JPS6038986B2 - Architectural panel manufacturing method and device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method and an apparatus for manufacturing a construction panel in which a sand decorative surface is formed on the front surface of a thin metal plate and a heat insulating material is filled on the back surface thereof.

More specifically, the surface has an uneven patterned surface, and only the concave surface is filled with sand, and a cosmetic paint is applied to the convex surface and the sand surface, and these paints are forcibly dried. The present invention relates to a construction panel in which a gutter-shaped part formed in a mold is filled with a heat insulating material, and a device for manufacturing a uniform product by continuously producing large quantities of such panels at high speed.

Generally, architectural panels using thin metal sheets, such as colored iron sheets, so-called metal siding, are used as exterior materials for buildings.

However, since colored iron plates are cold and have a smooth appearance, some kind of design improvement has been desired.

For example, there is a construction panel having a surface coated with so-called pseudo-mortar ricin with sand adhered to it. This was colder and less smooth than a panel made from simply colored iron plates, and the impression of the metal material was weakened. However, the decorative surface formed by the almost uniform sand scattering did not reach the level of adding three-dimensionality or patterns. In addition, a single metal thin plate lacks heat insulation properties and lacks the mechanical strength of a construction panel, which is a so-called multifunctional panel. Furthermore, manufacturing multifunctional panels using colored iron plates and the like has the disadvantage of intermittent and inefficient processes, resulting in inconsistent quality and high costs.
In order to eliminate these drawbacks, the present invention firstly utilizes the plasticity of the thin metal plate to provide uneven patterns in required areas in an arbitrary pattern, and secondly allows sand to exist only on the concave surfaces. , the third step is to form a decorative coating on the concave and convex patterned surfaces, the third step is to fill the back side of the molded material with heat insulating material, core material, etc. to make it multi-functional, and the fourth step is to create it through an integrated line. To provide a method for manufacturing architectural panels using an apparatus for producing uniform quality products in large quantities at low cost, and an apparatus therefor.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The method and apparatus for manufacturing a construction panel according to the present invention will be described in detail below with reference to the drawings.

First, the manufacturing method of architectural panels will be explained using Fig. 1.The first step is to prepare a thin metal plate as shown in Fig. 1a, for example, a willow color iron plate with a thickness of t=0.1 to 2, and surface treatment. Fig. 1 b,
The purpose is to form an uneven pattern 2 as shown in c. In other words, for the total width L of the thin metal plate 1, for example, one area that will be a decorative surface has a height H of 0.1 to 5 willows, usually 0.3 to 0.8.
The sail is textured. The uneven pattern 2 has a concave surface 3 and a convex surface 4 formed randomly, continuously or intermittently, as shown in FIG. 1c, and the top surface 4a of the convex surface 4 has a planar structure. Next, the second step is to form this metal thin plate 1 into a gutter shape as shown in FIG. 1d. This will help fill this gutter with the insulation material that will be described later. The molded part A has a decorative surface 5, a side wall 6, a male part 7, and a female part 8. Of course, the molded member is not limited to this shape, and other shapes as described below are also possible. As a third step, as shown in an enlarged view of a part of the uneven pattern 2 in FIG. is applied to form a so-called base coating film 10. As a fourth step, as shown in FIG.
It is to remove (wipe off) a. After this step is completed, the fifth step is to sprinkle sand 11 on the uneven patterned surface as shown in FIG. 1g. Sand 11 includes silica sand perlite grains, vermiculite, shirasu, shirasu balloons, rock powder, stone powder, gypsum, calcium carbonate, calcium sulfate, glass pieces, metal powder, artificial aggregate, plastic grains, marble powder, and These particles may be used singly or as a mixture, or may be colored, and their size may be arbitrary, such as those that do not protrude outward from the height of the sun, or those that have a particle size that protrudes. The shape may be spherical or any other complex polygon. Note that cinnabar sand is most suitable as the sand 11. As the sixth step, as shown in FIG.
1a is excluded from areas other than the decorative surface of the uneven pattern 2. As the seventh step, as shown in Figure 1i, surplus sand 11a is
Cosmetic paint 12 (hereinafter referred to as paint B) is applied to a decorative surface 5 consisting of an uneven pattern 2 that excludes
It is to form. Although the coatings 10 and 13 are shown separated in the drawing, they are actually mixed at the interface.
As the eighth step, the coating film 1 on the decorative surface 5 in such a state is
In the ninth step, as shown in FIG. be. The heat insulating material 14 may be a synthetic resin molded body, a raw material, a noncombustible plate, etc. In the case of a molded body, it is necessary to use an adhesive or to mold it into a structure that allows the heat insulating material to be held in the molding process. . Further, when the material is supplied as a raw material, it is preferable to foam it and utilize its self-adhesive properties at that time. A construction panel manufactured continuously in this manner is shown in FIG. Further, a well-known conveying means is used between these steps. And the conveyance speed from the 1st process to the 8th process and the 9th process
It is also possible that the transport speeds of the steps are different. Particularly member A
is different for a continuum and for a fixed length object. Next, the construction panel manufacturing apparatus according to the present invention will be explained in detail with reference to FIG. 3. A flat metal thin plate 1 of a fixed length as shown in FIG. 3a is fed to the embossing means 15.

As shown in FIG. 3b, this embossing means 15 has male,
By meshing the female rollers 16 and 17, a concavo-convex pattern, such as the pattern shown in FIG. 18 is a forming means which forms the thin metal plate 1 into a gutter shape as shown in FIG. 1D through a forming machine 19 as shown in FIG. 3D.

The sand saddle paint is applied to the decorative surface using a paint application means, for example, as shown in FIG. , 4 as shown in FIG. 1e.

The roll coater 21 includes upper and lower rollers 22, 23, a coating roll 24, and a paint hopper 25. Reference numeral 26 denotes a paint removing means, which removes only the paint present on the convex surface 4 of the paint Q applied to the uneven pattern 2 during the hardening state, as shown in FIG. As shown in Figure 3e, the guide roller RI...Rn and the wiping roller R
I'...Rn and cleaning roller rl...r
n, doctor knife D1...Dn, and cleaning tank S
I: Consists of Sn and cleaning agent W.

Of course, it is also possible to use belts, stands, etc. in place of the guide rollers. In addition, the gap between the o-ra RI and RI is such that the thickness of the thin metal plate 1 is 0.27 mm, and the height of the uneven surface is H.
=0.7 In the case of willow, it is about 0.3, and the material of RI is steel, and the material of RI'...Rn' is made of hard rubber only on the surface portion, and has a hardness of 30 to 400. Reference numeral 27 is a sand scattering means that uniformly spreads sand 11 by gravity so that it becomes the state shown in Fig. 1g on the uneven pattern where the paint Q exists only on the concave surface as shown in Fig. 3f. For example, a device such as that shown in Jitseki No. 52-72568 is used for spraying.

Reference numeral 28 denotes surplus sand removal means, which removes the so-called surplus sand 11a that has not come into contact with the paint Q out of the sand spread as described above, to the outside of the decorative surface 5 through a device as shown in FIG. 3g. As shown in FIG.

The blowing device 29 has at least a slit-shaped outlet 30 with a length larger than 1 shown in FIG. Exclude. Although the relative positional relationship between the spraying device and the enemy face 5 is arbitrary, it is preferable that they face each other at a certain angle 8 with respect to the direction of movement of the village A. It is also necessary to tilt the sand in the left and right directions depending on the amount of excess sand. In other words, if the wind pressure is too high, there is a risk that even the sand 11 on the concave surface will be blown away.
This is because sand is removed to the outside of the decorative surface 5, so that the amount of sand is larger than that on the left and right sides, which may cause an inconvenience that it remains in the center of the decorative surface 5. Reference numeral 31 denotes a cosmetic paint application means (shown in FIG. 3M) for applying paint B as shown in FIG. 1i to the decorative surface 5 in the state shown in FIG. 1h.

Although paints Q and 8 mix at the boundary, they are drawn separately for convenience. A flow coater or a spray gun is suitable as this device. Reference numeral 32 denotes a paint drying device (shown in FIG. 3 i) for curing the paints Q and 8 on the decorative surface 5 of the decorative surface 5 as shown in FIG. Use ultraviolet rays or other high-frequency heating equipment.

Reference numeral 33 denotes a heat insulating material filling stage, which is a device (as shown in FIG.
(shown in Figure 3i).

Examples of the heat insulating material 14 include gypsum board, asbestos slate, glass fiber, calcium carbonate, magnesium carbonate, and synthetic resin foam (there are two types: a molded product and a raw material state). Furthermore, the synthetic resin foams mentioned above include polyurethane foam, polyisocyanurate foam, phenol foam, polystyrene foam, polyimide foam, polyolefin foam, etc. For example, when polyurethane foam is used, Fig. 4 a and b Use a filling, heating and pressurizing device as shown in . That is, FIG. 4a shows an apparatus that is effective when the thin metal plate 1 is a fixed-length object, and FIG. 4b shows an apparatus that is effective when it is a hoop material. To explain in more detail, FIG. 4a shows a foaming mold consisting of a pair of upper and lower caterpillars, conveyors 34 and 35 such as steel belts, and a polyurethane foam raw material P being sprayed in a mixed state. It consists of a feeder 37 for the material u. The mold conveyors 34, 35 are heated to about 7,000 ℃, the gap T is approximately the same size as the height h of the member A, and a traveling cutter 38 is provided at the exit portion of the conveyor, if necessary. In the case of this fixed-length product, a reversing device 39 for the member A is used between the paint drying means 32 and the heat insulating material filling means 33, as shown in FIG. That is, a conveyor 40 supported at one end is arranged at the outlet of the drying means 32,
This conveyor 40 is opened and closed as shown by the arrows to continuously deliver the parts A in reverse order to a conveyor 41 connected to the entrance of the heat insulating material filling means 33. Fig. 4b shows a device useful when using a long material, for example a hoop material, which feeds the backing material u from below, discharges the foaming material into the backing village of the brackets, and conveyor 34, This is a case of integrating within 35. To explain a construction panel manufacturing apparatus according to yet another invention, it is an apparatus in which only the embossing means is removed from the above invention, and all other parts are constructed by the same means.

In other words, it is a useful device when the metal book board 1 is an embossed board. In addition, in the apparatus according to the present invention, an appropriate conveying means Y such as a V-belt,
Chains, rollers, etc. (indicated by two-dot chain lines) are used.
Next, an embodiment of the method and apparatus for manufacturing a construction panel according to the present invention will be described.

First, it is assumed that a construction panel as shown in FIG. 6 is to be manufactured. ()Material■ Metal thin plate (colored iron plate that has already been embossed) Length: Standard length of 8 shaku Plate thickness (t): 0.27 rib emboss depth. 0.7 sail and the pattern color is as shown in the figure...Glossy cream @paint 8 Alkyd resin is the main component for forming the coating film, and the viscosity is adjusted to 1000 centipoise at 25°C.

Color: Glossy brown coating 10 Thickness: 5 microns (wet)
．． Thickness of coating film 13...20 microns (wet) ■Sand 28-32 mesh cinnabar sand @ insulation material Made of polyol and polyisocyanate - Liquid reaction type polyurethane foam raw material bulk specific gravity...0. 0
28 Foam structure: Thickness of closed cell foam: 1. Polyethylene laminate (b) on backing material kraft paper. Molding means: For example, 45 layers. 6 in the shape of village A
Apparatus capable of forming at a speed of 0 m/min Paint application means Roll coater rotating at a circumferential speed of approximately 60 skins/min The distance between rolls 23 and 24 is 0.3, the surface of the roll 24 is made of synthetic rubber with a hardness of 50o. The paint removing means consists of a group of rolls configured as shown in FIG. 3, and thinner is used as the cleaning agent W.

Peripheral speed of roll group 60 skin/min Relationship between member A and roll RI...Rn As shown in Fig. 7, △1
Rr...Rn' are formed to have a width larger than the width of member A.

In this case, R1...R5, RI'...
It is configured in 5 stages of R5'. As for the sand spreading means, the device shown in Jitsoseki No. 52-72568 was adopted as it was.

Excess sand removal means The wind pressure was 8=60o and the decorative surface 5 was faced.

Decorative paint means Flocoater was used.

Paint drying means Gas combustion method for 5 minutes in the 50 to 900 zone and 1 minute in the 220°C zone The thickness is 1 side, the width is 50 arcs, the center axis of the driving wheel 34a and the driven wheel 34b is 40mm, the temperature inside the furnace is 70°C, and the peripheral speed of the conveyor is 60/min.

Cutting means A guillotine-type traveling cutter was used, which cuts the construction panel after synchronizing it with the traveling speed while the panel is traveling.

Therefore, the thin metal plate 1 as described above is formed into a gutter-like member A through the forming means 18, and a paint is applied to the entire surface of the decorative surface 5 having the uneven pattern using the roll coater 21.

Next, paint Q is applied to the entire decorative surface 5. Next, while the coating film on the decorative surface 5 is still uncured, it is led to a roller group type coating removal means 26 as shown in FIG. 1, for example, immediately after coating. This removing device removes the convex surface 4 by means of rollers R1...Rn.
The upper coating film 10a is wiped off while being in contact with the rubber surface material of the rollers RI'..."Rn' and while adding some elasticity to the rollers RI'..."Rn'. The surface of ' and the transfer roller rl formed by soaking in thinner W...
...rin to clean the paint that was wiped off, and remove thinner W with a doctor knife D1...Dn.
Transfer to the rollers Rr...Rn' and scrape off the paint Q. By such an operation, the state shown in FIG. 6 while the paint B of the flow coater 31 is flowing down like a curtain.
It is passed through at a speed of 0/min and led to the drying oven 32. In this drying oven, the coating films 10 and 13 as shown in FIG. 1 are baked and hardened to approximately 100% hardness. Bemura A who passed through this drying oven
is almost continuously supplied to the insulation material filling device shown in FIG. 4a through the inverter shown in FIG. 5. In this case, if a spring guard 42 fixed at one end is provided, reversal can be ensured. The polyurethane foam raw material immediately after being mixed from the polyurethane discharge device 36 into the gutter-shaped portion of the material 1 conveyed by the rollers 41 is uniformly distributed within the substantially gutter-shaped region by the nozzle. Thereafter, for example, when it is in the form of gel time, kraft paper U is placed thereon and fed together into the mold. In this mold, the polyurethane polymerizes to form a foam, and the components come out as a self-adhesive unit. The gap between the regular objects is detected and only the polyurethane foam is cut through the traveling cutter 38, thereby continuously producing architectural panels as shown in FIG. What has been described above is only one embodiment of the present invention, and it is possible to form a convex surface as shown in FIG. 8a, to mold member A as shown in FIG. It is also possible to make the sand 11 exist scattered on the concave surface.

As described above, according to the method and apparatus for manufacturing a construction panel according to the present invention, specular reflection and diffused reflection are randomly distributed to promote a three-dimensional effect, and the uneven pattern provides design and weather resistance. It has the characteristics of improving heat insulation and strengthening mechanical strength all at once, and can be completed in about 8 minutes from start to finish on an integrated line, and can be produced in large quantities.

[Brief explanation of the drawing]

FIGS. 1 a to i are explanatory diagrams of the method for manufacturing a construction panel according to the present invention, FIGS. 2 and 6 are perspective views showing an example of a construction panel obtained by the above method, and FIGS. 3 a to i 4 is a schematic diagram showing an example of the construction panel manufacturing apparatus according to the present invention; FIGS. 4a and 4b are explanatory diagrams showing an example of a heat insulating material filling means;
FIG. 7 is an explanatory diagram showing an example of a reversing machine, FIG. 7 is an explanatory diagram showing an example of a paint removing means, and FIGS. 8 a to 8 d are explanatory diagrams showing other embodiments. 1... Metal thin plate, 3... Concave surface, 4... Convex surface, 5... Decorative surface, 9... Paint Q,
11...Sand, 12...Paint 8, 15...
- Embossing means, 18... Molding means, 20...
... Paint application means, 26 ... Paint removal means, 27 ... Sand scattering means, 28 ... Excess sand removal means, 31 ... Ihi rudder paint Application means, 32.
... Paint drying means, 33 ... Insulating material filling means. Are you able to figure out what's going on? Box 4, 5, 6, 7, 8

Claims (1)

[Scope of Claims] 1. A first step of forming an uneven pattern on a predetermined portion of a thin metal sheet, a second step of forming the thin metal sheet into a gutter shape, and adhering sand to at least a surface portion of the thin metal sheet. a third step of applying a paint etc., a fourth step of removing uncured paint present on the convex surface, and a fifth step of scattering an appropriate amount of sand on the uneven patterned surface; a sixth step of removing excess sand from the uneven pattern surface of the sand; a seventh step of applying a cosmetic paint to the uneven pattern surface from which the excess sand has been removed; and a seventh step of applying a cosmetic paint to the uneven pattern surface from which the excess sand has been removed. A method for producing a construction panel, comprising an eighth step of drying the paint, and a ninth step of filling a gutter-like part of the thin metal plate with a heat insulating material. 2 Embossing means for forming an uneven pattern on a thin metal plate, forming means for bending the embossed thin metal plate into a gutter shape, and paint for applying sand adhesion paint to the decorative surface of the bent thin metal plate. a coating means, a paint removing means for removing the applied paint that is present on the convex surface, and a means for scattering an appropriate amount of sand on the removed convex surface and the concave surface where the paint is present; Excess sand removal means for removing excess sand from the thin metal plate; cosmetic paint application means for applying a cosmetic paint to the uneven patterned surface from which the excess sand has been removed; and the applied paint. and an architectural panel comprising a paint drying means for drying the sand adhesive paint, and a heat insulating material filling means for filling a gutter-like part of the dried thin metal plate having the decorative surface with a heat insulating material. Manufacturing equipment. 3. A forming means for bending a thin metal plate on which an uneven pattern is formed into a gutter shape, a paint application means for applying a sand adhesion paint to the decorative surface of the bent metal sheet, and among the applied paints. a paint removal means for removing paint present on a convex surface while it is still in an uncured state; a sand scattering means for scattering an appropriate amount of sand on the convex surface from which the paint has been removed and on the concave surface having the paint; Excess sand removal means for removing excess sand from the scattered sand to the outside of the thin metal plate; Cosmetic paint application means for applying a cosmetic paint to the uneven patterned surface in such a state; and the paint and the sand adhesion. 1. An apparatus for manufacturing a construction panel, comprising: a paint drying means for drying a paint for use in construction; and a heat insulating material filling means for filling a gutter-like part of a thin metal plate coming out of the drying means with a heat insulating material.