JPS5936574B2 - Method for continuously manufacturing fiber reinforced plastic foam - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for continuously producing fiber reinforced plastic foam.

Conventionally, as a method for dispersing glass fibers in a plastic foam such as polyurethane foam using a chemical reaction method, a method is known in which short fibers of 5N or less are mixed into a urethane foam foaming stock solution and then foamed.

However, the effect of adding glass fiber in this method is merely to increase the amount, and has almost no reinforcing effect. In order to expect the reinforcing effect of glass fibers, it is necessary that the fiber length is 10 mm or more, preferably 2 mm or more, but when such long fibers are mixed with the urethane foam stock solution and stirred, Due to the entanglement of the fibers, the fibers cannot be evenly distributed in the foam, resulting in a significantly non-uniform distribution of fibers in the foam.

One of the ways to overcome these drawbacks is to spray cut fibers at the same time during spray foaming. A method of spraying foam in the vertical direction and supplying cut fibers almost perpendicular to the flow of the spray. A method is known in which spraying and spraying of cut fibers are carried out in the same direction to form a random web and foam at the same time on the facing soil.

However, in these methods, the fiber content is increased (
For example, if you try to reduce the foam to about 10%, the foam will not penetrate into areas where the fibers are highly entangled, creating cavities, and the foam and fibers will scatter and fall off during spraying, resulting in large losses, resulting in high costs. There are disadvantages such as being up.
In addition, one method for foaming after impregnating a glass fiber mat with a urethane foaming solution is to distribute the urethane foaming solution onto the top surface of a mat that moves horizontally, stack the mats on top of it, compress it, and then release the undiluted solution. Continuous production methods have been proposed in which the fibers are infiltrated into the mat and then foamed in a confined space.

In this method, compared to the above-mentioned blow-foaming method, a foam containing a relatively uniform amount of fibers can be obtained, and there is almost no loss of fibers or foam, but there are still the following problems. That is, in this method, (a) the undiluted solution is distributed on one side of the fiber mat in a horizontal position, and then another fiber pine is stacked and pressurized to impregnate the undiluted solution into the mat, so that the undiluted solution permeates throughout the fiber mat; In particular, the permeation of the concentrate into the pine trees superimposed on the soil is insufficient;
(b) The stock solution distributed on a horizontal mat is difficult to flow and spread, so it is difficult to distribute the stock solution uniformly, and even when pressure is applied, it is not uniformly impregnated into the mat, resulting in non-uniformity. ←) Thick pine, such as 501
If it is 1 or more, the permeation of the stock solution is poor and therefore it is not possible to make a thick product; (d) After the cream time of the foaming stock solution, penetration into the mat is difficult due to the thickening and foaming of the stock solution. It is difficult to obtain a uniform fiber-containing foam, so the foaming reaction is rapid, and therefore it is not suitable for producing foam from a foaming stock solution with a short creaming time.

The inventors of the present invention have focused on the fact that the latter method has advantages over the former spray foaming method, and have conducted repeated studies to eliminate some of the drawbacks listed above regarding the latter method. The present invention has now been completed.

That is, the present invention allows the foaming solution to penetrate homogeneously into the fiber mat without loss of fibers or foaming solution, resulting in a uniform foamed product, and can be sufficiently applied even if the creaming time of the foaming solution is short. The purpose of the present invention is to provide a method for efficiently and continuously manufacturing thick products and various shaped products.

According to the present invention, this purpose is to provide a flexible surface material on both sides or a flexible surface material on one side of the outermost surface of one or more fiber mats that are continuously fed. A space formed between the mat and the surface material and/or between the mats by feeding and overlapping a rigid surface material on the other surface at an angle of 0 degrees or more and 90 degrees or less with respect to the vertical line. While distributing the foamable resin stock solution downward from both sides of the mat, the stacked mat and surface material are passed through a gap smaller than the thickness of the mat to compress the mat and allow the foamable resin stock solution to penetrate into the mat. After dispersion, the mat is foamed with or without restraint, and the foaming stock solution distributed above reaches the overlapping point of the mat and the surface material in a short time. Supply is accomplished by directing the feed downwards. To summarize the main points of the present invention, in this method, between two surface materials,
Continuously feed the fiber mat in a downward direction together with the surface material,
At the same time, a foaming solution is supplied to both sides of the mat, and these are passed through a narrow gap (the thickness of the mat).

Since the mat is oriented downward, the foaming solution flows downward in a short time, quickly reaching the overlapped area between the mat and the surface material, and the foaming solution is spread throughout the mat due to the force applied to the mat when passing through the narrow gap. This results in a product in which the fiber mat is uniformly present throughout the foam (by the subsequent foaming). The present invention will be explained in detail below.

The fiber mat used in the present invention is made by interlacing organic or inorganic fibers and is porous like cotton, and can be handled in the form of a sheet or plate, and is generally used as stuffing for futons or cushions. Refers to materials that can be used as is as materials or insulation materials.

And dense fabrics like rugs are not suitable. The apparent density varies depending on the type and thickness of the fiber, but is approximately in the range of 0.001 to 0.19/d.
Preferably, it is about 0.005 to 0.059/Cd, although it varies depending on the purpose of use. To give a specific example, the futon cotton of polyester fiber is about 0.005~
0.029/Cd, glass fiber insulation is approximately 0.005
~0.1g/CTlt, Balmrock is approximately 0.1g/C
It has an apparent specific gravity of

The type of pine fiber used in the method of the present invention is not particularly limited, and any organic or inorganic type can be used. Specifically, there are inorganic fibers such as glass fibers, aluminum fibers, iron fibers, and rock wool, and organic fibers include natural fibers, synthetic fibers, and artificial fibers. Specific examples of the latter include polyvinyl chloride, polyvinylidene chloride,
Fibers made from synthetic polymer materials such as nylon, aromatic nylon, polyethylene terephthalate, polyvinyl acetal, polyvinyl alcohol, phenol-formaldehyde polycondensates, polyacrylonitrile, artificial fibers such as rayon, acetate, cotton, linen, wool, Examples include natural fibers such as animal hair and coconut fiber. In the method of the present invention, the mat is compressed in order to impregnate the mat with the foaming stock solution, but it is desirable that the mat return to its original thickness after impregnation. Therefore, fibers with high elastic recovery are preferred.

However, this is not a necessary condition. This is because the impregnated stock solution swells with the fibers during foaming.
When the expansion ratio of the foam is small, a foam with substantially uniform fiber distribution can be obtained. The thickness, length, and degree of intertwining of the fibers are also selected appropriately depending on the type of product.

The thickness of the fibers is preferably in the range of approximately 1 to 50 deniers.
However, mats made of finer fibers, such as 0.5 denier, or thicker fibers, such as coconut fibers, hemp fibers, etc., can also be used. The length of the fibers may be as long as it can be formed into a cotton shape, for example, about 10
~100 TELI is about 300 if crimped.
It may be made of long fibers of mm or more.

Among the various fibers mentioned above, synthetic fibers, especially nylon, vinylon, acrylic fibers, and polyester fiber mats are preferred from the viewpoint of reinforcing effect, and are flame-retardant.゜From the viewpoint of effectiveness, glass wool and rock wool mats are preferable.

In the method of the present invention, there are two types of surface materials used to clamp the pine: flexible surface materials and rigid surface materials.

The former materials include paper, woven fabrics of various fibers, and... non-woven fabric,
Examples include plastic films and sheets, metal sheets such as aluminum, and foils. As rigid surface materials, plate-shaped bodies made of various materials are used, such as wooden boards, plywood, asbestos boards, gypsum boards, aluminum boards, iron boards, plastic boards, etc., and pipes such as iron pipes, aluminum pipes, plastic pipes, etc. Hidden items are also used. These modes of use are illustrated in the description of the accompanying drawings below. The foamable resin stock solution in the method of the present invention refers to a stock solution that produces plastic foam, and foams produced from such a stock solution include polyurethane foam, polyisocyanurate foam, polyoxazolidone foam, carbodiimide foam, polyamide foam, polyimide foam, When pyranyl foam, epoxy foam, phenol foam, area foam, or a combination of these forms are used, polymer production and gas generation can occur virtually simultaneously by mixing two or more liquid components. It is a soft or hard plastic foam.

In the method of the present invention, it is important from an industrial implementation point of view to mix the foamable stock solution without requiring special external heating, and the various foams described above meet this requirement. However, some phenol foams are made by adding a foaming agent to a powdered resol and foaming them by heating, and since such foams are not liquid, they have poor penetration into the fiber mat, and are therefore not suitable for the method of the present invention.

Liquid two-component phenol. Waohm undiluted solution can be used. Methods for manufacturing the various foams mentioned above are described in the literature. Next, embodiments of the method of the present invention will be explained with reference to the accompanying drawings.

1st~? The figures are explanatory diagrams schematically showing various aspects of carrying out the method of the present invention. In the figures, the same reference numerals have the same functions.

In the drawings, 1, Ia, Ib and 1c are fiber mats (
(hereinafter simply referred to as mat), 2, 3, 6, and T are rolls 2' that overlap and compress the mat and the surface material.
and 3' are rolls for overlapping the surface material on the mat; 4 and 5 are surface materials made of flexible materials; 8, 8', 9 and 9'
indicates the point where the foaming stock solution is supplied.

Reference numeral 10 designates a surface material made of a rigid material, and 11 and 12 designate slit-shaped guides for overlapping the surface material on the mat, guiding it downward, and compressing it.

Figures 1 to 5 show the sixth mat when one mat is continuously supplied.
The figure shows the case where two mats are continuously supplied, and Figure T shows the case where three mats are continuously supplied.

The mat is fed vertically or downward at a slight angle, and the surfacing material is fed at the same speed to sandwich the mat. θ and θ' in FIG. 1 indicate the angles formed between the surface materials 4 and 5 and the vertical line, and θ and θ' are selected from the range of 0 to 90 degrees, and even if θ and θ5 are the same, They can be different. If these angles are 90 degrees or more, it becomes difficult for the supplied foamed resin stock solution to be effectively sent downward with the mat.
The stock solution is not fully utilized. Therefore, these angles must be less than 90 degrees. The smaller the angle, the better the flow of the stock solution, but if it is too small, the installation of the stock solution supply pipe will be restricted, so the preferred range is 90 degrees or less, more preferably 4 to 86 degrees, and most preferably 30 to 60 degrees.
Selected from a range of degrees. As a modified example of the surface material supply method, as shown in Fig. 5, the surface material is first expanded to create a space for installing the stock solution supply pipe, and then made parallel, that is, at an angle of 0 degrees, so that a large space is not used as a whole. You may choose to do so.

The surface material is fed to both sides of the mat 1, or when using two or more mats 1a, 1b, or 1a, 1b, 1c, to the outermost surfaces of a group of these mats, so as to sandwich the mats. However, the use of a surface material prevents the foaming solution distributed from the top to the bottom of the mat from leaking out of the mat, and at the same time allows the foaming solution to be mixed between the mat and the surface material in a short time. This is to reach the overlapping point of the pine and spread it over the entire surface of the pine.

Depending on the purpose of the final product, the surface material may be one that is bonded to the foam to form a single body, or it may be a removable material that can be peeled off after foaming. Further, the surface material may be made of a flexible material on both sides of the mat, or may be made of a flexible material on one side and a rigid material on the other side (FIG. 4). It is necessary that the foaming stock solution be supplied from both sides of the mat.

Therefore, when there is only one mat (Figures 1 to 5), arrow 8,
It is fed between the surface material and the mat as shown by 9, but if there are two mats (Fig. 6) or three mats (Fig. 7), use the arrow 8'.
, 9', the stock solution is further supplied between the mats. If the width of the mat is large, the solution supply port should not be fixed at one point, but should be moved back and forth, or the solution supply port should be a long and narrow slit-shaped nozzle corresponding to the width of the mat. It is preferable that the tips of these supply ports be as close as possible to the overlapping point of the mat and the surface material. In order for the foaming resin stock solution to quickly reach the overlapping point between the mat and the surface material and to be compressed to uniformly permeate the mat, in addition to supplying the stock solution from both sides of the mat as described above, It is necessary to feed in a downward direction. This supply may be applied to the top of the mat or to the top of the facing. The mat and the surface material supplied with the foaming resin stock solution are forced to pass through a gap that is narrower than the thickness of the mat, where the stock solution permeates throughout the mat.

To pass through this gap, one set of rolls is used (Fig. 2), two sets of rolls are used (Fig. 1), and one set of rolls 2' and 3' is used to press lightly and forcefully to simply overlap the surface material on the mat. When providing a set of rolls 6 and 7 for compression (5th to 7th rolls)
Figure), slit-shaped guide 1 that gradually narrows, not a roll.
Various methods can be adopted, such as using 1 and 12 (FIG. 3). Using a guide like the one shown in Figure 3,
Since the gap becomes smaller towards the tip, there is the advantage that the residual air in the mat is completely forced upwards, resulting in a mat without any unimpregnated parts. The above gap distance is generally 2-70% of the original thickness of the pine;
The preferred range is 5-30%. From these ranges, it may be selected as appropriate depending on the density of the fiber mat used and the desired physical properties of the target product. Note that if the gap distance is too large, impregnation with the stock solution will be insufficient, and if it is too small, the impregnating liquid will be squeezed out, resulting in a small amount of impregnation.
The roll creating the narrow gap need not be a perfect cylinder; for example, it may be a roll with unevenness as shown in FIG. 8, and in the case of a slit-shaped guide, the slits may be wave-shaped.

When using such deformed rolls and deformed slits,
The pine is effectively impregnated with the undiluted solution.

The roll or guide may be made of any material. In the case of a cylindrical guide, iron, aluminum, rubber, or plastics are suitable, and in the case of a slit-shaped guide, iron, aluminum, plastic, etc. are suitable. The mat that has passed through the gap has not yet started foaming, so it is highly flexible and can be bent into any shape like a wet towel. can.

Therefore, this product can be made into a plate, a plate with an uneven or curved surface, a cylinder, a semi-cylindrical shape, or any other desired shape. In order to form such a special shape, foaming is generally performed using a foaming suppressing jig suitable for the shape. However, it may be advantageous to foam without a foam suppression jig. FIG. 9 is a schematic perspective view of an example of an apparatus used when carrying out the foaming step in the method of the present invention without a foaming suppressing jig.

In the figure, the numbers up to 12 are the same as those given in FIGS. 1 to 7 above.

13 is a guide roll, 14 is a cutting machine, 15 is a foamed and hardened foam, and 16 is a conveyor.

In the apparatus shown here, the 1t-
The flexible surface materials 4 and 5 are fed downward from Hijikata at the same speed as the mat 1 which continuously moves downward at a constant speed,
The foamed resin stock solution is supplied downward at a constant discharge rate as indicated by arrows 8 and 9 from the supply ports which simultaneously move back and forth.

This stock solution is 1. The vertical movement of the mat 1 and the downward movement of the surface material quickly reach the guides 11 and 12. Then, since the undiluted solution is supplied to both sides of the mat 1, it passes between the guides 12 and 13, and when the Yamatu, which has a narrow gap between the guides, is sequentially compressed, the remaining air is forced upward, and the undiluted solution is supplied to the entire mat. Penetrates evenly throughout. The pine and the surface material that have passed through the guides 11 and 12 are guided by guide rolls 13 to the soil on a conveyor 16, where they are foamed under unrestrained conditions to form a double-cured foam 15 and cut into a cutting machine 14. It is cut to a predetermined length by

At this time, if a silicone-treated release paper is used as a surface material, a fiber-reinforced foam without a surface material can be obtained, and if aluminum foil or kraft paper is used, a product with these adhered to the surface of the foam can be obtained. can get. FIG. 10 is a schematic front view of an example of an apparatus for carrying out the foaming step under restraint in the method of the present invention. In this device, a caterpillar-shaped foaming suppression jig IT is installed at the level of the conveyor 16, and by using this jig IT, a product with excellent flatness and a constant thickness can be obtained. By adjusting the distance between 16 and 16, the thickness of the product and the skin layer of the foam can be made as desired.

When using this device, the facings 4 and 5 are pulled by a puller (not shown), which exerts a force that compresses the foam during expansion.

To prevent the force applied at the start of foaming from working, press the compression roll 2.
It is preferable to provide a support 2a for lifting the surface material 4 on the way to the point where the surface material 4 has left the jig IT. 2a may be a rotating roll or a compressed air blowing pipe.

Further, vacuum may be used for these portions D to suction from above. According to the apparatus shown in FIG. 10, the lower and upper surfaces of the product form are flat, but the side surfaces are not. Therefore, when finishing, it is necessary to cut and remove this part, which reduces the yield of the product. This also creates waste disposal problems.

FIG. 11 is a schematic plan view of an example of a foaming zone of an apparatus for solving this problem (the foaming suppressing jig on the soil surface is omitted).

This device uses a conveyor 1 that transports while foaming.
Caterpillar type foam suppression jigs 18 and 19 are placed on both sides of 6.
is installed and runs at the same speed as the conveyor 16 during operation.

20 and 21 are release papers in contact with the foam.

If the surfaces of the jigs 18 and 19 in contact with the form are flat, a form with flat side surfaces can be obtained. Furthermore, by appropriately providing unevenness on the surfaces of the jigs 18 and 19, when the obtained plate-like foam products are arranged side by side, the side surfaces can be shaped to fit or mesh with each other. This is convenient because the product forms can be connected and used for larger widths. FIG. 12 is a schematic front view of another example of an apparatus for carrying out the method of the invention.

In this device, one surface material 5 is made of a flexible material,
The other surface material 10 is made of a rigid material. and surface material 10
is cut to a certain size, and this is conveyor 22.
and 23 successively. Then, in order to prevent the foamed resin stock solution from seeping out from the gaps between the individual rigid surface materials 10, the surface materials 10 are bonded in advance with, for example, urethane foam, and the release paper 24 is attached to a release paper supply roll. It is best to feed it from 25 and lay it under the surface material 10. Foaming is completed while the impregnated mat passes between the conveyor 16 and the caterpillar type foam suppression jig IT,
By cutting between the individual rigid surface materials 10, the rigid surface materials 1
A product is obtained in which a fiber-reinforced plastic foam is formed on the soil surface.

Figures 13, 14 and 15 illustrate the formation of fiber reinforced plastic foam on the outer surface of a pipe by the method of the present invention.

In the figure, reference numeral 26 denotes a pipe to be coated, and in the case shown in FIG. It also fulfills the purpose of 27 is a roll for making the flexible surface material 5 into a peelable state, and for peeling and guiding the surface material 5.

At the time of this peeling, foaming has not started, so the surface material 5
can be easily peeled off. On the other hand, only the mat impregnated with the foaming stock solution is wrapped around the surface of the pipe 26, and foaming is completed there without restraint. In the apparatus shown in FIG. 14, the surface materials 4 and 5 are both made of a peelable flexible material,
After the undiluted solution is sufficiently permeated into the mat through the guides 11 and 12, the surface materials 4 and 5 are peeled off and wound around the pipe 26, where foaming is completed.

In this way, a product in which the foam 15 and the pipe 26 are bonded is obtained. In the apparatus shown in FIG. 15, the operation is similar to that shown in FIG. 13, but the surface material 4 is wound around the pipe 26 as it is without being peeled off.

Since the surface material 4 does not adhere to the pipe 26, it can be separated from the pipe and used as a pipe cover. FIG. 16 is a perspective view showing how the foam is wound around a pipe when the apparatus shown in FIG. 15 is used.

The mat has a relatively small width, and the foam 15 is spirally wound around the pipe 26 by moving the pipe 26 laterally with respect to the foam 15 that is continuously fed. In the apparatus shown in FIGS. 13 and 14, the foam can be wrapped around the pipe 26 in the same manner. The method of wrapping mats around a pipe to produce an integrated pipe and form, or separating the pipe after wrapping to produce a pipe cover, is limited to the spiral wrapping described above. It's not something. For example, using a mat with a width corresponding to the length of the outer circumference of the pipe, make a mat impregnated with the undiluted solution using a device such as that shown in Figure 9, transport it by a conveyor, and when it is in an unfoamed state, move it into the pipe in the direction of flow of the mat. Place it vertically in 5 directions, wrap the pipe around it using an auxiliary tool,
It is also possible to perform foaming at the end. The mode of winding is shown in FIG. 17.

Further, an example of another method for forming a fiber-reinforced plastic foam on the outer periphery of a pipe while suppressing foaming is shown in FIGS. 18 and 19. Figure 18 is a schematic front view of the foaming zone used in this case, and Figure 19 is B of Figure 18.
- It is a longitudinal cross-sectional schematic diagram taken on the B line. The mat impregnated with the foaming stock solution is manufactured using, for example, an apparatus as shown in FIG. A pipe 26 is placed on the unfoamed mat thus released in a direction perpendicular to the flow of the mat, and the mat is successively wound around the pipe 26 using an auxiliary tool (the state is similar to that shown in FIG. 17). ), then the first
8. Feed from one side of the device shown in Figure 8. In the one shown in FIG. 18, caterpillar-type foaming suppression jigs 28 and 29 are stacked one above the other, semicircular recesses are formed in the wings of these caterpillars, and the portion where the upper and lower jigs 28 and 29 overlap. A circular space is formed in the space as shown in FIG.

Therefore, foaming is completed while passing between these jigs, and a foamed cylinder with a smooth surface and a uniform diameter is obtained. In FIG. 18, the form is omitted to avoid complexity. Pipe covers made by the method described above are much more easily mass-produced than pipe covers made by the conventional molding method, and also have less deformation and superior surface smoothness compared to pipe covers made by the conventional block cutting method. It has the advantage of being there.

20 and 21 are perspective views of examples of products obtained by the method of the present invention), FIG. 20 shows an example of a corrugated plate, and FIG. 21 shows an example of a cylinder.

All of these can be produced by impregnating a mat with a foaming stock solution in the same manner as described above, and foaming the mat while passing it through a foam-suppressing jig in the shape of a bell. 22nd
The figure is an explanatory diagram showing a process diagram of an example of an apparatus used for manufacturing foam suitable for manufacturing bucket seat cushions for automobiles, cushions for chairs, and the like. In this device, pine 30 cut to a certain length is continuously fed into a long pine picker, and peelable flexible surface materials 4 and 5 are fed at the same speed, and at the same time. Supply foamed resin stock solution.

When passing through the slit-shaped curls L'11 and 12, the mat is compressed and the undiluted solution permeates the entire mat, and while the impregnated mat is moved, the surface material is peeled off and the surface material 4
is wound on the roll 31, and the surface material 5 is rolled on the guide roll 32.
be collected in the same way.

The impregnated mats 33 are placed one after another into a mold 34 carried on a belt conveyor. Matsuto 33
The mold 34 that has been filled is covered with a lid 35, foaming is performed therein, and a foam 36 is formed according to the shape of the mold. Next, this foam 36 can be taken out. Foams of various shapes manufactured as described above can be used for various purposes.

For example, if the foam is made of hard 10 urethane foam or isocyanurate foam, it may be used as an exterior wall material for housing.
Core materials for curtain walls in buildings, partition materials for buildings, exterior wall materials for outdoor refrigerators, ultra-low temperature liquids (liquefied oxygen, nitrogen,
It is very well used as a tank insulation material for natural gas (such as natural gas), a pipe insulation material 15, etc., and when the foam is made of soft urethane foam, it is extremely well used as a cushion material for automobile seats, sofas, etc. As described above, according to the method of the present invention, the fiber mat is fed downward, the surface material is also fed downward at an angle of 2090 degrees or less with respect to the vertical line, and the foaming resin stock solution is fed downward and on both sides of the mat. However, by supplying it, a number of effects such as those described below can be achieved. (a) The fiber mat is effectively impregnated with the foamable resin stock solution.

That is, impregnation is performed uniformly and in a short time. (B)
Even highly reactive stock solutions such as isocyanurate foam can be easily impregnated.

←→ Apply the stock solution evenly and quickly to thick fiber mats.
It can be impregnated into a uniform thick foam.

(The fiber content in the $I foam can be easily adjusted.

Therefore, foam products with high bending strength, high compressive strength, etc. can be obtained at any time. By using glass wool as the pine fiber, a composite material that is highly flame resistant and flame retardant can be obtained.

For example, a self-extinguishing (ASTM, D-1692-68) foam can be obtained using a flammable urethane foam stock solution, and a semi-nonflammable material (J
IS●A●1321) is obtained. In addition to H-board products, pipes surrounded by heat insulating material or pipe covers can be manufactured easily and continuously.

1) A product with a small coefficient of linear expansion is obtained, and product A does not crack even when used as an ultra-low depth insulation material.

If applied to soft foam, tensile strength, tearing, compression fatigue, and cushioning properties will be significantly improved. Next, embodiments of the present invention will be described, but the scope of the present invention is not limited to these embodiments unless it deviates from the gist thereof. In this example, a soft 1° kneader reinforced with polyester fibers is used.

. . 0,.

I have one. Note that parts are parts by weight.゛):; The apparatus shown in the figure was used.

In this device, the slit width of the guides 11 and 12 is -50n at the upper part, and the passage length of the slit at the lower part is -50n.
150m is recommended. c) Polyester fiber commercially available for use in mat futons: ÷==
``.1≦::.;=Toichiri:I was obtained, and a good belt-shaped fiber mat with a width of about 30c!n and a thickness of about 4cm was made using this.

(d) Manufacture of foam The above-mentioned fiber mat was coated with a width of 3 mm on both sides using the apparatus shown in FIG.
Layer 0CrrL silicone release paper and make slits of 240CI from the top to the bottom! While moving at a speed of L/min, the mixture of liquids A and B is divided into two parts from a foaming machine at a speed of 33609/min and placed on top of the center of the overlap between two pieces of release paper and the fiber mat. supplied.

After passing through the slit, the impregnated mat is foamed on a caterpillar type conveyor without restraint, and the width is about 20α and the thickness is about 14 cr.
The form of fL was obtained.

Table 1 shows the physical properties of the foam after curing and the physical properties of a foam containing no fibers for comparison. In the above table, the improvement ratio is calculated according to 128B, as it is preferable for the elongation and compression set to be smaller.
All other values are based on d.

1B As is clear from Table 1 above, the products produced by the method of the present invention not only have greater strength than those of the comparative example, but also have better cushioning properties and are resistant to "bending" compared to conventional soft products. It shows excellent physical properties not found in urethane foam, making it an excellent material for cushioning.

Example 2 This example shows an example of manufacturing a rigid urethane foam reinforced with glass fibers by the method of the present invention.

The following foaming stock solution was used.

Note that parts are parts by weight.

Foam density: free foam, 0.032f! /c! l Using the same equipment as used in Example 1, the thickness was approximately 5 CI! L,
Width about 30c! N, density approximately 0.019/D. Lay silicon release paper with a width of about 30 cfn on both sides of the glass fiber mat and pass it through the slit (width of the narrow part 6.011 mm!).
While moving downward at a speed of 240 cm/min,
, B liquid mixture is supplied to the center of the overlap between the fiber mat and the release paper at a rate of 24009/min, dividing it into approximately two parts on the left and right, and after passing through the slit, the impregnated mat is further conveyed to the conveyor and above. (distance 1001
0, and then foam under control to a width of about 20C! IL
, thickness 10mm, density 0.052g/C! A rigid foam was obtained.

Although this urethane foam itself is flammable, the foam obtained by the above method was determined to be self-extinguishing according to the ASTM D-1692-59T test method. Example 3 This example describes the production of urethane-modified isocyanurate foam reinforced with glass fibers.

The formulation of the foaming stock solution used and its foaming characteristics are as follows. Note that parts are parts by weight. The foaming conditions and foaming device are the same as in Example 2.

The density of the obtained foam was 0.042f1/Cril, and in the test according to JISA●1321, Tdθ
It was 81, CA was 46, and there were no deformations or cracks that were harmful to fire protection, and it was recognized that it corresponded to class 2 flame retardancy according to the JIS test method.

[Brief explanation of drawings]

Figures 1 to T are explanatory diagrams showing various aspects of carrying out the method of the present invention, Figure 8 is a schematic front view and a schematic vertical cross-sectional view of a modified example of the compression roll used in the method of the present invention, and Figure 9 is A schematic perspective view showing an entire example of an apparatus for carrying out the method of the present invention, No. 10
The figure is a schematic front view of another example of an apparatus for carrying out the method of the invention, and FIG. 11 is a foaming zone of the apparatus for carrying out the method of the invention.

Claims (1)

[Claims] 1 The outermost surface of one or more fiber mats that are continuously fed is provided with a flexible surface material on both sides, or with a flexible surface material on one side and a rigid surface material on the other side, vertically 0 per line
Feeding and overlapping at an angle of 90 degrees or more and 90 degrees or less,
While distributing the foaming resin stock solution downward from both sides of the mat in the space formed between the mat and the surface material and/or between the mats, the stacked mat and surface material are pass through small gaps,
Compression of the mat and penetration of the foaming resin stock solution into the mat,
After dispersion, foaming is performed with or without restraint,
The fiber-reinforced plastic is characterized in that the mat is supplied from the top to the bottom so that the distributed foaming stock solution reaches the overlapping point of the mat and the surface material in a short time. Continuous foam manufacturing method.