JPS5927709B2 - Composite manufacturing method - Google Patents

Description

[Detailed description of the invention] The present invention relates to a method of manufacturing a composite material.

Conventionally, a flocculent aggregate is adhered to a sheet-like object by spraying a liquid adhesive onto the flocculent aggregate, or by applying a liquid adhesive to the sheet-like object and then pressing the two together. However, in the above method, if there is little pressure bonding, the bonding area is small, so it is easy to peel off, and if the pressure bonding is good and the flocculent material is bonded sufficiently, the flocculent aggregate will be compressed and the bulk of the flocculent aggregate will become smaller, which will improve the heat insulation effect. This had the disadvantage that the sound absorption effect etc. deteriorated.

Furthermore, when manufacturing a sandwich panel by sandwiching a flocculent aggregate between two sheet-like materials, a frame must be provided on the side surfaces since the flocculent aggregate is exposed on the side surfaces. Nakatsuta. The purpose of the present invention is to bond a sheet-like material and a floc-like material aggregate without compressing the floc-like material aggregate to reduce its bulk, and to prevent the floc-like material aggregate from being exposed by not using a frame around the periphery. An object of the present invention is to provide a method for easily manufacturing a composite material.

That is, the gist of the present invention is to partially compress a laminate in which sheet-like materials are laminated with heat-foamable thermosetting resin layers interposed on both sides of a cotton-like material aggregate, and to compress both of the laminates in the compressed portion. The sheet-like objects located on the surface are brought close to each other,
A composite material characterized in that the laminate is heated in this state, the thermosetting resin layer is foamed and cured, and the thermosetting resin layers on both sides of the flocculent aggregate in the compressed part are bonded together by foaming. It consists in the manufacturing method.

Examples of sheet materials used in the present invention include aluminum plates, steel plates, wood plates, cloth, plastic sheets, fiber-reinforced plastic sheets, and the like.

The heat-foamable thermosetting resin layer used in the present invention is formed from a thermosetting resin and a foaming agent.

As the thermosetting resin, for example, phenol resin, epoxy resin, unsaturated polyester resin, urea resin, etc. are preferably used. The blowing agent is not particularly limited, and blowing agents commonly used in producing synthetic resin foams such as polyolefins may be used, such as N, N'
- Pyrolytic blowing agents such as dinitrosopentamethylenetetramine and P7P oxybisbenzenesulfonyl hydrazide are preferably used.

In the present invention, the foamable thermosetting resin layer is formed from the above-mentioned thermosetting resin and the above-mentioned foaming agent, but if a catalyst is required to harden the resin, a catalyst is added. When the thermosetting resin is an epoxy resin, amines such as trimethylamine, dimethylaniline, and dimethylenetriamine are preferably used as the above catalyst, and when the thermosetting resin is an epoxy resin, amines such as benzoyl peroxide and dicumyl peroxide are preferably used. Oxides are preferably used. In addition, calcium carbonate, clay, talc, barium sulfate, alumina,
Fillers such as asbestos powder, colorants, etc. may be added. Examples of the flocculent aggregates used in the present invention include pine-like materials such as chopped strand mats made of cotton, glass wool, rock wool, etc., woven fabrics and non-woven fabrics of fibrous materials such as glass fibers and vinylon fibers, and open-celled fibers. Examples include polyurethane foam and the like.

Next, the manufacturing method of the present invention will be explained with reference to the drawings.
FIG. 1 is a sectional view showing an example of a laminate before foaming and hardening. In the figure, 1 and 1 are sheet-like materials, 2 and 2 are heat-foamable thermosetting resin layers provided on opposing surfaces of the two sheet-like materials 1 and 1, and 3 is an aggregate of cotton-like materials. These are laminates in which sheet-like materials 1, 1 are laminated with thermosetting resin layers 2, 2 interposed on both sides of a cotton-like material aggregate 3. Then, the peripheral parts 11, 11 of the laminate are compressed by a suitable mold, and in this compressed part, the sheet-like materials 1, 1 and the thermosetting resin layers 2, 2 are brought close to each other. . This compression is performed so that when the resin layers 2, 2 are foamed, the distance between them is maintained such that both resins expanded by foaming can be bonded to each other. In the present invention, the laminate installed and partially compressed as described above is heated to a temperature higher than the temperature at which the foamable thermosetting resin layers 2, 2 foam and harden, and the resin layers 2, 2 are foamed. It is then cured to produce a composite material.

FIG. 2 is a sectional view showing an example of the obtained composite material.

In FIG. 2, reference numeral 4 indicates a layer in which the resin layer 2 is foamed, the foam is embedded in the flocculent aggregate 3, and hardened.

In the peripheral parts 11, 11, the foamed bodies formed by foaming the resin layers 2, 2 are bonded to each other and integrated. Third
The figure is a sectional view showing another example of the obtained composite material.

This composite material is the peripheral part 11, 11 of the laminate shown in FIG.
was compressed with a stronger force than in the case of manufacturing the composite material shown in FIG. 2, and the flocculent aggregate in this portion was heated in a sufficiently compressed state.

Therefore, 5 is a resin layer in which the resin layers 2, 2 are hardened with almost no foaming, and contains flocculent aggregates such as FRP.
Further, 4 is a layer in which the resin layers 2, 2 are foamed and the foam formed is embedded in the flocculent material aggregate 3 and hardened. In the present invention, as described above, the sheet-like materials are partially thermally hardened together. A composite material bonded with thermosetting resin foam is manufactured, but the peripheral part of the sheet-like material, that is, the part where the flocculent aggregate is exposed on the side, is bonded with thermosetting resin foam, and the flocculent aggregate is bonded with thermosetting resin foam. It is preferable that the temperature is such that it is not exposed alone.

In addition, the above-mentioned foam has closed cells at °C, which is preferable because it has excellent heat insulation properties and reduces hygroscopicity. The composition of the present invention is as described above, and the heat-foamable thermosetting resin foams when heated and soaks into the flocculent aggregate. Due to the curing, the sheet-like material and the cotton-like material aggregate are firmly bonded.

Further, the sheet-like composite materials manufactured by the manufacturing method of the present invention are bonded together by the thermosetting resin foam, and when the peripheral portions of the sheet-like materials are bonded, the aggregate of flocculent material can be left alone outside. In particular, if the foam has a closed cell structure, a composite material with low hygroscopicity and excellent heat insulation properties can be obtained. In addition, in the composite material produced by the method of the present invention, the thermosetting resin is completely immersed in the flocculent aggregate in the areas that have undergone partial compression. However, this part becomes a foam reinforced with cotton-like fibers, or if the degree of compression is large, it contains almost no air bubbles like FRP, as shown in Figure 3. The result is a fiber-containing resin layer, and in either case, the sheet-like material of the surface material and the aggregate of the cotton-like material of the intermediate layer are firmly bonded to form a laminated composite that can be suitably used as a heat insulating material or a structural material. It is.

Next, the present invention will be explained with examples〇Example 1 Unsaturated polyester resin (viscosity 4.7 poise/25°C)
A composition consisting of 50 parts by weight, 50 parts by weight of talc (average particle size 1 μ), 1 part by weight of benzoyl peroxide, and 5 parts by weight of P,P'-oxybisbenzenesulfonyl hydrazide was coated on one side to a thickness of approximately 1.5 mm. Approximately 30C[
Two pieces of unsaturated polyester-impregnated glass fiber cloth (S.M.C. thickness 0.
8mm) were placed one above the other so that the coated surfaces faced each other, and between them, 10mm thick glass wool mats (bulk density 1
0 kg/Nl3) was inserted to form a scissor laminate.

Next, the dimensions are 30cIn x 60c [n is 1cIn from the outer edge.
The above laminate was sandwiched between two concave molds whose inner parts were deep by 5m71L, and fixed so that the distance between the outer edges of the molds was 5m1L.
C. and heated for 15 minutes, the composition foamed and hardened to obtain a composite material. In the center of the composite, the foam was embedded in the glass wool mat and cured, and the adhesion between the unsaturated polyester-impregnated glass fiber cloth and the glass wool mat was very good. In addition, the polyester resin is completely impregnated into the glass wool mat and cured in the peripheral area of the composite material, and the adhesive strength is high. No bubbles were generated from the composite material even when it was compressed by pressure. The expansion ratio of the foam was approximately 8 times, and the cells were closed cells. Example 2 100 parts by weight of epoxy resin and azobisisobutylene were added to the concave side of each of the two aluminum plates of the parking 111, which were drawn to a depth of 5 to match the mold used in Example 1. 50 parts by weight of a composition consisting of 1 part by weight of lonitrile, 0.3 parts by weight of polyethylene glycol alkyl phenyl ether, 1 part by weight of benzene and 6 parts by weight of diethyltriamine.
It was coated to a thickness of 1.5 mm at .

Next, the thickness is 101W! A semi-rigid polyurethane foam (open cells, average cell diameter 11!L7IL) is placed between the above two aluminum plates with the coated side of the aluminum plate facing the polyurethane foam, and the periphery of the aluminum plate is placed between the two aluminum plates. Fix it with a mold so that the interval between the
When heated for a minute, the above composition foamed and hardened, yielding a plate-shaped composite material with a thickness of 17 Lm at the center and 71 Lm at the periphery.

The expansion ratio of the foam was about 4 times or less in the peripheral part of the composite material, and about 8 times in the central part. All of the foams had closed cells.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view showing an example of a laminate before foaming and hardening, FIG. 2 is a cross-sectional view showing an example of a composite material obtained by the method of the present invention, and FIG. 3 is a cross-sectional view showing an example of a composite material obtained by the method of the present invention. FIG. 3 is a sectional view showing another example of a composite material obtained by using the same method. DESCRIPTION OF SYMBOLS 1... Sheet-like material, 2... Foamable thermosetting resin layer, 3... Cotton-like material aggregate, 4...
. . . Foam layer, 5 . . . Resin layer containing flocculent aggregates.

Claims (1)

[Claims] 1. A laminate in which sheet-like materials are laminated with heat-foamable thermosetting resin layers interposed on both sides of a cotton-like material aggregate is partially compressed, and both of the laminates in the compressed portion are compressed. The sheet-like materials located on the surface are brought close to each other, and the laminate is heated in this state to foam and harden the thermosetting resin layer, thereby thermosetting both sides of the flocculent material aggregate in the compressed portion. 1. A method for producing a composite material, which is characterized by bonding adhesive resin layers together by foaming. 2. The manufacturing method according to claim 1, wherein the thermosetting resin layer contains a thermosetting resin and a pyrolyzable foaming agent. 3. The manufacturing method according to claim 1 or 2, wherein the compressed portion of the laminate is a peripheral portion of the sheet-like material.