternatively, a panel 10 for a prefabricated water tank according to another exemplary embodiment of the present invention may further include a sub-protection layer 18 that is formed by coating a resin on the protection layer 16, as shown in FIG.

4.

[57] An acrylic resin, etc., can be used for the resin coated on the protection layer 16.

[58] When being formed by coating the acrylic resin, the sub-protection layer 18 endures well against rain, snow, sunlight, etc., for good weatherability of the acrylic resin. [59] Other than the above-mentioned configuration, the panel for a prefabricated water tank according to above-mentioned another exemplary embodiment of the present invention can be achieved in the same configuration as the panel for a prefabricated water tank according to the above exemplary embodiment of the present invention, such that a detailed description will not be provided. [60] Meanwhile, a method of manufacturing a panel for a prefabricated water tank according to an exemplary embodiment of the present invention is achieved by se- quentially stacking an SMC 12, a shock-absorbing sheet 14, and a metal layer 16 on a drag 34 (PlO), assembling a cope 32 with the drag 34 (P20), and forming the panel by pressing the cope 32 and the drag 34 heated to a predetermined temperature (P30).

[61] A non-woven fabric or a glass fiber mat is used for the shock-absorbing sheet 14.

[62] The metal layer 16 is formed of copper, aluminum, or stainless steel having a thickness of about 50 tol20μm.

[63] As shown in FIG. 7, an adhesive primer may be applied onto a side (bottom) of the metal layer 16 facing the SMC 12 to strengthen the adhesion, and a resin may be coated onto the other side (top) of the metal layer 16 to form the sub-protection layer 18.

[64] Epoxy-based adhesive primers can be used for the adhesive primer and an acrylic resin can be used for the resin coated to form the sub-protection layer 18.

[65] The press-forming is applied for about 3 to 10 minutes between the cope 32 and the drag 34 heated to about 120-150⁰C.

[66] Further, the panel for a prefabricated water tank according to an exemplary embodiment of the present invention, as shown in FIGS. 8 and 9, includes a plurality of bottom panels 110, a plurality of side panels 120, and a plurality of top panels 130.

[67] The plurality of bottom panels 110 are formed in plate shapes and disposed in connection with each other to form the bottom.

[68] The bottom panels 110 may have the same configurations as common panels widely used for water tanks.

[69] For example, the bottom panel 110, as shown in FIG. 10, has a flat plate 112, which is a plane with edges, and flanges 114 vertically bending in one direction (downward) from ends of the edges of the flat plate 112.

[70] Though not shown in the drawings, a reinforcement portion protruding upward

(inside the water tank) may be formed on the flat plate 112 of the bottom panel 110.

[71] The side panels 120 are disposed in connection with each other on planes perpendicular to the bottom panel 110 and of which lower ends are connected to the outer edges of the bottom to form side walls.

[72] The side panel 120, for example as shown in FIG. 11, has a flat plate 122, which is a plane with edges, flanges 124 vertically bending from ends of the edges of the flat plate 122, a side protection layer 126 made of ure thane foam and disposed at a side of the flat plate 122, and a side cover 128 formed of a thin metal plate and disposed on the side protection layer 126.

[73] A reinforcement portion 123 protruding to a side (inside the water tank) may be formed on the flat plate 122.

[74] Though not shown in the drawings, the side panel 120 may have the same configuration as common side panels widely used. [75] The top panels 130, as shown in FIG. 12 to FIG. 14, are disposed in connection with each other in planes perpendicular to the side panels 120 and facing the bottom panels 110, and of which the outer edges are connected with the upper ends of the side walls to form the top with the protection layer 138 on a side (the upper side).

[76] The top panel 130, for example, has a flat plate 132, which is a plane with edges, flanges 134 vertically bending down from ends of the edges of the flat plate 132, the protection cover 138 formed of a metal layer and adhering to the upper side of the top panel 130, and a shock- absorbing member 136 made of a fiber and interposed between the upper side of the flat plate 132 and the protection cover 138.

[77] The flat plate 132 and flanges 134 are made of SMCs.

[78] The protection cover 138 is formed of a material having a thickness of about

50-120μm, selected from aluminum, copper, and stainless steel.

[79] The shock-absorbing member 136 is made of a glass fiber mat or a non- woven fabric.

[80] The top panel 130 may further include, as shown in FIG. 15, a coating layer 140 formed by coating a resin, such as an acrylic resin, on the protection layer 138.

[81] While panels for a prefabricated water tank according to preferred embodiments of the present invention and a method of manufacturing the panels are described above, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

[1] A panel for a prefabricated water tank comprising: a main body made of an SMC in a plate shape; and a protection layer formed of a metal layer and adhering to a side of the main body.

[2] The panel for a prefabricated water tank of claim 1, wherein the main body has a flat plate, which is a plane with edges, and flanges vertically bending from ends of the edges of the flat plate in the opposite direction to the protection layer.

[3] The panel for a prefabricated water tank of claim 1, further comprising; a shock-absorbing layer made of a fiber and interposed between the side of the flat plate and the protection layer.

[4] The panel for a prefabricated water tank of claim 3, wherein the shock-absorbing layer is made of a glass fiber mat or a non- woven fabric.

[5] The panel for a prefabricated water tank of claim 1, further comprising: a sub-protection layer formed by coating a resin on the protection layer.

[6] The panel for a prefabricated water tank of claim 1, wherein the protection layer is formed of a material having about 50-120μm thickness, selected from aluminum, copper, and stainless steel.

[7] A method of manufacturing a panel for a prefabricated water tank, comprising: sequentially stacking an SMC, a shock-absorbing sheet, and a metal layer onto a drag; assembling a cope with the drag; and performing forming by pressing the cope and the drag that are heated to a predetermined temperature.

[8] The method of manufacturing a panel for a prefabricated water tank of claim 7, wherein the press-forming is applied for 3 to 10 minutes between the cope and the drag that are heated to 120 tol50°C, the shock-absorbing sheet is made of a non- woven fabric or a glass fiber mat, and the metal layer is formed of a material having about 50-120μm thickness, selected from aluminum, copper, and stainless steel.

[9] The method of manufacturing a panel for a prefabricated water tank of claim 7, wherein an adhesive primer is applied on the surface of the metal layer facing the

SMC.

[10] The method of manufacturing a panel for a prefabricated water tank of any one of claim 7 to claim 9, wherein a sub-protection layer is formed by coating a resin on the metal layer.

[11] A prefabricated water tank comprising: a plurality of bottom panels that form a bottom by being connected with each other; a plurality of side panels that are disposed in connection with each other on planes perpendicular to the bottom panels and of which lower ends are connected to the outer edges of the bottom to form side walls; and a plurality of top panels that are disposed in connection with each other on planes perpendicular to the side panels and facing the bottom panels and of which the outer edges are connected with the upper ends of the side walls, wherein the top panel includes a flat plate, which is a plane with edges, flanges vertically bending down from ends of the edges of the flat plate, a protection cover formed of a metal layer and adhering to the upper side of the top panel, and a shock-absorbing member made of a fiber and interposed between the upper side of the flat plate and the protection cover.

[12] The prefabricated water tank of claim 11 , wherein the shock-absorbing member of the top panel is made of a glass fiber mat or a non-woven fabric, and the protection cover of the top panel is formed of a material having about 50-120μm thickness, selected from aluminum, copper, and stainless steel.

[13] The prefabricated water tank of claim 11, wherein the top panel further comprises a coating layer formed by coating a resin on the protection cover.

[14] The prefabricated water tank of claim 11, wherein the side panel has a flat plate, which is a plane with edges, flanges vertically bending in one direction from ends of the edges, a side protection layer made of urethane foam and disposed on a side of the flat plate, and a side cover formed of a thin metal plate and disposed on the side protection layer.