JPH0481509B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention is a composite board, for example, a foamable synthetic resin is sandwiched between two base materials, and at least one of the base materials is printed on the decorative surface and has an uneven pattern, so-called. In addition to printing and embossing to promote design and three-dimensionality, the base material is formed into a gutter shape, and foamable synthetic resin raw material is laminated on the gutter-shaped portion and fed into a mold. The present invention relates to a composite board manufacturing apparatus that continuously manufactures a composite board in which these constituent materials are integrally bonded while passing through a mold.

BACKGROUND OF THE INVENTION Recently, composite boards using a metal plate or the like as a base material have been mass-produced as interior and exterior materials for buildings. However, there are almost no composite plates that have improved the coldness and smoothness of metals, have rich designs (embossed patterns), and suppress the undesirable appearance of the material.

Furthermore, when synthetic resin foam raw materials such as polyurethane resin and phenolic resin are used as the core material,
Since foam formation involves a chemical reaction that is greatly affected by various factors such as temperature, it has been desired to have a device that can set uniform conditions and can handle temperature changes to a certain extent.

Furthermore, since the temperature of the base material significantly changes the expansion ratio and fluidity of the raw material, low foaming or high foaming will occur if a deviation from the predetermined temperature of the raw material occurs. Therefore, in order to obtain a predetermined volume or density, it is necessary to increase the amount of raw materials, which has the disadvantage of increasing costs. In addition, when the foaming is highly foamed, the foam structure is weak and mechanical strength is lacking. Furthermore, when manufacturing composite boards using this type of raw material, the reaction foam curing is completed in 1 to 2 minutes, the foam expands 20 to 30 times, and the adhesiveness is strong, so the upper and lower panels can be easily bonded. If one was not present, these often adhered to the device and hardened, resulting in serious damage.

In order to eliminate the above-mentioned drawbacks and to meet the above-mentioned needs, the present invention draws an arbitrary pattern on the decorative surface of the lower base material using at least an ink mixed with a substance that foams when exposed to light, and then creates foams in the ink. A cosmetic coating film is applied to the cosmetic surface.
For example, by applying a clear coating to prevent cracks in the decorative coating, and to prevent changes in the printed pattern,
The embossed shading on the decorative surface, the shading drawn in the printed pattern, and the foamed ink protrusions provide the panel with sufficient three-dimensionality, design, and natural feel, and the coil-shaped lower base material. (Surface material) is continuously subjected to embossing, molding, and core material filling, and then an upper base material that becomes the back material is laminated to the core material, and is continuously fed as a product while curing. It is possible to produce the coiled lower base material cheaply and in large quantities on a batch line without damaging the surface of the lower base material, and to immediately eliminate distortions and deformations that occur during embossing in the width direction and movement direction. To form the material while releasing and straightening it according to the flower diagram of the forming roll, and forming it into a gutter shape that is structurally resistant to deformation and also functions as a molding material.
To more effectively foam the temperature-sensitive synthetic resin foam raw material and reduce the amount of expensive raw materials used to lower costs, and for the lower base material immediately after molding,
Filling with foam raw material and using foaming pressure to visually eliminate residual strain on the lower base material to create a beautiful decorative surface, cutting of the lower base material, detecting completion of use, leakage of raw materials into the equipment, etc. The present invention proposes a composite plate manufacturing apparatus that can prevent the wear and tear from occurring, and can impart weather resistance and abrasion resistance to the decorative surface.

DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a composite plate manufacturing apparatus according to the present invention will be described in detail below with reference to the drawings. FIG. 1 is a schematic configuration diagram of the above-mentioned apparatus, in which 1 is a lower base material delivery section, and an uncoiler 2 with a brake is equipped with a metal thin plate A (hereinafter simply referred to as base material A), which is the so-called lower base material. and pinch rollers 3, which are used to continuously feed the base material A to the next process. 4 is a printing section consisting of a back-up roller 5 and a coating roller 6, which performs gravure printing, offset printing, and screen printing of arbitrary patterns with ink B in one color or multiple colors on the decorative surface of the base material A, here the entire surface. , letterpress printing, or lithographic printing. The ink B contains at least a substance that foams when exposed to light, and printing is performed on the entire decorative surface or within a predetermined area. Substances that foam when exposed to light include azo compounds such as benzenediazonium chloride, 2-cyano-2-propylazoflumamide, 2,2-azobisisobutylnitrile, and 1-1-azobiscyclohexane-1-carbonitrile. It consists of seeds, and one of aqueous acrylic and vinyl acetate is used as the vehicle. Reference numeral 7 includes a light source 8 that foams the above-mentioned substance using a projector, and a conveyor 9, which foams the substance of the ink B during short-time conveyance. In addition, as the light source 8, a fluorescent lamp,
One or more types of high-pressure mercury lamps, infrared lamps (including far- and ultra-far-infrared lamps), and ultraviolet lamps are arbitrarily arranged, and the scale and shape of foaming can be selected. Reference numeral 10 denotes a coating unit for applying transparent paint or color paint (hereinafter simply referred to as clear) C to the patterned surface where the ink B on the decorative surface is undried or dry, such as a roll coater, a curtain, etc. It consists of one of a flow coater, spray, etc. 11 is a heating section, which includes a roller 12 and a heater 13;
It uses heat to dry or accelerate the reaction of ink B and clear C, and is also used to transport base material A to the next process. Note that the heating temperature ranges from about 30 to 110°C. 14 is a pinch roller; 15 is an embossing machine, which has male and female uneven patterns that engage with each other on the outer circumferential surfaces of upper and lower rolls 16 and 17; The structure is such that the support can be pressurized depending on the situation. Note that the uneven pattern may be the same as or different from the printed pattern, and can be arbitrarily processed to match or shift from the printed pattern during processing. 1
A molding machine 8 has a number of stages, such as 10 stages, 20 stages, 32 stages, etc., and molds the base material A into a substantially gutter shape. Note that the molding width can be either single width or double width. Further, the base material A formed in this manner prevents leakage of the foam raw material to the outside as described below by acting as a mold material, and also serves as reinforcement for the composite plate. In addition, since the molding machine 18 sequentially molds the base material A into a gutter shape along the flower diagram from its inlet to its exit, distortion and deformation during embossing are caused in the width direction of the base material A and in the transport direction. escape along,
The residual distortion and deformation can be minimized. 19 is a preheater that heats the base material A to 30 to 110°C, which serves to effectively react and foam the raw material for the synthetic resin foam discharged from the discharge section 20 described below, and also heats the base material A to a temperature of 30 to 110°C. This is useful for partially removing residual strain, deformation, etc. due to the synergistic effect with the foaming pressure of the raw material. Reference numeral 20 denotes a discharge section where a raw material for the synthetic resin foam, the so-called foamable reaction mixture D (hereinafter referred to as
This is for laminating materials (simply referred to as raw materials) on the gutter-like portion of the base material A. The discharging method includes, for example, a discharging method equipped with a rotary blade, a spray gun method (air, airless), and an injection method, and a method suitable for the purpose is used. Reference numeral 21 denotes an upper base material delivery section that continuously feeds out an upper base material E (hereinafter simply referred to as base material E), and transfers this base material E to raw material D.
It is for layering on top. The main structure of the upper base material delivery section 21 is an uncoiler-like mechanism. The base material E may be made of asbestos paper, kraft paper, aluminum foil, plastic sheet, asphalt roofing, or a composite sheet laminated with one or more of these materials. The upper base material delivery section 21 also includes a base material E.
Naturally, an additional mechanism such as a brake by a band is provided so that the tension is drawn out under a constant tension. Reference numeral 22 denotes a guide roller for guiding the base material E so that it is placed on the gutter-like portion of the base material A. The guide roller 22 is constructed as a mechanism capable of moving in either the horizontal or vertical direction to the position indicated by the two-dot chain line as required. This is particularly significant since the raw material D is a chemically reactive substance that is greatly influenced by temperature. Reference numeral 23 denotes a mold, and endless belt type molding materials 24 and 25, such as steel belts, caterpillar type molding materials, non-woven fabric, Net, or a shape material made of a combination of one or more of these, are faced to each other with a predetermined interval, which corresponds to the thickness of the so-called composite plate F, to form voids continuously, and after a certain period of time has elapsed, It is something that is repeatedly resolved. The mold 23 serves to cause the unreacted raw material D filled between the base material E and the base material A to react, foam, and harden while passing through the mold 23. Further, as a specific example of the type 23, the driven wheel 2
6, 27 and drive wheels 28, 29, each with a smooth metal endless belt (for example, made of stainless steel), or a caterpillar type pressure system (not shown) in which multiple pieces are connected by links etc. be. A plurality of reinforcing rollers 30 are arranged at regular intervals between the drive wheels, and are used to suppress the displacement of the sections 24 and 25 in order to obtain a predetermined thickness of the composite plate F, and to control the displacement of the sections 24 and 25. Prevents deformation etc.
Moreover, it is provided to smoothly transfer the shapes 24 and 25. 31 is a heating device, for example
This serves to heat the belt and the space around it to about 30 to 110°C. 32 is a cover that keeps the mold 23 and its intended space warm, and also protects against trichloromonofluoromethane released during the reaction of raw material D, carbon dioxide gas, carbon monoxide, etc. released from the heating device for safety and hygiene reasons. It is intended to be carried outside without being released into the work environment. In addition, the entrance and exit parts 2 of the mold 23
Only 3a and 23b have a structure that can prevent gas leakage within the mold 23 to the maximum extent, such as an air curtain.

Next, the operation of the composite plate manufacturing apparatus according to the present invention will be explained. Now, as base material A, a 0.27 mm thick pre-coated metal plate (width 1000 mm) wound around a 1000 m bobbin was attached to uncoiler 2. In addition, as ink B, water-based acrylic varnish (fixed amount: 40
%), organic pigment, and 1-1-azobis-cyclohexane-1-carbonitrile in a polymerization ratio of 100:10:
This is a composition consisting of a ratio of 30% to 30%, and is printed on a decorative surface using a gravure printing method. A polyurethane resin was prepared as the clear C, and the temperature of the heating section 11 was set at 60°C. Therefore, a composite plate F was formed as shown in Figure 2.
Assume that you manufacture First, the starting end of the base material A is guided to the pinch roller 3, and then fed to the printing section 4 . In the printing section 4 , printing is performed on the decorative surface of the base material A using a gravure printing machine as shown in FIG. 3a. In addition, in a, only the substance that foams due to light is depicted, and the others are omitted. Next, the base material A is fed to the floodlight 7 , and the third
As shown in Figure b, the foamable material is foamed by light. Next, as shown in FIG. 3c, clear C is applied to the decorative surface of the base material A from the coating section 10, and is fed to the heating section 11 , where the ink B and clear C are dried and cured. A is reversed and fed to the embossing machine 15 via the pinch roller 14. The embossing machine 15 applies embossing to the entire width, a certain width, or a portion of the base material A as shown in FIG. The molding machine 18 molds the base material A into the cross-sectional shape shown in FIG. 3e, and feeds the base material A to the preheater 19. This preheater 19 heats the base material A to 60° C. and feeds it to the discharge section 20. In the discharge section 20, the unfoamed polyurethane resin raw material D is discharged into the recess A' of the base material A, as shown in FIG. 3f, and is sent to the next step. Then, at the timing when the raw material D changes from cream-like to gel-like and foams and expands to some extent, the base material E is laminated via the guide roller 22 as shown in FIG. 3g. Next, this is fed to the mold 23, and while passing through the mold 23, the raw material D is reacted, foamed,
After being cured, it is fed from the outlet 23b as a band-shaped composite plate F with a cross section as shown in FIG. Of course, at this time, the base material A and the base material E are fixed together by the self-adhesive property of the raw material D. The composite plate F sent out from the mold 23 is then cut into a predetermined length using various means. The thus manufactured composite plate F was subjected to a salt spray test (JIS-Z-2371,
1000 hours), no rust was observed at all. This is the result of Clear C's greatly improved wear resistance during embossing and molding. As a comparative example, when the decorative surface of base material A without Clear C was tested in the same way, cracks were observed in the finished coating film in some areas during embossing, and in even more areas after molding. Moreover, as a result of deeper cracks, the salt spray test was poor. Furthermore, in the comparative example, the printed pattern on the decorative surface was directly exposed during embossing and molding, resulting in a lack of aesthetics, but the example did not have such an appearance.

What has been described above is only one embodiment of the apparatus according to the present invention, and as shown by the dashed line in FIG.
In order to detect the cutting of the base material E, that is, the presence or absence of the base material E, a detector G is provided between the upper base material delivery section 21 and the guide roller 22, and when the base material E is not present, the discharge section 20 etc. is activated. It can also be configured to generate a stop signal. As a specific example, a plurality of phototubes corresponding to the entire width of the base material E are continuously arranged in a straight line, receivers are arranged correspondingly on the opposing surfaces, and the output end is operated to supply the core material. It is configured such that it is connected to a switch for use, and the supply is immediately stopped when cutting the base material E, etc. Also,
The base materials A and E may be formed of the same material, or one or more types of pearlite grains, shirasu balloons, silica sand, borax, boric acid compounds, fibrous materials, etc. may be formed in the discharge part 20 at the same time as the raw material D, or with a time difference. It can be configured to be added before entering 23. Moreover, the mold members 24 and 25 can also be constructed from rollers.

As described above, according to the composite plate manufacturing apparatus according to the present invention, arbitrary patterns can be printed in one color or in multiple colors on the decorative surface of commercially available base materials, such as color steel plates, surface steel plates, pre-coated plates, aluminum plates, copper plates, etc. ,
Finishing paint, such as transparent clear paint, is applied on top of it, resulting in a pattern with vivid shadows and rich colors.
Moreover, it has the advantage of being able to produce composite boards with excellent weather resistance. The base material is printed using ink mixed with a substance that foams when exposed to light, and after foaming, the pattern is embossed at any depth and with any uneven pattern, which doubles the three-dimensional effect, and the printed pattern is clear. Because it is coated with a composite plate, it does not shrink or expand during embossing or molding, causing excessive damage to its appearance, and can produce composite plates with excellent corrosion resistance. It is characterized by being able to heat the base material according to the reaction system of the temperature-sensitive raw material, and to match the timing of laminating the base material to the raw material very easily using guide rollers.
Since printing, embossing, supplying raw materials for the core material to the back side, and laminating the base materials can be performed continuously, it has the feature that it can be manufactured at low cost, homogeneously, and in large quantities. Since embossing can be applied only to the required width of the base material, distortion of the base material,
Deformation can be minimized, and since it is formed into a gutter-like shape immediately after embossing, the distortion and deformation caused by embossing can be released in the width direction and longitudinal direction, and dimensional deformation due to residual strain can be avoided. It has a feature that can suppress the occurrence of unevenness.
After molding, the base material is heated to 30 to 110℃, filled with a foaming and hardening raw material, and in order to foam the raw material, the deformation and distortion of the base material is slightly corrected by the above temperature and foaming pressure, It has the characteristic of suppressing dimensional changes.
Since the inside of the mold is sealed, heat retention is improved,
This system significantly improves worker safety and hygiene by reducing leakage of toxic gases and combustion gases into the working environment. Because it uses a base material shaped like a gutter,
Another advantage is that side moldings are not required.

[Brief explanation of the drawing]

FIG. 1 is a schematic configuration diagram showing an embodiment of a composite plate manufacturing apparatus according to the present invention, and FIG. 2 is a perspective view showing an example of a composite plate manufactured by the above-mentioned apparatus according to the present invention.
FIGS. 3a to 3g are explanatory diagrams showing the manufacturing process of the composite plate. 1 ...Lower base material delivery section, 4 ...Printing section, 7...
Floodlight, 10... Painting section, 11 ... Heating section, 15
... Embossing machine, 18 ... Molding machine, 23 ...
Type, A...lower base material, E...upper base material.

Claims (1)

[Claims] 1. A lower base material delivery section consisting of an uncoiler and a pinch roller, a printing section that prints an arbitrary pattern on the decorative surface of the lower base material using at least an ink containing a substance that foams when exposed to light, and a printed decorative surface. a projector that irradiates light onto the decorative surface, a coating section that applies paint to the entire surface of the decorative surface, a heating section that dries the ink and transparent paint applied to the decorative surface, and a lower base material that is sent out from the heating section. an upper and lower roll type embossing machine that has a concavo-convex pattern on its outer circumferential surface that performs arbitrary embossing on a predetermined area of the base material; and a molding machine that continuously shapes the embossed lower base material into a substantially gutter shape. , a discharge section that supplies a foamable reaction mixture having self-adhesive properties to the gutter-like portion of the lower base material, and an upper base material delivery section that continuously supplies the upper base material covering the discharged mixture; An endless type material that is wide and stretched and driven by a driven wheel and a driving wheel is placed between a pair of upper and lower molds that face each other with a predetermined interval, and an upper base material between the former upper base material delivery section and the mold entrance. A guide roller that guides the lower base material to be laminated at a predetermined position and is displaced according to the dispersion and reaction state of the mixture, and a guide roller that can heat the space containing the mold material to 30 to 110°C and heat the inside of the space. 1. A composite board manufacturing device comprising: a cover that prevents gas from leaking to the outside;