JPS6221625B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a novel method for manufacturing a foam board whose surface is reinforced with fibers.

In recent years, hard synthetic resin foam boards have become
It is often used as a structural member such as the core wall of a building, or as a heat insulating material, but it is widely used to reinforce the surface or interior with fibers, etc., which increases the structural strength and resistance to thermal stress. It is well known that efforts are being made to further expand its uses.

In this case, depending on the purpose of use, reinforcing only the surface of the synthetic resin foam board with fibers may be sufficient in order to save on reinforcing material;
In terms of heat insulation performance or ability to withstand bending stress, a so-called Sanderch structure has excellent effects, and reinforcing only the surface portion may be preferable in some cases.

By the way, as a known method for manufacturing a foam board whose surface is reinforced with fibers, there is a method in which a fiber material is bonded and integrated with the surface of a pre-formed foam using an adhesive. There is also a method in which the synthetic resin is foamed and cured into one piece.

However, the foam board obtained by the former method has the disadvantage that its adhesive strength decreases over time, causing it to peel off.On the other hand, in the latter method, the foam board from the synthetic resin that oozes out from the outside of the fiber material is difficult to obtain. As a result, the fibrous material is pushed inward and hardened, which tends to reduce the effectiveness of surface reinforcement. As one of the countermeasures against this problem, a method of mooring the fiber material by coating the inner wall of the mold with gel is known, for example, from Japanese Patent Application Laid-open No. 19177-1983. In cases where it is a disordered aggregate of fibers,
Even if the fibers were anchored to the mold wall with gel coating or the like, the disadvantage was that the fibers would be spread out due to the foaming of the resin that entered the inside of the mat.

Moreover, manufacturing using molds is not suitable for mass production, and it is especially difficult to retain such fiber materials in continuous mass production methods using conveyors, etc.
It had flaws such as not being applicable.

The present invention eliminates these drawbacks and enables mass production of synthetic resin foam boards whose surfaces are reinforced with fiber materials by continuous means, such as a conveyor system, while maintaining sufficient strength and performance. It was developed in an attempt to provide a new manufacturing method in which it is possible to produce a foamed board, and in particular, it is a process of continuously supplying an aggregate layer formed by laminating fiber materials in a sandwich pattern on both sides of a foam board base material. A step of spraying a synthetic resin foaming stock solution from above, a pressing step of pressing and compressing the assembled layer from both sides and dispersing and impregnating the foaming stock solution into the voids inside the layer, and a step of introducing a continuous device that integrates the foam by curing. It is characterized by a structure consisting of.

Hereinafter, the present invention will be further described in detail with reference to the accompanying drawings.

FIG. 1 is a conceptual diagram of a manufacturing apparatus used to carry out the method of the present invention, and illustrates a conveyor-type continuous manufacturing apparatus.

The above device includes a pair of guide rollers 7a and 7b arranged in parallel with a predetermined interval, one guide roller 7c arranged on the downstream side of the guide roller 7a, and a stock solution discharging device 5, for example, one wide nozzle or guide. A plurality of nozzles arranged in parallel to the axis of the roller 7c, a pressing means, for example, a pair of pinch rollers 6
a, 6b, continuous type device For example, a pair of belt conveyors 8, 8, which are installed vertically and run in the same direction and at the same speed, are horizontally installed in order from the upper side to form a series of manufacturing devices, and are formed into a series of manufacturing devices. Foam board 40 that is continuous in width
It has become possible to produce the products in an integrated manner.

The foam board 40 has a first fiber material 1 and a second fiber material 2.
and a base material 3 as elements, and has a sandwich structure in which the first fiber material 1 and the second fiber material 2 are laminated on both sides of the base material 3.

The first fiber material 1 and the second fiber material 2 are woven fabrics made of inorganic fibers such as glass fibers and carbon fibers, synthetic resins such as polyamide and polyester, or other long or short fibers such as artificial fibers and natural fibers. Alternatively, it is a non-woven fabric, mesh-like or mat-like material that is liquid-retaining, and the thickness of the fibers and the thickness of the fiber material can be selected as appropriate depending on the purpose of use of the final product, the foam board. Mat-like materials are particularly suitable for the method of the invention.

On the other hand, the base material 3 is a material that affects the performance, thickness, etc. of the foam board, and is a foaming stock solution 4 that is sprayed from the stock solution discharge device 5 after being pressed by the nip rollers 6a and 6b.
The reinforcing material serves to hold the fiber materials 1 and 2 on both surfaces throughout the process until the completion of foaming and hardening, and may be made of a material that is not very strong and inexpensive. It is not necessary to have the performance as . However, the material must be able to be deformed by pressure, and have enough elasticity that it can be restored to a thickness close to that of the target product when the pressure is released after deformation, and the foaming stock solution 4 can easily penetrate to impregnate and disperse the material. For example, a bulky member having elasticity and having a large number of voids in the layer, such as open-cell flexible polyurethane foam or animal or plant felt, is suitable.

Further, the foamable stock solution 4 is hard polyurethane,
It is a foaming liquid of polyisocyanurate, and although it is of course possible to use a foaming stock solution of phenol resin, urea resin, or other synthetic resin, it is preferable to use a foaming liquid with a relatively high viscosity so that it can be easily impregnated into the fiber materials 1 and 2 and the base material 3. It is preferable that there be.

Next, a specific embodiment of the method of the present invention will be explained using the apparatus shown in the first figure.
The second fiber material 2 is then superimposed on the base material to form an aggregate layer 9 (second (see figure) is continuously supplied to nip rollers 6a, 6b and belt conveyors 8, 8 via guide roller 7c.

When the aggregate layer 9 has passed the guide roller 7c, the foaming stock solution 4 is sprayed onto it by the stock solution discharging device 5, and then the nip roller 6a,
6b presses the aggregate layer 9.

The pressing force at this time is preferably set to an appropriate pressure such that the foamable stock solution 4 does not ooze out from the collection layer 9 and especially does not drip from the first fibrous material 1.

By this pressing, the foaming stock solution 4 is impregnated and dispersed over the internal voids of the collective layer 9, and then introduced between the belt conveyors 8, 8, where the foaming stock solution 4 is foamed and hardened. , second fiber material 1,
2 and the base material 3 are integrated with a cured resin 4' as shown in FIG. 3, and the manufacture of the foam board is completed.

After that, the foam board 40 may be cut into required dimensions.

The pressing means 6 is used to press the fibrous material 1, since the amount of sprayed foaming stock solution 4 is generally small compared to the product volume.
Since there is a possibility that 2 is not sufficiently wetted, the foaming stock solution 4 applied by pressing acts to sufficiently impregnate and disperse the entire layer of the aggregate layer 9. It is also possible to add pairs or three pairs.

On the other hand, the continuous type device 8 is used to control the thickness or width of the surface-reinforced synthetic resin foam 40 that is the final product, and heating means and cooling means can be added as necessary.

Therefore, when the pressurizing means is applied, the foaming stock solution 4
may seep out and drip from both fiber materials 1 and 2, and in the case of foam curing, both fiber materials 1 and 2
Since there is a sufficient possibility that the fiber material may fly out from the surface and harden, as a preventive measure, the release sheet 10 is fed out together with the first fiber material 1, and
FIG. 1 shows an example in which a release sheet 10 is fed out onto the outer surface of the second fibrous material 2 immediately before introduction into the continuous type device 8. This is a preferred embodiment because it has the advantage of making the surface of the foamed board 40 smooth and beautiful, and playing a protective role against the occurrence of external damage.

As is clear from the above explanation, the present invention can easily and easily solve the conventional difficulty of continuously manufacturing a surface-reinforced foam board in which fibers are embedded in the surface part by integral foaming. It can be manufactured at low cost, and the foaming stock solution is sufficiently impregnated and dispersed in the aggregate layer by the pressing means, and both the first and second fiber materials are It is firmly held on the surface throughout the processing process, and it hardens and integrates with the base material in close contact with the base material, so there is no peeling phenomenon between the materials even over time, and it has high strength and high quality. A stable surface-reinforced foam board can be manufactured efficiently and at low cost.

The veneer board obtained by the method of the present invention exhibits excellent properties and is suitable for use in structural materials in various fields, especially equipment and structures related to fisheries and sewage treatment, where corrosion is a problem in wood. The present invention makes a significant contribution to this field by providing a method for manufacturing a surface-reinforced foam board.

[Brief explanation of the drawing]

Fig. 1 is a conceptual diagram of the manufacturing equipment used to carry out the method of the present invention, Fig. 2 is a partially enlarged sectional view of an aggregate layer which is an intermediate product of a foam board obtained by carrying out the method of the present invention, and Fig. 3 The figure is also a partially enlarged sectional view of the final product of the foam board. 1... First fiber material, 2... Second fiber material, 3... Base material,
4... Synthetic resin foamable stock solution, 5... Stock solution discharge device, 6
a, 6b...pressing means, 8...continuous type device, 9...aggregate layer, 10...mold release sheet, 40...foam board.

Claims (1)

[Claims] 1. A first fibrous material and a second fibrous material having liquid impregnation properties on both surfaces are continuously fed while continuously feeding a base material having a large number of communicating voids in the layer and having restoring elasticity in the thickness direction. A synthetic resin foaming stock solution is applied from above while the aggregate layer is being fed, and then the aggregate layer is compressed by being squeezed from both sides by pressing means. This aggregate layer is introduced into a continuous device having a gap corresponding to the thickness when it is restored by depressurization, and the restoration of the base material in the thickness direction and the foaming and curing of the synthetic resin foaming stock solution are carried out in the continuous device. A method for producing a surface-reinforced foam board, characterized in that the foam board is made into one piece.