JPS5949195B2 - Manufacturing method for architectural plate members - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a plate-shaped architectural member comprising a facing material, a backing material, and a foam.

When a metal plate surface material, a flexible lining material, and a mainly synthetic resin foam are laminated together to form an architectural plate-like member suitable for external walls, floors, ceilings, partitions, etc., the back side is attached to both edges. A metal plate with a rising portion facing upward is turned over and fed in one direction while feeding the foam raw material into the metal plate with a U-shaped end. Next, a backing material is layered on top of the metal plate and foaming is performed in a mold. Techniques have already been proposed in which body raw materials are foamed to form a molded product of a predetermined shape by integrating these materials. The present invention improves this technique so that the backing material can be easily joined to the metal plate and efficiently formed into a predetermined shape without fear of deformation.

The embodiments of the present invention will be described below with reference to the drawings. A belt-shaped iron plate or other metal plate having a plating layer, a paint layer, or other rust-preventive or decorative coating layer on its surface is erected on both sides of the iron plate or other metal plate. The raised portions 2 and 3 thus formed are bent and formed, and they are further bent to form insert-type connecting portions 4 and 5 extending in a direction parallel to the metal plate, and the central portion is made to protrude toward the back side. The rising parts 2 and 3 and the connecting part 6 for forming the connecting part following them are bent and formed to form two U-shaped end surfaces consisting of a surface part T of an appropriate width and the rising parts 2 and 3 with connecting parts on both sides thereof. The surface material 8 is formed into a regular tatoo body. FIG. 1 shows a mold 13 in which two mold members 11 and 12 arranged vertically face each other and move in one direction on a substantially horizontal plane.
An example of a molding apparatus in which a foam body 9 is foam-formed is shown. The mold members 11 and 12 are made of stainless steel or carbon steel strips, and have a smooth surface with a rust-proof and anti-corrosion plating layer, a silicone resin layer with good releasability for molded products, and other protective layers as necessary. Drum-shaped drive wheels 14 and 15, each of which is composed of an endless belt and driven by a prime mover (not shown), and a drum-shaped guide ring 16 supported by a movable bearing and whose tension can be adjusted, are wrapped around IT, and are wrapped around the mold for forming. Auxiliary wheels 18 in the part forming 13,
19 and hold it parallel. These mold members 11, 12
is built into a heating furnace 20 having an inlet 20a and an outlet 20b for heated air, and is provided with injection pipes 21 and 22 for spraying heated air from the back toward the portion where the mold 13 is to be formed. In front of the entrance of the heating furnace 20, a conveyor 23 consisting of a large number of rotors is provided to convey a metal plate integrally formed with two surface materials 8 toward the heating furnace 20, and a raw material supply device 24 for the foam 9 is provided. It is installed above it, and there is also paper,
A backing material 10 made of tar felt, asbestos paper, metal foil, synthetic resin film, or a laminated combination of these materials is introduced into the mold 13 from between the raw material supply device 24 and the heating furnace 20 .

The raw material supply device 24 includes tanks 25 and 25 that separately house raw materials for making the foam 9 of a two-component synthetic resin such as urethane resin.
26 and a tank 27 containing inorganic aggregate for improving physical condition.
, a mixer 28 connecting these, and a spout 29. Two sets of these may be provided corresponding to the two surface materials 8, or the tanks 25, 26, 27 and, in some cases, the mixer 28 may be used in common. It is constructed by branching out the nozzle 29, and the nozzle 29 is located above the center of each surface material 8. The metal plate is turned upside down, placed on the conveyor 23 with the space surrounded by the surface part 7 and the rising parts 2 and 3 open upward, and is fed longitudinally at a constant speed, passing through a preheating furnace if necessary for preheating. After that, a fixed amount of liquid raw material 30 is continuously pressurized and injected from the nozzle 29 of the raw material supply device 24 and is received in the space.

As shown in FIG. 2, the raw material 30 is diffused in a conical shape from the nozzle 29 and sprayed into the space inside the surface material 8, and at this time, both ends of the spread of the raw material 30 are connected to the joints on both side edges. 4,5
Also, it is sprayed onto the back side of the central connection part 6 to make a thin layer, so that some of the raw material sprayed on both ends of the front surface part 1 bounces back and adheres to the connection parts 4 and 5 and the connection part 1. There is also. The metal plate supplied with the raw material 30 advances to the heating furnace 20
The backing material 10 containing FC is placed on the lower mold member 12 and is fed along the upper mold member 11 to the connecting portion 4.
, 5 and the connecting portion 6 (see FIG. 3). A protrusion 31 made of a stretchable material such as heat-resistant rubber is attached to the center of the lower mold member 12 over the entire length or partially, and the rising parts 2 and 3 at the center of the metal plate support this protrusion 31. It is held in such a way that it does not shift in the width direction.

The surface material 8 and the backing material 10 are sandwiched between the upper and lower mold members 11 and 12 in the mold 13 and moved together with them, and the raw material 30 is heated and foamed to form the surface material 8 and the backing material. The mold member 1 fills the space surrounded by 10 to form a foam 9 (see figure 4), and is turned upside down by drive wheels 14 and 15.
It is sent out from between 1 and 12. Further, the raw material adhering to the connecting parts 4, 5 and the intermediate connecting part 6 is thin foam layer 9a,
Form 9b. Next, the connecting portion 6 is cut from the center, the left and right surface materials 8 are separated, and the necessary bending is performed to connect the connecting portions 4 and 5.
The product is obtained by forming the

The facing 8 and backing 10 are integrally joined to the foam 9 and thin foam layers 9a, 9b. Three or more surface materials 8 may be formed in parallel on one metal plate, and instead of using a material with a width that is approximately equal to the entire width of the bent metal plate, the backing material 10 has a width that is equal to the width of one product. Pieces of approximately equal width may be fed in parallel toward the mold 13.

The nozzle 29 of the raw material supply device 24 is not limited to one, but a plurality of nozzles may be arranged in parallel for one surface material 8, and the shape of the nozzle 29 is arbitrary, such as a round hole or a long hole, and the raw material 30 can be sprayed. In addition, it may also be supplied by means such as pouring down. In addition, side walls 32 similar to the protrusions 31 are provided on both side edges of the mold member 12 below the mold 13, and the rising portions 2 and 3 at both ends are suppressed from the outside to prevent the metal plate from shifting in the width direction. It may be possible to prevent this. Furthermore, the mold members 11 and 12 are composed of endless metal bands with smooth surfaces, and the lower mold member 1 in contact with the metal plate
It is possible to change the design by configuring 2 with a large number of divided mold pieces, and omit the heating furnace 20 and either or both of the injection pipes 21 and 22 to form the foam 9 at room temperature and pressure. It may also form. Note that the foam 9 is desirably made of thermoplastic synthetic resin among polymeric substances. In particular, when urethane resin is used and asbestos paper is used as a backing material, lubricants such as talc, silicone, and wax contained in asbestos paper react with isocyanate, which is the raw material for urethane resin, resulting in excess polyether. This is what changes the composition of the urethane resin to make it flexible, and as a result, the surface layer that comes into contact with the mold part becomes flexible, and even if slippage occurs between the mold part and the mold part, it buffers and absorbs this and is used as a backing material. There is no possibility of damaging the foam or causing cracks in the foam. In addition, the aggregates to be added as necessary include borates such as borax and tuda metaborate, silicates such as sodium silicate and sodium metasilicate, and phosphoric acids such as dibasic sodium phosphate, sodium metaphosphate, and sodium metaphosphate. Salts and other inorganic substances that foam and expand when heated to a temperature below the heat resistance temperature of the polymeric substances that make up the foam, or aluminum hydroxide, alumina, silica sand,
Examples include inorganic substances that do not have foam expansion properties such as soda carbonate and silica, short inorganic fibers such as glass fiber and rock wool, inorganic foam particles such as perlite particles and cellular glass, and other known flame retardants. One or more of these may be used as appropriate.

Alternatively, porous particles such as pearlite particles, shirasu balloons, pumice, clay mineral particles, etc. filled with the above-mentioned inorganic substances are also suitable as aggregates. As described above, the present invention connects a surface material consisting of a surface portion, rising portions extending toward the back side of both side edges of the surface portion, and connecting portions extending substantially parallel to the surface portion from the surface portion through a connecting portion where the two connecting portions are formed. Two or more metal plates integrally molded in parallel are turned over and fed in the length direction, and a foam material made of a polymeric material is inserted into the space surrounded by the surface portion and the rising portion and open upward, and into the connecting portion and the back surface of the connecting portion. The lining material is then layered on top of the lining material, which is sandwiched between molds for foaming, so the raw material attached to the joints at both ends and the middle joint foams, forming the lining material and the surface. The materials are completely bonded together, and when the raw material inside the cavity gradually foams and fills, the foaming gas does not escape, making it possible to completely fill the cavity with foam.

In addition, since the foam and backing material are combined and integrated with two or more surface materials at the same time, not only can they be manufactured efficiently by cutting the connecting portions, but also the connecting portions and the following rising portions can be cut. In addition to reinforcing the metal plate, the connecting part and the surface part are in contact with the upper and lower mold members, respectively, so there is no problem of the surface material being deformed by the foaming pressure when it is sandwiched between molds and foamed, and the plate member of a predetermined shape can be formed. We can provide it. Furthermore, since the connecting parts on both side edges have a thin foam layer, when used, when they are overlapped or inserted into each other and connected, their elasticity allows them to be tightly overlapped and made watertight. .

[Brief explanation of the drawing]

FIG. 1 is a schematic side view showing an embodiment of the present invention, FIG.
3 and 4 are enlarged sectional views taken along lines X-X, Y-Y and Z-Z in FIG. 1, and FIG. 5 is an enlarged partial sectional view of the product. 2, 3... Rising part, 4, 5... Connection part, 6... Connection part, 7... Surface part, 8
...Surface material, 9...Foam, 10...
... Backing material, 11, 12 ... Mold member, 13
...Molding mold, 20...Heating furnace, 24
・・・・・・Raw material supply device.

Claims (1)

[Claims] 1 Two or more surface materials consisting of a surface portion, rising portions facing the back side of both side edges thereof, and connecting portions extending from the surface portion substantially parallel to the surface portion are integrated in parallel via a connecting portion where two connecting portions are formed. Using a formed metal plate, turn it over and feed it in the lengthwise direction to feed the raw material for the polymeric foam into the open space surrounded by the surface part and the rising part, which is open upward, and into the back surface of the connecting part and the connecting part. Next, the backing material is layered on top of the joints and connections and placed in a mold that moves in one direction, in which the raw material is foamed to form a foam and the surface material and backing material are 1. A method for manufacturing a plate-like member for construction, which comprises integrating a foam member with the foam member, and further cutting the connecting portion to the left and right.