JPH0140744B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a novel continuous manufacturing method for synthetic resin corrugated sheets and an apparatus for use in the method. More specifically, the present invention relates to a method and apparatus for continuous production of corrugated sheet, which allows the corrugation of a corrugated sheet product to be changed without interrupting the execution of the forming operation.

In the conventional technology for continuously manufacturing synthetic resin corrugated sheets, the process begins with extrusion molding of the synthetic resin raw material into a sheet-like object, and then completes the entire forming process such as polishing, waving, trimming, cutting, and feeding of the sheet-like object. A method is adopted in which corrugated plates having one type of corrugation are continuously mass-produced using large-scale molding equipment that includes multiple processes. For example, in a conventional continuous corrugated plate manufacturing apparatus as shown in FIG.
A thermoplastic synthetic resin raw material, such as polyvinyl chloride (PVC), is extruded to obtain a sheet with a thickness of 0.6 to 1.0 mm. The sheet thus obtained is passed through a polishing roll 2 and then in a corrugating section 3, e.g.
A desired corrugation is applied by a corrugation device in which a plurality of sets of corrugation rolls as shown in Figures A or B are arranged. The corrugated sheet that comes out of the corrugation device is cooled and solidified, and after being trimmed at both ends by a trimming device 4, it is taken off by a take-up roll 5.
The corrugated sheet is held by a vise 6 that moves in synchronization with the corrugated sheet, and cut into a predetermined length by a cutter 7. The corrugated veneer P thus produced is separated from the forming device by a kick-out roll 8 and stored at a predetermined location.

However, in such a conventional method, when changing the corrugation of a corrugated sheet product, it is necessary to replace the extruder and the equipment performing the steps after the polishing roll. In other words, the part from the corrugation device to the deburring roll that was used to manufacture the previous corrugated sheet is removed from the entire forming process, and the part from the corrugation device to the deburring roll used to form the next different corrugated sheet is removed from the entire forming process. A series of equipment must be replaced and installed. Normally, a series of devices from the corrugating device to the edged rolls are fixed on one trolley, but the interruption time required for forming operations from the start of device changeover work to the restart of operation due to the production of different types of corrugated sheets is It takes at least 4 hours or more, and the labor and time loss in manufacturing corrugated sheets is significant.

In the past, when attempting to manufacture corrugated sheets with different waveforms, it was impossible to avoid the large-scale replacement work of equipment as described above, which resulted in many problems as described below. That is, when an extruder and a corrugating device are used in series as described above, the molding operation is interrupted to replace them, resulting in the following inconvenience: Generally speaking, as a thermoplastic synthetic resin,
PVC is used, but the PVC remaining in the extruder and die is easily thermally decomposed, so if the extrusion operation is interrupted, the PVC will decompose in the extruder and die and attack the extruder and die. Polishing and assembly require a long time of 20 hours or more, resulting in a large time loss; in order to prevent the above time loss, when replacing the corrugating device and below while the extruder is running, it is necessary to However, the amount of raw material resin lost is equivalent to the time required for replacement work. The raw resin discharge rate of the extruder was increased to 170Kg/hr.
This will result in a resin loss of at least 680 kg; in order to prevent the above raw resin loss, the synthetic resin sheet extruded from the extruder can be cooled and crushed into recycled pellets during the corrugation equipment replacement period. , such regeneration work has the disadvantage of requiring considerable effort and separate equipment; separate corrugating equipment for imparting different waveforms and other such equipment for pre-preparation and storage. It requires a large space and requires a large working area to replace the equipment; generally, the entire equipment below the corrugating equipment is integrated and held by a frame, forming a large equipment, so it cannot be moved. The work is not easy.

Conventionally, in the production of synthetic resin corrugated sheets, product prices are kept low by producing small quantities of corrugated sheet products in large quantities, but in response to the recent demand for producing small quantities of many kinds of products, it is necessary to replace the corrugated sheets as described above. There are many difficulties and problems in its industrial manufacture have not yet been solved.

The present inventor has researched a method for continuously manufacturing corrugated sheets of thermoplastic synthetic resin, in which corrugated sheets of different shapes can be manufactured continuously without interrupting the extrusion operation, and has found many drawbacks of the conventional methods as described above. The present invention has been completed which eliminates the

SUMMARY OF THE INVENTION Therefore, the object of the present invention is to provide a method for continuously manufacturing corrugated sheets with different corrugations by easily changing the corrugation without interrupting the extrusion sheet molding operation of thermoplastic synthetic resin, and an apparatus for carrying out the method. It is to provide.

According to the invention, different waveforms, such as small waves (pitch: about 30-70 mm), large waves (pitch: about 70-130 mm)
Corrugated sheets such as rectangular and square corrugated sheets can be manufactured continuously by a process that includes only one series of continuous corrugated sheet manufacturing equipment.

An object of the present invention is to supply a thermoplastic synthetic resin sheet to be continuously extruded to a corrugated roll unit having a row of upper and lower pairs of corrugated rolls in the sheet supply surface, and to pass the sheet through hot passage between the upper and lower pairs of corrugated rolls. In a method for continuously manufacturing a thermoplastic synthetic resin corrugated sheet by Can be replaced at the sheet feeding surface without interrupting the molding operation,
A continuous manufacturing method for corrugated sheet, characterized in that the corrugated sheet is taken up by matching the waveform of the take-up roll of the take-up roll unit to the waveform of the corrugated roll; thermoplastic synthetic resin sheet extruder, polishing roll, preheating. unit, corrugated roll unit, trimming unit,
In a continuous corrugated plate manufacturing apparatus including a take-up roll unit, a vise/cutter unit, etc., the corrugated roll unit includes pairs of corrugated rolls with different corrugations in two stages, upper and lower, and the row of pairs of corrugated rolls in the upper or lower stage is It has a lifting mechanism for raising and lowering a corrugated roll unit for positioning the sheet in the synthetic resin sheet supply surface, and a take-up roll unit that takes up the corrugated sheet by matching the corrugation of the take-up roll to the waveform of the corrugated roll. A continuous corrugated plate manufacturing device; and a thermoplastic synthetic resin sheet extruder, a polishing roll, a preheating unit, a corrugating roll unit, a trimming unit, a take-up roll unit, and a vise cutter unit. In a continuous corrugated sheet manufacturing apparatus, the corrugated roll unit includes pairs of corrugated rolls with different waveforms in two stages, upper and lower, and the row of the upper or lower corrugated roll pairs is positioned within the synthetic resin sheet supply surface. It has a lifting mechanism for raising and lowering a corrugated roll unit for lifting the corrugated sheet, a flexible large-diameter roll that supports the corrugated sheet with a take-up roll unit from below, and a flexible large-diameter roll that has a shape corresponding to the waveform of the corrugated sheet and that This can be achieved by a continuous corrugated sheet manufacturing apparatus characterized by comprising a row of press rolls that can be switched according to the corrugation.

The present invention will be described below with reference to the drawings.

FIG. 2 shows an apparatus for carrying out the method of the invention. In FIG. 2, a thermoplastic synthetic resin raw material, such as polyvinyl chloride resin or polycarbonate resin, is extruded from a die of an extruder 11 as a sheet having a thickness of 0.6 to 1.0 mm at a speed of 3 to 3.5 m/min.
This sheet then passes through a polishing roll 12 and is heated to a temperature of 120-130 DEG C. by means of a preheating unit 12'. The sheet preheated to this temperature is sent to the corrugating roll unit 13.

The details of this corrugated roll unit 13 will be explained with reference to FIG. As is clear from Figure 4, the pair of A-type corrugated rolls in the lower row and the B-type corrugated roll in the upper row
Pairs of corrugated rolls are arranged one above the other in the lifting platform frame 33. Eight two-stage take-up units 36 are installed on both the left and right sides of this lifting platform frame, and the lower stage has a pair of A-type corrugated rolls consisting of eight upper and lower pairs of A-type corrugated rolls, and the upper stage In this case, a B-type corrugated roll pair consisting of eight pairs of upper and lower corrugated rolls each having a B-type corrugation is provided in the take-up unit. The elevating mechanism 32 is arranged at the four corners of the elevating frame 33, and is placed on a trolley 31 that can move on the rails 10, supporting the elevating frame and transporting machinery such as gears. The take-up unit 36 can be moved up and down by physical means or pressure means such as hydraulic pressure, water pressure, or pneumatic pressure. Pipes 34, 34' are connected to each corrugated roll by a rotary joint, and the temperature of the corrugated roll is controlled by a heating medium such as hot water through these pipes. Note that the elevating platform frame 33 is prevented from rolling by a reinforcing sliding frame 35.

The sheet preheated to a predetermined temperature and supplied to the corrugating roll unit 13 is corrugated between the upper and lower pairs of corrugated rolls of the A-type corrugated roll pair (see, for example, FIG. 3A for the corrugation of the rolls). The roll temperature is controlled to have a negative gradient from the inlet to the outlet of the roll unit, and the corrugated sheet exiting the roll unit is cooled and solidified, making it convenient for the next trimming operation. The solidified corrugated sheet is trimmed at both ends by the trimming unit 14 to have a constant width, and then transferred to the take-up roll unit 15.
The sheet is taken up by the A-type corrugated roll according to the extrusion molding speed of the sheet and sent to the next vise cutter unit. The corrugated sheet advances through the passage of the vise/cutter unit and the passage of the delivery roll unit 18, and when its tip contacts the limit switch 20, the vice 16 closes to prevent the corrugated sheet P from moving. However, when the vise is closed, the vise cutter unit moves in the direction of movement of the corrugated sheet in synchronization with the traveling speed of the corrugated sheet, and when the corrugated sheet has traveled a certain distance, the cutter 17 cuts the corrugated sheet. When cutting is complete, the vise opens and the vise/cutter unit returns to its original position. on the other hand,
The cut corrugated sheet P is quickly sent to a stacker by a delivery roll and recovered as a corrugated sheet product.

According to the above process, a corrugated sheet product having an A-type corrugation is obtained, but according to the present invention, a corrugated sheet having a B-type corrugation can be produced without interrupting the extrusion operation of the synthetic resin sheet as follows: A pair of B-type corrugated rolls (see, for example, FIG. 3B for the waveforms of the rolls) provided in the upper stage of the corrugated roll unit 13 is controlled in advance to a predetermined temperature with hot water. Next, the sheet coming out of the extruder is cut, and the sheets that continue to be fed from the extruder are separated from each other until the B-type corrugated roll pair changes to the A-type corrugated roll pair and comes onto the corrugated plate forming line. Hold. On the other hand, the motor for operating the lifting mechanism 32 of the corrugated roll unit is turned on, and the take-up unit 36 is lowered via the lifting platform frame 33 to move the B-type corrugated roll pair.
It is stopped on the corrugated plate forming line where the A-type corrugated roll pair was previously located. At this time, the A-type corrugated roll pair is located below the corrugated plate forming line by the height difference between the A-type corrugated roll and the B-type corrugated roll. Next, the leading end of the cut sheet, which has been held separately, is inserted between the upper and lower pairs of the B-type corrugated rolls, and is sent from the corrugating roll unit 13 to the trimming unit 14 and then to the take-up roll unit 1.
5. At this time, the corrugation of the take-up rolls is immediately switched from A type to B type via the fulcrum 15' in response to the exchange of the A type corrugated roll pair row to the B type corrugated roll pair row, and the B type corrugated sheet is formed. Ensure that work is carried out smoothly. In this way, the production of the B-type corrugated sheet is started, and thereafter, B-type corrugated sheet products can be continuously manufactured in the same manner as the above-mentioned manufacture of the A-type corrugated sheet.

Note that the time required to replace the A-type corrugated roll pair with the B-type corrugated roll pair in the corrugated roll unit 13 is as short as 3 to 4 minutes, and the sheet extruded during this time is about 10 m long. After replacing the roll pair, the corrugated sheet can be easily inserted into a new corrugated roll pair and production of corrugated sheet can be continued.

The take-up roll unit 15 consists of a roll group A or B that applies pressure from above to the troughs of the corrugated sheet corresponding to the A-type or B-type corrugation, and a large-diameter rubber roll C that supports the corrugated sheet from below. The roll group can be rotated about a fulcrum 15' to match the waveform of the corrugated sheet.

Unit 1 for performing each unit process of corrugated sheet manufacturing
2, 13, 14, 16, 18 are a pair of rails 10
By arranging the corrugated plates one after the other, the direction of movement of the corrugated plates can be easily maintained constant, but one rail engages the wheels to keep the unit rows in a straight line, while the other rail is flat. By allowing wheels to run freely on the top, the entire device can be moved and placed easily.

In addition, the corrugated roll (see Fig. 3A) can be constructed from unit members a as shown by broken lines, and when such a corrugated roll is used, adjustment of the width of the corrugated sheet; handling ( (light); switching between upper and lower pairs of corrugated rolls; exchanging upper and lower pairs of unused corrugated rolls; work efficiency is extremely high.

The present invention has been described in detail above. According to the present invention, since the corrugated rolls can be changed quickly, corrugated sheets can be manufactured continuously without stopping the operation of the extruder. Therefore, there is almost no loss of raw materials, and compared to conventional technology, the switching area is limited, so the switching work is not only easy and requires fewer workers, but also the corrugation forming work can be restarted after switching. Excellent effects can be obtained, such as being carried out quickly. In addition, by replacing the unused corrugated roll pair in the corrugated roll pair with a third corrugated roll pair having a different waveform during the manufacture of one corrugated sheet, corrugated sheets with many different types of corrugations can be continuously manufactured. It has the advantage that it can also be done.

[Brief explanation of drawings]

FIG. 1 is a diagram showing a conventional corrugated sheet continuous manufacturing device, FIG. 2 is a diagram showing a corrugated sheet continuous manufacturing device according to the present invention, and FIG. 3 A and B are views showing the corrugated roll pair side. FIG. 4 is a perspective view of a corrugated roll unit according to the present invention. Codes in the figure: 1... Extruder; 2... Glazing roll; 3... Corrugated portion; 4... Trimming device; 5...
...Take-up roll; 6... Vise; 7... Cutter; 8... Edged roll; 10... Rail; 1
1... Extruder; 12... Polishing roll; 12'...
...preheating unit; 13...corrugated roll unit; 14...trimming unit; 15...take-up roll unit; 15'...fulcrum;16...vice;17...cutter; 18...feeding roll unit; 20... Limit switch; 31...
...Dolly; 32... Lifting mechanism; 33... Lifting platform frame;
34, 34'... Pipe piping; 35... Reinforcement sliding frame; 36... Take-up unit; A, B...
...corrugated roll; P...corrugated sheet.

Claims (1)

[Scope of Claims] 1. A thermoplastic synthetic resin sheet to be continuously extruded is supplied to a corrugated roll unit having a row of upper and lower pairs of corrugated rolls in the sheet supply surface, and the sheet is heated between the upper and lower pairs of corrugated rolls. In a method for continuously manufacturing a thermoplastic synthetic resin corrugated sheet by passing
The corrugated roll unit includes a row of pairs of corrugated rolls having different corrugations above and below, and the corrugated roll unit can be raised and lowered to be replaced at the sheet supply surface without interrupting the sheet extrusion forming operation, and the corrugated roll unit can be replaced at the sheet supply surface without interrupting the sheet extrusion molding operation, and the corrugated roll unit can be replaced at the sheet supply surface without interrupting the sheet extrusion molding operation. A method for continuous production of corrugated sheet, characterized in that the corrugated sheet is taken up by matching the waveform of a take-up roll of a unit to the waveform of a corrugated roll. 2. In a continuous corrugated plate manufacturing apparatus including a thermoplastic synthetic resin sheet extruder, a polishing roll, a preheating unit, a corrugated roll unit, a trimming unit, a take-off roll unit, a vise cutter unit, etc., the corrugated roll unit is It includes corrugated roll pairs having different waveforms in two upper and lower stages, and has an elevating mechanism for raising and lowering the corrugating roll unit for positioning the upper or lower row of corrugated roll pairs within the synthetic resin sheet supply surface, A continuous manufacturing apparatus for corrugated sheet, characterized in that it has a take-up roll unit that takes over the corrugated sheet by matching the waveform of the take-up roll to the waveform of the corrugated roll. 3. In a continuous corrugated plate manufacturing apparatus including a thermoplastic synthetic resin sheet extruder, a polishing roll, a preheating unit, a corrugated roll unit, a trimming unit, a take-off roll unit, a vise cutter unit, etc., the corrugated roll unit includes pairs of corrugated rolls with different corrugations in two upper and lower stages, and has an elevating mechanism for raising and lowering the corrugated roll unit to position the upper or lower row of corrugated roll pairs within the synthetic resin sheet supply surface. , consisting of a flexible large-diameter roll that supports the corrugated plate with a take-up roll unit from below, and a row of pressure rolls that have a shape corresponding to the waveform of the corrugated plate and can be switched in accordance with the waveform. A continuous manufacturing device for corrugated sheets.