Plate manufacturing method and apparatus and plate

Abstract

It is possible to continuously obtain, through simple steps, a plate which can gain sufficient strength, which is very lightweight and easy to handle, and which has the optimal heat insulating effect. A plate 1 is manufactured by: guiding a glass fiber containing member 5 into a space formed by an outer mold 11 and a center mold 12; injecting a resin 4 into the space formed by the outer mold 11 and the center mold 12; integrating the resin 4 with the glass fiber containing member 5 to form a hollow panel 2; and injecting a foaming material into a hollow part formed in the hollow panel 2, and causing the foaming material to foam and integrate with the hollow panel 2.

What is claimed is:  
     
         1 . A method for continuously manufacturing a plate, comprising: 
 a guiding step of guiding a glass fiber containing member into a space formed by an outer mold and a center mold placed inside the outer mold and at a specified distance from the outer mold;    a resin injecting step of injecting a resin into the space formed by the outer mold and the center mold;    a hollow panel forming step of forming a hollow panel by integrating the resin with the glass fiber containing member;    a foaming material injecting step of injecting a foaming material into a hollow part formed within the hollow panel; and    an integrating step of causing the foaming material to foam and integrate with the hollow panel.    
     
     
         2 . The plate manufacturing method according to  claim 1 , wherein the glass fiber containing member has a plurality of roving threads and a sheet.  
     
     
         3 . The plate manufacturing method according to  claim 1 , wherein the panel forming step includes the step of wetting the glass fiber containing member with the resin by pressing the resin.  
     
     
         4 . The plate manufacturing method according to  claim 1 , wherein the temperature of the outer mold is adjusted at a specified temperature.  
     
     
         5 . The plate manufacturing method according to  claim 1 , wherein the guiding step includes the step of guiding a print sheet with a desired picture image printed thereon to the outer surface of the glass fiber containing member, and the hollow panel forming step includes the step of integrating the print sheet, the glass fiber containing member, and the resin, thereby forming the hollow panel.  
     
     
         6 . The plate manufacturing method according to  claim 1 , wherein the foaming material is supplied from a plurality of supply ports and is mixed immediately before injection into the center mold.  
     
     
         7 . The plate manufacturing method according to  claim 1 , further comprising a resin layer providing step of providing a resin layer over the surface of the hollow panel.  
     
     
         8 . The plate manufacturing method according to  claim 1 , wherein the resin layer providing step comprises the step of supplying a resin over the surface of the hollow panel and the step of rolling the supplied resin.  
     
     
         9 . The plate manufacturing method according to  claim 1 , wherein the foaming material is injected at a temperature of 50° C. or lower.  
     
     
         10 . The plate manufacturing method according to  claim 1 , wherein the foaming material is injected at a temperature not higher than 30° C. and not lower than 20° C.  
     
     
         11 . A plate manufacturing apparatus for continuously manufacturing a plate, comprising: 
 a hollow panel forming device for forming a hollow panel, the device having an outer mold and a center mold placed inside the outer mold and at a specified distance from the outer mold;    a guiding device for guiding a glass fiber containing member into a space formed by the outer mold and the center mold;    a resin injecting device for injecting a resin into the space formed by the outer mold and the center mold; and    a foaming material injecting device for injecting a foaming material into a hollow part formed within the hollow panel; wherein the injected foaming material is caused to foam and integrate with the hollow panel.    
     
     
         12 . The plate manufacturing apparatus according to  claim 11 , wherein the glass fiber containing member comprises a plurality of roving threads and a sheet.  
     
     
         13 . The plate manufacturing apparatus according to  claim 11 , wherein the hollow panel forming device includes a pressure device capable of pressing the resin to wet the glass fiber containing member with the resin.  
     
     
         14 . The plate manufacturing apparatus according to  claim 11 , wherein a thermostat for adjusting the temperature of the outer mold at a specified temperature is connected to the outer mold.  
     
     
         15 . The plate manufacturing apparatus according to  claim 11 , wherein the guiding device includes a print sheet guiding device for guiding a print sheet with a desired picture image printed thereon to the outer surface of the glass fiber containing member, and the hollow panel forming device integrates the print sheet, the glass fiber containing member, and the resin, thereby forming the hollow panel.  
     
     
         16 . The plate manufacturing apparatus according to  claim 11 , wherein the foaming material injecting device comprises a plurality of supply ports for supplying the foaming material, and a mixing mechanism for mixing the foaming material supplied from the plural supply ports immediately before injection into the space formed within the hollow panel.  
     
     
         17 . The plate manufacturing apparatus according to  claim 11 , further comprising a resin layer providing device for providing a resin layer over the surface of the hollow panel.  
     
     
         18 . The plate manufacturing apparatus according to  claim 17 , wherein the resin layer providing device comprises a resin supplying device for supplying a resin over the surface of the hollow panel, and a rolling device for rolling the supplied resin.  
     
     
         19 . The plate manufacturing apparatus according to  claim 11 , wherein the foaming material injecting device comprises a temperature control device for controlling the temperature of the foaming material to be injected.  
     
     
         20 . The plate manufacturing apparatus according to  claim 19 , wherein the foaming material injecting device controls the temperature of the foaming material to be maintained at 50° C. or lower.  
     
     
         21 . The plate manufacturing apparatus according to  claim 19 , wherein the foaming material injecting device controls the temperature of the foaming material to be maintained not higher than 30° C. and not lower than 20° C.  
     
     
         22 . A plate manufactured by a plate manufacturing method comprising: 
 a guiding step of guiding a glass fiber containing member into a space formed by an outer mold and a center mold placed inside the outer mold and at a specified distance from the outer mold;    a resin injecting step of injecting a resin into the space formed by the outer mold and the center mold;    a hollow panel forming step of forming a hollow panel by integrating the resin with the glass fiber containing member;    a foaming material injecting step of injecting a foaming material into a hollow part formed within the hollow panel; and    an integrating step of causing the foaming material to foam and integrate with the hollow panel.    
     
     
         23 . A plate manufactured by a plate manufacturing apparatus comprising: 
 a hollow panel forming device for forming a hollow panel, the device having an outer mold and a center mold placed inside the outer mold and at a specified distance from the outer mold;    a guiding device for guiding a glass fiber containing member into a space formed by the outer mold and the center mold;    a resin injecting device for injecting a resin into the space formed by the outer mold and the center mold; and    a foaming material injecting device for injecting a foaming material into a hollow part formed within the hollow panel; wherein the injected foaming material is caused to foam and integrate with the hollow panel.    
     
     
         24 . A plate comprising: a hollow panel formed by integrating a resin with a glass fiber containing member; and a foamed body filling the hollow panel.  
     
     
         25 . The plate according to  claim 24 , wherein the glass fiber containing member includes a plurality of roving threads, and a glass fiber sheet.  
     
     
         26 . The plate according to  claim 25 , wherein a sheet with a desired picture image printed thereon is further provided on the outer surface of the glass fiber sheet.  
     
     
         27 . The plate according to  claim 24 , wherein the surface of the plate is mirror-finished.