JP4186455B2 - Manufacturing method of heat insulation panel and form material installation formwork - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
TECHNICAL FIELD The present invention relates to a method for manufacturing a heat insulating panel and a face material installation formwork, and more specifically, a method for manufacturing a heat insulating panel in which polyurethane foam is used as a heat insulating material and a surface material is sandwiched on the outside thereof, and a face material setting type used in this method. Regarding the frame.
[0002]
[Prior art]
A heat insulating panel in which foamed polyurethane is arranged in the middle and thin face materials are sandwiched on both sides thereof is widely used as an interior / exterior material. As the face material, paper, resin plates such as polypropylene, FRP (reinforced plastic) and vinyl chloride, metal plates such as steel and aluminum, and wood materials are used. Often used for convenience.
[0003]
For example, as shown in FIGS. 4 and 5, such a heat insulating panel is manufactured by placing the upper surface material 3 and the lower surface material 4 in advance in the upper and lower molds 1 and 2 having a hinge mechanism and waiting for about 75 ° or more. The mixing head 6 for pouring the polyurethane foam stock solution 5 at an angle θ ₀ is moved (traverse) sequentially from a predetermined position in the width direction and the length direction of the lower surface material. Injection is performed so that the entire surface of the material 4 is uniform. When the injection is completed, the mixing head 6 is withdrawn, and then the upper surface material 3 in the open position is quickly moved in a single-open state in the closing direction and pressed so as to cover the injected polyurethane foam stock solution to a predetermined pressure. Pressurize.
[0004]
When the upper surface material 3 is a steel plate, a magnet (permanent magnet) 7 is provided on the upper mold frame 1 side to dispose the upper surface material 3 in the upper mold frame 1, so that the upper surface material 3 is placed in the upper mold frame 1. It can be easily and reliably arranged. In the case where the top material 3 is a resin other than a magnetic material such as a steel plate, aluminum, paper, woody material, or a composite of these, it cannot be attached or detached using a magnet, but exclusively using an adhesive tape or the like. I was putting on and taking off.
[0005]
[Problems to be solved by the invention]
However, in the above-described prior art method, the mixing head 6 that has finished injecting the polyurethane foam stock solution is retracted each time. Therefore, it is necessary to control the reaction speed of the polyurethane foam stock solution according to the retracting operation of the mixing head 6. However, it was not always possible to increase productivity by requiring fine adjustments. Moreover, even in the step of superimposing the upper surface material 3 after the mixing head 6 is retracted, there is a frustration that the upper surface material cannot be quickly rotated to the closed position because the standby angle on the upper surface material side is large. That is, as shown in FIGS. 4 and 5, in the so-called oven pouring method in which the upper and lower molds are opened and the polyurethane foam stock solution is poured here, the polyurethane starts to foam immediately after the filling, so that the upper mold It is necessary to perform rotation within the closed position and press against the foaming pressure usually within 30 seconds. Such a series of operations must be performed quickly, and the delay of the operations is not allowed.
[0006]
On the other hand, even if the reaction time of the polyurethane foam stock solution is slowed, there is a limit when considering the aging time of the foamed polyurethane, and this is reflected in the rise in production costs. I was waiting.
[0007]
Further, in the above prior art, the face material other than the magnetic material is fixed to the mold with the adhesive tape. However, this method is not necessarily good in workability, and the adhesive tape is handled as a consumable item. It was disadvantageous in cost. Recently, the use of materials other than steel plates that are particularly heavy as face materials tends to increase, and there is a high demand for improved technology.
[0008]
Therefore, in view of the above-described problems of the prior art, the object of the present invention is to improve productivity by shortening the overlay time of the top surface material after the injection of the polyurethane foam stock solution and improving workability. An object of the present invention is to provide a method for manufacturing a sandwich-like heat insulation panel that can be increased to reduce manufacturing costs.
[0009]
[Means for Solving the Problems]
The above object can be achieved by the inventions described in the claims. That is, the characteristic configuration of the method for manufacturing a heat insulating panel according to the present invention is that a polyurethane foam stock solution is provided between an upper surface material fixed to an upper mold frame arranged at an open position and a lower surface material fixed to a lower mold frame. In a method of injecting and superposing them into a sandwich shape,
The upper mold frame and the lower mold frame have one end as a fulcrum and can be rotated around the fulcrum.
Either or both of the upper mold frame and the lower mold frame have a suction device mounting portion having a number of suction hole groups, and the suction device can be mounted on the suction device mounting portion. And the face material installed on the upper mold can be sucked and fixed,
The upper surface material is sucked by a suction device provided on the upper mold and fixed to the upper mold ,
Injecting the polyurethane foam stock solution from the outside of the upper and lower molds toward the lower material fixed to the lower mold, and rotating the upper mold to a closed position, The top surface material is superposed on the polyurethane foam stock solution injected above to integrate them into a sandwich.
[0010]
According to this configuration, since the polyurethane foam stock solution is injected from the outside of the upper and lower molds, there is no need to retract the injection device after the injection is completed, and the upper surface material fixed to the upper mold can be quickly removed. Since it can be superimposed on the injected polyurethane foam stock solution side, the time reduction during this period can be significantly achieved as compared with the prior art. Therefore, it is not necessary to slow down the reaction time of the polyurethane foaming stock solution, and it is not necessary to adjust the material forcibly, so that the workability is stabilized and the production yield is high and the production efficiency is high. In the present invention, the outer side means outside the rotation trajectory of the mold when the upper and lower molds are rotated to the closed position.
[0011]
As a result, according to the present invention, it is possible to increase the productivity by shortening the superposition time of the top material after the injection of the polyurethane foam stock solution, and improve the workability and reduce the manufacturing cost. It was possible to provide a method for manufacturing a thermal insulation panel.
[0012]
It is preferable that the upper surface material is fixed to the upper mold frame by suction with a suction device provided on the upper mold frame.
[0013]
According to this configuration, even if the face material is a non-magnetic material such as resin, aluminum, paper, wood, etc., the upper face material can be easily and stably fixed to the upper mold frame, so that the fixing work is accelerated. In addition, since it is not necessary to use a consumable tape as in the prior art, it is convenient to reduce the manufacturing cost.
[0014]
It is preferable that the upper mold frame to which the upper surface material is fixed waits at the open position at a standby angle of 5 to 20 ° with the lower mold frame to which the lower surface material is fixed.
[0015]
According to this configuration, when the standby angle of the upper mold frame (corresponding to the opening angle) is small with respect to the lower mold frame, the time for rotating the upper mold frame to the closed position after injecting the polyurethane foam stock solution is reduced. It can be made shorter and convenient. When the standby angle is less than 5 °, it becomes difficult to uniformly inject the polyurethane foam stock solution when the face material has a large area. When the standby angle exceeds 20 °, the time required for rotating the upper mold can be shortened. It cannot be achieved so much, which is not preferable. In particular, the standby angle is more preferably 10 to 15 °. However, when the width of the lower surface material is remarkably wide (injection distance becomes long), it is preferable in terms of work to set the opening height at the open position to a standby angle that can secure about 150 to 200 mm.
[0016]
In addition, the characteristic configuration of the face material installation mold according to the present invention includes an upper mold frame and a lower mold frame that have one end portion as a fulcrum and can be rotated around the fulcrum. The suction tool for sucking and fixing the face material to the mold side can be attached to either or both of the frames.
[0017]
According to this configuration, since one end of the mold is used as a fulcrum, it can be rotated around the fulcrum, so that the polyurethane foam stock solution can be quickly injected and the face material used can be resin, aluminum, paper Even if it is a non-magnetic material such as wood material, the face material can be easily and stably fixed to the formwork, so not only the fixing work is accelerated, but also a consumable tape like the conventional technology is used Therefore, it is convenient to reduce the manufacturing cost of the heat insulation panel.
[0018]
Either or both of the upper mold frame and the lower mold frame have a suction device mounting portion having a number of suction hole groups, and the suction device can be mounted on the suction device mounting portion. Thus, it is preferable to suck and fix the face material installed on the upper mold.
[0019]
According to this configuration, it is possible to prevent the foamed polyurethane from locally applying an excessive foaming pressure to a portion corresponding to the suction device mounting portion of the face material, and it is convenient that the face material can be stably fixed and held.
[0020]
It is preferable that a magnet is provided on one or both of the upper mold frame and the lower mold frame.
[0021]
According to this configuration, it is possible to easily and reliably fix the face material to the upper mold frame by using the suction instrument and the magnet together. In addition, if a magnet is provided in the lower mold frame, the positioning of the lower surface material to the lower mold frame becomes easy and reliable, and it is convenient that the heat insulation panel manufacturing work can be performed more efficiently.
[0022]
DETAILED DESCRIPTION OF THE INVENTION
The manufacturing method of the heat insulation panel which concerns on embodiment of this invention, and the face material installation formwork used for this are demonstrated in detail with reference to FIGS. FIG. 1 shows a face material installation form A in which an upper surface material 3 and a lower surface material 4 are respectively fixed in advance to upper and lower molds 1, 2 having a hinge mechanism in the same manner as shown in FIG. This face material installation form A is different from the prior art in that it has a standby angle θ of about 10 to 15 ° in a single-open shape, and is placed on the lower face material 4 housed and fixed in the lower form 2, A mixing head 6 for injecting the polyurethane foam stock solution 5 is arranged outside the upper and lower molds 1 and 2.
[0023]
In this embodiment, the mixing head 6 is arranged on the outer side of the upper and lower molds 1 and 2 so as to inject the polyurethane foam stock solution 5. Therefore, after the injection of the polyurethane foam stock solution 5 is finished, the mixing head 6 is retracted. Without this, the upper mold 2 can be quickly laid down to the closed position. In addition, since the standby angle θ itself is much smaller than that of the prior art, the upper mold frame 2, that is, the upper surface material 3 can be quickly rotated to the closed position. The opening and closing operation of the upper and lower molds 1 and 2 may be performed manually, or an electric motor for driving the motor to rotate while providing a rotation shaft at the end where both molds are close to each other. And may be mechanically performed by driving the rotating shaft by the electric motor.
[0024]
As shown in FIG. 1, the polyurethane foam stock solution 5 is injected from the mixing head 6 while moving the mixing head 6 along the long side direction of the lower mold 1 and moving the injection port 6 a of the mixing head 6 somewhat up and down. Rock and inject. By doing so, the injection of the polyurethane foam undiluted solution 5 is sufficiently spread to the back side of the lower surface material 4 accommodated and fixed in the lower mold 1 (the connection side end of the upper and lower molds 1 and 2). be able to. Of course, the mixing head 6 may be configured to move up and down without swinging the injection port 6a of the mixing head 6 or with the vertical swing of the injection port 6a. For the injection of the polyurethane foam stock solution 5, an optimum injection method can be selected by adjusting the height of the mixing head 6, the swing angle of the injection port 6a, the discharge amount, and the like.
[0025]
Further, as shown in FIG. 2, the upper mold frame 1 is provided with a plurality of suction device mounting portions 8 having a diameter of about 150 mmφ as an example on the entire surface of the upper mold frame (eight in FIG. 2). The upper surface material 3 is fixed by arranging the suction device 9 on the suction device mounting portion 8 and sucking it by a suction device (not shown). The suction device is not particularly limited. For example, the suction device may have a pressure reducing mechanism connected to a vacuum pump, or may be a suction type using a suction blower. In particular, the latter apparatus is advantageous because it has a lower suction cost than the former, but is low in equipment cost and easy in continuous suction.
[0026]
A large number of small-diameter suction holes 8a are formed through the upper mold 1 in the suction device attachment portion 8, and a suction pad 9 as a suction device is attached to the suction device attachment portion 8, and the suction hole 8a is passed through the suction hole 8a. By sucking, the upper surface material 3 is securely fixed to the upper mold 1. For example, a suction blower (not shown) is connected to the suction pad 9 and a solenoid valve is disposed in the middle of the suction pad 9 to control the opening and closing of the solenoid valve (not shown). It is conceivable to control the suction force to be optimal according to the above instruction, and at the same time, a mechanism for instructing the start or end of the suction operation of the blower by the control device. That is, when fixing the upper surface material to the upper mold 1, the initial suction force is weakened to facilitate the positioning of the upper surface material, and the suction force is increased when the positioning is completed, and the polyurethane foam stock solution 5 is injected. The suction operation is stopped when the upper mold 1 is laid down to the closed position. However, the suction mechanism or the suction cycle is not limited to such a method, and various changes can be employed depending on the work content. Further, the shape such as the number and size of the suction device mounting portions 8 can be appropriately changed depending on the material and shape of the face material, and is not limited to the examples shown in FIGS. The number, shape, etc. of 8a can also be selected according to purpose.
[0027]
【Example】
An attempt was made to produce a heat insulation panel for bathrooms using two FRP plates having a width and length of about 1 × 2 m as upper and lower face materials and foamed polyurethane as a heat insulation layer between both face materials. First, the face materials 3 and 4 are fixed and arranged in the upper and lower molds 1 and 2 made of aluminum having a thickness of 4 mm shown in FIG. On the surface of the upper mold 1, four suction instrument mounting portions 8 having a diameter of 150 mmφ as shown in FIG. The upper mold frame 1 is formed so that 600 to 800 suction holes 8a of about 5 mm are arranged substantially evenly.
[0028]
A suction pad 9 as shown in FIG. 3 is attached to these suction device attachment portions 8, and the upper surface material 3 is fixed to the upper mold frame 1 by suction through the suction holes 8 a. Suction control with respect to the suction pad 9 was performed by connecting a suction blower to the suction pad 9 and placing an electromagnetic valve in the middle of the suction pad 9 and instructing a controller that controls the opening and closing of the electromagnetic valve.
[0029]
The upper and lower molds were kept at a standby angle of about 15 °, and the polyurethane foam stock solution was injected while moving the injection port 6a of the mixing head 6 up and down along the long side direction of the molds. After the injection, the upper mold frame was immediately turned to the closed position without retracting the mixing head 6 and further pressed by a press. The time required from the start of injection of the polyurethane foam stock solution to the end of foaming was within 20 seconds. The finished sandwich panel did not show any bending, distortion, unevenness or other appearance defects.
[0030]
[Another embodiment]
(1) In the above embodiment, an example in which a non-magnetic material such as a resin plate is used as a face material has been described. However, in order to enhance convenience when a magnetic material such as a steel plate is used as a face material, In particular, a magnet 7 made of a permanent magnet may be attached to the upper mold as shown in FIG. In this case, the combined use of the suction device 9 and the magnet 7 is preferable because the face material can be fixed and arranged easily and reliably in the mold, and the heat insulating panel manufacturing work can be performed more easily. In this case, the strength of the magnetic force of the magnet can be appropriately changed according to the purpose of use. Furthermore, it is more preferable to attach a magnet not only to the upper mold frame but also to the lower mold frame, because the positioning work when the lower surface material is accommodated and fixedly arranged in the lower mold frame becomes easy.
[0031]
(2) In the above-described embodiment, the method of moving the mixing head 6 along the long side direction of the formwork has been described. However, the method is not necessarily limited to this, and the method of moving the mixing head 6 along the short side direction is adopted. May be. In addition, a computer control method using a CPU as a control device may be employed for the moving operation of the mixing head 6, the swinging operation of the injection port 6a, the injection control, the suction operation of the suction tool, the opening and closing operation of the upper and lower molds, and the like. it can.
[0032]
(3) In the above embodiment, the lower mold 2 has an example of a structure having an edge around the periphery, but is not necessarily limited to a structure having an edge, and the lower mold itself is composed of a smooth single plate. In addition, the structure may be such that the corresponding thing is arranged around the four sides to prevent the polyurethane stock solution to be poured out.
[Brief description of the drawings]
FIG. 1 is a schematic side view for explaining a method for producing a heat insulating panel according to the present invention. FIG. 2 is a schematic perspective view from the back side of the face material installation mold shown in FIG. FIG. 4 is a cross-sectional view showing a state in which the frame is in a closed position. FIG. 4 is a schematic diagram for explaining a conventional method for manufacturing a heat insulating panel. FIG. 5 is a schematic side view of FIG.
DESCRIPTION OF SYMBOLS 1 Upper mold frame 2 Lower mold frame 3 Upper surface material 4 Lower surface material 5 Polyurethane foam undiluted solution 7 Magnet 8 Suction device attachment part 8a Suction hole 9 Suction device

Claims (3)

A polyurethane foam stock solution is injected between the upper surface material fixed to the upper mold frame placed in the open position and the lower surface material fixed to the lower mold frame, and these are stacked to form a sandwich. In the manufacturing method,
The upper mold frame and the lower mold frame have one end as a fulcrum and can be rotated around the fulcrum.
Either or both of the upper mold frame and the lower mold frame have a suction device mounting portion having a number of suction hole groups, and the suction device can be mounted on the suction device mounting portion. And the face material installed on the upper mold can be sucked and fixed,
The upper surface material is sucked by a suction device provided on the upper mold and fixed to the upper mold ,
Injecting the polyurethane foam stock solution from the outside of the upper and lower molds toward the lower material fixed to the lower mold, and rotating the upper mold to a closed position, A method for manufacturing a heat insulating panel, wherein the upper surface material is superposed on the polyurethane foam stock solution injected above to integrate them into a sandwich.  The manufacturing method of the heat insulation panel of Claim 1 which makes the said upper mold frame which fixed the said upper surface material stand by in the said open position with the said lower mold frame which fixed the said lower surface material at a standby angle of 5-20 degrees.  The manufacturing method of the heat insulation panel of Claim 1 or 2 with which the magnet is provided in any one or both of the said upper formwork or the lower formwork.

Images