JPH0673866B2 - Method for producing phenolic resin foam and coating device used therefor - Google Patents
Method for producing phenolic resin foam and coating device used thereforInfo
- Publication number
- JPH0673866B2 JPH0673866B2 JP63178878A JP17887888A JPH0673866B2 JP H0673866 B2 JPH0673866 B2 JP H0673866B2 JP 63178878 A JP63178878 A JP 63178878A JP 17887888 A JP17887888 A JP 17887888A JP H0673866 B2 JPH0673866 B2 JP H0673866B2
- Authority
- JP
- Japan
- Prior art keywords
- foaming
- doctor
- phenol resin
- stock solution
- foam
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
- B29C44/30—Expanding the moulding material between endless belts or rollers
- B29C44/306—Longitudinally shaping, e.g. the belt
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Molding Of Porous Articles (AREA)
Description
【発明の詳細な説明】 〔産業上の利用分野〕 本発明は、フェノール樹脂発泡体の製造方法及びこれに
用いる塗布装置に関するものである。TECHNICAL FIELD The present invention relates to a method for producing a phenol resin foam and a coating apparatus used for the method.
近年、フェノール樹脂発泡体は、耐熱・耐火性及び低発
煙性等に優れるため、耐火性断熱材として注目されるよ
うになり建材、家具、工業用資材等の用途に使用される
ようになってきた。In recent years, phenol resin foams have been attracting attention as fire-resistant heat insulating materials because they are excellent in heat resistance, fire resistance, low smoke generation, etc., and have come to be used in applications such as building materials, furniture, and industrial materials. It was
従来、フェノール樹脂発泡体の製造方法としては、上下
二段に設けられると共に所定の間隔に保持された２個の
エンドレスベルトコンベアから構成される加熱装置を備
えたダブルコンベア部を有し、かつ各ベルトコンベアは
同一の速度で互いに反対方向に連続的に回転するように
設定されたベルトコンベア装置を使用し、下段エンドレ
スベルトコンベアと共に走行する下面材上に吐出ノズル
よりレゾール型フェノール樹脂、整泡剤、発泡剤及び硬
化触媒、また必要に応じてその他の添加物を含む発泡性
フェノール樹脂原液（以下単に発泡原液と略称する）を
供給し、次いで上面材を連続的に重ね合わせて積層体を
形成すると共に発泡硬化させ、これをダブルコンベア部
に案内し発泡体の厚みを規制しつつ発泡及び硬化を完了
させて発泡体を製造する方法が知られている。Conventionally, a method for producing a phenol resin foam has a double conveyor section provided with a heating device which is provided in upper and lower two stages and is composed of two endless belt conveyors held at predetermined intervals, and The belt conveyor uses a belt conveyor device that is set to continuously rotate in the opposite directions at the same speed, and the resol type phenol resin and foam stabilizer from the discharge nozzle on the lower surface material that runs with the lower endless belt conveyor. A foamable phenol resin stock solution (hereinafter simply referred to as a foam stock solution) containing a foaming agent, a curing catalyst, and other additives as necessary is supplied, and then the upper surface materials are continuously stacked to form a laminate. Foaming and curing, and guiding it to the double conveyor section to regulate the thickness of the foam and complete the foaming and curing to produce the foam. It is known how to.
そして、このようなフェノール樹脂発泡体の製造におけ
る発泡原液の塗布手段としては、一定の速度で走行す
る下面材上に一個ないしは複数個の吐出ノズルより発泡
原液を連続的に吐出し、又は吐出ノズルを面材幅方向に
トラバースさせながら発泡原液を連続的に散布してその
自己流延性により面材を塗布する方法、又は上下面材
を対向配置して積層体を形成した後、まだ充分な流延性
を有する発泡初期に複数個又は上下複数対からなるレギ
ュレーターローラを用いて強制的に押し拡げる方法が採
用されている。And, as a means for applying the foaming undiluted solution in the production of such a phenol resin foam, the undiluted foaming solution is continuously discharged from one or a plurality of discharge nozzles on the lower surface material traveling at a constant speed, or a discharge nozzle. While traversing the face material in the width direction, the foaming stock solution is continuously sprayed and the face material is applied by its self-casting property, or the upper and lower face materials are arranged facing each other to form a laminate, and then sufficient casting property is obtained. In the initial stage of foaming, a method is adopted in which a plurality of or a plurality of pairs of upper and lower regulator rollers are used to forcefully expand.
しかしながら、発泡原液は一般に硬化反応の進行に伴っ
て急速に増粘する性質を有するため、基本的に拡がり
性、即ち自己流延性に欠けるという問題を有する。加え
て自己流延時又は強制押し拡げ時にエアーの抱き込みや
残留応力の生成を伴い易く、しかも流延しながら発泡が
進行することや発泡初期に激しくもまれたり押圧される
ことから、横長や縦長の気泡が形成され易く、一様な気
泡方向性を持つ発泡体を得にくいなどの問題がある。However, since the foaming undiluted solution generally has the property of rapidly thickening with the progress of the curing reaction, it basically has a problem of lack of spreadability, that is, self-casting property. In addition, during self-casting or forced expansion, air is likely to be caught and residual stress is generated.Because the foaming progresses while casting, and it is violently pinched or pressed in the initial stage of foaming. There are problems that cells are easily formed and it is difficult to obtain a foam having uniform cell orientation.
そのため、次のような製造上及び性能上の問題が指摘さ
れてきた。Therefore, the following manufacturing and performance problems have been pointed out.
幅方向の寸法コントロールが非常に難しく製品幅のバ
ラツキを生じ易いので、一般に大きめのサイズから所定
サイズに裁断して製品化されてきた。Since it is very difficult to control the size in the width direction and variations in the product width are likely to occur, the product has generally been cut into a predetermined size from a larger size for commercialization.
そのため、利用価値のない裁断屑が多量に発生しその処
理に多くの経費を要し不経済であること。Therefore, it is uneconomical because a large amount of cutting waste that is not useful is generated, and it costs a lot of money to dispose of it.
流延時又は強制押し拡げ時にエアーを抱き込み易いた
めエアーボイドの多い発泡体となること。Since it is easy to hold air during casting or forced expansion, it should be a foam with many air voids.
幅方向における密度のバラツキや方向性の異なる気泡
を生じ易く、しかも残留応力の生成を伴い易いため、得
られた発泡体は機械的強度も低くかつバラツキも大き
く、しかも収縮やソリ等の寸法変化や亀裂など実用上の
問題を発生する危険性を有すること。Since the density in the width direction and bubbles with different directions are easily generated, and residual stress is easily generated, the resulting foam has low mechanical strength and large dispersion, and also dimensional changes such as shrinkage and warpage. There is a risk of causing practical problems such as cracks and cracks.
この様な理由から、これまで増粘性の小さな発泡原液の
開発が多く試行されてきた。しかし、いずれも硬化が遅
く、又形成される気泡膜も脆弱で強度的に問題を有する
など未だ満足し得る結果を得るに至らずその改善が強く
望まれていた。For this reason, many attempts have been made to develop an undiluted foaming stock solution having a small viscosity increase. However, in all cases, the curing is slow, and the formed bubble film is fragile and has problems in strength, so that satisfactory results have not yet been obtained, and improvement thereof has been strongly desired.
本発明は、このような要望にこたえ、製品幅のコントロ
ールが容易で、エアーボイドの形成や残留応力の生成を
抑制し、かつ均一な密度特に製品幅方向における密度の
バラツキが小さく、しかも気泡生成の等方性に優れたフ
エノール樹脂発泡体を容易にかつ効率的に製造できる方
法、及びこれに用いる塗布装置を提供することを目的と
してなされたものである。The present invention, in response to such a demand, is easy to control the product width, suppresses the formation of air voids and the generation of residual stress, and has a uniform density, in particular, a small variation in the density in the product width direction, and further the formation of bubbles. The object of the present invention is to provide a method for easily and efficiently producing a phenol resin foam having excellent isotropy, and a coating apparatus used for the method.
本発明者等は，前に述べたような問題点の発生原因は、
発泡原液の塗布方法にあることに注目して鋭意研究を行
った結果、一定速度で走行する面材上に発泡原液を非ク
リーム状に維持しながら、円弧状もしくはナイフ状エッ
ヂ又は任意の逃げ角度を設けた円弧状もしくはナイフ状
エッヂを有するドクターを用いて塗布する方法は、従来
の問題点解消に極めて有効で優れた性能を持つフエノー
ル樹脂発泡体を経済的に提供し得ることを見出し本発明
を完成するに至った。The inventors of the present invention are responsible for the causes of the problems described above.
As a result of diligent research focusing on the method of applying the foaming undiluted solution, as a result of maintaining the foaming undiluted solution on the surface material that runs at a constant speed in a non-cream form, arc-shaped or knife-shaped edges or any escape angle It has been found that the method of applying using a doctor having an arc-shaped or knife-shaped edge provided with can economically provide a phenol resin foam having excellent performance and being extremely effective in solving conventional problems. Has been completed.
すなわち，本発明によるフェノール樹脂発泡体の製造方
法は、一定速度で走行する面材上に発泡性フェノール樹
脂原液を連続的に塗布した後、発泡硬化させてフェノー
ル樹脂発泡体を製造する方法において、前記発泡性フェ
ノール樹脂原液を非クリーム状に維持しながら円弧状も
しくはナイフ状エッヂを有するドクターを用いて塗布す
ることに特徴を有するものである。That is, the method for producing a phenolic resin foam according to the present invention is a method for producing a phenolic resin foam by foaming and curing after continuously applying a foamable phenolic resin stock solution on a surface material that runs at a constant speed. It is characterized in that the foamable phenol resin stock solution is applied while using a doctor having an arc-shaped or knife-shaped edge while maintaining a non-cream form.
また、この発明によるフェノール樹脂発泡体の製造方法
は、一定速度で走行する面材上に発泡性フェノール樹脂
原液を連続的に塗布した後、発泡硬化させてフェノール
樹脂発泡体を製造する方法において、前記発泡性フェノ
ール樹脂原液を非クリーム状に維持しながら任意の逃げ
角度を設けた円弧状もしくはナイフ状エッヂを有するド
クターを用いて塗布することに特徴を有するものであ
る。Further, the method for producing a phenol resin foam according to the present invention is a method for producing a phenol resin foam by foaming and curing after continuously applying a foamable phenol resin stock solution on a surface material that runs at a constant speed, It is characterized in that the foamable phenol resin stock solution is applied while using a doctor having an arc-shaped or knife-shaped edge provided with an arbitrary clearance angle while maintaining the non-cream form.
さらに、この発明で用いる塗布装置は、一定速度で走行
する面材上に非クリーム状の発泡性フェノール樹脂原液
を連続的に塗布する塗布装置であって、円弧状もしくは
ナイフ状エッヂ又は任意の逃げ角度を設けた円弧状もし
くはナイフ状エッヂを有するドクターと、該ドクターを
支持し且つ面材とドクターエッヂの間隙を設定するため
の間隙調節機構部を備えたドクターホルダーよりなるこ
とに特徴と有するものである。Further, the coating device used in the present invention is a coating device for continuously coating a non-creamy foamable phenolic resin stock solution on a surface material that runs at a constant speed, and is an arc-shaped or knife-shaped edge or any relief. Characterized by comprising a doctor having an arcuate or knife-shaped edge provided with an angle, and a doctor holder having a clearance adjusting mechanism for supporting the doctor and setting a clearance between the face material and the doctor edge Is.
以下、第１図〜第５図を参照して本発明を更に詳しく説
明する。Hereinafter, the present invention will be described in more detail with reference to FIGS. 1 to 5.
第１図〜第５図は、本発明に係るフェノール樹脂発泡体
の製造方法及びこれに用いる塗布装置を説明するために
示す図であって、第１図は本発明方法を実施する装置の
一例を示す側面図、第２図は第１図の平面図、第３図は
第２図のＡ−Ａ線に沿う断面図、第４図は円弧状もしく
はナイフ状エッヂを有する代表的なドクターの切欠き側
面図、及び第５図は任意の逃げ角度を設けた円弧状もし
くはナイフ状エッヂを有する代表的なドクターの切欠き
側面図である。1 to 5 are views for explaining a method for producing a phenol resin foam according to the present invention and a coating apparatus used for the method, and FIG. 1 is an example of an apparatus for carrying out the method of the present invention. FIG. 2 is a side view, FIG. 2 is a plan view of FIG. 1, FIG. 3 is a sectional view taken along the line AA of FIG. 2, and FIG. 4 is a typical doctor having an arc-shaped or knife-shaped edge. FIG. 5 is a cutaway side view of a typical doctor having an arc-shaped or knife-shaped edge provided with an arbitrary relief angle.
第１図において、符号1,2は矢印方向に一定速度で走行
する金網、金属板等の離形性部材からなるベルト或るい
はスラットなどのエンドレスベルトコンベア（以下単に
コンベアと略称する）であり、上下面材をラインスピー
ドで走行させる役割を持つものである。また、この上下
一対のコンベア1,2は、上段コンベア２を下段コンベア
１の始端部より後方に位置せしめ、かつ所定の発泡体厚
みに相当する間隔を設けて上下に対向する構造としたダ
ブルコンベア部を構成している。In FIG. 1, reference numerals 1 and 2 are endless belt conveyors (hereinafter simply referred to as conveyors) such as belts or slats made of releasable members such as wire nets and metal plates that run at a constant speed in the arrow direction. , Has the role of running the upper and lower surface materials at line speed. The pair of upper and lower conveyors 1 and 2 is a double conveyor in which the upper conveyor 2 is located rearward of the starting end of the lower conveyor 1 and is vertically opposed to each other with an interval corresponding to a predetermined foam thickness. Make up part.
このダブルコンベア部は、連続的に案内されるほぼ発泡
終期にある発泡体を最終的な製品厚みに調整すると共
に、該ダブルコンベアに設けられた加熱装置（図示せ
ず）で発泡及び硬化を完了させる役割をもっものであ
る。This double conveyor unit adjusts the foam continuously guided at the almost end of foaming to the final product thickness, and completes foaming and curing by a heating device (not shown) provided in the double conveyor. It has a role to play.
符号３は、前記コンベア１の始端部上方に位置するミキ
シングヘッド４で調製された発泡原液を一定速度で走行
する下面材上に連続的に投入する吐出ノズルであり、下
面材の移動によって後方に位置する塗布装置８へ発泡原
液を供給する役割をもっている。Reference numeral 3 is a discharge nozzle that continuously feeds the foaming stock solution prepared by the mixing head 4 located above the starting end of the conveyor 1 onto the lower surface material that runs at a constant speed, and is moved backward by the movement of the lower surface material. It also has a role of supplying the foaming undiluted solution to the coating device 8 located.
なお、後述する塗布装置８による発泡原液の塗布を継続
して円滑に遂行するには、急激な粘度上昇と発泡を伴う
クリームタイム以内、即ち発泡原液を非クリーム状に維
持しながら塗布操作を行う必要性がある。In order to continuously and smoothly apply the foaming undiluted solution by the application device 8 described later, the application operation is performed within the cream time accompanied by a rapid increase in viscosity and foaming, that is, while maintaining the undiluted foaming solution. There is a need.
そのため、発泡原液の供給については、発泡原液自体の
調節は勿論、吐出量の調節及び吐出ノズルの設置位置な
どの配慮が必要である。即ち、塗布装置８へ供給された
発泡原液の粘度が上昇して発泡初期のクリーム状に至る
と、該塗布装置に設けられたドクター14による塗布面の
平滑性が損なわれるのみならず、実質的な塗布厚みも保
証されず、しかも連続的な塗布操作が困難となる。更に
は、面材幅方向への拡がりが阻害されて従来と同様な問
題を生じるなど本発明の目的を達成することができな
い。Therefore, regarding the supply of the foaming undiluted solution, it is necessary to consider not only the adjustment of the foaming undiluted solution itself, but also the adjustment of the discharge amount and the installation position of the discharge nozzle. That is, when the viscosity of the foaming undiluted solution supplied to the coating device 8 rises to reach the creamy state at the initial stage of foaming, not only the smoothness of the coating surface by the doctor 14 provided in the coating device is impaired, but also substantially. The coating thickness is not guaranteed and continuous coating operation becomes difficult. Furthermore, the object of the present invention cannot be achieved, for example, the spread in the width direction of the face material is obstructed and the same problem as in the conventional case occurs.
符号８は、吐出ノズル３より供給される発泡原液の塗布
装置であって、下面材供給ロール５よりガイドローラ等
のテンション付与機構部６を介して送給される下面材７
上に発泡原液を一定の幅に維持しつつ均一な塗布厚みに
塗布する役割をもつものである。Reference numeral 8 is a coating device for the foaming stock solution supplied from the discharge nozzle 3, and the bottom surface material 7 is fed from the bottom surface material supply roll 5 through a tension applying mechanism portion 6 such as a guide roller.
It also has the role of applying a uniform solution thickness while maintaining the foaming stock solution at a constant width.
なお、ここでいう面材とは、例えば離形紙、プラスチッ
クフイルム、金属箔、紙、不織布、織布、繊維質板、無
機質板など当該技術分野で一般的に使用されているもの
であって特に限定されるものではない。また、特に軟質
面材を使用する場合には、該面材に波打ちや捩れ等が生
じないようにテンションを負荷するなどの配慮を施して
平滑な表面状態で送給することが肝要であり、本発明方
法の特徴をより効果的に発揮することができる。The face material referred to here is, for example, a release paper, a plastic film, a metal foil, a paper, a non-woven fabric, a woven fabric, a fibrous plate, an inorganic plate or the like which is generally used in the technical field. It is not particularly limited. Further, particularly when a soft surface material is used, it is important to feed the surface material in a smooth surface state with consideration given to tension such that the surface material is not wavy or twisted. The characteristics of the method of the present invention can be exhibited more effectively.
前記塗布装置８は、第３図に示すように、円弧上もしく
はナイフ状エッヂ又は任意の逃げ角度を有する円弧状も
しくはナイフ状エッヂを有するドクター（第４図及び第
５図参照）14のエッヂ部と、コンベア１に密着しつつ走
行する面材との間には一定の間隙が設けられ、更に、該
ドクター14の両端は間隙の微調節可能な機構部15を介し
てドクターホルダー13に昇降自在に支持された構造とな
っている。As shown in FIG. 3, the coating device 8 has an edge portion of a doctor (see FIGS. 4 and 5) 14 having an arc or knife edge or an arc or knife edge having an arbitrary clearance angle. And a face material that runs while being in close contact with the conveyor 1 are provided with a constant gap, and further, both ends of the doctor 14 can be raised and lowered to a doctor holder 13 via a mechanism part 15 capable of finely adjusting the gap. The structure is supported by.
また、該塗布装置には必要に応じて前記ドクターの刃形
形状に対応する摺接先端部を有しかつ幅方向の調節を可
能とする脱着自在な一対の側板を設けてもよい。If necessary, the applicator may be provided with a pair of detachable side plates having a slidable tip end portion corresponding to the blade shape of the doctor and enabling adjustment in the width direction.
なお、前記ドクターのエッヂ部と下面材との間隙は発泡
原液の粘度や発泡体の製造条件及び要求特性等に応じて
適宜選択されるが、良好な塗布性を得るには通常0.1〜5
mm程度が適当であり、好ましくは0.3〜4mmである。The gap between the edge part of the doctor and the lower surface material is appropriately selected depending on the viscosity of the foaming stock solution, the manufacturing conditions of the foam, the required characteristics, etc., but usually 0.1 to 5 to obtain good coatability.
mm is suitable, and preferably 0.3 to 4 mm.
このような塗布装置を用いることにより、一定速度で走
行する下面材７と共に移動してドクターに至った非クリ
ーム状の発泡原液９は、ドクターの「ダム的作用」によ
って面材幅方向へ容易に流延し、面材上に一定の塗布幅
を形成すると共に、直線精度の高められたドクターエッ
ヂ部の「液切り作用」によって一定の塗布厚みが形成さ
れる。By using such a coating device, the non-creamy foaming undiluted solution 9 that has moved to the doctor by moving together with the lower surface material 7 traveling at a constant speed is easily moved in the width direction of the surface material by the "dam action" of the doctor. It is cast to form a constant coating width on the face material, and a constant coating thickness is formed by the "draining action" of the doctor edge portion with improved linear accuracy.
すなわち、発泡原液の粘度及び供給量、面材の走行速度
（ラインスピード）及びドクターエッヂ部と面材の間隙
等を一定に設定することによって、均一な塗布厚みと一
定の塗布幅を有する非クリーム状の塗布面を連続的に形
成することが可能であり、従来の塗布方法で見られるよ
うなエアーの抱き込み、横長や縦長の混成気泡又は残留
応力等の生成を抑制することができる。That is, by setting the viscosity and supply amount of the foaming undiluted solution, the running speed (line speed) of the face material, and the gap between the doctor edge and the face material to be constant, a non-cream having a uniform coating thickness and a constant coating width. It is possible to continuously form a striped coating surface, and it is possible to suppress the entrapment of air, the formation of horizontally or vertically long mixed bubbles, residual stress, and the like, which are seen in conventional coating methods.
このようにして塗布処理された下面材７は、コンベア１
の上方に位置する上面材供給ロール5aよりガイドローラ
等のテンション付与機構部6aを介して送給される上面材
（下面材と同種又は異種）7aと連続的に重ね合わせられ
て積層体に形成される。The lower surface material 7 thus coated is the conveyor 1
The upper surface material supply roll 5a positioned above the upper surface material is continuously superposed on the upper surface material (same or different kind as the lower surface material) 7a fed through the tension applying mechanism 6a such as a guide roller to form a laminated body. To be done.
引続き、発泡程度に応じた段階的に設けられ且つ所定の
温度に制御された、片側又は一定の間隔をもって対向配
置されたフリーローラ群から構成されるレギュレータゾ
ーン13へ案内される。Then, it is guided to a regulator zone 13 which is provided stepwise according to the degree of foaming and is controlled to a predetermined temperature, and which is composed of a group of free rollers which are opposed to each other on one side or at regular intervals.
ここで、該積層体は加熱により発泡硬化してほぼ発泡終
期状態の発泡前駆体11に形成されると共に、前記ローラ
群によって、該発泡前駆体は表面の凹凸を軽く均す程
度、即ち発泡体の表面部がローラ表面に軽く接触する程
度に段階的に押圧されて目標の厚みに調節される。Here, the laminated body is foamed and hardened by heating to form a foamed precursor 11 in a substantially final state of foaming, and the roller group allows the foamed precursor to lightly smooth the surface irregularities, that is, the foamed body. The surface of the roller is pressed stepwise to such an extent that it comes into contact with the roller surface, and the target thickness is adjusted.
次いで、この発泡前駆体はコンベア1,2で形成されたダ
ブルコンベアの間隙部へ案内され、最終製品厚みに調製
されると共に、該ダブルコンベアに設けられた加熱手段
（図示せず）により完全に発泡及び硬化を完了させて発
泡体とされる。Next, this foaming precursor is guided to the gap portion of the double conveyor formed by the conveyors 1 and 2 and adjusted to the final product thickness, and completely heated by the heating means (not shown) provided in the double conveyor. Foaming and curing are completed to give a foam.
なお、上面材を重ね合わせる時期については特に制限さ
れないが、下面材上に塗布された発泡原液９が発泡初期
を示すクリーム状に至るまでが適当である。また、ダブ
ルコンベアの間隙部へ案内される直前の発泡前駆体の発
泡状態としては、製品発泡体厚みの約60〜95％程度の発
泡率に調節することが好ましくより良好な発泡体を得る
ことができる。The time at which the upper surface material is overlaid is not particularly limited, but it is appropriate that the foaming undiluted solution 9 applied on the lower surface material reaches a creamy form indicating the initial foaming. Further, as the foaming state of the foaming precursor immediately before being guided to the gap portion of the double conveyor, it is preferable to adjust the foaming rate to about 60 to 95% of the product foam thickness to obtain a better foam. You can
本発明に係る塗布装置を用いて製造されるフェノール樹
脂発泡体が優れた品質を有する理由については、必ずし
も明確ではないが次のように推察される。The reason why the phenol resin foam produced using the coating apparatus according to the present invention has excellent quality is not necessarily clear, but it is presumed as follows.
すなわち、本発明における発泡原液の塗布は、以下に述
べるような新規な塗布機構に基づいてなされるため、一
定の塗布幅を維持しつつ均一な塗布厚みに塗布すること
ができる。そのため、従来の問題点が改善されるのみな
らず、発泡体の性能上及び製造上に係わるその他の効果
を発揮するものと推察される。That is, since the foaming undiluted solution in the present invention is applied on the basis of a novel application mechanism as described below, it is possible to apply a uniform application thickness while maintaining a constant application width. Therefore, it is presumed that not only the conventional problems are improved but also other effects relating to the performance and manufacturing of the foam are exhibited.
塗布装置に供給される発泡原液は非クリーム状で自己
流延性に富むため、ドクターの「ダム的作用」によって
幅方向へ流延し易く、発泡原液の粘度及び供給量面材の
走行速度（ラインスピード）及びドクターエッヂ部と面
材の間隙等を一定に設定保持することによって、発泡原
液を一定の幅に塗布することが可能となる。The foaming undiluted liquid supplied to the coating device is non-creamy and rich in self-casting, so it is easy to flow in the width direction due to the "dam-like action" of the doctor. ) And the gap between the doctor edge portion and the face material are set and maintained constant, it is possible to apply the foaming stock solution to a constant width.
ドクターの先端部における吐出ノズル側の開口部面積
がエッヂ部の開口部面積より大きく設けられているた
め、面材の走行力によりエッヂ部に非常に大きな液圧が
負荷される。所謂「強力な押出し作用」によって発泡原
液はエッヂ部の間隙より面材と共に速やかに且つ定量的
に流出される。そのため、ドクター部における発泡原液
の滞留は非常に短時間となり粘度の上昇が抑えられるの
でエッヂ部での「液切れ」が容易となり平滑かつ均一な
塗布厚みの塗布面を形成することができる。Since the opening area on the discharge nozzle side at the tip of the doctor is larger than the opening area of the edge part, a very large hydraulic pressure is applied to the edge part by the running force of the face material. The so-called "strong extrusion action" causes the foaming stock solution to flow out quickly and quantitatively together with the face material from the gaps in the edge portion. Therefore, the foaming stock solution stays in the doctor part for a very short time, and the increase in viscosity is suppressed, so that “liquid break” at the edge part is facilitated and a coated surface having a smooth and uniform coating thickness can be formed.
次に実施例により本発明をさらに詳細に説明するが、本
発明はこれらの例によってなんら限定されるものではな
い。Next, the present invention will be described in more detail with reference to examples, but the present invention is not limited to these examples.
〔実施例１〕 先ず、装置の調節を次のとおり実施した。[Example 1] First, adjustment of the apparatus was carried out as follows.
第１図に示すように、下段及び上段スチール製コンベア
の表面に坪量75g/m2のクラフト紙（幅100cm）をガイド
ローラを介してそれぞれ張設した。As shown in FIG. 1, Kraft paper (width 100 cm) having a basis weight of 75 g / m 2 was stretched on the surfaces of the lower and upper steel conveyors via guide rollers.
また、塗布装置としては、第３図に示すように、ドクタ
ーホルダーに支持された逃げ角度を設けた円弧状エッヂ
を有するドクター（第５図のｆ参照）を使用し、ドクタ
ーエッヂ部と下面材との間隙は1mmとした。なお、レギ
ュレータゾーンとしては、上下複数対からなる４区分の
フリーローラ群（図示しない）から構成された全長6mに
亘るものを使用し、レギュレータゾーンの入口温度は60
℃に出口温度は80℃に調節した。更に、上下複数対に設
けられたフリーローラ群の間隔は、発泡原液が発泡しそ
の表面がフリーローラに軽く接触する程度の間隙に調節
し、出口で23mmとした。As the coating device, as shown in FIG. 3, a doctor (see f in FIG. 5) having an arc-shaped edge supported by a doctor holder and having an escape angle is used. The gap between and is 1 mm. In addition, the regulator zone is composed of a group of four pairs of free rollers (not shown) consisting of upper and lower pairs, and has a total length of 6 m. The inlet temperature of the regulator zone is 60 m.
The outlet temperature was adjusted to 80 ° C. Further, the space between the upper and lower pairs of free rollers was adjusted to such a space that the foaming stock solution foamed and its surface was in slight contact with the free roller, and was 23 mm at the outlet.
また、長さ12mのダブルコンベア部は、全長に亘って80
〜90℃の温度に制御し、又その間隙は発泡体製品厚みの
25mmに調節した。In addition, the 12m long double conveyor section is
Control the temperature to ~ 90 ° C, and make sure that the gap is
Adjusted to 25 mm.
一方、発泡性フェノール樹脂原液（発泡原液）は、20℃
に温調された整泡剤を含む発泡用レゾール型フェノール
樹脂液（Ａ液）、63重量％フェノールスルホン酸水溶液
（Ｂ液）及び1.1.2−トリクロロトリフルオロエタン
（Ｃ液）等の原料をＡ液/B液/C液＝100/13/19（重量
比）の組成割合でミキシングヘッド４により混合して下
面材上に所定流量で連続的に投入するようにした。On the other hand, the foamable phenol resin stock solution (foaming stock solution) is 20 ℃
A raw material such as a resol-type phenol resin solution for foaming (A solution), a 63% by weight phenolsulfonic acid aqueous solution (B solution) and 1.1.2-trichlorotrifluoroethane (C solution) containing a temperature-controlled foam stabilizer. Liquid A / liquid B / C liquid = 100/13/19 (weight ratio) were mixed by the mixing head 4 and continuously fed onto the lower surface material at a predetermined flow rate.
この発泡原液の25℃での反応性はクリームタイム25秒、
ゲルタイム100秒であった。（但し、500ccの紙コップに
約100gの発泡原液を採取した際の特性である） 次いで、以上の諸条件に調整した装置又は発泡原液を用
いて発泡体の製造を次のとおり実施した。The reactivity of this effervescent stock solution at 25 ° C is cream time of 25 seconds,
The gel time was 100 seconds. (However, this is the characteristic when about 100 g of the foaming stock solution was collected in a 500 cc paper cup.) Next, the production of the foam was carried out as follows using the apparatus or the foaming stock solution adjusted to the above conditions.
下段スチール製コンベアと共に7m/minの速度で走行する
下面材上に吐出ノズルより上記発泡原液（液温20℃）を
3500cc/minの流量で吐出し、塗布装置により幅95cmに塗
布し、次いで上面材を積層した後、上記条件で発泡硬化
させてダブルコンベア部より送り出される発泡体は、幅
方向の寸法が最大96cm、最少95cmであり、サイドカッタ
ーで94cmに連続的に切断した。又長手方向は180cmの長
さに切断した。The above foaming stock solution (liquid temperature 20 ° C) is discharged from the discharge nozzle onto the lower surface material that runs at a speed of 7 m / min with the lower steel conveyor.
Discharge at a flow rate of 3500 cc / min, apply with a coating device to a width of 95 cm, then stack the top material, foam cure under the above conditions and send out from the double conveyor part, the width dimension is up to 96 cm The minimum size was 95 cm, and it was continuously cut to 94 cm with a side cutter. Further, the longitudinal direction was cut into a length of 180 cm.
得られた発泡体は48時間放置して諸性能を測定した。そ
の結果は表−１に示す通りであった。The obtained foam was left standing for 48 hours and various properties were measured. The results are shown in Table 1.
［実施例２］ 実施例１において、発泡原液の流量を2000cc/minとする
以外は実施例１と同様にしてフェノール樹脂発泡体を作
成した。得られた発泡体の諸性能は表−１に示す通りで
あった。[Example 2] A phenol resin foam was prepared in the same manner as in Example 1, except that the flow rate of the foaming stock solution was 2000 cc / min. The various properties of the obtained foam were as shown in Table 1.
［実施例３］ 実施例１において、発泡原液をＡ液/B液/C液＝100/13/1
2の組成割合で調製し、その流量を7000cc/minとし、ド
クターエッヂと下面材の間隙を2mmとする以外は実施例
１と同様にしてフェノール樹脂発泡体を作成した。得ら
れた発泡体の諸性能は表−１に示す通りであった。[Example 3] In Example 1, the foaming stock solution was changed to A solution / B solution / C solution = 100/13/1.
A phenol resin foam was prepared in the same manner as in Example 1 except that the composition ratio was 2, the flow rate was 7,000 cc / min, and the gap between the doctor edge and the lower surface material was 2 mm. The various properties of the obtained foam were as shown in Table 1.
［実施例４］ 実施例１において、発泡原液をＡ液/B液/C液＝100/15/1
9の組成割合で調製し、その流量を6000cc/minとし、下
面材の走行速度（ラインスピード）を12mとする以外は
実施例１と同様にしてフェノール樹脂発泡体を作成し
た。得られた発泡体の諸性能は表−１に示す通りであっ
た。[Example 4] In Example 1, the foaming undiluted solution was changed to A solution / B solution / C solution = 100/15/1.
A phenol resin foam was prepared in the same manner as in Example 1 except that the flow rate was 6000 cc / min and the running speed (line speed) of the lower surface material was 12 m. The various properties of the obtained foam were as shown in Table 1.
［比較例１］ 実施例１において、塗布装置（ドクター）を使用しない
こと以外は実施例１と同様にしてフェノール樹脂発泡体
を作成した。得られた発泡体の諸性能は表−１に示す通
りであった。Comparative Example 1 A phenol resin foam was prepared in the same manner as in Example 1 except that the coating device (doctor) was not used. The various properties of the obtained foam were as shown in Table 1.
［比較例２］ 実施例１において、塗布装置（ドクター）は使用せず
に、発泡原液の流延性を高めるため液温を30℃に温調
し、更には発泡剤を増量した組成割合Ａ液/B液/C液＝10
0/16/25の発泡原液を用いた。また、レギュレータゾー
ンの出口での幅方向の寸法が91cmになるようにフリーロ
ーラ群の間隙を調節した。なお、レギュレータゾーン内
ではクリーム状態でフリーローラにより激しく揉まれて
いるのが観察された。得られた発泡体の諸性能は表−１
に示す通りであった。[Comparative Example 2] A composition ratio A liquid obtained by adjusting the liquid temperature to 30 ° C in order to enhance the casting property of the foaming stock solution without using a coating device (doctor) in Example 1 and further increasing the foaming agent. / B liquid / C liquid = 10
The foaming stock solution of 0/16/25 was used. Further, the clearance between the free roller groups was adjusted so that the widthwise dimension at the exit of the regulator zone was 91 cm. In the regulator zone, it was observed that the cream roller was vigorously rubbed by the free roller. The performance of the obtained foam is shown in Table-1.
It was as shown in.
〔発明の効果〕 以上詳述したように，本発明は、発泡原液を特定の状態
に維持しながら、簡便な塗布装置を用いるという新規な
塗布思想に基づいてなされるたものであって、従来技術
の問題点を改善するにとどまらず、性能上及び製造上に
係わる有用な効果を提供し得る工業的利用価値の極めて
高いものである。 [Effects of the Invention] As described in detail above, the present invention is based on the novel coating concept of using a simple coating device while maintaining the foaming stock solution in a specific state. It is extremely valuable for industrial use, not only for improving technical problems but also for providing useful effects in terms of performance and manufacturing.
幅方向の寸法コントロールが容易であるため、所望幅
の発泡体を従来より極めて少ないカットロスで提供でき
る。そのため、従来のように大きなサイズから裁断して
製品化する必要もなく、利用価値のない裁断屑の処理や
無駄な経費の節約が図れる。Since the size control in the width direction is easy, it is possible to provide a foam having a desired width with a cut loss which is extremely smaller than that of the conventional foam. Therefore, it is not necessary to cut the product from a large size and commercialize it unlike the conventional case, and it is possible to process cutting waste that is not useful and to save useless expenses.
発泡原液塗布時におけるエアーの巻き込みを防止でき
るため、エアーボイドのない発泡体を製造することがで
きる。Since it is possible to prevent the entrainment of air when applying the foaming stock solution, it is possible to produce a foam without air voids.
発泡原液を所望幅に塗布した後に発泡が始まるため、
残留応力の存在しない、しかも縦長の気泡を主体とする
一様な気泡方向性を有する発泡体を提供できる。そのた
め、従来技術で観察されるような密度のバラツキ、気泡
の異方性あるいは残留応力の存在等に基づいて生じる、
機械的強度の低さ及びバラツキ、収縮やソリ等の寸法変
化あるいは亀裂などの実用上の問題を改善することがで
きる。Since the foaming begins after applying the foaming undiluted solution to the desired width,
It is possible to provide a foam having no residual stress and having uniform cell directionality mainly composed of vertically elongated cells. Therefore, the density variation as observed in the prior art, the anisotropy of the bubbles or the presence of residual stress, etc.,
It is possible to improve practical problems such as low mechanical strength and variations, dimensional changes such as shrinkage and warpage, and cracks.
新規な塗布思想に基づく方法を採用しているため、次
のような有用な効果を提供し得る。Since the method based on the novel coating concept is adopted, the following useful effects can be provided.
イ．従来、発泡原液の拡がり性を高めるため多量に用い
ていた発泡剤の量を低減できる。逆に、従来と同様に多
量の発泡剤を用いた場合には低密度の発泡体を製造する
ことが可能である。I. It is possible to reduce the amount of the foaming agent, which has been used in a large amount in the past to enhance the spreading property of the foaming stock solution. On the contrary, when a large amount of foaming agent is used as in the conventional case, it is possible to produce a foam having a low density.
ロ．ラインスピードを高め得ることが可能であり、発泡
体の生産効率を向上させることができる。B. The line speed can be increased and the foam production efficiency can be improved.
ハ．独立気泡率が大幅に向上する。C. The closed cell ratio is greatly improved.
ニ．吸水量が大幅に低下する。D. The amount of water absorption is greatly reduced.
第１図は本発明方法を実施する装置の一例を示す側面
図、第２図は第１図の平面図、第３図は第２図のＡ−Ａ
線に沿う断面図、第４図は円弧状もしくはナイフ状エッ
ヂを有する代表的なドクターの切欠き側面図、及び第５
図は任意の逃げ角度を設けた円弧状もしくはナイフ状エ
ッヂを有する代表的なドクターの切欠き側面図である。 １……下段エンドレスベルトコンベア ２……上段エンドレスベルトコンベア ３……吐出ノズル、４……ミキシングヘッド 5,5a……下上面材供給ロール 6,6a……テンション付与機構部 7,7a……下上面材、８……塗布装置 ９……発泡原液 10……レギュレーターゾーン 11……発泡前駆体、12……発泡体 13……ドクターホルダー 14……ドクター 15……ドクターと下面材との間隙を調節するための調節
機構部FIG. 1 is a side view showing an example of an apparatus for carrying out the method of the present invention, FIG. 2 is a plan view of FIG. 1, and FIG. 3 is AA of FIG.
FIG. 4 is a cross-sectional view taken along the line, FIG. 4 is a cutaway side view of a typical doctor having an arc-shaped or knife-shaped edge, and FIG.
The figure is a cutaway side view of a typical doctor having an arcuate or knife-shaped edge with an arbitrary clearance angle. 1 ...... Lower endless belt conveyor 2 ...... Upper endless belt conveyor 3 …… Discharge nozzle 4 …… Mixing head 5,5a …… Lower upper surface material supply roll 6,6a …… Tensioning mechanism 7,7a …… Lower Top material, 8 coating device 9 Foaming stock solution 10 Regulator zone 11 Foaming precursor, 12 Foam material 13 Doctor holder 14 Doctor 15 ... Gap between doctor and bottom material Adjusting mechanism for adjusting
───────────────────────────────────────────────────── フロントページの続き (72)発明者 阪元 正美 愛知県丹羽郡扶桑町大字南山名字新津26― ４ 旭有機材工業株式会社愛知工場内 (72)発明者 為本 和雄 愛知県丹羽郡扶桑町大字南山名字新津26― ４ 旭有機材工業株式会社愛知工場内 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Masami Sakamoto, 26, Niitsu, Minamiyama, Fuso-cho, Niwa-gun, Aichi prefecture 26-4 Niitsu, Minamiyama, Azai Organic Materials Co., Ltd. Aichi factory
Claims (3)
ール樹脂原液を連続的に塗布した後、発泡硬化させてフ
ェノール樹脂発泡体を製造する方法において、前記発泡
性フェノール樹脂原液を非クリーム状に維持しながら円
弧状もしくはナイフ状エッヂを有するドクターを用いて
塗布することを特徴とするフェノール樹脂発泡体の製造
方法。1. A method for producing a phenol resin foam by continuously applying a foamable phenol resin stock solution onto a surface material that runs at a constant speed, and then foaming and curing the foamable phenol resin stock solution, wherein the foamable phenol resin stock solution is non-creamed. A method for producing a phenol resin foam, which comprises applying a doctor resin having an arc-shaped or knife-shaped edge while maintaining the shape.
ール樹脂原液を連続的に塗布した後、発泡硬化させてフ
ェノール樹脂発泡体を製造する方法において、前記発泡
性フェノール樹脂原液を非クリーム状に維持しながら任
意の逃げ角度を設けた円弧状もしくはナイフ状エッヂを
有するドクターを用いて塗布することを特徴とするフェ
ノール樹脂発泡体の製造方法。2. A method for producing a phenol resin foam by continuously applying a foamable phenol resin stock solution onto a surface material that runs at a constant speed and then foaming and curing the same, wherein the foamable phenol resin stock solution is non-creamed. A method for producing a phenol resin foam, characterized in that the coating is carried out by using a doctor having an arc-shaped or knife-shaped edge provided with an arbitrary clearance angle while maintaining the shape.
の発泡性フェノール樹脂原液を連続的に塗布する塗布装
置であって、円弧状もしくはナイフ状エッヂ又は任意の
逃げ角度を設けた円弧状もしくはナイフ状エッヂを有す
るドクターと、該ドクターを支持し且つ面材とドクター
エッヂの間隙を設定するための間隙調節機構部を備えた
ドクターホルダーよりなることを特徴とする塗布装置。3. A coating device for continuously coating a non-creamy foamable phenolic resin stock solution on a surface material that runs at a constant speed, which is an arc or knife edge or a circle provided with an escape angle. A coating apparatus comprising: a doctor having an arc-shaped or knife-shaped edge; and a doctor holder having a gap adjusting mechanism for supporting the doctor and setting a gap between the face material and the doctor edge.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP63178878A JPH0673866B2 (en) | 1988-07-18 | 1988-07-18 | Method for producing phenolic resin foam and coating device used therefor |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP63178878A JPH0673866B2 (en) | 1988-07-18 | 1988-07-18 | Method for producing phenolic resin foam and coating device used therefor |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH0226713A JPH0226713A (en) | 1990-01-29 |
| JPH0673866B2 true JPH0673866B2 (en) | 1994-09-21 |
Family
ID=16056279
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP63178878A Expired - Lifetime JPH0673866B2 (en) | 1988-07-18 | 1988-07-18 | Method for producing phenolic resin foam and coating device used therefor |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH0673866B2 (en) |
Families Citing this family (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6309194B1 (en) | 1997-06-04 | 2001-10-30 | Carrier Corporation | Enhanced oil film dilation for compressor suction valve stress reduction |
| US6468060B1 (en) | 1998-03-02 | 2002-10-22 | Carrier Corporation | Oil film dilation for compressor suction valve stress reduction |
| US6099275A (en) * | 1998-04-15 | 2000-08-08 | Carrier Corporation | Biased open suction valve |
| US6565336B1 (en) | 1998-05-06 | 2003-05-20 | Carrier Corporation | Normally unseated suction valve |
| US6102680A (en) * | 1998-07-01 | 2000-08-15 | Carrier Corporation | Suction valve with release timing chamber |
| US6476090B1 (en) | 1998-07-03 | 2002-11-05 | Asahi Kasei Kabushiki Kaisha | Phenolic foam |
| JP2013015169A (en) * | 2011-07-01 | 2013-01-24 | Fujitsu Ltd | Valve, heat pump and information processing system |
| JP6936023B2 (en) * | 2016-03-07 | 2021-09-15 | 積水化学工業株式会社 | Phenol formaldehyde foam |
| JP6936024B2 (en) * | 2016-03-07 | 2021-09-15 | 積水化学工業株式会社 | Phenol formaldehyde foam |
| JP6163602B1 (en) * | 2016-12-20 | 2017-07-12 | 積水化学工業株式会社 | Phenol resin foam and method for producing phenol resin foam |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5496560A (en) * | 1978-01-14 | 1979-07-31 | Kanto Leather | Method of making synthetic resin sheet with embossing design |
| JPS6079919A (en) * | 1983-10-07 | 1985-05-07 | Mitsubishi Petrochem Co Ltd | Continuous manufacture of phenol resin foamed body with skin layer |
-
1988
- 1988-07-18 JP JP63178878A patent/JPH0673866B2/en not_active Expired - Lifetime
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5496560A (en) * | 1978-01-14 | 1979-07-31 | Kanto Leather | Method of making synthetic resin sheet with embossing design |
| JPS6079919A (en) * | 1983-10-07 | 1985-05-07 | Mitsubishi Petrochem Co Ltd | Continuous manufacture of phenol resin foamed body with skin layer |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH0226713A (en) | 1990-01-29 |
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