Manufacturing apparatus for panel bodies and manufacturing apparatus for heat-insulating panels

Abstract

Provided is a manufacturing apparatus for a panel body or the like that can cut a panel body into a size according to an order with a small dead area while continuously flowing a plate material in a continuous production line. 【Solution means】The manufacturing apparatus for the air-conditioning panel 10 includes a plate material supply unit 100 that continuously supplies two plate materials from two uncoilers around which the plate material 11 is wound in a coil shape, a welding unit 600 that welds the two supplied plate materials 11, a cutting unit 700 that cuts the two supplied plate materials 11, and a control device 900 that controls these. The control device 900 controls the welding unit 600 so as to perform welding at predetermined lengths in the supply direction of the two supplied plate materials 11, and to perform multiple-pass welding, which is two-pass welding for at least two of a plurality of welding points. The control device 900 identifies two of the multiple-pass welded points as cutting planned points, and controls the cutting unit 700 to perform cutting between the multiple-pass welds at the identified cutting planned points.

Description

Technical Field

[0001] The present invention relates to a manufacturing apparatus for a panel body and a manufacturing apparatus for a heat insulating panel.

Background Art

[0002] Conventionally, a highly heat-insulating sandwich panel having a structure in which a foamed heat insulating material such as polyurethane, polyisocyanurate, or phenolic resin is sandwiched between metal plates has been known. Such a sandwich panel is used in building materials such as wall panels and roof panels, and in the loading boxes of trucks. Here, in mass-producing the sandwich panel, a coil plate is fed out from two sets of uncoilers, a foaming resin is filled between the plates, and the resin is poured while being constrained by a slat conveyor from above and below the coil plate, and heated to foam the resin (see, for example, Patent Documents 1 to 4). In such a continuous production line, the flow rate of the coil is about 1 m / min to 15 m / min, and the productivity is very high.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Summary of the Invention

Problems to be Solved by the Invention

[0004] The applicant of the present application is considering making the inside of a plate-shaped hollow body vacuum and enabling the introduction of a refrigerant, and using it as a panel body capable of exhibiting an air-conditioning function, and researching the manufacture of this panel body by a continuous production line.

[0005] Here, such a panel body needs to be manufactured in a size according to the customer's order. However, on the other hand, the panel body needs to be welded to form partitions of a certain size to enable refrigerant circulation. Therefore, welding needs to be performed every time a predetermined length flows through the continuous production line.

[0006] Furthermore, considering production efficiency, it is necessary to cut the panel body in a size according to the order in the continuous production line, and it is conceivable to cut at a location adjacent to the welding location. However, in this case, there is no problem on one side of the welding location, but on the other side, the internal space will be in a state of communicating with the outside, resulting in a dead area that cannot be used as a product.

[0007] The present invention is made to solve such problems, and its object is to provide a manufacturing apparatus for a panel body and a manufacturing apparatus for a heat insulation panel that can cut the panel body into a size according to the order with few dead areas while continuously flowing a plate material in a continuous production line.

Means for Solving the Problem

[0008] The manufacturing apparatus for a panel body according to the present invention is a manufacturing apparatus for a panel body formed in a panel shape and having an airtight internal space, and includes a supply means for continuously supplying two plate materials from two uncoilers around which the plate materials are wound in a coil shape, and for forming the internal space, continuous welding is performed along the supply direction on the left and right end portions of the two plate materials supplied by the supply means, and continuous welding extending in the width direction is performed on the two plate materials supplied by the supply means. Welding means, cutting means for cutting the two plate materials supplied by the supply means, and control means for controlling at least the welding means and the cutting means, and the control means Input information on a planned cutting location that can be arbitrarily set in a specified length unit, Welding is performed at predetermined lengths in the supply direction of the two plate materials supplied by the supply means, and among a plurality of welding locations in the width direction including the start point and the end point of the planned cutting locationControl the welding means so as to perform double wire welding in which at least two are two continuous welds at an interval within 10 cm, and among the double wire welded portions the start point and the end point identify two of them as planned cutting locations, and control the cutting means to perform cutting between the double wire welds at the identified planned cutting locations.

[0009] Further, the manufacturing apparatus for a heat insulating panel according to the present invention includes panel body supply means for continuously supplying two sets of panel bodies manufactured by the panel body manufacturing apparatus described above, and heat insulating body forming means for forming a heat insulating body between the two sets of panel bodies supplied by the panel body supply means.

Effect of the Invention

[0010] According to the present invention, it is possible to provide a manufacturing apparatus for a panel body or the like that can cut with a small dead area and to a size according to an order while continuously flowing a plate material in a continuous production line.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Mode for Carrying Out the Invention

[0012] Hereinafter, the present invention will be described in accordance with preferred embodiments. The present invention is not limited to the embodiments shown below, and can be appropriately changed without departing from the gist of the present invention. Further, in the embodiments shown below, there are some places where the illustration and description of some configurations are omitted. However, regarding the details of the omitted technology, it goes without saying that well-known or well-known technologies are appropriately applied within the range where there is no contradiction with the content described below.

[0013] FIGS. 1 and 2 are configuration diagrams showing a heat insulation panel manufactured by a heat insulation panel manufacturing apparatus according to the first embodiment. FIG. 1 shows a perspective view, and FIG. 2 shows a cross-sectional view. The heat insulation panel 1 shown in FIGS. 1 and 2 includes two air-conditioning panels (panel bodies) 10, a heat insulating body 20, and a flow path 30.

[0014] The air-conditioning panel 10 is configured by processing two plate materials 11 to form an internal space IS and welding the edge portions 12 to form a hollow body. The internal space IS is, for example, evacuated to a reduced pressure state. The air-conditioning panel 10 has a large structure with a long side of at least 60 cm or more. The two plate materials 11 are each made of a material with a thickness of 0.8 mm or less, and the air-conditioning panel 10 is designed to be lightweight. Hereinafter, although the description will be made assuming a large air-conditioning panel 10 having a side of 60 cm or more, it is not particularly limited thereto, and it may be applied to those having a long side of less than 60 cm. Also, the thickness of the plate material 11 may exceed 0.8 mm. Hereinafter, the air-conditioning panel 10 will be described assuming a large one with a long side of at least 60 cm or more and a thickness of the plate material 11 of 0.8 mm or less.

[0015] In such an air-conditioning panel 10, as shown in FIGS. 1 and 2, a number of convex portions 13 are formed on both of the plate materials 11. The number of convex portions 13 is formed so as to face each other with the two plate materials 11, and the tops of the convex portions 13 are in contact with each other. For this reason, the two plate materials 11 are separated from each other in the internal space IS by the height of two convex portions 13. Further, since the tops of the convex portions 13 are in contact with each other, the air-conditioning panel 10 in which the internal space IS is evacuated is more resistant to external pressure. Although 32 convex portions 13 are formed in FIGS. 1 and 2, actually, since the plate material 11 of the air-conditioning panel 10 is thin and has a large structure, a larger number will be formed. Specifically, in the air-conditioning panel 10 having a width of 930 mm and a length of 2000 mm, for example, thousands of convex portions 13 are formed on each plate material 11.

[0016] Also, in the present embodiment, although a number of convex portions 13 are formed on both of the two plate materials 11 of the air-conditioning panel 10, it is not particularly limited thereto, and a number of convex portions 13 may be formed only on one of the plate materials 11, and the other plate material 11 may be a flat plate.

[0017] Such two air-conditioning panels 10 are configured such that a refrigerant flows through two flow paths 30. The two air-conditioning panels 10 are configured such that heat on one side of the air-conditioning panel 10 can be discarded from the other side of the air-conditioning panel 10 through the flow of the refrigerant. Further, a heat insulator 20 is provided between the two air-conditioning panels 10 to ensure heat insulation. For this reason, the heat-insulating panel 1 prevents heat from the other side from penetrating to one side by the heat insulator 20, and allows heat on one side to penetrate to the other side through the refrigerant circulation.

[0018] When causing such heat transfer, one of the two air-conditioning panels 10 functions as an evaporator E, and the other functions as a condenser C. More specifically, the liquid refrigerant evaporates in the evaporator E due to the heat from one side. As a result, the space S1 side facing the air-conditioning panel 10 on one side has its latent heat of evaporation taken away and is cooled. On the other hand, the vapor refrigerant, which is the evaporated refrigerant, reaches the condenser C through the first flow path 31. In the condenser C, the vapor refrigerant is liquefied into a liquid refrigerant by the heat on the space S2 side facing the air-conditioning panel 10 on the other side. The latent heat of condensation when the vapor refrigerant liquefies is discarded to the space S2 side. Further, the liquefied liquid refrigerant reaches the evaporator E again through the second flow path 32. As described above, the heat-insulating panel 1 allows the heat on one side to pass through to the other side.

[0019] Here, at least the air-conditioning panel 10 on the evaporator E side has a wick layer 14 formed on at least one plate material 11 (the plate material 11 on the side far from the condenser C) from the viewpoint of promoting the evaporation of the liquid refrigerant. The wick layer 14 sucks up and holds the liquid refrigerant stored on the lower side of the evaporator E by capillary action. Due to such a wick layer 14, the evaporation area of the evaporator E expands along the height direction, enabling efficient evaporation in the height direction.

[0020] Here, the air-conditioning panel 10 according to the present embodiment has a large structure. For this reason, if the convex portions 13 are not welded to the counterpart plate material 11 (the convex portions 13), the tops of the convex portions 13 will shift, causing the air-conditioning panel 10 to bend. As a result, it is difficult to use for vertical surfaces and the like, and it is also difficult to use as a building material.

[0021] Therefore, the tops of a large number of convex portions 13 of the air-conditioning panel 10 according to the present embodiment are welded together. Here, although the wick layer 14 is formed on the air-conditioning panel 10 on the evaporator E side, the wick layer 14 of the air-conditioning panel 10 according to the present embodiment is formed so as to avoid the tops of the convex portions 13.

[0022] FIG. 3 is a cross-sectional view showing another example of the heat insulation panel 1 according to the first embodiment. The heat insulation panel 1 may have a structure that is long in, for example, one direction by connecting those shown in FIGS. 1 and 2. Here, the air-conditioning panel 10 needs to be divided at predetermined intervals for refrigerant circulation. For this reason, in order to manufacture the long heat insulation panel 1, it is necessary to divide the air-conditioning panel 10 at regular intervals and weld them. Such a welded portion is called a partition forming portion 15. The heat insulation panel 1 can be configured to be long in one direction while allowing refrigerant circulation by being divided at regular intervals by the partition forming portion 15. Note that the partition forming portion 15 is also formed in the heat insulation panel 1 shown in FIGS. 1 and 2.

[0023] Hereinafter, a manufacturing apparatus for such a heat insulation panel 1 will be described. FIG. 4 is a configuration diagram showing a manufacturing apparatus for the heat insulation panel 1 according to the first embodiment. As shown in FIG. 4, the manufacturing apparatus for the heat insulation panel 1 includes a plate material supply unit (supply means) 100, a mold unit 200, a powder coating unit 300, a powder removal unit 400, a heating unit 500, a welding unit (welding means) 600, a cutting unit (cutting means) 700, a heat insulation layer forming unit (heat insulator forming means) 800, and a control device (control means) 900.

[0024] Note that in the present embodiment, the manufacturing apparatus for the heat insulation panel 1 includes a manufacturing apparatus for the air-conditioning panel 10 configured by the plate material supply unit 100, the mold unit 200, the powder coating unit 300, the powder removal unit 400, the heating unit 500, the welding unit 600, the cutting unit 700, and the control device 900. That is, the manufacturing apparatus for the heat insulation panel 1 is obtained by adding the heat insulation layer forming unit 800 to the manufacturing apparatus for the air-conditioning panel 10. In particular, since the manufacturing apparatus for the heat insulation panel 1 can continuously manufacture (supply) two sets of the air-conditioning panels 10 as will be described later, the respective units 100, 200, 300, 400, 500, 600, 700, 900 function as supply means (panel body supply means) for two sets of the air-conditioning panels 10.

[0025] The sheet supply unit 100 is configured to have, for example, four uncoilers. The coil body wound around the uncoiler constitutes a long sheet material 11, and is continuously supplied so as to be fed out from the uncoiler. In particular, the long sheet material 11 supplied from the sheet supply unit 100 has a thickness of 0.8 mm or less. Note that the sheet supply unit 100 is provided with four uncoilers, but is not particularly limited thereto, and may be provided with two or more uncoilers.

[0026] The mold unit 200 performs a pressing process (first press) in a trapezoidal shape in order to form a welding portion that becomes a partitioning portion 15 (see FIGS. 1 to 3) on the four sheets of the sheet material 11 supplied from the four uncoilers. Further, the mold unit 200 performs an embossing process (second press) on the four sheets of the sheet material 11. By this embossing process of the mold unit 200, a large number of convex portions 13 are formed in a direction orthogonal to the supply direction of the sheet material 11. In the example shown in FIGS. 1 to 3, the air-conditioning panel 10 has a trapezoidal cross-section along the conveyance direction (supply direction) of the sheet material 11 formed on both of the two sheets of the sheet material 11, but is not particularly limited thereto, and may be formed on only one of the two sheets of the sheet material 11.

[0027] FIG. 5 is an end view showing an example of the mold configuration in the mold unit 200 shown in FIG. 4, where (a) shows the first state and (b) shows the second state. As shown in FIG. 5, the mold unit 200 includes a first die set (first pressing means) 210 and a second die set (second pressing means) 220 configured in five stages, and a movable portion 230.

[0028] The first die set 210 includes first to fifth layer dies 211 to 215, and a long plate material 11 is supplied one by one between the dies 211 to 215 of each layer. The plate material 11 supplied between each layer is formed into various shapes by being press-pressed, for example, from the fifth layer die 215 toward the first layer die 211. The second die set 220 also includes first to fifth layer dies 221 to 225, and the long plate material 11 that has passed through the first die set 210 is supplied one by one between the dies 221 to 225 of each layer. The second die set 220 also forms various shapes by press-pressing from the fifth layer die 225 toward the first layer die 221. In particular, the first die set 210 and the second die set 220 are simultaneously press-pressed by the same press machine.

[0029] Here, the first die set 210 includes a trapezoidal processing portion 210a and a flow path opening portion 210b. As described above, the air-conditioning panel 10 needs to be divided at predetermined sizes to perform refrigerant circulation. Therefore, it is necessary to form a welded portion extending in the width direction of the long plate material 11 every time the long plate material 11 flows a certain distance. Thus, the trapezoidal processing portion 210a of the first die set 210 is press-processed into a trapezoid to form a welded portion that becomes the partition forming portion 15. Note that in the air-conditioning panel 10 shown in FIGS. 1 to 3, both plate materials 11 are press-processed into a trapezoid, but as shown in FIG. 5, only one of the plate materials 11 may be press-processed into a trapezoid.

[0030] Further, the flow path opening portion 210b is provided with a hole for connecting the flow path 30 between the air-conditioning panels 10. The hole is formed by being bored through, for example, in a rectangular shape so as to be adjacent to the partition forming portion 15.

[0031] Specifically, the first die set 210 includes a trapezoidal convex portion 213a1 that protrudes downward on the lower surface of the third-layer mold 213 and a trapezoidal convex portion 213a2 that protrudes upward on the upper surface. Also, the second-layer mold 212 and the fourth-layer mold 214 each have trapezoidal concave portions 212b and 214b that match the shapes of the trapezoidal convex portions 213a1 and 213a2 of the third-layer mold 213 at positions facing the trapezoidal convex portions 213a1 and 213a2. Therefore, among the four long plate materials 11 (hereinafter shown in the order of reference numerals 11a to 11d from the bottom), trapezoidal portions for forming a welded portion that becomes the partition forming portion 15 are produced in the second plate material 11b and the third plate material 11c. Note that since the trapezoidal convex portions 213a1 and 213a2 and the trapezoidal concave portions 212b and 214b are continuously formed in the width direction of the plate material 11 (i.e., the depth direction in FIG. 5), the trapezoidal portions are also continuous in the width direction.

[0032] Furthermore, the first die set 210 has through-convex portions 213c and 214c for forming hole portions on the lower surfaces of the third-layer mold 213 and the fourth-layer mold 214, respectively. Also, member receiving portions 212d and 213d for discarding the penetrated members are provided on the upper surfaces of the second-layer mold 212 and the third-layer mold 213 that face the through-convex portions 213c and 214c. Here, the through-convex portions 213c and 214c and the member receiving portions 212d and 213d are not continuous in the width direction of the plate material 11 but are in a scattered state. Therefore, hole portions are formed in the second plate material 11b and the third plate material 11c among the four long plate materials 11 at positions adjacent to the partition forming portion 15.

[0033] Further, the second die set 220 includes an embossing portion 220a. The embossing portion 220a is for forming a number of convex portions 13. Specifically, on the upper surface of the first-layer die 221, the lower and upper surfaces of the third-layer die 223, and the lower surface of the fifth-layer die 225, two rows of convex portions 221a, 223a1, 223a2, 225a arranged in the supply direction of the plate material 11 are formed. The two rows of convex portions 221a, 223a1, 223a2, 225a are formed with a large number arranged in the width direction of the plate material 11. For example, 35 are arranged in one row. Also, on the lower and upper surfaces of the second-layer die 222 and the lower and upper surfaces of the fourth-layer die 224 at these opposing positions, two rows of concave portions 222b1, 222b2, 224b1, 224b2 arranged in the supply direction of the plate material 11 are formed. The two rows of concave portions 222b1, 222b2, 224b1, 224b2 are also formed with a large number arranged in the width direction of the plate material 11. For example, 35 are arranged in one row. For this reason, 70 convex portions 13 are formed on the four long plate materials 11a to 11d every time the second die set 220 operates.

[0034] Furthermore, the movable portion 230 is a member having a wedge shape that tapers from the second die set 220 toward the first die set 210. The base side of this movable portion 230 is attached to the third-layer die 223 of the second die set 220, and the tip side is in a state of being engaged with the wedge recess 213e of the third-layer die 213 of the first die set 210. The wedge recess 213e is a recess having a shape along the wedge shape of the movable portion 230. Further, the third-layer die 213 has a lower die 213f and an upper die 213g that can move up and down. A trapezoidal convex portion 213a1 and a through convex portion 213c are formed on the lower die 213f. A trapezoidal convex portion 213a2 and a member receiving portion 213d are formed on the upper die 213g.

[0035] Here, the mold part 200 according to this embodiment includes a drive part 240. The drive part 240 adjusts at least the distance between the first die set 210 and the second die set 220. The drive part 240 includes a straight gear part 241 formed to extend in the conveyance direction of the plate material 11, a worm gear 242 that meshes with the teeth of the straight gear part 241, and a motor part 243 that rotates the worm gear 242. The worm gear 242 is a gear of a rotary ball spline using a ball spline structure and is movable along the rotation axis 242a.

[0036] In such a drive part 240, the worm gear 242 is connected to the first die set 210, and the first die set 210 can be moved along the conveyance direction according to the position of the worm gear 242 on the straight gear part 241. Therefore, by driving the motor part 243 to change the position of the worm gear 242, the distance between the first die set 210 and the second die set 220 can be adjusted.

[0037] Here, the first state shown in FIG. 5(a) shows a state where the distance between the first die set 210 and the second die set 220 is short. On the other hand, the second state shown in FIG. 5(b) is a state where the distance between the first die set 210 and the second die set 220 is long.

[0038] When the distance between the two becomes long as shown in Fig. 5(b), the amount of penetration of the tip side of the movable part 230 into the third-layer mold 213 of the first die set 210 becomes small. As a result, the lower mold 213f of the third-layer mold 213 moves slightly upward, and the upper mold 213g of the third-layer mold 213 moves slightly downward. Thereby, the trapezoidal convex portions 213a1, 213a2, the through convex portion 213c, and the member receiving portion 213d are in a retracted state, and even when the first die set 210 performs a pressing operation, neither the trapezoidal portion nor the hole is formed. On the other hand, when the distance between the two becomes short as shown in Fig. 5(a), the amount of penetration of the tip side of the movable part 230 becomes large, the lower mold 213f of the third-layer mold 213 moves slightly downward, and the upper mold 213g of the third-layer mold 213 moves slightly upward. Thereby, the trapezoidal convex portions 213a1, 213a2, the through convex portion 213c, and the member receiving portion 213d are in a protruding state, and when the first die set 210 performs a pressing operation, a trapezoidal portion and a hole are formed.

[0039] In this way, the mold part 200 is configured to be able to switch between a state where a trapezoidal portion and a hole are formed and a state where they are not formed by adjusting the distance between the first die set 210 and the second die set 220. Specifically, assume that the convex portion 13 is formed at a pitch of 25 mm in the supply direction of the plate material 11, and the trapezoidal portion and the hole are formed every 2 m. In this case, the mold part 200 drives the drive part 240 to press once in the state of Fig. 5(a) approximately every 37 presses in the state of Fig. 5(b). Thereby, while forming a large number of convex portions 13, a trapezoidal portion and a hole can be formed every 2 m.

[0040] Although not shown, the mold part 200 also performs a Z-fold on the side portion. As shown in Fig. 1, the air-conditioning panel 10 has a Z-fold portion 16 formed on the side portion. The mold part 200 preferably performs a Z-fold in the first die set 210.

[0041] Also, as shown in FIG. 5, the drive unit 240 of the mold unit 200 includes a pinion gear 244 such that the teeth thereof mesh with the straight gear unit 241. Therefore, the straight gear unit 241 functions as a so-called rack gear. The straight gear unit 241 is connected to the second die set 220. Therefore, by rotating the pinion gear 244, the entire first die set 210 and the second die set 220 can be moved. Thereby, for example, the first die set 210 and the second die set 220 can be moved in the conveying direction in accordance with the conveying speed of the plate material 11, and press working can also be performed during this movement. Thus, it is not necessary to convey the plate material 11 in a step-by-step manner, and press working can be performed on the continuously conveyed plate material 11, and the productivity can be further improved.

[0042] Referring to FIG. 4 again. The plate materials 11a to 11d that have passed through the mold unit 200 are supplied to the powder coating unit 300. The powder coating unit 300 applies powder to the first and fourth plate materials 11a and 11d that have been embossed. The powder forms the wick layer 14 by being heated in the heating unit 500 located at the subsequent stage of the powder coating unit 300.

[0043] Also, in the present embodiment, the powder coating unit 300 sprays powder onto the region including the numerous convex portions 13 formed by embossing. Therefore, powder is also provided on the top portions of the respective convex portions 13. Here, in the present embodiment, the powder coating unit 300 uses electrostatic coating when providing powder to the plate material 11. The powder is, for example, alumina powder having an average particle diameter of 50 μm or more and mixed with about 10% of low melting point glass frit having an average particle shape of 10 μm or less. Ceramics and glass such as alumina have little electrical conductivity. Therefore, such powder is electrostatically powder-coated without having little electrical conductivity and being charged.

[0044] More specifically, assume a case where partition forming portions 15 are formed every 2 m on a coiled long stainless steel plate with a plate thickness of 0.3 mm and a plate width of 930 mm. Also, assume that the convex portions 13 have a frustum of a cone shape with a pitch of 25 mm, a bottom diameter of 15 mm, a top diameter of 8 mm, and a height of 3 mm. Here, excluding the Z-fold portions 16 on both sides with a width of 20 mm at both ends of the plate width, it is necessary to provide powder in the remaining 890 mm width portion to form the wick layer 14. Also, excluding the partition forming portions 15, the powder installation area is 890 mm in the width direction and 1925 mm in the length direction. The powder coating portion 300 performs electrostatic coating in such an area (the area excluding the edge portion 12).

[0045] FIG. 6 is a perspective view showing details of the powder coating portion 300 shown in FIG. 4. For convenience of illustration in FIG. 6, each plate material 11 that has passed through the mold portion 200 is shown in a flat plate shape. Also, for convenience of illustration, the illustration of reference numerals is omitted for some of the same configurations.

[0046] The powder coating portion 300 shown in FIG. 6 includes a powder spraying portion 310, a masking plate portion 320, and a masking belt portion 330. The powder coating portion 300 sprays powder onto the portions including the numerous convex portions 13 by the powder spraying portion 310, and performs masking by the masking plate portion 320 and the masking belt portion 330 so that powder is not provided at the locations corresponding to the partition forming portions 15 and the Z-fold portions 16.

[0047] The powder spraying portion 310 sprays powder onto the first plate material 11a from above the first plate material 11a and also sprays powder onto the fourth plate material 11d from below the fourth plate material 11d.

[0048] The masking plate portion 320 includes an endless belt 321, a number of plate-like masking plates 322 attached along the outer peripheral side of the endless belt 321, a driving portion 323, and a cleaning portion 324. Such a masking plate portion 320 is provided on both sides in the width direction of the first plate material 11a and the fourth plate material 11d.

[0049] The endless belt 321 of the masking plate portion 320 is wound around two pulleys arranged at a distance in the conveying direction of the plate material 11. Therefore, the operating direction of the endless belt 321 is generally along the conveying direction of the plate material 11. Also, since a large number of masking plates 322 are provided on the outer periphery of the endless belt 321, they are arranged so as to cover the positions of the Z-fold portions 16 on both sides of the first plate material 11a from above and the positions of the Z-fold portions 16 on both sides of the fourth plate material 11d from below. The drive unit 323 rotates the endless belt 321. The cleaning unit 324 blows off the powder adhered to the large number of masking plates 322 by sending compressed air to the large number of masking plates 322.

[0050] The powder spraying unit 310 performs electrostatic powder coating in a state where the endless belt 321 is rotated by the drive unit 323 of the masking plate portion 320. Thereby, installation of powder at locations corresponding to the Z-fold portions 16 is prevented by the large number of masking plates 322 provided along the outer periphery of the endless belt 321. Also, at this time, powder adheres to the masking plates 322. However, since the endless belt 321 is rotating, the masking plates 322 with powder adhered are supplied to the cleaning unit 324, the powder is removed, and they move again to the locations corresponding to the Z-fold portions 16 to prevent powder installation.

[0051] Also, the masking belt portion 330 includes an endless belt 331, a drive unit 333, and a cleaning unit 334. The endless belt 331 of the masking belt portion 330 is wound around two pulleys arranged in the width direction of the first plate material 11a and the fourth plate material 11d. At least one of the two pulleys is a drive unit 333 capable of rotational operation. Each of the plate materials 11a, 11d is conveyed so as to pass inside the endless belt 331. The cleaning unit 334 blows off the powder adhered to the endless belt 331 by sending compressed air to the endless belt 331.

[0052] The powder spraying unit 310 performs electrostatic coating of powder while the endless belt 331 is rotated by the drive unit 333 of the masking belt unit 330. This prevents the powder from being placed at the location corresponding to the partition forming unit 15 by the endless belt 331. Also, at this time, the powder adheres to the endless belt 331. However, as the endless belt 331 rotates, the portion where the powder adheres reaches the cleaning unit 334 and the powder is removed.

[0053] Regarding this powder coating unit 300 as well, the powder spraying unit 310 and the masking belt unit 330 can be moved in accordance with the conveyance speed of the plate material 11. As a result, it is possible to mask the continuously conveyed plate material 11 without having to convey the plate material 11 in a step-by-step manner. Note that the masking plate unit 320 preferably includes a mechanism that moves in accordance with the conveyance speed of the plate material 11, although it depends on the number of masking plates 322.

[0054] Referring to FIG. 4 again. The plate materials 11a to 11d that have passed through the powder coating unit 300 are supplied to the powder removing unit 400. The powder removing unit 400 removes the powder at the locations corresponding to the numerous convex portions 13 of the first and fourth plate materials 11a and 11d. The powder removing unit 400 may remove the powder at the tops of the numerous convex portions 13 by compressed air, or may remove the powder by scraping it off by bringing a cleaning plate into contact with the tops of the numerous convex portions 13. In particular, in this embodiment, although the powder is provided on the first and fourth plate materials 11a and 11d, it adheres only to the extent of electrostatic force or intermolecular force, and thus can be removed without difficulty by these removal configurations.

[0055] The plates 11a to 11d that have passed through the powder removal section 400 are supplied to the heating section 500. The heating section 500 is constituted by, for example, a tunnel furnace, and heats the first and fourth plates 11a and 11d to melt the powder and form the wick layer 14. Here, the powder at the tops of the numerous convex portions 13 is removed in the powder removal section 400, and the powder in other portions remains. By performing heating by, for example, a tunnel furnace in this state, the wick layer 14 is formed except for the tops of the numerous convex portions 13. When the powder is as described above, this heating section 500 heats to about the melting point of the low melting point glass. As a result, the low melting point glass spreads by wetting on the surfaces of both the alumina powder and the plate 11. Thereafter, the plate 11 is cooled, for example, in a normal temperature environment. Thereby, the low melting point glass solidifies and the alumina powder is fixed as the wick layer 14.

[0056] The plates 11a to 11d that have passed through the heating section 500 are supplied to the welding section 600. The welding section 600 welds by combining the first plate 11a and the second plate 11b, and the third plate 11c and the fourth plate 11d.

[0057] FIG. 7 is a perspective view showing details of the welding section 600 shown in FIG. 4. For convenience of illustration in FIG. 7, each plate 11 is shown in a flat plate shape. As shown in FIG. 7, the welding section 600 includes a plurality of spot welding machines 610, a first seam welding machine 620, and a second seam welding machine 630.

[0058] The plurality of spot welding machines 610 weld the tops of the numerous convex portions 13 and the mating plate 11. The plurality of spot welding machines 610 are arranged side by side in the width direction of the plate 11, and are arranged on the lower surface side of the first plate 11a and the upper surface side of the second plate 11b, and on the lower surface side of the third plate 11c and the upper surface side of the fourth plate 11d to weld two plates 11 from the front and back. The plurality of spot welding machines 610 according to the first embodiment are, for example, laser welding machines.

[0059] Here, a plurality of spot welders 610 are configured to perform welding on some of the numerous convex portions 13 and not perform welding on the remaining convex portions 13. To perform such welding, the number of spot welders 610 is made less than the number of the numerous convex portions 13 provided in the width direction. For example, when 35 convex portions 13 are formed in the width direction, seven spot welders 610 are provided at intervals of, for example, 125 mm in the width direction. Thereby, the spot welders 610 thin out the welding points in a range where the bending of the air-conditioning panel 10 is less affected, aiming to improve productivity.

[0060] Also, the first seam welder 620 welds the side portion that becomes the Z-fold portion 16 of the plate material 11. This first seam welder 620 also welds two sheets of the plate material 11 from the front and back.

[0061] The second seam welder 630 welds the location that becomes the partition forming portion 15 of the plate material 11. This second seam welder 630 is configured such that the welding location can move in the width direction, and welds two sheets of the plate material 11 from the front and back. In particular, the second seam welder 630 can also perform welding while reciprocating with respect to one partition forming portion 15.

[0062] FIG. 8 is a perspective view showing a state of being welded by the first seam welder 620 and the second seam welder 630 shown in FIG. 7. As shown in FIG. 8, the Z-fold portion 16 of two sheets of the plate material 11 is welded by the first seam welder 620. Further, the second seam welder 630 can also perform two substantially parallel welds in the partition forming portion 15. That is, the second seam welder 630 can selectively perform single-line welding and multi-line welding with respect to one partition forming portion 15. Although the distance between the multi-lines is assumed to be, for example, 20 mm, it is not limited to 20 mm as long as it is particularly 10 cm or less.

[0063] Here, as shown in FIG. 7, it is preferable that the spot welder 610 and the second seam welder 630 are movable along the conveyance direction of the plate material 11 and perform welding while moving in accordance with the conveyance speed of the plate material 11. Thereby, instead of feeding the plate material 11 in a stepwise manner, it is possible to perform welding with the spot welder 610 and the second seam welder 630 while continuously feeding, and thus it is possible to further improve the productivity.

[0064] Referring to FIG. 4 again. The cutting part 700 cuts the two plate materials 11 welded by the welding part 600. The cutting part 700 performs, for example, press cutting. In particular, the cutting part 700 cuts the double-line weld interval shown in FIG. 8. Thereby, the waste portion of the plate material 11 is reduced. That is, in the case of single-line welding, when the partitioning formation part 15 is cut adjacent to the single-line welding part, a hollow body can be manufactured on one side, but on the other side, the internal space IS is in an open state, resulting in a dead area. However, in the case of double-line welding, by cutting between the double lines, it is possible to contribute to reducing the dead area without the internal space IS being opened on both the one side and the other side.

[0065] The plate materials 11a to 11d that have passed through the cutting part 700 are supplied to the heat insulation layer forming part 800. The heat insulation layer forming part 800 performs flow path attachment, foam installation, and foaming.

[0066] First, in the heat insulation layer forming part 800, the flow path 30 is attached to the hole formed by the flow path opening part 210b of the mold part 200. FIG. 9 is a perspective view showing the flow path 30 attached by the heat insulation layer forming part 800 shown in FIG. 4. The hole formed by the flow path opening part 210b of the mold part 200 is substantially rectangular. The flow path 30 includes two opposing rectangular plates 30a (only one is shown in FIG. 9), a pipe part 30b connecting these, and small pipes 30c formed in the pipe part 30b.

[0067] The two plates 30a are shaped to match the shape of the hole portion. The pipe portion 30b connects the internal spaces IS of the two air conditioning panels 10 and is for the circulation of the refrigerant. The small pipe 30c is a pipe for evacuating the internal space IS or enclosing the refrigerant, and is sealed after these operations are completed. In the heat insulation layer forming portion 800, such a flow path 30 is attached. Also, in the heat insulation layer forming portion 800, after the attachment of the flow path 30, evacuation and refrigerant filling may be performed, but it is not limited to this. For example, in a later process, the heat insulator 20 may be provided so that the tip of the small pipe 30c is exposed from the heat insulator 20, and evacuation and refrigerant filling may be performed using the small pipe 30c with the exposed tip.

[0068] In addition, when the two plates 30a and the second and third plate materials 11b, 11c are resistance welded, the flow path 30 may be attached before the second and third plate materials 11b, 11c are respectively overlapped with the first and fourth plate materials 11a, 11d. For this reason, for example, the flow path 30 may be attached in the process of being conveyed from the mold portion 200 to the powder coating portion 300. By attaching the flow path 30 at such a timing, the second and third plate materials 11b, 11c can be conveyed while stabilizing the interval between the second plate material 11b and the third plate material 11c by using the flow path 30.

[0069] Referring to FIG. 4 again. After the attachment of the flow path 30, the heat insulation layer forming portion 800 installs and foams the foam. Thereby, the heat insulator 20 is formed. The heat insulation layer forming portion 800 injects the raw material 21 of the foamed heat insulating material between the two air conditioning panels 10 after the attachment of the flow path. Thereafter, the heat insulation layer forming portion 800 foams the injected raw material 21 of the foamed heat insulating material. The foaming is performed by various methods such as gas, heating, chemicals, etc. Also, the raw material 21 of the foamed heat insulating material is pre-mixed with gas so as to foam at the installation stage like a spray of foamed urethane foam, and the foaming may simply wait for the passage of time after the injection of the raw material 21.

[0070] Here, it is preferable that the cutting portion 700 is also provided at the subsequent stage of the heat insulation layer forming portion 800. In this case, by cutting with the cutting portion 700 at the subsequent stage of the welding portion 600, it is first made to a certain length, and then it is cut and straightened again according to the order by the cutting portion 700 at the subsequent stage of the heat insulation layer forming portion 800. As a result, the line can be divided into two before and after cutting by the cutting portion 700 at the subsequent stage of the welding portion 600, and the degree of freedom regarding the layout in the factory can be increased because the line does not become straight. Further, the cutting portion 700 may be provided only at the subsequent stage of the heat insulation layer forming portion 800.

[0071] The control device 900 controls each of the above-described portions 100 to 800. In particular, the control device 900 according to the present embodiment has a function of causing double-sided welding and cutting to be executed at a selected location among the section forming portions 15 formed at every predetermined length.

[0072] First, when the predetermined length is, for example, 2 m, the control device 900 receives information input regarding the cutting locations in units of 2 m. That is, the control device 900 receives information input such as 2 m, 4 m, 6 m, etc.

[0073] Thereby, the control device 900 causes double-sided welding to be performed on the section forming portions 15 that are the start point and the end point of the length for which information has been input. For example, when the control device 900 receives information input of 6 m, it causes double-sided welding to be performed on the section forming portion 15 at the 0 m location that is the start point of 6 m and the section forming portion 15 at a position 6 m away from this section forming portion 15.

[0074] Then, the control device 900 identifies the section forming portion 15 that has been double-sided welded as the cutting planned location. Next, the control device 900 controls the cutting portion 700 to control cutting to be performed at the identified cutting planned location.

[0075] Note that in the above, the double-wire welding is performed at two locations, namely the start point and the end point of the location where the information input is received, but it is not limited to this. For example, if the control device 900 performs double-wire welding at at least two locations, it may cause the welding portion 600 to perform double-wire welding at locations that are not cut, such as all of the partition forming portion 15. In this case, the control device 900 identifies two planned cutting locations from at least two double-wire welding locations. For example, the control device 900 identifies the locations that are the start point and the end point of the input length of information as the planned cutting locations, and causes the cutting portion 700 to perform cutting.

[0076] In this way, according to the manufacturing apparatus for the air-conditioning panel 10 according to the first embodiment, welding is performed at predetermined lengths in the supply direction of the two plate materials 11, at least two of the plurality of welding locations are double-wire welded, two of the double-wire welded locations are identified as planned cutting locations, and cutting is performed between the double-wire welds of the identified planned cutting locations. Thereby, while performing welding at a predetermined length to form partitions, at least a part of the welding locations is made into double-wire welding, and the area between the double-wire welds is cut to minimize the dead area as much as possible. In particular, if a part of the welding locations at each predetermined length is not set as a planned cutting location and the planned cutting locations are identified with sizes according to the order, cutting according to the order can be performed. Therefore, it is possible to provide a manufacturing apparatus for the air-conditioning panel 10 that can reduce the dead area and cut to a size according to the order while continuously flowing the plate material 11 in the continuous production line.

[0077] Also, according to the manufacturing apparatus for the heat-insulating panel 1 according to the first embodiment, since two sets of the air-conditioning panels 10 are continuously supplied and the heat-insulating body 20 is provided therebetween, it is possible to provide a manufacturing apparatus for the heat-insulating panel 1 using the above air-conditioning panel 10.

[0078] Next, a second embodiment will be described. The manufacturing apparatuses for the air-conditioning panel 10 and the heat-insulating panel 1 according to the second embodiment are the same as those of the first embodiment, but some control contents and the like are different. Hereinafter, the description will focus on the differences from the first embodiment.

[0079] FIG. 10 is a cross-sectional view showing a heat insulation panel according to the second embodiment. The heat insulation panel 2 according to the second embodiment is not of a predetermined unit length but is formed with an arbitrary length. For this reason, for example, it is composed of a first part 2a partitioned by a predetermined length such as 2 m, and a second part 2b partitioned by a length shorter than the predetermined length.

[0080] Next, a manufacturing apparatus for the heat insulation panel 2 according to the second embodiment will be described. First, the control device 900 according to the second embodiment accepts input of information on a location to be cut at an arbitrary length, not limited to a 2 m unit when the predetermined length is 2 m, for example. For this reason, the control device 900 accepts input of information not only such as 2 m, 4 m, 6 m, etc., but also input of information such as 2.5 m, 3.2 m, 4.8 m, etc.

[0081] Here, assume that the predetermined length is 2 m and the control device 900 accepts input of information of 2.5 m. In this case, the control device 900 controls the die part 200 to form trapezoidal parts in units of 2 m, and also forms trapezoidal parts at a position 0.5 m away from the 2 m position (the 2.5 m position). That is, the control device 900 forms trapezoidal parts not only at the predetermined length but also at arbitrary length positions. Note that the control device 900 also forms hole parts adjacent to the trapezoidal parts.

[0082] Also, in the present embodiment, the die part 200 forms a large number of convex parts 13 as well. Therefore, the control device 900 performs the following control. That is, the control device 900 controls the die part 200 to first form a trapezoidal part at the 0 m position which is the start point of 2.5 m by the first die set 210. After that, assuming that the large number of convex parts 13 are formed at a 25 mm pitch, the control device 900 causes the second die set 220 to perform the second press 38 times (an example of the set number of second presses), and among them, 1 time the first die set 210 performs the first press 1 time to form a trapezoidal part at the 2 m position.

[0083] Next, the control device 900 sets the number of second presses according to the length that is the fractional part of the input information length. When information of 2.5 m is input, the control device 900 sets the number of second presses to 8 times according to the fractional part of 0.5 m. Then, the control device 900 causes the second die set 220 to perform the second press 8 times (an example of the set number of second presses). Further, the control device 900 forms a trapezoidal portion at the 2.5 m position by the first die set 210. Note that the control device 900 will perform the second press again after the 2.5 m position in order to manufacture the heat insulation panel 2 or the like of other lengths.

[0084] Thereafter, the control device 900 controls the welding portion 600 to perform double-sided welding on at least the partition forming portion 15 that is the start point and the end point of the input information. That is, the control device 900 causes double-sided welding to be performed on the partition forming portion 15 at the 0 m point that is the start point of 2.5 m and the partition forming portion 15 at a position 2.5 m away from this partition forming portion 15. Note that in this case, the partition forming portion 15 at the position 2 m from the start point may be single-sided welding or double-sided welding.

[0085] Then, the control device 900 identifies the cutting planned location from the double-sided welded location. In this case, since 2.5 m of information is input, the control device 900 identifies the 0 m location that is the start point and the 2.5 m location that is the end point as the cutting planned locations. Next, the control device 900 controls the cutting portion 700 to control cutting at the identified cutting planned locations.

[0086] As described above, the control device 900 can manufacture the heat insulation panel 2 having an arbitrary length with a fractional part in addition to a predetermined length unit such as 2 m.

[0087] In this way, according to the manufacturing apparatus for the air-conditioning panel 10 according to the second embodiment, similar to the first embodiment, it is possible to provide a manufacturing apparatus for the air-conditioning panel 10 that can reduce the dead area and cut to a size according to the order while continuously flowing the plate material 11 in the continuous production line.

[0088] Also, in order to control welding and cutting at any location of the two plate materials 11, even when, for example, the order is not an integral multiple of a predetermined length, the dead area can be reduced and the cutting can be performed to a size that matches the order.

[0089] Also, while performing the second press for forming the convex portions 13 a set number of times, the first press for the partition forming portion 15 is performed between the locations on the plate material 11 where the next second press is to be performed, and welding is performed at the locations where the first press has been performed. For this reason, while forming a large number of convex portions 13 by performing the second press to make the air-conditioning panel 10 easily withstand external pressure, a trapezoidal portion can be formed by the first press to facilitate welding and cutting.

[0090] Also, according to the manufacturing apparatus for the heat insulation panel 2 according to the second embodiment, a manufacturing apparatus for the heat insulation panel 2 using the air-conditioning panel 10 as in the first embodiment can be provided.

[0091] As described above, the present invention has been described based on the embodiments, but the present invention is not limited to the above embodiments, and modifications may be made without departing from the spirit of the present invention. Also, the techniques of the embodiments may be combined with each other, or known or well-known techniques may be combined within the possible range.

[0092] For example, in the above embodiment, the flow path 30 is a separate flow path for the vapor refrigerant and the liquid refrigerant, but is not particularly limited thereto, and may be a common flow path through which both the vapor refrigerant and the liquid refrigerant can flow. Also, it is preferable that a check valve, a temperature sensing valve, etc. are provided in the flow path 30 as necessary.

[0093] Furthermore, in the above embodiment, the heat insulator 20 is formed using a foam, but is not particularly limited thereto, and the heat insulator 20 may be provided by other methods, for example, by disposing a molded heat insulator 20 between two hollow bodies.

[0094] Also, in the above embodiment, the air-conditioning panel 10 has a number of convex portions 13, but it is not particularly limited thereto. The manufacturing apparatus may not form a number of convex portions 13, for example, when the size of the air-conditioning panel 10 is small, or the convex portions 13 may not be welded.

[0095] Furthermore, in the above, an example in which the pressing direction of the mold part 200 is the direction from the fifth-layer molds 215 and 225 to the first-layer molds 211 and 221 has been described, but it is not particularly limited thereto, and the reverse direction may also be possible. Also, the mold part 200 may press so as to sandwich from above and below. In this case, the positions of the third-layer molds 213 and 223 can be made substantially fixed, and the operability of the movable part 230 can be easily ensured.

[0096] Note that, in the above embodiment, an example of the manufacturing apparatus for the panel body is the manufacturing apparatus for the air-conditioning panel 10, but it is not particularly limited thereto. For example, the air-conditioning panel 10 shown in FIG. 1 can be used as a vapor chamber alone and can be used as a heat-radiating panel. Also, in the above embodiment, the wick layer 14 is not aimed at capillary action, but is an uneven layer that simply increases the surface area or aims at a turbulent flow effect in order to improve the heat exchange efficiency, and may be used as a heat exchanger. In addition, in the above embodiment, silica gel powder may be used instead of alumina powder, and a resin (a resin with a generally low melting point such as an acrylic resin) may be used instead of the low-melting glass to form an uneven surface having silica gel (an adsorbent layer that adsorbs water vapor components) and used as a total heat exchanger.

Explanation of reference numerals

[0097] 1, 2: Heat-insulating panel 10: Air-conditioning panel (panel body) 11: Plate material 13: A number of convex portions 20: Heat-insulating body 100: Plate material supply unit (supply means, panel body supply means) 200: Mold part (panel body supply means) 210: First die set (first pressing means) 220: Second die set (second pressing means) 600: Welding part (welding means, panel body supply means) 700: Cutting part (cutting means, panel body supply means) 800: Heat insulation layer forming part (heat insulating body forming means) 900: Control device (control means, panel body supply means) IS: Internal space

Claims

1. An apparatus for manufacturing a panel body that is formed in a panel shape and has an airtight internal space, comprising: feeding means for continuously feeding two plate materials from two uncoilers around which the plate materials are wound in a coil shape; welding means for performing continuous welding along the feeding direction on the left and right end portions of the two plate materials fed by the feeding means to form the internal space, and for performing continuous welding extending in the width direction on the two plate materials fed by the feeding means; cutting means for cutting the two plate materials fed in the feeding means; control means for controlling at least the welding means and the cutting means, wherein the control means inputs information on a cutting planned position that can be arbitrarily set in units of a predetermined length, and performs welding at every predetermined length in the feeding direction of the two plate materials fed by the feeding means, and controls the welding means to perform double-wire welding, which is two continuous welds with a distance of within 10 cm between at least two of the plurality of welding positions in the width direction including the start point and the end point of the cutting planned position, specifies the two of the start point and the end point among the double-wire welded positions as the cutting planned positions, and controls the cutting means to perform cutting between the double-wire welds of the specified cutting planned positions; An apparatus for manufacturing a panel body, characterized in that.

2. First pressing means for performing a first press to form a hole for installing a flow path for connecting the internal spaces with another panel body on at least one of the two plate materials fed by the feeding means at every predetermined length; Second pressing means for performing a second press to form a large number of convex portions in a direction orthogonal to the feeding direction on at least one of the two plate materials fed by the feeding means, wherein the control means controls the first pressing means to perform the first press so as to form the hole between a location on the plate material where the second pressing means performs the set number of second presses and a location on the plate material where the second press is to be performed next. The apparatus for manufacturing a panel body according to claim 1, characterized in that.

3. The control means further controls the welding means to weld any part of the two plate materials supplied by the supply means, and controls the welding means to perform the multi-pass welding on at least two of the plurality of welding points including the any part at an interval within 10 cm. Two of the multi-pass welded points including the any part are specified as cutting planned points, and the cutting means is controlled to perform cutting during the multi-pass welding of the specified cutting planned points. The panel body manufacturing apparatus according to claim 1, characterized in that.

4. A panel body supply means for continuously supplying two sets of panel bodies manufactured by the panel body manufacturing apparatus according to claim 2. A flow path forming means for forming a flow path connecting the hole portions of the two sets of panel bodies supplied by the panel body supply means. A heat insulating body forming means for forming a heat insulating body between the two sets of panel bodies supplied by the panel body supply means. A heat insulating panel manufacturing apparatus, characterized by comprising.

5. The control means of the panel body manufacturing apparatus further controls the welding means to weld any part of the two plate materials supplied by the supply means, and controls the welding means to perform the multi-pass welding on at least two of the plurality of welding points including the any part at an interval within 10 cm. Two of the multi-pass welded points including the any part are specified as cutting planned points, and the cutting means is controlled to perform cutting during the multi-pass welding of the specified cutting planned points. The heat insulating panel manufacturing apparatus according to claim 4, characterized in that.

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