Patent Application
20240190111
The present disclosure relates to a panel production device and a panel production method.
In the related art, there is known a method of producing a composite sheet in which a first sheet and a second sheet that are overlapped with each other are fused by ultrasonic vibration (refer to, for example, PTL 1). The first sheet is formed into a corrugated shape by a first roll and is fused to the second sheet having a plate shape.
An example of a panel such as the composite sheet includes a so-called sandwich panel in which a corrugated core member is disposed between two faceplates. In PTL 1, the core member serving as the first sheet is fused with the faceplate on one side serving as the second sheet to produce the composite sheet. On the other hand, there is no description or suggestion in PTL 1 regarding the fusion between the panel such as the composite sheet and the faceplate on the other side, and there is room for improvement.
An object of the present disclosure is to provide a panel production device and a panel production method capable of suitably producing a panel composed of two faceplates and a core member.
A panel production device of the present disclosure includes a transfer part that transfers, in a transfer direction, a panel having a core member that includes a thermoplastic resin and is formed in a corrugated shape, and a first faceplate that includes a thermoplastic resin, is formed in a plate shape, and is joined to a surface on one side of the core member, a supply part that supplies, toward a surface on the other side of the core member, a second faceplate that includes a thermoplastic resin and is formed in a plate shape, a heating part that heats at least one surface of respective surfaces of the core member and the second faceplate facing each other, and a pressurizing part that pressurizes and welds the core member of the panel and the second faceplate.
A panel production method according to the present disclosure includes a step of transferring, in a transfer direction, a panel having a core member that includes a thermoplastic resin and is formed in a corrugated shape, and a first faceplate that includes a thermoplastic resin, is formed in a plate shape, and is joined to a surface on one side of the core member, a step of supplying, toward a surface on the other side of the core member, a second faceplate that includes a thermoplastic resin and is formed in a plate shape, a step of heating at least one surface of respective surfaces of the core member and the second faceplate facing each other, and a step of pressurizing and welding the core member of the panel and the second faceplate.
According to the present disclosure, it is possible to suitably produce a panel composed of two faceplates and a core member.
Hereinafter, an embodiment according to the present disclosure will be described in detail based on drawings. The invention is not limited to the embodiment. Further, components in the following embodiment include components that can be easily replaced by those skilled in the art or components that are substantially the same. Furthermore, the components described below can be combined as appropriate, and in a case where there are a plurality of embodiments, the respective embodiments can also be combined.
In a panel production device 10 according to a first embodiment, faceplates 6 and 7 having a plate shape are joined to both surfaces of a core member 5 having a corrugated shape to produce a sheet-shaped sandwich panel (hereinafter, simply referred to as panel 1). Prior to the description of the panel production device 10, the panel 1 will be described.
The core member 5 is formed in the corrugated shape. Specifically, the core member 5 has a wave shape in which peaks and valleys are alternately and continuously formed in the length direction, and is formed such that tops of the peaks and bottom portions of the valleys extend in the width direction. The corrugated shape is not particularly limited to the above-mentioned shape, and may be, for example, an embossed shape in which undulations are formed in a staggered manner. That is, any shape may be employed as long as the shape can be continuously formed in the transfer direction in the panel production device 10 described below.
The first faceplate 6 is joined to a surface on one side (upper side in
The second faceplate 7 is joined to a surface on the other side (lower side in
In the panel 1, the core member 5 and the first faceplate 6 are first joined to form a panel 1a, and then the panel 1a and the second faceplate 7 are joined to form the sandwich panel shown in
Next, the panel production device 10 will be described with reference to
The single facer 11 is a device that joins the core member 5 and the first faceplate 6 to form the panel 1a. The single facer 11 includes a belt roll 41, a tension roll 42, a pressurizing belt 43, an upper corrugating roll 44, and a lower corrugating roll 45.
The belt roll 41 can be driven and rotated by a drive device (not shown). The tension roll 42 is rotatably supported at a predetermined spacing from the belt roll 41. The pressurizing belt 43 is an endless belt and is wound around the belt roll 41 and the tension roll 42. The upper corrugating roll 44 can be driven and rotated by a drive device (not shown), and the outer peripheral surface thereof is formed in a wave shape. The upper corrugating roll 44 is disposed below the pressurizing belt 43 in a vertical direction between the belt roll 41 and the tension roll 42, and the wave-shaped outer peripheral surface comes into contact with a lower surface of the pressurizing belt 43 in a pressurized state. As in the upper corrugating roll 44, the lower corrugating roll 45 has the outer peripheral surface formed in a wave shape and is engaged with the outer peripheral surface of the upper corrugating roll 44 below the upper corrugating roll 44 in a vertical direction.
The first faceplate 6 supplied to the single facer 11 is wound around a guide roller 47 on an upstream side and then wound around a guide roller 46 on a downstream side. Thereafter, together with the pressurizing belt 43 guided by the belt roll 41, the first faceplate 6 is sandwiched between the pressurizing belt 43 and the upper corrugating roll 44 and is pressurized. On the other hand, the plate-shaped core member 5 before shaping is shaped into a wave shape at the engaging portion between the upper corrugating roll 44 and the lower corrugating roll 45, and then guided by the upper corrugating roll 44 to be supplied between the pressurizing belt 43 and the upper corrugating roll 44.
Further, the single facer 11 includes a joining device (not shown) that joins the first faceplate 6 and the core member 5. The joining device melts the top of the peak of the core member 5 by heating. In the single facer 11, the core member 5 whose top of the peak is melted is transferred between the pressurizing belt 43 and the upper corrugating roll 44 and is pressurized, together with the first faceplate 6, between the pressurizing belt 43 and the upper corrugating roll 44 to join the core member 5 and the first faceplate 6. The single facer 11 joins the core member 5 and the first faceplate 6 to form the panel 1a and transfers the formed panel 1a toward the double facer 12.
The double facer 12 is a device that joins the panel 1a and the second faceplate 7 to form the panel 1 to be the sandwich panel. The double facer 12 includes a transfer part 51, a supply part 52, a heating part 62, and a pressurizing part 61.
The transfer part 51 is a device that transfers the panel 1a in the transfer direction. The transfer part 51 sandwiches, from both sides, the panel 1 after the second faceplate 7 is joined to the panel 1a and delivers the panel 1 in the transfer direction to transfer the panel 1a. The transfer part 51 may be configured by using a plurality of transfer rollers or may be configured by using an endless belt such as the pressurizing belt 43 of the single facer 11.
The supply part 52 is a device that supplies the second faceplate 7 toward the surface on the other side of the core member 5 of the panel 1a. The supply part 52 has a pair of transfer rollers 57 that sandwiches the second faceplate 7 and delivers the second faceplate 7 toward the pressurizing part 61.
The heating part 62 heats surfaces of the core member 5 and the second faceplate 7 facing each other to raise the temperature to a temperature at which heat welding is possible. Specifically, the heating part 62 is, for example, a heating heater, a laser, or a heating lamp, and is provided at a position on an upstream side in the transfer direction of the pressurizing part 61. The heating part 62 is provided in a space formed between the core member 5 and the second faceplate 7 and heats the surface on the other side of the core member 5 and the surface of the second faceplate 7 facing the core member 5. Specifically, the heating part 62 has a wedge shape that tapers toward a space where the core member 5 and the second faceplate 7 are welded. Therefore, the heating part 62 can perform the heating until immediately before the core member 5 and the second faceplate 7 are welded. The heating part 62 is not particularly limited to the wedge shape and may have a flat plate shape extending toward a space between the core member 5 and the second faceplate 7. In the heating part 62, a distance to the bottom portion of the valley of the core member 5 is closer than a distance to the top of the peak of the core member 5. Thus, it is possible to raise the temperature for the bottom portion of the valley of the core member 5. Further, in the heating part 62, since the distance to the top of the peak of the core member 5 is far from the distance to the bottom portion of the valley of the core member 5, unnecessary temperature rise in other portions including the top of the peak of the core member 5 can be suppressed. Accordingly, it is possible to perform the welding while suppressing deformation of the entire panel 1.
The pressurizing part 61 pressurizes and joins the heated panel 1a and second faceplate 7 to form the welding part 9. The pressurizing part 61 has a pressurizing roller 65. The pressurizing roller 65 is in rolling contact with an outer surface of the second faceplate 7. The pressurizing roller 65 may be heated by a heating source (not shown) to contribute to the joining between the core member 5 and the second faceplate 7.
The panel 1a transferred from the single facer 11 to the double facer 12 is supplied toward the pressurizing roller 65 by the transfer part 51. Further, the second faceplate 7 supplied to the double facer 12 is supplied toward the pressurizing roller 65 by the transfer roller 57. In this case, the second faceplate 7 is supplied to the surface on the other side of the core member 5 of the panel 1a.
In the double facer 12, the heating part 62 heats the surfaces of the core member 5 and the second faceplate 7 facing each other, respectively to raise the temperature to the temperature at which the heat welding is possible. Thereafter, in the double facer 12, the pressurizing roller 65 pressurizes the supplied panel 1a and second faceplate 7 to weld the bottom portion of the valley of the core member 5 of the panel 1a and the second faceplate 7.
The double facer 12 discharges the panel 1 obtained by joining the panel 1a and the second faceplate 7. The discharged panel 1 may be discharged as it is or may be cut into a single-wafer sheet, and is not particularly limited.
The control device 15 is connected to the single facer 11 and the double facer 12 and controls the drive thereof. Specifically, in the double facer 12, the control device 15 is connected to the heating part 62 and controls the heating by the heating part 62.
Next, a panel production method of producing the panel 1 using the panel production device 10 will be described. As shown in
As shown in
Next, a panel production device 70 according to a second embodiment will be described with reference to
As shown in
The foam material supply part 73 is a device that supplies a foam material 71 to a space partitioned by the core member 5 and the first faceplate 6 before the joining of the core member 5 and the first faceplate 6. The foam material supply part 73 is provided at a position where the foam material 71 can be supplied to the core member 5 after being shaped by the upper corrugating roll 44 and the lower corrugating roll 45 and before being joined to the first faceplate 6.
The foam material supply part 73 has a pair of pulleys 76 and 77 and an endless transfer belt 78 wound around the pair of pulleys 76 and 77. With the disposition of the foam material 71 on the transfer belt 78 and rotation of the pair of pulleys 76 and 77, the foam material 71 on the transfer belt 78 is supplied toward the core member 5.
The foam material supply part 73 is not particularly limited to the above device configuration, any device configuration may be employed as the device configuration is such that the foam material 71 can be supplied to the space partitioned by the core member 5 and the first faceplate 6.
As shown in
The configuration shown in
In the double facer 12 of the panel production device 70, the foam material supply part 75 supplies the foam material 71 to the space partitioned by the core member 5 and the second faceplate 7. Thereafter, in the double facer 12, the pressurizing roller 65 pressurizes the panel 1a and the second faceplate 7 at the time of the joining of the panel 1a and the second faceplate 7. In this case, since the foam material 71 is included between the panel 1a and the second faceplate 7, a reaction force against the pressurization by the pressurizing roller 65 can be obtained from the foam material 71. That is, since the shape of the core member 5 can be maintained by the foam material 71, it is possible to increase the pressurization applied to the panel 1a. Accordingly, the pressurizing part 61 can increase the pressurization at the time of the joining of the panel 1a and the second faceplate 7 by an amount that the reaction force can be obtained from the foam material 71.
Next, a panel production device 80 according to a third embodiment will be described with reference to
As shown in
As shown in
An example of the welding part 9 formed by the heating part 82 will be described with reference to
The pressurizing part 83 has a pair of pressurizing rollers 65a on a heating side and a pair of pressurizing rollers 65b on a cooling side, instead of the single pressurizing roller 65 of the first embodiment. That is, the pair of pressurizing rollers 65b on the cooling side functions as a cooling part.
The pair of pressurizing rollers 65a is provided on an upstream side of the pair of pressurizing rollers 65b in the transfer direction and is provided at the same position as the pressurizing roller 65 of the first embodiment. The pair of pressurizing rollers 65a is a heating roller and is heated by a heating source (not shown) to contribute to the joining of the core member 5 and the second faceplate 7. The pressurizing roller 65a is connected to the control device 15, and the control device 15 controls a heating temperature.
The pair of pressurizing rollers 65b is provided on a downstream side of the pair of pressurizing rollers 65b in the transfer direction. The pair of pressurizing rollers 65b serves as a cooling roller and is cooled by a cooling source (not shown) to suppress alteration in the welding part 9 between the core member 5 and the second faceplate 7. The pressurizing roller 65b is connected to the control device 15, and the control device 15 controls a cooling temperature.
The first temperature sensor 84 is a temperature sensor that measures a temperature of a heated part, which is the welding part 9 heated by the heating part 82. The first temperature sensor 84 is connected to the control device 15, and the control device 15 controls the heating by the heating part 82 or controls the heating by the pressurizing roller 65a of the pressurizing part 83 based on a measurement result of the first temperature sensor 84.
The second temperature sensor 85 is a temperature sensor that measures a temperature of the welding part 9 cooled by the pressurizing roller 65b. The second temperature sensor 85 is connected to the control device 15, and the control device 15 controls the cooling by the pressurizing roller 65b of the pressurizing part 83 based on a measurement result of the second temperature sensor 85.
Next, a panel production device 90 according to a fourth embodiment will be described with reference to
As shown in
In the double facer 12 of the panel production device 90 of the fourth embodiment, the supply part 92 is a device that supplies the second faceplate 6 toward a surface on one side of the core member 5 and supplies the second faceplate 7 toward a surface on the other side of the core member 5. The supply part 92 has a pair of transfer rollers 57a that sandwiches the first faceplate 6 and delivers the first faceplate 6 toward the pressurizing part 83. The supply part 92 has a pair of transfer rollers 57b that sandwiches the second faceplate 7 and delivers the second faceplate 7 toward the pressurizing part 83.
The heating part 82 includes two laser irradiation devices 86a and 86b that emit the laser and two scanning parts 87a and 87b that bend and scan the laser. The heating part 82 heats the core member 5 to a temperature at which the heat welding is possible. Specifically, the heating part 82 is provided at a position on an upstream side in the transfer direction of the pressurizing part 83. In the heating part 82, the laser irradiation device 86a and the scanning part 87a are provided in a space formed between the core member 5 and the first faceplate 6, and the surface of the core member 5 facing the first faceplate 6 is heated. Further, in the heating part 82, the laser irradiation device 86b and the scanning part 87b are provided in a space formed between the core member 5 and the second faceplate 7, and the surface of the core member 5 facing the second faceplate 7 is heated. The laser irradiation devices 86a and 86b and the scanning parts 87a and 87b are the same as those in the third embodiment, and thus the description thereof will be omitted.
In the heating using the laser irradiation devices of the third and fourth embodiments, the first faceplate 6 and the second faceplate 7 may be heated in addition to the core member 5.
In the first to fourth embodiments, the core member 5, the first faceplate 6, and the second faceplate 7, which have a continuous sheet shape, are continuously supplied. However, the core member 5, the first faceplate 6, and the second faceplate 7 may be intermittently supplied as single wafers.
As described above, the panel production devices 10, 70, 80, and 90, the panel production method, and the panel 1 described in the embodiments are grasped as follows, for example.
Panel production devices 10, 70, 80, and 90 according to a first aspect include a transfer part 51 that transfers, in a transfer direction, a panel 1a having a core member 5 that includes a thermoplastic resin and is formed in a corrugated shape and, a first faceplate 6 that includes a thermoplastic resin, is formed in a plate shape, and is joined to a surface on one side of the core member 5, supply parts 52 and 92 that supply, toward a surface on the other side of the core member 5, a second faceplate 7 that includes a thermoplastic resin and is formed in a plate shape, heating parts 62 and 82 that heat at least one surface of respective surfaces of the core member 5 and the second faceplate 7 facing each other, and pressurizing parts 61 and 83 that pressurize and weld the core member 5 of the panel 1a and the second faceplate 7.
With the above configuration, the heating parts 62 and 82 heat at least one surface of respective surfaces of the core member 5 and the second faceplate 7 facing each other, and thus it is possible to suitably weld the core member 5 and the second faceplate 7 without deformation of the core member 5 due to the pressurization of the pressurizing parts 61 and 83.
In a second aspect, the heating parts 62 and 82 have a wedge shape that tapers toward a space between the core member 5 and the second faceplate 7 to be welded or a flat plate shape extending toward a space between the core member 5 and the second faceplate 7 to be welded.
With the above configuration, since the heating part 62 can perform the heating until immediately before the core member 5 and the second faceplate 7 are welded, it is possible to suitably weld the core member 5 and the second faceplate 7.
In a third aspect, a first temperature sensor 84 that measures a temperature of a heated part (welding part 9) heated by the heating parts 62 and 82, and a control unit (control device 15) that controls the heating by the heating parts 62 and 82 based on a measurement result of the first temperature sensor 84 are further provided.
With the above configuration, in a case where the core member 5 of the panel 1a and the second faceplate 7 are joined to each other, it is possible to set the heating temperature of the heated part to an appropriate temperature.
In a fourth aspect, a cooling part (pressurizing roller 65b) that cools the welded panel 1a and second faceplate 7 is further provided.
With the above configuration, since the welding part 9 where the core member 5 of the panel 1a and the second faceplate 7 are welded can be cooled, it is possible to suppress the alteration of the welding part 9.
In a fifth aspect, a second temperature sensor 85 that measures a temperature of a cooled part cooled by the cooling part, and a control unit (control device 15) that controls the cooling by the cooling part based on a measurement result of the second temperature sensor 85 are further provided.
With the above configuration, it is possible to set the cooling temperature of the welding part 9 to an appropriate temperature.
In a sixth aspect, the panel 1a further has a foam material 71 provided in a space partitioned by the core member 5 and the first faceplate 6.
With the above configuration, since the reaction force can be obtained from the panel 1a by the foam material 71 in a case where the pressurization by the pressurizing part 61 is performed, it is possible to suppress deformation of the core member 5 and to suitably perform the pressurization.
In a seventh aspect, a foam material supply part 73 that supplies the foam material to the space partitioned by the core member 5 and the first faceplate 6 before the joining of the core member 5 and the first faceplate 6 is further provided.
With the above configuration, it is possible to produce and supply the panel 1a including the foam material 71 with the foam material supply part 73.
A panel production method according to an eighth aspect includes a step of transferring, in a transfer direction, a panel having a core member that includes a thermoplastic resin and is formed in a corrugated shape and, a first faceplate that includes a thermoplastic resin, is formed in a plate shape, and is joined to a surface on one side of the core member, a step of supplying, toward a surface on the other side of the core member, a second faceplate that includes a thermoplastic resin and is formed in a plate shape, a step of heating at least one surface of respective surfaces of the core member and the second faceplate facing each other, and a step of pressurizing and welding the core member of the panel and the second faceplate.
With the above configuration, at least one surface of the respective surfaces of the core member 5 and the second faceplate 7 facing each other is heated, and thus it is possible to suitably weld the core member 5 and the second faceplate 7 without deformation of the core member 5 due to the pressurization. With intermittent heating of the top of the peak of the core member 5, it is possible to weld the core member 5 and the second faceplate 7 without deformation of the core member 5.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2021-069993 | Apr 2021 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2022/005669 | 2/14/2022 | WO |
