JPS6259652B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a construction board, and relates to a method of manufacturing a board made of synthetic resin, in which a recess 1 is formed over the entire length, leaving flat parts 6a and 7a on both sides. 2 is transferred by a transfer device 3, and the recess 1 is filled with a synthetic resin foam heat insulating material such as a urethane foam material, and a forming roll 5 having a protruding strip 4 is transferred in a direction perpendicular to the transfer direction. This construction board is characterized in that foam molding is carried out by pressing the foamed synthetic resin heat insulating material against the upper surface thereof, and by contacting the annular surface portions 5a, 5a at both ends of the forming roll 5 with the flat portions 6a, 7a on both sides of the substrate 2. This relates to the manufacturing method.

As shown in Fig. 1, the conventional manufacturing method for construction boards is to fill a synthetic resin substrate 2 and a recess 1 in the substrate 2 using a so-called double conveyor in which molding conveyors long in the transport direction are placed vertically opposite each other. The synthetic resin foam heat insulating material, such as a urethane foam material, is transferred and held between the legs and continuously foam-molded. However, with this method, the synthetic resin foam heat insulating material is pressed over its entire length and over a long range in the transport direction, so a large foaming pressure is applied to the substrate 2 made of vinyl chloride resin or the like. This has the disadvantage that the substrate 2 is distorted and the smoothness of its surface is impaired. In addition, there was a problem in that in order to increase the strength of the resulting construction board, it was necessary to increase its thickness. Furthermore, when the synthetic resin foam shrinks over time, this shrinkage cannot be absorbed, resulting in the construction board being warped.

The present invention has been made in view of these conventional drawbacks, and its purpose is to prevent large foaming pressure from reaching the substrate, ensure the smoothness of the surface of the product, and improve the quality of synthetic resin. By forming a high-density skin layer on the surface of the foam and by forming rib-like parts on the synthetic resin foam, the strength of the product can be increased without increasing the thickness. To provide a method for manufacturing a construction board capable of absorbing shrinkage of a resin foam and suppressing the occurrence of warpage in the product.

Embodiments of the present invention will be described in detail below with reference to the drawings.

Reference numeral 2 denotes a substrate, which is previously extruded from a synthetic resin such as vinyl chloride resin. The substrate 2 is formed to have a substantially U-shaped cross section so that the recess 1 is formed over the entire length thereof. An ear portion 6 is integrally formed on one side of the substrate 2, and an engagement recess 7 into which the ear portion 6 can be inserted is formed on the other side. 8 is a conveyor as the transfer device 3, which also serves as a lower mold. 5 is a forming roll, and as shown in FIG. 4, a large number of protrusions 4 are formed on the outer periphery at equal intervals. A plurality of forming rolls 5 are rotatably disposed upstream in the direction of conveyance by the conveyor 8 and substantially orthogonal to the direction of conveyance. In this case, the pitches of the ridges 4 of the 5 groups of forming rolls are made equal. These forming rolls 5 are appropriately driven by a drive device. Reference numeral 9 denotes a material discharge section that is connected via piping to a supply device (not shown) that supplies a urethane foam material as an example of a synthetic resin foam heat insulating material. This material discharge section 9 is provided above the starting end of the conveyor 8. Reference numeral 10 denotes an upper conveyor which also serves as an upper mold and serves as a transfer device 3, and is disposed on the transfer downstream side of the group of forming rolls 5. As shown in FIG. 2, the substrate 2, which has been extruded in advance, is transferred by the conveyor 8, and is filled into the recess 1 by being discharged from the urethane foam material discharge section 9. During the transfer, the urethane foam material is foamed while pressing the ridges 4 of the forming roll 5 against the urethane foam material from above. Since the surface of the urethane foam material is pressed with the convex strips in this manner, a high-density skin layer can be formed on the pressed uneven surface layer, and the strength of the urethane foam material can be increased.
In such a case, the annular surface portions 5a on both sides of the forming roll 5
are the ear part 6 of the board 2 and the flat part 6a of the engagement recess 7,
7a to prevent the urethane foam material from escaping laterally. After that, the urethane foam is foamed on the upper conveyor 10 as the upper mold and the conveyor 8 as the lower mold, which are almost flush with the respective flat parts 6a and 7a of the ear part 6 and the engagement recess 7 of the substrate 2. The body and the substrate 2 are transferred and held between the upper and lower conveyors 10 and 8 to completely foam and harden.

As described above, in the method of the present invention, a synthetic resin substrate having a recess formed along its entire length is transferred by a transfer device, and a synthetic resin foam such as a urethane foam material is inserted into the recess. Foaming of the synthetic resin foam heat insulating material is carried out while pressing a molding roll filled with heat insulating material and having convex stripes in a direction perpendicular to the transfer direction onto the upper surface of the synthetic resin foam heat insulating material being transferred. The inside can be pressed by forming rolls and is not sealed like a conventional double conveyor, which prevents large foaming pressure from being applied to the synthetic resin substrate on the surface, resulting in distortion of the substrate. This method has the advantage that it can suppress the occurrence of scratches, and that the surface smoothness of the obtained architectural board is not impaired and a good finish can be achieved. Moreover, since the synthetic resin foam heat insulating material is foam-molded while being pressed by a forming roller having convex stripes in a direction perpendicular to the transport direction, a high-density skin layer can be formed on the surface of the synthetic resin foam.
In addition, rib-like parts can be formed in synthetic resin foam,
These have the advantage that the strength of the product can be increased without increasing the thickness. Furthermore, since troughs are formed between the rib-like parts, it is possible to absorb the shrinkage of the synthetic resin foam due to changes over time, suppressing the occurrence of distortion such as warping of architectural boards. A recess is formed along the entire length in the horizontal direction, and by forming this recess, a rib effect can be obtained on the side wall of the recess, and the rib effect increases the bending strength in the longitudinal direction of the substrate. Although it is possible to
Grooves are formed in the synthetic resin foam insulation material filled in the recesses of the substrate using a forming roll in a direction perpendicular to the length direction of the substrate, and recesses are formed along the entire length of the board. It is possible to increase the bending strength in the width direction of the board, which increases the overall strength of the board, and is advantageous in construction boards that connect to adjacent ones. When forming grooves in the synthetic resin foam heat insulating material, the annular surfaces at both ends of the forming roll are brought into contact with the flat parts on both sides of the substrate. It does not become too shallow, and when the protruding stripes penetrate into the synthetic resin foam insulation material, they can be prevented from escaping onto the flat parts on both sides of the synthetic resin foam material substrate, and the grooves can be made well with the forming rolls. The advantage is that it can be done.

[Brief explanation of the drawing]

FIG. 1 is a side view of the device used in the conventional manufacturing method, FIG. 2 is a perspective view of a construction board obtained by the same method, and FIG. 3 is a side view of the device used in the manufacturing method of the present invention. Figure 4 is a perspective view of the forming roll same as above;
FIG. 5 is a partial rear perspective view of the construction board obtained as above, and FIG. 6 is a cross-sectional view taken along line A-A in FIG.
1 is a recess, 2 is a substrate, 3 is a transfer device, 4 is a protrusion,
5 is a forming roll.

Claims (1)

[Claims] 1. A synthetic resin substrate with a recess formed along its entire length with flat parts left on both sides is transferred by a transfer device, and a synthetic resin foam insulation material such as urethane foam material is inserted into the recess. A forming roll having protrusions in a direction perpendicular to the transfer direction is pressed against the upper surface of the synthetic resin foam insulation material being transferred, and the annular surfaces at both ends of the forming roll are brought into contact with the flat parts on both sides of the substrate. A method for manufacturing a construction board, characterized by performing foam molding while contacting the board.