JPH0146309B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for continuously manufacturing a corrugated thermoplastic synthetic resin sheet, and more specifically, the present invention relates to a method for continuously manufacturing a corrugated thermoplastic synthetic resin sheet, and more specifically, a continuously extruded thermoplastic synthetic resin sheet P is corrugated by a plurality of upper and lower pairs of rolls a. In the method of forming, two or more sets of a plurality of corrugating roll units A and B including adjacent upper and lower pairs of rolls having different corrugations m and n are arranged in the extrusion direction, and one set of roll units A has adjacent upper and lower pairs. By arranging the pair of rolls a to face each other on the sheet P passing surface, and separating the adjacent upper and lower pairs of rolls b of the remaining roll unit B above and below the sheet P passing surface,
This invention relates to a continuous manufacturing method for corrugated sheets in which two or more types of corrugated sheets M and N having different waveforms are continuously formed.

Conventionally, when manufacturing thermoplastic synthetic resin corrugated plates M' and N', as shown in Fig. 1, a sheet P extruded from an extruder 1 is polished by a polishing roll 2 and then corrugated. After the corrugated sheet M is corrugated into a desired shape and solidified by the device 3, and both ends of the corrugated sheet M are cut by the trimming device 4, the cutter 7 is held while being held by a vise 6 that moves in synchronization with the take-up speed of the take-up roll 5. The product is cut into a certain size at , separated from the device by a kick-off roll 8 , and placed on a product table 9 .

In such conventional devices, when changing the corrugated shape of the corrugated sheet, at least the corrugating device 3 and the take-up roll 5 must be replaced among a series of devices, and replacing these devices takes a long time. This process takes time and requires the extruder to be stopped, resulting in various problems such as time loss, disassembly/assembly of molds, and replacement of equipment due to stopping of the extruder.

The present invention has been made in view of the above-mentioned drawbacks, and relates to a manufacturing method that can change the wave shape of a corrugated sheet without replacing a series of devices or stopping the extruder. The details will be explained based on the following.

FIG. 2 is a schematic view schematically showing an upper and lower pair of rolls a and b of the corrugating device 3 for carrying out the present invention. The sheet P continuously extruded by the extruder 1 passes through a polishing roll 2 and then is sent into a corrugating device 3 . Inside the device 3, there is a roll unit A in which three upper and lower pairs of rolls A for corrugating a single waveform m on the sheet P are lined up in close proximity, and three upper and lower pairs of rolls B for corrugating another waveform n. Roll units B are arranged in series in the extrusion direction. In the state shown in FIG. 2A, a corrugated sheet M having m waveforms is obtained by the roll unit A, and in the state shown in FIG. 2B, a corrugated sheet N having n waveforms is obtained by the roll unit B. As is clear from the figure, while the corrugation is being performed by the roll unit A, the roll b of the roll unit B is vertically separated from the surface of the sheet P.
Further, while the corrugation is being performed by the roll unit B, the roll a of the roll unit A is vertically separated from the surface of the sheet P. In the figure, three rolls a and b are shown in roll units A and B, but various rolls can be selected depending on the synthetic resin material, extrusion conditions, molding conditions, etc. Although two sets of roll units A and B are used, by adding other roll units, even more corrugated sheets can be manufactured on the same molding line.

FIG. 3 shows details of the corrugating device 3 used in the present invention. Small waves (pitch: 30-70
It consists of a corrugating device 3a for small waves that manufactures a corrugated plate M having a corrugated shape of mm), and a corrugating device 3b for large waves that manufactures a corrugated plate N having a corrugated shape of a large wave (pitch: 70 to 140 mm). The corrugating devices 3a and 3b are each installed on a trolley 10 and are movable on rails 11. The corrugating device 3a for small waves is arranged on the extruder side, and includes a sheet heating heater 12 that heats the sheet P from above and below, and a heated sheet P.
It consists of a roll unit A that corrugates the material into a small wave shape. The roll unit A consists of a large number of upper and lower pairs of adjacent rolls a, which press the sheet P from above and below to create small waves. These rolls a are each connected to an air cylinder 16, and can be vertically opposed to and separated from the sheet P surface. Further, the seat heating heater 12 is also connected to the air cylinder 16 and is freely movable up and down. On the other hand, the corrugating device 3b for large waves is arranged behind the corrugating device 3a for small waves, and similarly consists of a heater 13 for heating the sheet and a roll unit B.
The roll unit B consists of a large number of adjacent upper and lower pairs of rolls b, which press the sheet P from above and below to create large waves.
In the figure, the roll b is spaced apart from the surface of the sheet P and does not participate in the corrugation forming of the small wave shape.
Among the upper and lower pairs of rolls b, the upper roll b is completely separated from the surface of the sheet P, but the lower roll b is not completely separated, and the flat plate 15 is placed on the surface of the roll b. , and are spaced apart to a position where the lower surface of the valley of the corrugated sheet M and the flat plate 15 come into contact with each other, so as to serve as a cradle for the corrugated sheet M. Incidentally, if the corrugated sheet M is strong, there is no need for the lower roll b to serve as a pedestal, and it is completely separated downward. These upper and lower pairs of rolls b and sheet heaters 13 are also connected to the air cylinder 16.
It is connected to the sheet P surface and can freely move up and down, such as facing and separating from the sheet P surface. In addition, rolls a and b are connected to the pipe by a rotary joint,
The temperatures of rolls a and b may be controlled by a heating medium such as hot water or oil sent through a pipe. In the corrugating device 3 configured as described above, the sheet P sent is corrugated into a small wave shape by the roll unit A of the small wave corrugating device 3a, and after being cooled and solidified, the sheet P is next formed into a small wave corrugated sheet M. It is sent to the process of

FIG. 4 shows a production line for continuously producing corrugated sheets according to the invention. A thermoplastic resin such as vinyl chloride resin or polycarbonate resin is extruded as a sheet P by an extruder 1, passes through a gloss roll 2, and is sent to a corrugating device 3a for small waves. The sheet P sent to the corrugating device 3a is heated by a sheet heating heater 12, and then sent to a roll unit A for forming small waves, where it is corrugated into a small wave shape pressed by a pair of upper and lower rolls a. molded. At this time, the sheet P is formed into a small wave shape when passing through the first roll a, and is cooled and solidified while being kept in shape by the second and third rolls a and a. The solidified small wave corrugated plate M passes between the upper and lower pair of rolls b while contacting the flat plate 15 on the surface of the roll b in the large wave corrugating device 3b,
The next trimming device 4 trims both sides to a constant width, and then the sheet P is taken up by a take-up roll 5 in synchronization with the extrusion speed of the sheet P and sent to the next vise cutter unit. The corrugated plate M passes through the path of the vise cutter unit and the path of the kicking roll 8, and its tip reaches the limit switch 1.
Vise 6 so that the corrugated plate M does not move when it comes into contact with 7.
closes to hold the corrugated sheet M, and as the corrugated sheet M is fed out, the vice/cutter unit moves together with the corrugated sheet M, and when the corrugated sheet M is moved a certain distance, the corrugated sheet M is cut by the cutter 7. When the corrugated sheet M is cut, the vise 6 opens and the vise cutter unit returns to its original position. On the other hand, the cut corrugated sheet M is sent out by a kick-off roll 8, separated from the line, and placed on a product stand 9 as a corrugated sheet product.

A corrugated plate M with small waves is obtained through the series of steps described above, but in order to convert this process into a process to obtain a corrugated plate N with large waves, the following steps are performed. First, the flat plate 15 placed on the lower roll b of the roll unit B of the large wave corrugating device 3b is removed. Also, the sheet heating heater 13 in front of the roll unit B is energized.
If necessary, a heating medium is passed through roll b to heat it to meet the conditions for large wave forming. After that, without cutting the sheet P sent from the extruder, the upper and lower pair of rolls a of the roll unit A of the corrugating device 3a for small waves are separated upwardly and downwardly and put into the corrugating device 3b for large waves. Allow sheet P to be fed. Next, the upper and lower rolls b of the roll unit B of the large wave wave forming device 3b are moved to the air cylinder 1.
6, the upper and lower rolls b are opposed to each other so that the sheet P can be pressed and formed into large waves of a fixed shape. At this time, the sheet heating heater 12 in the small wave corrugating device 3a stops energizing and moves upward and downward to separate them, and the roll waveform of the take-up roll 5 is switched from one for small waves to one for large waves. In addition, if necessary, the corrugation device 3 for small waves
Even if the lower roll a of the roll unit A of a is lowered once and the flat plate 15 is placed on the upper surface of the roll a, it is raised to a position where the lower surface of the sheet P touches the upper surface of the flat plate and serves as a guide for the sheet P. good.
Further, the sheet heating heaters 12 may be placed opposite each other on the sheet surface in a energized state to prevent the sheet from cooling. In this way, the manufacturing line for the small wave corrugated sheet M is changed very smoothly to the manufacturing line for the large wave corrugated sheet N, and thereafter, the large wave corrugated sheet N is continuously manufactured.

The take-up roll 5 includes a rubber roll 18 that supports the troughs of each corrugated sheet from below, and pressure rolls 19 and 20 in small and large wave shapes that press down each corrugated sheet from above.
Therefore, the presser rolls 19 and 20 are at the fulcrum 21.
It rotates around the center to match the waveform to be manufactured.

Figures 5A and 5B show other embodiments, and Figure 5A is a corrugation device 3 in which a square wave corrugation device 3c is added so that three types of corrugated sheets can be manufactured on the same production line. This is what I did. As in this embodiment, a corrugating device can be easily added, and a cutting line suitable for high-mix, low-volume production can be created.

FIG. 5B shows the corrugation device 3 that is entirely covered with a box body 24, and the inside temperature of the box body 24 can be maintained at a constant temperature by means of a heater, hot air, etc., so that the corrugation conditions of the sheet P can be adjusted. It is easy to keep constant at all times, and high quality corrugated sheets can be manufactured. The box body 24 may cover the entire body as shown in the figure, or each corrugating device 3 may
a and 3b may be covered individually, or only one of the corrugating devices 3a may be covered and made movable, and moved to the corrugating device 3a side that is performing forming. Only the device may be covered.

As described above, when the present invention is used, the waveform can be changed simply by switching the roll unit without cutting the sheet, and can be done smoothly in an extremely short time. In addition, there is no need to stop the extruder or replace the corrugating device or take-up roll each time, unlike in the past, making the corrugation switching operation much easier. Furthermore, since switching is easy as described above, it is possible to manufacture a wide variety of corrugated sheets depending on the application. Furthermore, since the rolls that perform corrugation forming each form a unit, corrugation forming can be performed reliably even when changing the waveform. In particular, even with sheets such as polycarbonate resin, which have a high molding temperature and are rapidly cooled and are prone to internal distortion after molding, corrugation can be performed reliably and smoothly using a roll unit that includes multiple pairs of upper and lower rolls in close proximity. It is something that

[Brief explanation of drawings]

FIG. 1 is an explanatory diagram showing a conventional corrugated plate manufacturing apparatus, FIG. 2 A and B are conceptual diagrams showing the arrangement of upper and lower pairs of rolls for carrying out the present invention, and FIG. 4 is a side view of a corrugating apparatus having a corrugating arrangement, FIG. 4 is a layout diagram of the entire apparatus for continuous production of corrugated sheets according to the present invention, and FIGS. It is. Explanation of symbols, 1... Extruder, 2... Glazing roll, 3... Corrugating device, 4... Trimming device, 5
...Take-up roll, 6...Vise, 7...Cutter, 8...Kick-out roll, 9...Product table, P...
...Sheet, A, B...Roll unit, a, b...
...roll, M, N...corrugated sheet.

Claims (1)

[Claims] 1. In a method of corrugating a continuously extruded thermoplastic synthetic resin sheet with a plurality of upper and lower pairs of rolls, a plurality of corrugating roll units including upper and lower pairs of rolls having different corrugations and close to each other are moved in the extrusion direction. By arranging two or more sets of rolls in the same manner, by arranging the adjacent upper and lower pairs of rolls of one set of roll units to face each other on the sheet passing surface, and by separating the adjacent upper and lower pairs of rolls of the remaining roll units above and below the sheet passing surface, two types of rolls can be produced. A continuous corrugated plate production method that continuously forms corrugated plates with different waveforms as described above.