JP4853592B2 - Rain gutter and its manufacturing method - Google Patents

Description

  The present invention relates to a rain gutter formed by extrusion and having a plurality of layers, and a method for manufacturing the same.

  Japanese Laid-Open Patent Publication No. 2003-251724 discloses a molded product made of a conventional thermoplastic resin. This molded product is formed by multilayer extrusion molding. This molded product is used for rain gutters and the like by being processed.

  Such a gutter has a main layer and a surface layer. The main layer is made of a resin composition mainly composed of a vinyl chloride resin which is strong and inexpensive. The surface layer is made of a resin composition mainly composed of an acrylic resin having excellent weather resistance.

  A rain gutter having a main layer made of foamed resin and a surface layer made of non-foamed resin is also known. The main layer is made of a foamable resin composition in which a foaming agent is mixed with a vinyl chloride resin. A surface layer made of a non-foamed resin composition mainly composed of an acrylic resin is formed on the entire surface of the main layer. In such rain gutters, the main layer is formed thick in order to increase the strength. On the other hand, since the main layer contains many bubbles inside, the gutter having such a main layer is light.

  However, the surface of a conventional rain gutter has a smooth surface, and this surface has a gloss unique to synthetic resins. When this gutter is attached to a building, the surface has a gloss unique to synthetic resin, so that it can be seen at a glance that it is a synthetic resin product. Therefore, there has been a problem of a cheap appearance.

  In order to solve such a problem, it is conceivable to mechanically form a plurality of concave portions on the surface of the rain gutter with an emboss roll. However, the recess formed by the embossing roll is relatively large. Therefore, the effect of erasing the surface of the rain gutter cannot be sufficiently obtained by the recess formed by the embossing roll. In addition, there is a problem that the recess formed by the embossing roll is conspicuous. Furthermore, this recessed portion is formed by an embossing roll. Therefore, the concave part of the same shape is repeatedly formed on the surface of the gutter. Therefore, it was not possible to obtain a rain gutter having a surface with a reduced gloss.

  The present invention has been made in view of the above problems. A first object of the present invention is to provide a rain gutter with a surface having a non-uniform shape. Accordingly, it is to provide a rain gutter having no luster, not being made of a synthetic resin, having a calm appearance, and excellent weather resistance. In addition, a second object of the present invention is to provide a method for manufacturing a rain gutter having a surface having a non-uniform shape.

  In order to solve the above problems, the gutter of the present invention comprises a main layer and a surface layer. The main layer is made of a non-foamed resin. The surface layer is laminated on the surface of the main layer and is made of a foamed resin. The surface layer has a surface on which 30 to 50 recesses are formed per square millimeter. The recesses are formed when the bubbles in the foamed resin break, and the recesses are spaced apart from other recesses at irregular intervals.

  In this case, despite the synthetic resin, it does not have a gloss characteristic of the synthetic resin. Therefore, a rain gutter that does not look like a synthetic resin and has a calm appearance can be obtained.

The opening area of the recess is preferably 1000 .mu.m ² or more 30000Myuemu ² or less.

  The gutter has a length and a width. It is preferable that the surface of the surface layer further has a plurality of convex portions running in the width direction. Each of the plurality of convex portions is spaced at irregular intervals in the length direction of the surface layer.

  In this case, despite the synthetic resin, it does not have a gloss characteristic of the synthetic resin. Therefore, a rain gutter that does not look like a synthetic resin and has a more calm appearance can be obtained.

  The rain gutter is manufactured by a manufacturing method having a main body layer forming step, a surface layer forming step, a foaming step, and a finishing step. In the main layer forming step, a resin is supplied to the mold of the extrusion molding machine to form a main layer having a length and a width. In the surface layer forming step, a molten resin containing a foaming agent is supplied to the mold of the extruder at a predetermined pressure. This forms a melted surface layer on the upper surface of the main layer. In the foaming step, the predetermined pressure is released, and thereby the foaming agent contained in the molten resin is foamed. Then, bubbles are broken on the surface of the surface layer to form 30 to 50 irregular recesses per square millimeter. In the finishing step, the thickness of the molten surface layer is adjusted.

  In this case, although it is a synthetic resin, a rain gutter having no gloss specific to the synthetic resin can be obtained. Therefore, a rain gutter that does not look like a synthetic resin and has a calm appearance can be obtained.

  In the finishing step, it is preferable that the surface of the melted surface layer is rubbed along the length direction. Thereby, the thickness of the surface layer is adjusted. This also forms a plurality of linear protrusions running in the width direction and spaced apart in the length direction.

  In this case, although it is a synthetic resin, a rain gutter having no gloss unique to the synthetic resin can be obtained. Therefore, a rain gutter that does not look like a synthetic resin and has a more calm appearance can be obtained.

It is a perspective view of the rain gutter in the embodiment of the present invention. (A) is an enlarged cross-sectional view of a portion X in FIG. 1 when a metal plate is embedded in the main layer, and (b) is an enlarged cross-sectional view of the portion X in FIG. 1 when a metal plate is not embedded in the main layer. is there. It is a schematic perspective view which shows the extrusion molding apparatus for manufacturing the gutter of this invention. It is a principal part expanded sectional view same as the above. 2 is a photograph of the surface layer of the rain gutter of Example 1. Both (a) and (b) are photographs of the surface layer of the rain gutter of Example 2. (A) is the photograph of the surface of the rain gutter of Example 2, (b) is the graph which showed the level | step difference along the broken line in the surface of the photograph of (a).

  A rain gutter according to an embodiment of the present invention and a manufacturing method thereof will be described with reference to the accompanying drawings. FIG. 1 shows a perspective view of an embodiment of a rain gutter 1 of the present invention. As shown in FIG. 1, the gutter has a length and a width. The gutter 1 has a main layer 2 and a surface layer 3. The surface layer 3 is laminated on the whole or part of the outer surface of the main layer 2. The surface layer 3 is integrally formed with the main layer 2 by extrusion molding.

  In the main layer 2, there are a case where the metal plate 12 is embedded integrally in a portion between the thickness directions and a case where the metal plate 12 is not embedded. FIG. 2A shows an enlarged cross-sectional view of a portion X of FIG. 1 of a rain gutter 1 having a main layer 2 and a surface layer 3 in which a metal plate 12 is embedded. FIG. 2B shows an enlarged cross-sectional view of the X portion of FIG. 1 of the rain gutter in which the main layer 2 not provided with the metal plate 12 and the surface layer 3 are laminated on the outer surface thereof.

  When the metal plate 12 is embedded in the main layer 2, a steel plate is generally used as the metal plate 12. The metal plate 12 preferably has a thickness of 0.08 mm or more so that the steel plate 12 is not damaged even if the steel plate receives a tensile force when the gutter 1 is extruded. Moreover, in order to cut the rain gutter 1 with a cutting tool easily, the thickness of the metal plate 12 is preferably 0.2 mm or less. Therefore, the metal plate 12 embedded in the main layer 2 has a thickness of 0.08 mm to 0.2 mm.

  In any rain gutter 1 described above, the resin portion of the main layer 2 is made of the non-foamed resin composition 4. The surface layer 3 is laminated on the surface of the main layer 2. The surface layer 3 consists of the foamable resin composition 5 containing the synthetic resin which has a weather resistance. The surface of the surface layer 3 is provided with a plurality of irregular fine recesses 6 which are traces of bubbles of fine bubbles, whereby the surface of the surface layer 3 is rough. The recess 6 is spaced an irregular distance from the other recess 6. Each recess 6 has a depth of 50 μm or more. In addition, each recess 6 has an irregular opening area.

  Thus, as shown in FIG. 5, the rain gutter 1 of the present embodiment has a surface layer 3, which is the outer surface, formed of a foamable resin composition 5 containing a weather-resistant synthetic resin. Therefore, the gutter 1 has weather resistance. On the other hand, the surface of the surface layer 3 is a rough surface provided with a plurality of fine recesses 6 which are broken bubbles of fine bubbles. Each recess 6 is spaced apart from other recesses 6 at irregular intervals. Therefore, the rain gutter 1 of this embodiment does not have the gloss unique to the synthetic resin in spite of the synthetic resin. Therefore, the rain gutter 1 that does not look like a synthetic resin and has a calm appearance can be obtained.

  In addition, as shown in FIGS. 6A and 6B, the rain gutter 1 of the present embodiment has a plurality of fine recesses 6 and a plurality of linear shapes in which the outer surface layer 3 runs in the width direction. It is the rough surface provided with the convex part 60. The linear protrusions meander on the surface of the surface layer. Moreover, each linear convex part is spaced apart at irregular intervals of 200 to 700 μm from the convex part on the line located next to the rain gutter in the length direction. Therefore, the rain gutter 1 of this embodiment does not have the gloss unique to the synthetic resin in spite of the synthetic resin. Therefore, the rain gutter 1 that does not look like a synthetic resin and has a calm appearance can be obtained.

  As the non-foamed resin composition 4 forming the main layer 2, for example, a vinyl chloride resin mixed with a filler, a stabilizer, a lubricant, a pigment and the like is used. As the filler, for example, calcium carbonate can be used. As the stabilizer, calcium stearate or the like can be used. As the lubricant, a fatty acid ester or the like can be used.

As the foamable resin composition 5 containing a weather-resistant synthetic resin, an acrylic resin mixed with rubber, an ultraviolet absorber, a light stabilizer, a foaming agent, or the like is used. In the foamable resin composition 5, it is preferable to use an acrylic resin having a glass transition point of 100 ° C. or higher. In the foamable resin composition 5, it is preferable to use an acrylic resin having a melting point of 230 ° C. or lower. The foamable resin composition 5 may further contain a colorant, a lubricant, and the like. As the pigment, a bengar (bengara: Fe ₂ O ₃ ) or the like can be used.

  Moreover, as a ultraviolet absorber, a benzotriazole type ultraviolet absorber, a benzophenone type ultraviolet absorber, a salicylate type ultraviolet absorber, and a triazine type ultraviolet absorber can be used.

  Examples of benzotriazole-based ultraviolet absorbers include 2- (2′-hydroxy-5′-methylphenyl) benzotriazole and 2- (2′-hydroxy-5′-tert-butyl) as benzotriazole-based ultraviolet absorbers. Phenyl) benzotriazole, 2- (2′-hydroxy-3 ′, 5′-di-tert-butylphenyl) benzotriazole, 2- (2-hydroxy-5-tert-octylphenyl) benzotriazole, 2- (2 -Hydroxy-5-tert-octylphenyl) benzotriazole, 2- (2-hydroxy-3,5-di-tert-octylphenyl) benzotriazole, 2- [2'-hydroxy-3 ', 5'-bis ( α, α'-dimethylbenzyl) phenyl] benzotriazole), methyl-3- [3- tert-butyl-5- (2H-benzotriazol-2-yl) -4-hydroxyphenyl] propionate and polyethylene glycol (molecular weight 300) (“TINUVIN 1130” manufactured by Ciba Specialty Chemicals), isooctyl -3- [3- (2H-benzotriazol-2-yl) -5-tert-butyl-4-hydroxyphenyl] propionate ("TINUVIN 384" manufactured by Ciba Specialty Chemicals), 2- (3-dodecyl) -5-methyl-2-hydroxyphenyl) benzotriazole ("TINUVIN571" manufactured by Ciba Specialty Chemicals Co., Ltd.), 2- (2'-hydroxy-3'-tert-butyl-5'-methylphenyl) -5 -Chlorobenzotriazole, 2- 2'-hydroxy-3 ', 5'-di-tert-amylphenyl) benzotriazole, 2- (2'-hydroxy-4'-octoxyphenyl) benzotriazole, 2- [2'-hydroxy-3'- (3 ″, 4 ″, 5 ″, 6 ″ -tetrahydrophthalimidomethyl) -5′-methylphenyl] benzotriazole, 2,2-methylenebis [4- (1,1,3,3-tetramethyl Butyl) -6- (2H-benzotriazol-2-yl) phenol], 2- (2H-benzotriazol-2-yl) -4,6-bis (1-methyl-1-phenylethyl) phenol (Ciba Specialty chemicals "TINUVIN900") etc. can be illustrated.

  Examples of the benzophenone ultraviolet absorber include 2,4-dihydroxybenzophenone, 2-hydroxy-4-methoxybenzophenone, 2-hydroxy-4-methoxybenzophenone-5-sulfonic acid, 2-hydroxy-4-n-octoxybenzophenone, 2-hydroxy-4-n-dodecyloxybenzophenone, 2-hydroxy-4-benzyloxybenzophenone, bis (5-benzoyl-4-hydroxy-2-methoxyphenyl) methane, 2,2'-dihydroxy-4-methoxybenzophenone 2,2′-dihydroxy-4,4′dimethoxybenzophenone, 2,2′-dihydroxy-4,4′-tetrahydroxybenzophenone, 4-dodecyloxy-2-hydroxybenzophenone, 2-hydroxy-4-methoxy-2 '-Cal Carboxymethyl benzophenone, and the like can be exemplified 2-hydroxy-4-stearyloxy benzophenone.

  Examples of salicylate ultraviolet absorbers include pt-butylphenyl salicylate and 2,4-di-t-butylphenyl-3,5-di-t-butyl-4-hydroxybenzoate.

  Examples of the triazine-based ultraviolet absorber include hydroxyphenyl triazine-based “TINUVIN400”, “TINUVIN411L”, “TINUVIN1577FF” manufactured by Ciba Specialty Chemicals Co., Ltd., and “CYASORB UV- 1164 "and the like.

  In addition, a hindered amine light stabilizer can be used as the light stabilizer. As the high molecular weight type hindered amine light stabilizer, poly ((6- (1,1,3,3-tetramethylbutyl) amino-1,3,5-triazine-2,4-diyl) ((2, 2,6,6-tetramethyl-4-piperidyl) imino) hexamethylene ((2,2,6,6-tetramethyl-4-piperidyl) imino)), N, N ′, N ″, N ″ '-Tetrakis- (4,6-bis- (butyl- (N-methyl-2,2,6,6-tetramethylpiperidin-4-yl) amino) -triazin-2-yl) -4,7-diazadecane -1,10-diamine and a mixture of (dimethyl succinate and 4-hydroxy-2,2,6,6-tetramethyl-1-piperidineethanol), dibutylamine, 1,3,5-triazine, N, N'-bis (2,2,6,6 Examples thereof include a polycondensate of tetramethyl-4-piperidyl-1,6-hexamethylenediamine and N- (2,2,6,6-tetramethyler-4-piperidyl) butylamine, etc. Low molecular weight type hindered amine Examples of the light stabilizer include bis (2,2,6,6-tetramethyl-4-piperidyl) succinate, bis (2,2,6,6-tetramethylpiperidyl) sebacate, bis (1,2,2, 6,6-pentamethyl-4-piperidyl) 2- (3,5-di-tert-butyl-4-hydroxybenzyl) -2-butylmalonate, 1- [2- [3- (3,5-di- tert-butyl-4-hydroxyphenyl) propynyloxy] ethyl] -4- [3- (3,5-di-tert-butyl-4-hydroxyphenyl) propynyloxy -2,2,6,6-tetramethylpiperidine, bis (1,2,2,6,6-pentamethyl-4-piperidyl) sebacate and methyl-1,2,2,6,6-pentamethyl-4-piperidyl -Mixture of sebacate ("TINUVIN292" manufactured by Ciba Specialty Chemicals Co., Ltd.), bis (1-octoxy-2,2,6,6-tetramethyl-4-piperidyl) sebacate, Ciba Specialty Chemicals Co., Ltd. Examples thereof include “TINUVIN123” and the like.

  As the foaming agent, for example, azodicarbonamide (ADCA), sodium bicarbonate, or the like is used. Of course, these chemical foaming agents can be blended in the foamable resin composition 5 to form the surface layer. However, it is also possible to use a physical foaming agent such as air or carbon dioxide. When a physical foaming agent is used as the foaming agent, the physical foaming agent is injected into the melted resin, followed by foam molding.

  The main layer 2 preferably has a thickness of about 0.88 mm to 3.2 mm. Here, in the case of the main layer 2 in which the metal plate 12 shown in FIG. 1 is embedded, the thickness of the resin composition 4 located on one side surface of the metal plate 12 and the resin composition 4 located on the other side surface of the metal plate 12. The sum total of the thickness is preferably about 0.8 mm to 3.0 mm.

  The thickness of the surface layer 3 is preferably 0.15 mm to 0.3 mm. When the surface layer 3 is formed of a weather resistant resin such as an acrylic resin, the weather resistance is usually ensured by setting the thickness of the surface layer 3 to 0.1 mm to 0.2 mm. On the other hand, in order to ensure weather resistance, a thickness of 0.2 mm or more is not necessary. In addition, when a surface layer having a thickness of 0.2 mm or more is formed, thermal shrinkage increases, which causes warpage. Therefore, it is not preferable that the surface layer has a thickness of 0.2 mm or more.

Therefore, in the rain gutter 1 of the present invention, the thickness of the surface layer 3 having weather resistance is set to 0.15 mm to 0.3 mm as described above. The surface layer 3 includes bubbles inside, and a fine recess 6 formed by the bubbles breaking is formed on the surface. Therefore, the distance between the bottom of the recess 6 and the back surface of the surface layer can be about 0.1 mm to 0.2 mm. On the other hand, the surface layer 3 has 30 to 50 concave portions 6 per square millimeter formed on the surface thereof. The recess 6 has an opening area of 1000 .mu.m ² or more 30000Myuemu ² or less. And the sum of the opening area of the recessed part 6 formed per square millimeter becomes 1 square millimeter or less. Thereby, as shown in FIG. 5, the rain gutter 1 can have sufficient weather resistance while eliminating the gloss peculiar to the synthetic resin due to the fine recesses 6.

  Moreover, the rain gutter 1 of the present invention has a plurality of linear convex portions 60 that run in the width direction of the gutter 1 as shown in FIGS. 6A and 6B in addition to the fine concave portions 6. Is formed. Therefore, the linear convex portion has a length along the width direction of the gutter. The convex portions 60 are spaced apart from other convex portions at irregular intervals in the length direction of the rain gutter 1. And the length of this linear convex part is 100 micrometers-2000 micrometers. And the level | step difference defined between the bottom of the recessed part 6 and the vertex of the convex part 60 has a height of 75 micrometers-200 micrometers. Thereby, the rain gutter 1 can have sufficient weather resistance while eliminating the gloss peculiar to the synthetic resin by the plurality of fine concave portions 6 and the plurality of linear convex portions 60. Moreover, it is preferable that the level | step difference defined between the bottom of the recessed part 6 and the vertex of the convex part 60 has a height of 100 micrometers-175 micrometers. In this case, the occurrence of warpage due to heat shrinkage can be further suppressed.

  FIG. 3 shows a perspective view of an embodiment of an extrusion apparatus 7 for producing the gutter 1 of the present invention. FIG. 4 shows an enlarged cross-sectional view of the main part of the extrusion molding device 7. The extrusion molding apparatus 7 shown in FIGS. 3 and 4 is an example of an apparatus for manufacturing the rain gutter 1 in which the metal plate 12 shown in FIG. 2A is embedded.

  As shown in FIG. 3, the extrusion molding device 7 includes a metal plate processing device 13, a molding die 8, a main layer extruder 9 connected to the molding die 8, a surface layer extruder 10, a sizing device 14, a take-up A device 15 is provided.

  The molding die 8 includes a metal plate inlet 17, an opening 11, a first inlet 109, a second inlet 110, and a cavity 16. An opening 11 is formed at the front end of the molding die 8, and a metal plate entrance 17 is formed at the rear end. The opening 11 and the metal plate entrance 17 communicate with the outside of the molding die and the cavity 16, respectively. The metal plate inlet 17 is provided for feeding the metal plate 12 from the outside of the molding die 8 to the cavity 16. The first injection port 109 is formed in the molding die 8 so as to be positioned between the metal hole entrance and the opening 11. The first injection port 109 is provided to send the resin sent from the main layer extruder 9 to the cavity 16. The second inlet 110 is provided to send the resin sent from the surface layer extruder 10 to the cavity 16.

  A metal plate 12 such as a steel plate is first sent to a metal plate processing apparatus 13. The metal plate processing device 13 is processed so as to have substantially the same cross-sectional shape as that of the gutter 1. Further, the processed metal plate 12 has a length and a width. The metal plate 12 processed so as to have a predetermined cross-sectional shape is sent from the metal plate processing apparatus 13 to the molding die 8 at a predetermined speed. As a result, the metal plate 12 is introduced into the molding die 8 from the metal plate inlet 17 at one end of the cavity 16 provided in the molding die 8.

  The main layer extruder 9 is connected to the molding die 8. The non-foamed resin composition 4 is supplied from the main layer extruder 9 to the cavity 16 of the molding die 8. Thereby, the outer surface of the metal plate 12 in the cavity 16 is covered with the non-foamed resin composition 4 over the length direction and the width direction of the metal plate 12. In this way, the main body layer is formed. That is, this process is a main layer forming process.

  The surface layer extruder 10 is connected to the second inlet 110 of the molding die 8. That is, the surface layer extruder 10 is disposed between the main layer extruder 9 and the opening 11. Therefore, the position of the non-foamed resin composition 4 for forming the main layer from the main layer extruder 9 is shifted to the opening 11 side of the molding die 8 from the position at which the cavity 16 of the molding die 8 is supplied. The foamable resin composition 5 is supplied to the cavity 16 of the molding die 8 from the surface layer extruder 10 connected to the second inlet 110 at a predetermined pressure. As a result, a molten surface layer 3 is formed on the surface of the main layer 2 over the length direction and the width direction of the main layer. That is, this process is a surface layer forming process.

  After the surface layer 3 is integrally laminated on the outer surface of the main layer 2 in the molding die 8, the main layer 2 and the molten surface layer 3 are extruded from the opening 11 of the molding die 8. This process is a foaming process.

  The main layer 2 and the melted surface layer 3 are formed to have a desired thickness by the sizing device 14 while maintaining a temperature of about 130 ° C., for example. In this way, the gutter 1 is manufactured. This process is a finishing process.

  Here, the molding die 8 is formed so that the thickness t of the surface layer 3 formed by injecting the foamable resin composition 5 into the outer surface of the main layer 2 in the molding die 8 is 0.05 to 0.1 mm. Designed. The gas dispersed in the surface layer extruder 10 is melted and dispersed in the resin of the foamable resin composition 5 because a pressure higher than atmospheric pressure is applied in the molding die 8. . That is, the resin of the foamable resin composition 5 is melt-dispersed in the molding die 8 at a pressure higher than atmospheric pressure so that the foaming agent contained in the melted surface layer does not foam.

  That is, the space formed inside the molding die 8 has three heights. The metal plate path A from the metal plate entrance 17 to the cavity 16 has a thickness M1. This thickness M1 is set so that only the metal plate 12 can pass through. The cavity 16 includes a main layer forming region B between the first inlet 109 and the second inlet 110 and a surface layer forming region C between the second inlet 110 and the opening 11. The main layer forming region B has a thickness M2. This thickness M2 is set to a thickness equal to the thickness of the main layer 2 formed by coating the outer surface of the metal plate 12 with the foamable resin composition 4. The surface layer forming region C has a thickness M3. The thickness M3 is set as shown in the following relational expression. M3 = M2 + (0.05 mm to 0.1 mm) In addition to this, for the surface layer for extruding the foamable resin composition 5, the cylinder temperature and the rotational speed in the surface layer extruder 10 for extruding the non-foamed resin composition 4 The cylinder temperature, the number of revolutions, the temperature of the molding die 8, the extrusion speed from the molding die 8 and the like in the extruder 10 are adjusted as appropriate.

  Thus, the thickness of the cavity 16 is set so that the thickness of the surface layer 3 formed by injecting the foamable resin composition 5 onto the surface of the main layer 2 in the molding die 8 is 0.05 mm to 0.1 mm. Is set. In addition, the foaming agent is adjusted so that the foaming agent is melt-dispersed in the resin of the foamable resin composition 5 inside the mold 8.

The surface layer 3 is regulated by the cavity 16 so that the thickness thereof is 0.05 mm to 0.1 mm. Furthermore, the surface layer 3 is laminated on the outer surface of the main layer 2 in a state where the foamable resin composition 5 is melted. The surface layer 3 is extruded from the opening 11 together with the main layer 2. When the surface layer is extruded from the molding die 8, it is exposed to the outside air that is atmospheric pressure. When the surface layer 3 is exposed to the outside air at atmospheric pressure, the gas that has been melted and dispersed in the resin in the molten surface layer is foamed. The surface layer 3 expands when the gas is foamed. In this way, a surface layer made of foamed resin is formed. Further, when the gas is foamed, irregularities are formed on the surface of the surface layer 3. And when gas bubbles, bubbles break up on the surface of the surface layer. Due to this bubble breakage, a plurality of fine recesses 6 which are the bubble breakage marks of the fine bubbles are formed on the surface of the surface layer 3. Each recess 6 is spaced apart from other recesses at irregular intervals. Each recess 6 has a depth of 50 μm or more. The surface layer 3 has 30 to 50 recesses per square millimeter. The recess 6 has an opening area of 1000 .mu.m ² or more 30000Myuemu ² or less. The total opening area per square millimeter is 1 square millimeter or less. Thus, the surface of the surface layer 3 is formed as a rough surface.

  Since foaming in the surface layer 3 is not uniform, the thickness of the surface layer 3 varies depending on the location of the surface layer 3. Therefore, the thickness of the surface layer 3 is adjusted to 0.15 mm to 0.3 mm by passing the main layer 2 and the molten surface layer 3 through the sizing device 14. Thus, the gutter 1 of the present invention is manufactured.

  The sizing device 14 has an opening 141 for allowing the main body layer 2 and the molten surface layer 3 to pass therethrough. The sizing device 14 has a lower surface 142 that is rubbed against the surface layer 3 so that the surface layer 3 has a predetermined thickness. The lower surface 142 is fixed so as not to move. The main layer 2 and the molten surface layer 3 formed on the metal plate 12 are sent to the sizing device 14 at a predetermined speed. The main layer 2 and the surface layer 3 in the molten state are introduced into the sizing device 14 from the opening 141 along the length direction thereof. The main layer 2 and the surface layer 3 pass through the inside of the sizing device 14 while the surface of the molten surface layer 3 is in contact with the lower surface of the sizing device 14. In this way, the surface layer 3 is rubbed against the lower surface of the sizing device 14 at a predetermined speed along its length direction. The speed at which the surface of the surface layer 3 is rubbed against the lower surface 14 is 1 to 15 m / min. The speed at which the surface of the surface layer 3 is rubbed against the lower surface 14 is preferably 3 to 8 m / min. By rubbing the surface layer 3 on the lower surface of the sizing device 14 at a predetermined speed, the surface layer 3 includes a plurality of irregular fine recesses 6 that are broken bubbles of fine bubbles as shown in FIG. 5 and has a thickness of 0.15 mm. A surface layer 3 of ˜0.3 mm is obtained. Moreover, the surface layer 3 is rubbed against the lower surface of the sizing device 14 at a high speed by increasing the conveying speed of the metal plate 12 sent from the metal plate processing apparatus 13 to the molding die 8. As a result, a plurality of irregular fine recesses 6 that are broken bubbles of fine bubbles as shown in FIGS. 6A and 6B and a plurality of protrusions 60 that run in a plurality of width directions. And a surface layer 3 having a thickness of 0.15 mm to 0.3 mm is obtained. And each convex part 60 is winding, and has run the surface of the surface layer in the width direction.

  Such a linear convex part is considered to occur for the following reason. First, a protruding rough edge is formed around the recess due to bubble breaking. This rough edge is rubbed against the lower surface 142 of the sizing device. The plurality of rough edges are gathered together by being rubbed against the lower surface 142, and as a result, linear protrusions are formed. And the length of a linear convex part turns into 100 micrometers-2000 micrometers.

  In addition, although shown as the rain gutter 1 in the said embodiment, various gutter parts, such as a cylindrical gutter or a gutter joint, may be sufficient.

Next, specific examples of manufacturing the rain gutter 1 made of the multilayer extruded product of the present invention will be described. In this example and comparative example, calcium carbonate (CaCO ₃ ) was used as a filler. Calcium stearate was used as a stabilizer. Fatty acid esters were used as lubricants. A petal (Bengala: Fe ₂ O ₃ ) was used as a pigment. TINUVIN234 manufactured by Ciba Specialty Chemicals Co., Ltd. was used as a benzotriazole ultraviolet absorber. CHIMASSORB 944FDL manufactured by Ciba Specialty Chemicals Co., Ltd. was used as a hindered amine light stabilizer.
Example 1
As the metal plate 12, a steel plate having a thickness of 0.17 mm was used. The non-foamed resin composition 4 was prepared by mixing 100 parts by mass of a vinyl chloride resin, 10 parts by mass of a filler, 3 parts by mass of a stabilizer, 1 part by mass of a lubricant, and 1 part by mass of a pigment. As foamable resin composition 5, 70 parts by mass of acrylic resin, 30 parts by mass of acrylic silicon rubber, 0.5 parts by mass of benzotriazole-based UV absorber, 0.1 part by mass of light stabilizer, azodicarbonamide Was prepared by mixing 0.1 part by mass.

  A gutter 1 was produced by an extrusion molding device 7 using the metal plate 12, the non-foamed resin composition 4, and the foamable resin composition 5. Here, the speed of the metal plate 12 sent out from the metal plate processing apparatus 13 was set to 0.9 m / min. Accordingly, the extrusion molding apparatus 7 was set so that the main layer, the surface layer, and the metal plate 12 were sent out from the opening 11 at 0.9 m / min. That is, the surface of the surface layer was rubbed against the lower surface 142 at 0.9 m / min. Moreover, the extrusion molding apparatus 7 was set to 190 degreeC, and the foamable resin composition 5 was shape | molded.

FIG. 5 is a photograph showing the surface of the gutter of the present example. As shown in FIG. 5, the gutter 1 was provided with a surface layer having a surface on which a plurality of irregular fine recesses 6, which are broken bubbles of fine bubbles, were formed. The recess 6 had a depth of 50 μm or more. And as for the surface layer, 30-50 recessed part 6 was formed per square millimeter. The fine recesses 6, the opening area was 30000Myuemu ² from 1000 .mu.m ^2. The sum of the opening areas per square millimeter was 1 square millimeter or less. And this gutter 1 did not have the luster peculiar to a synthetic resin, and it became the external appearance which did not seem to be made of synthetic resin at first glance. Moreover, since the surface layer consists of the acrylic resin which has a weather resistance, the rain gutter 1 of a present Example had the outstanding weather resistance.
(Example 2)
Using the metal plate 12, the non-foamed resin composition 4, and the foamable resin composition 5 of Example 1, a gutter 1 was produced by an extrusion molding device 7. Here, the speed of the metal plate 12 sent out from the metal plate processing apparatus 13 was 1 m / min. Accordingly, the extrusion molding apparatus 7 was set so that the main layer, the surface layer, and the metal plate 12 were sent out from the opening 11 at 1 m / min. That is, the surface of the surface layer was rubbed against the lower surface 142 at 1 m / min. Moreover, the extrusion molding apparatus 7 was set to 190 degreeC, and the foamable resin composition 5 was shape | molded.
(Example 3)
Using the metal plate 12, the non-foamed resin composition 4, and the foamable resin composition 5 of Example 1, a gutter 1 was produced by an extrusion molding device 7. Here, the speed of the metal plate 12 sent out from the metal plate processing apparatus 13 was 3 m / min. Accordingly, the extrusion molding apparatus 7 was set so that the main layer, the surface layer, and the metal plate 12 were sent out from the opening 11 at 3 m / min. That is, the surface of the surface layer was rubbed against the lower surface 142 at 3 m / min. Moreover, the extrusion molding apparatus 7 was set to 190 degreeC, and the foamable resin composition 5 was shape | molded.
Example 4
Using the metal plate 12, the non-foamed resin composition 4, and the foamable resin composition 5 of Example 1, a gutter 1 was produced by an extrusion molding device 7. Here, the speed of the metal plate 12 sent out from the metal plate processing apparatus 13 was 5 m / min. Along with this, the extrusion molding apparatus 7 was set so that the main layer, the surface layer, and the metal plate 12 were sent out from the opening 11 at 5 m / min. That is, the surface of the surface layer was rubbed against the lower surface 142 at 5 m / min. Moreover, the extrusion molding apparatus 7 was set to 190 degreeC, and the foamable resin composition 5 was shape | molded.
(Example 5)
The gutter 1 was manufactured by the extrusion molding apparatus 7 using the non-foamed resin composition 4 and the foamable resin composition 5 without using the metal plate 12 of Example 1. Here, the extrusion molding apparatus 7 was set so that the main layer and the surface layer were sent out from the opening 11 at 8 m / min. That is, the surface of the surface layer was rubbed against the lower surface 142 at 8 m / min. Moreover, the extrusion molding apparatus 7 was set to 190 degreeC, and the foamable resin composition 5 was shape | molded.
(Example 6)
Using the metal plate 12, the non-foamed resin composition 4, and the foamable resin composition 5 of Example 1, a gutter 1 was produced by an extrusion molding device 7. Here, the speed of the metal plate 12 sent out from the metal plate processing apparatus 13 was set to 15 m / min. Accordingly, the extrusion molding apparatus 7 was set so that the main layer, the surface layer, and the metal plate 12 were sent out from the opening 11 at 15 m / min. That is, the surface of the surface layer was rubbed against the lower surface 142 at 15 m / min. Moreover, the extrusion molding apparatus 7 was set to 190 degreeC, and the foamable resin composition 5 was shape | molded.
(Comparative Example 1)
Using the metal plate 12, the non-foamed resin composition 4, and the foamable resin composition 5 of Example 1, a gutter 1 was produced by an extrusion molding device 7. Here, the speed of the metal plate 12 sent out from the metal plate processing apparatus 13 was 16 m / min. Accordingly, the extrusion molding device 7 was set so that the main layer, the surface layer, and the metal plate 12 were sent out from the opening 11 at 16 m / min. That is, the surface of the surface layer was rubbed against the lower surface 142 at 16 m / min. Moreover, the extrusion molding apparatus 7 was set to 190 degreeC, and the foamable resin composition 5 was shape | molded.

  Table 1 is a table showing the conditions of Examples 1 to 6 and Comparative Example 1. Here, in the column of “Generation of fine concave portions” in Table 1, “◯” means that fine concave portions of 50 μm or more were formed. In the column “Generation of convex portions on line”, “◯” means that a step having a height of 75 μm to 200 μm was formed. Further, in the column “Generation of convex portions on line”, “◎” means that a step having a height of 100 μm to 175 μm was formed.

図５は、実施例１の雨樋の表面を示す写真である。図５に示すように、雨樋１の表層の表面には、微細気泡の破泡跡である不規則な微細凹部６が複数形成されていた。表層３は、１平方ミリメートル当たり３０〜５０個の凹部が形成されていた。この微細な凹部６は、その開口面積が１０００μｍ²から３００００μｍ²であった。１平方ミリメートル当たりの総開口面積は、１平方ミリメートル以下であった。そして、この雨樋１は、合成樹脂特有の光沢が無く、これにより一見して合成樹脂でできたように見えないような外観となった。また、表層が耐候性を有するアクリル樹脂からなるため、実施例１の雨樋１は、優れた耐候性を有した。

FIG. 5 is a photograph showing the surface of the rain gutter of Example 1. As shown in FIG. 5, a plurality of irregular fine recesses 6, which are broken bubbles of fine bubbles, were formed on the surface of the surface of the rain gutter 1. The surface layer 3 was formed with 30 to 50 recesses per square millimeter. The fine recesses 6, the opening area was 30000Myuemu ² from 1000 .mu.m ^2. The total open area per square millimeter was 1 square millimeter or less. And this gutter 1 did not have the luster peculiar to a synthetic resin, and it became the external appearance which did not seem to be made of synthetic resin at first glance. Moreover, since the surface layer consists of the acrylic resin which has a weather resistance, the gutter 1 of Example 1 had the outstanding weather resistance.

FIG. 6 is a photograph showing the surface of the rain gutter of Example 2. As shown in FIG. 6, the surface of the surface of the rain gutter 1 is formed with a plurality of irregular fine recesses 6 which are traces of bubbles of fine bubbles, and a plurality of linear shapes along the width direction. The convex part 60 of was formed. The length of this linear convex part was 100 micrometers-2000 micrometers. The surface layer 3 was formed with 30 to 50 recesses per square millimeter. The fine recesses 6, the opening area was 30000Myuemu ² from 1000 .mu.m ^2. The sum of the opening areas per square millimeter on the surface of the surface layer was 1 square millimeter or less. And this gutter 1 did not have the luster peculiar to a synthetic resin, and it became the external appearance which did not seem to be made of synthetic resin at first glance. Moreover, since the surface layer consists of the acrylic resin which has a weather resistance, the gutter 1 of Example 1 had the outstanding weather resistance. Also in Example 6, a similar surface layer surface was obtained.

  FIG. 7A shows a photograph showing the surface of the rain gutter of Example 2. FIG.7 (b) is the graph which showed the height of the surface along the broken line of the surface layer of Fig.7 (a). As can be seen from the graph, the surface layer 3 has a step defined by the distance between the bottom of the recess 6 and the apex of the linear protrusion. The height of the step was 75 μm to 200 μm.

Also in Examples 3 to 6, the surface of the surface of the rain gutter 1 has a plurality of irregular fine recesses 6 that are traces of bubbles of fine bubbles, and a plurality of lines along the width direction. A convex portion 60 was formed. The length of this linear convex part was 100 micrometers-2000 micrometers. This linear convex part was 200-700 micrometers away from the other linear convex part. The surface layer 3 was formed with 30 to 50 recesses per square millimeter. Minute recessed portions 6, the opening area was 30000Myuemu ² from 1000 .mu.m ^2. And this gutter 1 did not have the luster peculiar to a synthetic resin, and it became the external appearance which did not seem to be made of synthetic resin at first glance. Moreover, since the surface layer consists of the acrylic resin which has a weather resistance, the gutter 1 of Example 1 had the outstanding weather resistance.

  Also in Examples 3 to 5, the surface layer 3 was formed with a step defined by the distance between the bottom of the recess 6 and the apex of the linear protrusion. The concave portion had a depth of 50 μm or more. The height of the step was 100 μm to 175 μm at the maximum.

On the other hand, in Comparative Example 1, no fine recess was formed on the surface of the surface of the gutter 1. Further, no linear protrusion was formed on the surface of the surface of the gutter 1. The reason for this is considered that the rain gutter 1 is introduced into the sizing device at a high speed, and the rough edges gathered cover the recess 6.
(Example 7)
As the metal plate 12, a steel plate having a thickness of 0.17 mm was used. The non-foamed resin composition 4 was prepared by mixing 100 parts by mass of a vinyl chloride resin, 10 parts by mass of a filler, 3 parts by mass of a stabilizer, 1 part by mass of a lubricant, and 1 part by mass of a pigment. As the foamable resin composition 5, 70 parts by mass of an acrylic resin, 30 parts by mass of acrylic silicon rubber, 0.5 parts by mass of a benzotriazole-based UV absorber, 0.1 parts by mass of a light stabilizer, and a foaming agent A baking soda was prepared by mixing 0.5 parts by mass.

A gutter 1 was produced by an extrusion molding device 7 using the metal plate 12, the non-foamed resin composition 4, and the foamable resin composition 5. Here, the speed of the metal plate 12 sent out from the metal plate processing apparatus 13 was 3 m / min. Accordingly, the extrusion molding apparatus 7 was set so that the main layer, the surface layer, and the metal plate 12 were sent out from the opening 11 at 3 m / min. That is, the surface of the surface layer was rubbed against the lower surface 142 at 3 m / min. Moreover, the extrusion molding apparatus 7 was set to 200 degreeC, and the foamable resin composition 5 was shape | molded.
(Example 8)
The non-foamed resin composition 4 was prepared by mixing 100 parts by mass of a vinyl chloride resin, 10 parts by mass of a filler, 3 parts by mass of a stabilizer, 1 part by mass of a lubricant, and 1 part by mass of a pigment. As the foamable resin composition 5, 70 parts by mass of an acrylic resin, 30 parts by mass of acrylic silicon rubber, 0.5 parts by mass of a benzotriazole-based UV absorber, 0.1 parts by mass of a light stabilizer, and a foaming agent A baking soda was prepared by mixing 0.5 parts by mass.

  Using the non-foamed resin composition 4 and the foamable resin composition 5, a gutter 1 was produced by an extrusion molding device 7. Here, the speed of the metal plate 12 sent out from the metal plate processing apparatus 13 was 8 m / min. Accordingly, the extrusion molding device 7 was set so that the main layer, the surface layer, and the metal plate 12 were sent out from the opening 11 at 8 m / min. That is, the surface of the surface layer was rubbed against the lower surface 142 at 8 m / min. Moreover, the extrusion molding apparatus 7 was set to 200 degreeC, and the foamable resin composition 5 was shape | molded.

  Table 2 is a table showing the conditions of Example 7 and Example 8.

実施例７及び実施例８においても、雨樋１の表層の表面には、微細気泡の破泡跡である不規則な微細な凹部６が複数形成されており、且つ、幅方向に沿った複数の線状の凸部６０が形成された。この線状の凸部の長さは、１００μｍ〜２０００μｍであった。この線状の凸部は、他の線状の凸部から、２００〜７００μｍ離間していた。表層３は、１平方ミリメートル当たり３０〜５０個の凹部が形成されていた。微細な凹部６は、その開口面積が１０００μｍ²から３００００μｍ²であった。１平方ミリメートル当たりの開口面積の和は、１平方ミリメートル以下であった。凹部は、５０μｍ以上の深さを有していた。そして、表層３は、凹部６の底と線状の凸部の頂点との間の距離で定義される段差が形成されていた。この段差は、最大で１００μｍ〜１７５μｍであった。この雨樋１は、合成樹脂特有の光沢が無く、これにより一見して合成樹脂でできたように見えないような外観となった。また、表層が耐候性を有するアクリル樹脂からなるため、実施例１の雨樋１は、優れた耐候性を有した。

Also in Example 7 and Example 8, the surface of the gutter 1 is formed with a plurality of irregular fine recesses 6 that are broken bubbles of fine bubbles, and a plurality along the width direction. The linear convex part 60 was formed. The length of this linear convex part was 100 micrometers-2000 micrometers. This linear convex part was 200-700 micrometers away from the other linear convex part. The surface layer 3 was formed with 30 to 50 recesses per square millimeter. Minute recessed portions 6, the opening area was 30000Myuemu ² from 1000 .mu.m ^2. The sum of the opening areas per square millimeter was 1 square millimeter or less. The concave portion had a depth of 50 μm or more. And the surface layer 3 was formed with the level | step difference defined by the distance between the bottom of the recessed part 6, and the vertex of a linear convex part. This step was 100 μm to 175 μm at the maximum. This rain gutter 1 had no gloss peculiar to a synthetic resin, and thus, at first glance, it looked like it was not made of a synthetic resin. Moreover, since the surface layer consists of the acrylic resin which has a weather resistance, the gutter 1 of Example 1 had the outstanding weather resistance.

Claims (3)

A rain gutter that Ru and a main layer and the surface layer,
The main layer is made of non-foamed resin,
The surface layer is laminated on the surface of the main layer, and is made of a foam resin.
The surface layer has a surface concave portion is formed,
The recess is formed when bubbles in the foamed resin are broken, whereby the recess is spaced apart from other recesses at irregular intervals ,
The gutter has a length and a width;
A plurality of linear protrusions running in the width direction are further formed on the surface of the surface layer, and the plurality of linear protrusions are spaced apart at irregular intervals in the length direction of the surface layer. And
The linear protrusions are formed by gathering together the edges formed around the recesses by rubbing bubbles along the length direction of the gutters on the surface of the melted surface layer. A rain gutter characterized by that. (A) supplying a resin to a mold of an extruder and forming a main layer having a length and a width;
(B) After the main layer forming step, a molten resin containing a foaming agent is supplied to the mold of the extrusion molding machine at a predetermined pressure, thereby forming a molten surface layer on the upper surface of the main layer. Forming process;
(C) After the surface layer forming step, the predetermined pressure is released, whereby the foaming agent contained in the molten resin is foamed, bubbles are broken on the surface of the surface layer, and are not discharged from other recesses. A foaming process for forming recesses spaced at regular intervals;
(D) a finishing step of adjusting the thickness of the molten surface layer;
With
In the (c) foaming step, an edge located around the recess is formed on the surface of the surface layer,
(D) in the finishing step, the edges are rubbed and gathered along the length direction of the surface layer at a predetermined speed, thereby adjusting the thickness of the surface layer, and thereby running in the width direction, A method of manufacturing a rain gutter comprising forming a plurality of linear convex portions spaced apart at irregular intervals in the length direction. The method for manufacturing a rain gutter according to claim 2, wherein the predetermined speed is 3 to 8 m / min.

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