JPS637142B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a laminate, in which an upper roller conveyor is connected to a lower roller conveyor at least at an inlet portion thereof.
A laminate is formed continuously between the two facing roller conveyors, which are arranged in close proximity to each other in a shape of a letter. The present invention relates to a method for producing a novel laminate.

Traditionally, this type of laminate has been used as construction materials such as interior and exterior wall materials due to its excellent heat and sound insulation properties and light weight, but with the recent demands of the times for energy conservation, production volume has increased significantly. Improved manufacturing methods are desired.

The general method for continuous production of laminates is as follows:
A method is known in which a space between two endless belts placed above and below that are driven in the same direction by power is used as a mold for molding, and foam raw materials are foamed and expanded in the mold. 53-160742).

In addition, as a known manufacturing method limited to laminate boards, which is a type of laminate board, an endless belt is not used, but two face materials are placed on a single roller conveyor that serves as a support base, and the measuring method is There is also known a method in which a foam raw material is supplied between the facing materials through rolls, foamed and spread, and the resulting laminate is taken up with a take-up roll having a drive section (Japanese Patent Application Laid-Open No. 157190/1983).

However, the former method tends to cause discrepancies between the conveyance speeds of the upper and lower belts and unbalance of belt tension, which often leads to operational difficulties and deterioration of product quality such as foam raw material leakage, wrinkles, and scratches. It was. Also, since it encourages such troubles,
It was also difficult to improve productivity by increasing belt speed. Furthermore, since the belt surface pressure is large, a large amount of power is required for driving.

In addition, the latter method does not have a roller conveyor at the top, so the surface is not smooth, and when the conveyance speed is increased, vertical vibrations occur, causing warpage on the laminate board, resulting in poor product appearance and poor construction. You will get something inconvenient. Furthermore, this method has drawbacks such as difficulty in manufacturing a laminate using a metal face material whose lower side is shaped.

In order to improve the above-mentioned drawbacks, the inventor of the present invention conducted extensive research, and as a result, fixedly arranged two roller conveyors, and passed between the two roller conveyors a laminate plate in which two face materials and a foam were integrated. By transporting the foam itself using a power-driven transport device, and by pressing the foam being transported from above and below mainly by the tangent between the roller and the laminate, in other words, by the line, the above-mentioned difficulties in operability can be overcome. ,
We have found that it is possible to eliminate quality deterioration, easily improve productivity, and save driving power and equipment costs. By arranging the rollers so that they approach each other in a letter-shaped manner and by setting the ratio of the roller pitch to the conveying speed of the face material within a specific range, together with the above improvements, the expansion of the foam raw material is stabilized even when the foaming speed fluctuates. However, the present inventors have discovered that the filling property is also improved, and product quality, drivability, productivity, economic efficiency, etc. can be further improved, and the present invention has been completed.

That is, in the present invention, the foam raw material is placed on the lower facing material near the entrance of a space constituted by two vertically opposing facing materials being conveyed between two roller conveyors disposed above and below. In this method, the upper and lower rollers are free to rotate, and the upper and lower rollers are free to rotate. The conveyor is arranged close to the lower roller conveyor in a V-shape at one or more locations including the entrance portion, and the ratio L/R of the roller pitch Lcm to the conveying speed Rcm/sec of the facing material is This is a method for continuous production of a laminate, characterized in that the manufacturing time is 0.01 to 0.6 seconds.

The foam raw material used as the raw material for producing the laminate of the present invention generally includes a known resin raw material, a blowing agent, a catalyst, a surfactant, and the like. Mixing these results in gas production and polymer production, forming a foam. Examples of resin raw materials include urethane resin raw materials, isocyanurate resin raw materials, epoxy resin raw materials, phenol/formaldehyde initial condensates, urea/formaldehyde initial condensates, etc., especially those that are normally used for resin foams. It is not a restriction. As a foaming agent,
Gases (e.g. air, dichlorodifluoromethane), liquids (e.g. trichlorofluoromethane, hexane), agents that react with components of the resin feedstock to generate gases (e.g. water for polyisocyanates), decompose to generate gases drugs (e.g., azobisisobutyronitrile, sodium bicarbonate).

A catalyst is necessary to cure the foam stock. Surfactants have foaming and other effects. In short, the foam raw material of the present invention refers to the raw material for conventional resin foam production.

The foam raw materials are mixed in advance using, for example, a mixer included in the supply device, and then supplied onto the lower surface material from the discharge port of the supply device. Pipe nozzles, spray nozzles, porous nozzles, etc. are used for the discharge port, but they can prevent clogging, loss, and loss of foam raw materials.
In consideration of spreadability, a tubular nozzle is preferred. There may be two or more discharge ports. The supplied foam raw material generally expands and expands due to self-heating and appropriate heating, and spreads into the space between the facing materials, filling this space while smoothing the surface by the action of a roller conveyor via the upper and lower facing materials. In this process, the foam and the two face materials are bonded together to form a laminate, which is then taken out by a conveying device.

The facing material used in the present invention forms a part of the laminate, and is used to reinforce and decorate the foam during the production of the laminate. The surface material used for this purpose is, for example, plate-shaped, sheet-shaped, film-shaped, cylindrical, laminated, etc., and these may be coated, plated, waterproofed, or otherwise processed. The materials used range from hard to soft metals such as iron, aluminum, and steel, paper, synthetic resin, asbestos paper, and inorganic fiber paper.
When a combination of hard and soft facing materials is used, the hard facing material is usually conveyed along a lower roller conveyor. The shape of the face material is usually planar, but the lower face material may be formed by shaping a metal sheet and have a shape that can cover the side surface.

Next, the present invention is characterized in that the upper roller conveyor is disposed close to the lower roller conveyor in a V-shape at one or more locations including the entrance portion. This is because after the foam raw material is supplied from the discharge port of the supply device onto the lower facing material, foaming progresses and the volume gradually increases, but the overflow of the foam raw material is prevented at the inlet of the double facing material. This allows the foam raw material to stably spread between the two-sided materials, producing the effect of being filled. It is also effective in cases where the foam bumps after passing between narrow spaces between face materials. This prevents foam raw materials from leaking out due to overflow or bumping, contaminating the outer surface of the product, and causing operational troubles. In this case, the V-shaped approach is most effective. V-shape refers to the relative spacing between the facings that gradually narrows and gradually widens, but the lower roller conveyor is usually horizontal. Moreover, the narrowest part may be a mode in which a horizontal part continues to some extent. It is preferable that the distance between the double-sided materials at the narrowest point is 1/6 to 1/2 of the thickness of the laminate at the widest point. When this distance is more than 1/2, a sufficient spreading effect cannot be expected, and when it is less than 1/6, the foaming efficiency deteriorates. In the present invention, it is necessary that the upper roller conveyor forms a V-shape and is arranged close to the lower roller conveyor at least at the entrance part.
There may be more than one location.

Next, whereas in the conventional technology, an endless belt was driven by power, and the surface materials etc. were conveyed along with the belt, the present invention adopts a method of forcibly conveying the manufactured laminate. A method is adopted in which the strips, face materials, etc. are conveyed toward the exit on rollers that can rotate freely. Therefore, in the conventional technology,
Since the belt is under tension due to strong tension, it receives the foaming pressure as a surface pressure, whereas in the present invention, the belt is not used and the foaming pressure is received by the roller via the surface material. . In this case, if the speed of the facing material is slow, the facing material expands between the rollers, causing wrinkles, scratches, cracks, breaks, etc. on the surface of the laminate, and is likely to cause operational trouble. After various experiments, the inventor found that when the roller pitch (distance between cores) is Lcm and the conveying speed of the facing material is Rcm/sec, L/R≦0.9sec, preferably 0.01 to 0.6sec. If the roller pitch and laminate conveying speed are determined so that the product quality is good,
We confirmed that the vehicle can be operated with little trouble.
If this value is too low, the product quality will deteriorate, such as damage to the surface material, and more problems will occur during operation. Moreover, if it is too high, a sufficient linear pressure effect cannot be expected, and for example, the thickness of the laminate becomes non-uniform. The length, shape, and pitch of the rollers must be uniform throughout, such as changing the length and shape of the roller depending on the shape of the lower surface material, and changing the roller pitch depending on the reactivity of the foam raw material. However, the present invention also includes partial changes as necessary.

Next, the present invention will be explained in more detail with reference to the drawings.

FIG. 1 is a schematic configuration diagram for explaining an embodiment of the present invention, FIG. 2 is a plan view, and FIG. 3 is a sectional view taken along line A-A' in FIG. 1.

In the drawing, two roller conveyors 1 and 2 arranged vertically opposite each other,
Multiple rollers 3 made of stainless steel with a diameter of 60 mm
and the pitch between the cores of each roller is 150
configured in mm. The upper roller conveyor 1 is arranged close to the lower roller conveyor 2 in a V-shape at an interval of 3 mm at the entrance portion. Paper laminated with 0.25 mm aluminum foil (hereinafter referred to as laminated paper) 4 is conveyed along the lower roller conveyor 2 between the roller conveyors 1 and 2, and at the same time, it is weighed along the upper roller conveyor 1. A kraft paper 5 of 150 g/m ² is conveyed, and the laminated paper 4 and the kraft paper 5 are sandwiched between a take-up device 6 with an adjustable interval provided at the exit of the upper and lower roller conveyors. Next, the take-up device 6 is driven by power to remove the facing material 4,
At the same time, the isocyanurate foam raw material 8 consisting of isocyanate, polyol, freon, catalyst, and surfactant is continuously supplied from the foam raw material supply device 7 through the forked pipe nozzle 9. . The mixed liquid 8 supplied onto the laminated paper 4 passes through the cream state, foams freely, and increases in volume, while the laminated paper 4 and the kraft paper are conveyed under tension along the upper and lower roller conveyors 1 and 2. The foam is introduced between the sheets of paper 5, and at the same time as the foam comes into contact with the kraft paper 5, it is generated in the kraft paper 5 while being spread in the lateral direction due to the action of the roller 3 which is in contact with the kraft paper 5 and rotates around. Laminate paper 4 and craft paper 5 while smoothing out wrinkles.
Almost the entire space formed by this process is filled uniformly.
In addition, since the two-sided materials were close to each other at the entrance, it was observed that the foam raw material was subsequently spread and filled smoothly without overflowing. The laminated board 10, in which the formed foam and two face materials were integrated, was taken up at a speed of 20 m/min.
It was produced continuously through a take-off device.

In this embodiment, unlike the method using an endless belt, there is no leakage of foam raw material due to meandering of the endless belt. Since the double-sided materials are arranged close to each other in a V-shape at the entrance, there is no overflow of the foam raw material, and spreading and filling are good. Furthermore, since the roller 3 rotates at the same speed as the laminated paper 4 and kraft paper 5 that are in contact with it, there is no misalignment that occurs between the belt and the double-sided material, so there are no scratches, wrinkles, or cracks on the laminate 10. , no breakage occurred. Problems such as uneven thickness, wrinkles on the surface, reduction in surface smoothness, and warping, which are observed in the method of using a roller conveyor only on the lower side, did not occur.

FIG. 3 shows another embodiment in which a metal plate with shaped side surfaces is used as the lower surface material in the above embodiment. In this example, there was no leakage of the foam raw material due to the meandering of the endless belt, and the spreading and filling were good. When an endless belt is used, misalignment occurs between the belt and the double-sided material, which often results in scratches, wrinkles, cracks, and breaks in the laminate; however, in this example, such drawbacks were not observed. Nakatsuta.

4 to 9 are explanatory diagrams illustrating embodiments of the present invention. In both cases, the laminates are transported from left to right. FIG. 4 shows a case where the upper roller conveyor is arranged close to the lower roller conveyor in a V-shape at the entrance. FIG. 5 shows a case where the upper roller conveyor is disposed close to the lower roller conveyor in a V-shape at the entrance and at one point in the middle. In Fig. 6, as in Fig. 4, the upper roller conveyor is arranged close to the lower roller conveyor at the entrance part in a V-shape, but from the closest part to the exit direction. This is the case where the slope continues gently to the exit. Figure 7 is the same as Figure 4 in that they approach each other in a V-shape at the entrance, but the upper roller conveyor and lower roller conveyor are slightly closer together at the closest point. In this case, the length of the paper is parallel to the transport direction. Fig. 8 has a V-shaped approach in two places as in Fig. 2, but the approach at the entrance has a somewhat parallel portion at the closest point as in Fig. 7. be. FIG. 9 shows a case where the roller pitch is partially changed.

As detailed above, the present invention is a novel continuous manufacturing method for laminates with improved product quality, operability, productivity, economic efficiency, etc., and the obtained laminates have excellent heat insulation and sound insulation properties. It is excellent and lightweight, making it extremely useful as a building material for interior and exterior walls.

[Brief explanation of the drawing]

FIG. 1 is a partially omitted structural diagram showing an embodiment of the present invention, FIG. 2 is a plan view, and FIG. 3 is a sectional view taken along line A-A' in FIG. 1. 4 to 9 are explanatory diagrams illustrating embodiments of the present invention. 1, 2... Roller conveyor, 3... Roller, 4... Laminated paper, 5... Kraft paper, 6
... Take-up device, 7 ... Supply device, 8 ... Foam raw material, 9 ... Nozzle, 10 ... Laminate board, 11 ... Kraft paper roll, 12 ... Guide roll, 13 ...
Foam, 14... Holding device, 15... Shaped metal plate, 16... Upper surface material, 17... Lower surface material, 1
8... Foam raw material, 19... Laminate board.

Claims (1)

[Claims] 1. Foam raw material is continuously supplied onto the lower facing material near the entrance of a space consisting of two vertically opposing facing materials being conveyed between two roller conveyors arranged above and below. In this method, the foam is foamed, spread, and cured, and the foam and face material are integrated to produce a laminate continuously.The upper and lower rollers are free to rotate, and the upper roller conveyor is is arranged close to the lower roller conveyor in a V-shape at one or more locations including
A continuous manufacturing method for a laminate, characterized in that R is 0.01 to 0.6 sec.