JPS5852494B2 - Composite structural material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a composite structural material mainly made of fiber-reinforced synthetic resin foam and used for building materials and the like.

Recently, fiber-reinforced synthetic resin foams have been provided as structural materials for building materials, etc., but these have low surface strength and are easily scratched, and their compressive strength is low, causing localized pressure to build up. It has the disadvantage that it is easy to create a dent in that part.

Sand inch structural materials are also known, which have a synthetic resin foam core and an FRP board as a surface material. Although this structural material can improve the surface strength, it increases the compressive strength and causes local damage. In order to prevent dents from occurring due to excessive pressure, it is necessary to use a surface material with a certain thickness, which results in high costs and poor economic efficiency. It is necessary to increase the thickness or use a surface material with a certain thickness.

In view of the above-mentioned drawbacks of conventional structural materials using synthetic resin foam, the present invention has excellent surface strength and compressive strength, excellent bending rigidity and bending strength, and can be manufactured at low cost, making it economical. This was achieved as a result of various studies in an effort to provide an excellent structural material. A plurality of sheet-like fiber layers are provided, and aggregate and synthetic resin foam are filled between the sheet-like fiber layers, and the synthetic resin foam molded product, the sheet-like fiber layer, the aggregate and The synthetic resin foam exists in a composite structural material characterized in that it is integrated by mutually adhering to each other.

The synthetic resin foam molded product used in the present invention is reinforced by embedding a large number of fibers, but the types of resins that make up this foam molded product include conventionally used thermosetting resins and Thermoplastic resins may be used as appropriate.

In the present invention, for reasons such as ease of manufacture and heat resistance required as a structural material, the foamed molded article is manufactured using heat obtained by foaming and curing a foamable thermosetting resin liquid. It is preferable to use a curable resin foam, and specific examples of synthetic resins that are preferably used include polyurethane resins, unsaturated polyester resins, phenol resins, urea resins, and the like.

Next, the types of fibers to be embedded in the synthetic resin foam molding include glass fibers, carbon fibers, metal fibers, natural fibers, synthetic fibers, rayon, etc. Glass fibers are particularly preferred.

Although short fibers can be used as the fiber shape, long fibers are preferred from the viewpoint of reinforcement, and continuous long fibers are particularly preferred.

In addition, in order to prepare a synthetic resin foam molded product in which a large number of fibers are embedded, for example, a fiber bundle consisting of a large number of fibers is impregnated with a foamable resin liquid, and this is foamed and simultaneously cured to form an appropriate shape. Other known methods may be used, such as molding into foam, foam molding of a large number of fibers dispersed in expandable resin particles.

Next, a sheet-like fiber layer containing synthetic resin refers to a sheet-like fiber layer with a synthetic resin added to it, which is then integrated into a layered layer. The fibers that can be used include the types of fibers already mentioned,
Particularly preferably, glass fibers are used, and the fibers can be formed into a sheet by weaving the fibers, forming a nonwoven fabric, forming a net, or collecting short fibers into a mat. .

In addition, in order to integrate synthetic resin into sheet-like fibers, it is possible to impregnate the sheet-like fibers with a curable resin liquid and cure it, or to impregnate the sheet-like fibers with a synthetic resin solution prepared by dissolving the synthetic resin in a solvent. This can be done by letting the solvent volatilize, or heating and melting the thermoplastic synthetic resin so that it is interposed between the fibers, but it is particularly preferable in the present invention to use a thermosetting resin liquid.

Accordingly, aggregate and synthetic resin foam are filled between the plurality of synthetic resin-containing sheet-like fiber layers provided on at least one side of the synthetic resin foam molded article. refers to a granular or coarse-grained solid substance, such as silica sand, calcium carbonate, talc, shirasu balloon, perlite, glass balloon, etc.

Further, the resin used for the synthetic resin foam may be the same type as the synthetic resin foam molding or a different type, and furthermore, it may be a thermoplastic resin or a thermosetting resin. However, it is particularly preferable to use a thermosetting resin from the viewpoints of durability, heat resistance, ease of manufacture, and the like.

In the composite structural material of the present invention, the synthetic resin foam molding, the sheet-like fiber layer, the aggregate, and the synthetic resin foam are integrated by adhering to each other. In order to integrate the synthetic resin foam molded product, sheet-like fiber layer, etc. into one body, adjoining parts may be fixed together using the adhesive property of the synthetic resin liquid used when the synthetic resin liquid is cured, or a separate material may be prepared. These may be bonded together using an adhesive.

Next, the composite structural material of the present invention will be explained with reference to the drawings.

FIG. 1 is a perspective view showing one embodiment of the present invention, and FIG. 2 is a perspective view showing one embodiment of the present invention.
FIG. 3 is a perspective view showing another embodiment; 1 is a synthetic resin foam molded product reinforced with fibers; 2 is a synthetic resin foam molded product 1; FIG. 3 is a sheet-like fiber layer containing synthetic resin, 4 is an aggregate, and 5 is a synthetic resin foam.

The composite structure material shown in Fig. 1 has fibers 2 aligned in one direction.
Two sheet-like fiber layers 3 are provided on both sides of the synthetic resin foam molded body 1 reinforced by the above-mentioned synthetic resin foam, and aggregate 4 and synthetic resin foam 5 are filled between these two layers.

Next, the composite structural material shown in FIG. 3 is constructed by providing three sheet-like fiber layers 3 on each side of a synthetic resin foam molded product 1 similar to that shown in FIG. 1.

Of the three layers of sheet-like fibers, aggregate 4 with a large particle size and synthetic resin foam 5 are filled between the inner layer and the middle layer, and between the middle layer and the outer layer small aggregate 4
It has a structure filled with a synthetic resin foam 5, and such a structure having multiple aggregate filled layers has even better compressive strength and bending strength.

Further, the composite structural material of the present invention may be one in which a plurality of sheet-like fiber layers 3 are provided on only one side of the synthetic resin foam molded product 1, and the number of the plurality of sheet-like fiber layers may be may be determined as necessary.

Next, in order to manufacture the composite structural material of the present invention, a synthetic resin foam molded product reinforced with a large number of embedded fibers, a sheet-like fiber layer containing a synthetic resin, an aggregate and a synthetic resin foam are required. The structure of the present invention may be created by separately preparing plate-like products made of the above materials and laminating them and bonding them together with a suitable adhesive. A sheet-like fiber layer impregnated with a curable resin liquid is placed on at least one side of the material impregnated with a foamable resin liquid, and a sheet-like fiber layer impregnated with a curable resin liquid is placed on top of the sheet-like fiber layer impregnated with a curable foamable resin liquid. A layer of material is provided, and then covered with the same sheet-like fiber layer as above, the above-mentioned aggregate layer and sheet-like fiber layer are repeatedly provided as necessary, and the multilayer structure thus obtained is molded into an appropriate mold. It is efficient to mold the resin liquid in one piece by introducing the resin into the mold and curing and foaming the resin liquid within the mold.

Since the composite structural material of the present invention has the above-mentioned configuration, it includes a plurality of sheet-like fiber layers provided on at least one side of a synthetic resin foam shape reinforced with fibers, and the sheet-like fiber layer. The filling layer made of aggregate and synthetic resin foam provided between the layers improves the surface strength and makes the surface less likely to be scratched.It also has excellent bending rigidity and strength, as well as compressive strength. This superior mechanical strength is due to the fact that the foaming ratio of synthetic resin foam is higher than that of conventional structural materials. Even if it is higher than that, it can still be filled.

Furthermore, the composite structural material of the present invention is economically advantageous because inexpensive materials such as aggregate can be used.

Furthermore, if the fibers used in the sheet-like fiber layer are transparent fibers such as glass fibers, the pattern of the aggregate used will appear on the surface, so the color tone and size of the aggregate should be selected appropriately. As a result, marble patterns, mosaic patterns, and other desirable patterns can be provided on the surface of the composite structural material of the present invention.

[Brief explanation of drawings]

FIG. 1 is a perspective view showing one embodiment of the present invention, and FIG. 2 is a perspective view showing one embodiment of the present invention.
FIG. 3 is an enlarged view of a portion surrounded by a circle in the figure, and is a perspective view showing another embodiment. In the figure, 1 is a synthetic resin foam reinforced with fibers, 2
3 is a sheet-like fiber layer containing a synthetic resin, 4 is an aggregate, and 5 is a synthetic resin foam.

Claims (1)

[Scope of Claims] 1. A plurality of sheet-like fiber layers containing synthetic resin are provided on at least one surface of a synthetic resin foam molded product reinforced with a large number of embedded fibers, Aggregate and synthetic resin foam are filled between the fiber layers, and the synthetic resin foam molded product, sheet-like fiber layer, aggregate, and synthetic resin foam are integrated by adhering to each other. A composite structure characterized by: 2. The composite structural material according to claim 1, wherein the synthetic resin is a thermosetting synthetic resin. 3. The composite structural material according to claim 1 or 2, wherein the fibers are glass fibers.