JPS58376B2 - Tobira Panel Noseizouhou - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a door panel by simultaneously bonding a surface material and injecting and foaming a rigid foam core.

Conventionally, doors and partitions have been made by pasting thin iron or aluminum sheets or decorative plywood onto frames made of iron, aluminum, or wood, and ribs are used to prevent distortion and twisting caused by the thinness of the sheets. A method of reinforcing the structure was used.

Recently, as flush doors have become popular, their weight has been reduced, and it has become necessary to use materials that cannot be welded, such as PVC steel plates, as surface materials, making it difficult to use conventional methods.

Flush door panels have steel plates, aluminum plates,
The core material is made by injecting and foaming polyurethane resin, polyepoxy resin, or phenol resin into a hollow structure covered with plywood, but when the surface material is made thinner to reduce weight, injection foaming At the same time, air bubbles that come into contact with the surface material lift the surface material, making it extremely uneven and reducing the product value by half.

In addition, when using plywood with a decorative resin board, iron plate, or aluminum plate attached in advance as a surface material, the surface material may be distorted or twisted due to the difference in material, making it difficult to foam. An excellent product could not be obtained.

The present invention is a further improvement over the current method of using lightweight rigid foams, and is economical by simultaneously performing injection foaming of the core material and adhesion of the surface material, shortening the process and providing a good finish. It is about a practical and rational method.

The method of the present invention will be explained below with reference to the drawings.

Fig. 1 is a cross-sectional view of a door panel manufactured by the method of the present invention, and Fig. 2 shows the state of the panel before and after injection foaming of a synthetic resin foam stock solution in order to explain the present invention in detail. However, perforated boards 2 are attached to both sides of a frame 4 made of iron, aluminum, or wood using nails or adhesive.

Iron is applied to the surface of the panel-like hollow structure made in this way.
The aluminum or resin thin plate 1 is placed on it as it is, or it is dot-bonded to prevent it from moving.

Alternatively, if a sheet 3 with an open cell structure made of soft urethane foam and non-woven fabric with a thickness of 1 to 3 mm is sandwiched between the perforated board and the surface material, foaming between the perforated board and the surface material can be achieved. Filling the body goes smoothly and is effective.

Various frame 4, perforated board 2, open cell structure sheet 3,
A synthetic resin foam stock solution such as polyurethane resin, polyepoxy resin, and phenol resin is mixed and injected into a hollow structure panel composed of the surface material 1 using a foaming machine.

As the injected foam stock solution foams and hardens, the resin flows through the holes 2' of the perforated board 2 and into the open cell structure sheet 3 sandwiched between the perforated board 2 and the surface material 1, or between the perforated board 2 and the surface material 1. When the foam 5 is completely filled and solidified, it also hardens to bond the perforated board and the surface material.

In this case, if the size, number, and position of the holes in the perforated board are appropriate, it is possible to bond almost the entire surface, and a strong sandwich panel door can be obtained.

Note that if the foam 5 soaks into the open-cell structured sheet 3 through the holes 2' and is hardened, the surface material 1 can be pressurized and bonded to the perforated board 2 to make it a stronger surface material, which is a feature of the present invention. can demonstrate even more.

As described above, according to the method of the present invention, it is possible to omit the process of gluing the surface material later, which is not only economical, but also causes no warping or twisting of the panel, and also prevents slight distortion. Excellent products can be obtained even with twisted surface materials.

The method of the present invention is effective not only for panels made of the same material on both sides, but also when using different facing materials, and is effective as a processing method for all sandwich panels, including not only door panels but also wall panels, partition panels, etc. It is.

[Brief explanation of the drawing]

FIG. 1 is a sectional view of a door panel manufactured by the method of the present invention, and FIG. 2 is a partially enlarged sectional view of A before injection and foaming of a synthetic resin foam stock solution and B after injection and foaming.

Claims (1)

[Claims] 1 Place the thin plate surface material directly on the structure with perforated boards attached to both sides of the frame, or dot-glue it so that it does not move, and place a breathable sheet between the perforated board and the surface material. A door panel characterized in that injection foaming of a core material and adhesion of a surface material are simultaneously performed by filling a synthetic resin foam stock solution into a hollow structural panel formed by sandwiching or not sandwiching the foam. Manufacturing method.