JPS5947977B2 - Manufacturing method for lightweight structural materials - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a lightweight structure made of synthetic resin foam and fibers.

Various structural materials using synthetic resin foam have been proposed in the past, such as those in which the surface of synthetic resin foam is covered with asbestos slate or metal plates, and structures in which fiber materials are dispersed in the foam. BACKGROUND OF THE INVENTION Synthetic resin foams reinforced with fibers are known.

However, in the former case, when asbestos slate is used, it is weak against impact and has poor workability when cutting with a saw, etc., and when a metal plate is used, workability is poor;
In either case, sufficient weight reduction cannot be achieved, and even if the surface of the synthetic resin foam is covered with a synthetic resin plate reinforced with fibers, the surface is hard and the impact resistance is not sufficient. In addition, in the case of the latter synthetic resin foam reinforced by dispersing fiber materials, impact resistance, processability,
Even if it has excellent strength, if the foaming ratio is increased, the air bubbles will become open at the interface with the fibers contained in it, making it easier to absorb water.As a result, the weight will increase due to water absorption, and the insulation properties will be impaired. The magnification must be kept low, which poses problems in terms of weight and economy. In view of the drawbacks of conventional structural materials using synthetic resin foam as described above, the present invention provides a method for manufacturing structural materials that are lightweight, have excellent strength such as impact resistance, and have excellent workability. The gist is that a foamed curable resin liquid is impregnated between two layers of surface material in which a fiber material impregnated with a foamed curable resin liquid is sandwiched between sheet materials. The present invention relates to a method for manufacturing a lightweight structural material, which comprises supplying a foamed curable resin liquid to a mold, and foaming and curing a foamed curable resin liquid within the mold.

The foamed curable resin liquid used in the present invention refers to a synthetic resin liquid that can be foamed and cured in a short time, such as hard polyurethane, unsaturated polyester, phenolic resin,
Resin liquids such as urea resins, melamine resins, and epoxy resins can be used after being imparted with foaming and curable properties.

Among these resin liquids, hard polyurethane is particularly suitable. The type of fiber material impregnated with the foamed curable resin liquid is not particularly limited; examples include inorganic fibers such as glass fibers, carbon fibers, and asbestos fibers; cotton, rayon, and nylon fibers; Organic fibers such as polyester fibers, vinyl fibers, and polypropylene fibers can be used, but glass fibers are particularly preferred from the viewpoint of strength, elastic modulus, and economical efficiency. Further, the shape of the fiber material may be either short fibers or long fibers as long as it can be impregnated with the synthetic resin liquid. Next, the type of sheet material is not particularly limited as long as it is a flexible sheet-like material, and for example, a synthetic resin film or a cloth-like material made from the above-mentioned fiber materials can be suitably used.

Then, a fibrous material impregnated with a foamed curable resin liquid is sandwiched between the sheet materials to form a surface layer material, and the aforementioned foamed curable resin liquid is supplied between the two layers of this surface layer material. However, the resin liquid used therein may be of the same type as the resin liquid with which the fiber material is impregnated, or may be of a different type. Further, among the sheet materials forming the surface layer portion, the sheet material on the side that comes into contact with the foamed curable resin liquid supplied between the surface layer portions is a sheet-like material formed from fibers or a porous film. This is preferable because the resin liquid permeates into the sheet material and hardens, thereby strengthening the adhesion to the foam. Further, the sheet material on the opposite side, that is, the sheet material forming the outer surface of the lightweight structural material to be manufactured, is appropriately selected depending on the use of the structural material,
For example, a film with excellent weather resistance, printability, etc. is preferably used, and a film that does not adhere well to the foam produced from the foamed curable resin liquid is used, and the film is peeled off from the structural material after molding. is also possible. Next, the mold used in the present invention is not particularly limited, but it is preferable to use a molding passage constituted by an endless belt as the mold to enable continuous production. This is preferable.

Next, the method of the present invention will be explained with reference to the drawings.

FIG. 1 is an explanatory diagram showing one embodiment of the method of the present invention, in which 1, 2, 1, 2, and 21, 22 are storage tanks for each component of the foamed curable resin liquid; 3,4,23,2
4 is a pump for feeding the resin liquid component, 5
, 5, 25 are mixers for mixing resin liquid, 6, 6,
26 is a motor for driving the mixer.

The resin liquid components are mixed in the mixers 5, 5, and 25 to form a foamed curable resin liquid, which is then supplied through the supply pipes 7, T, and 2T. The supply pipe 2T is equipped with a moving device 28 for moving the supply pipe in a direction perpendicular to the direction of movement of the material to uniformly supply the resin liquid, and a motor 2 for driving the moving device 28.
9 is connected. Next, 13, 13, 14, 14 are sheet materials, which are each used after being unwound from a roll, and 13, 13 are film-like sheets, and 14, 14 are porous sheets. sheet is used.

Then, between these fiber materials 13 and 14, short fibers and long fibers 9 obtained by cutting the fiber material 8 by the fiber cutting machine 12 are added, and the foamed curable resin liquid is further added. The surface layer material 20 is formed by impregnating these fiber materials and sandwiching them between the sheet materials 13 and 14. Similarly, short fibers and long fibers 9 obtained by cutting the fiber material 8 and a resin liquid are added between the sheet materials 13 and 14 by the fiber cutting machine 12, and these are sandwiched to form the surface layer material 20. It is formed.

In the figure, 10, 11, 10, 11 are respectively guide rolls of fiber material, 15, 16, 15, 16 are impregnation rolls for improving the impregnation of the foam curable resin liquid into the fiber material, IT, 18, l9 is the surface layer material 20, 17,
Reference numerals 18 and 19 are guide rolls for guiding the surface layer material 20, respectively, and the surface layer materials 20 and 20 are guided to a forming path composed of endless belts 32, 33, support rolls 34, 34, 35, 35, etc. They are introduced in a superimposed state. At that time, the foamed hardening resin liquid is supplied between the two layers of surface layer materials 20 and 20 through the supply pipe 27, and aggregate 30 is further supplied through the quantitative feeder 31. While being held in between, the resin liquid is guided to a molding path, where the resin liquid is foamed and hardened, and the lightweight structural material 36 is taken out by a tensioning machine 3T and cut into an appropriate length. be done. Note that the aggregate 30 does not necessarily need to be used in the present invention, but the aggregate 30
When 0 is used, as the aggregate, in addition to various commonly used aggregates and fillers, crushed plastic layers, cut wood layers, etc. may be appropriately selected and used.

Next, FIG. 2 is a sectional view showing a lightweight structural material 36 obtained in the embodiment of the present invention shown in FIG. It has a structure in which a sheet material 14, a foam layer 39 in which aggregate is dispersed, a porous sheet material 14, a fiber-reinforced foam layer 38, and a film-like sheet material 13 are laminated in this order and integrated.

Since the method for manufacturing the lightweight structural material of the present invention is as described above, not only the surface layer and center portion are made of synthetic resin foam and is excellent in lightness, but also the surface layer is made of fiber material. This makes it possible to easily manufacture structural materials that are reinforced with aluminum and have excellent impact resistance, strength, and rigidity.

In addition, the lightweight structural material manufactured by the present invention can be cut with a wood saw and nailed in the same way as wood, so it has excellent workability, and it does not require the use of ordinary adhesives for gluing. It is possible.

Furthermore, the synthetic resin foam in the center can be made into a closed-cell material with a low density, so it hardly absorbs water even when used outdoors or underwater for long periods of time. Light weight and excellent heat insulation properties can be maintained for a long period of time. The above-mentioned lightweight structural materials manufactured by the method of the present invention can be used as insulating wall materials for houses, floor materials, materials for benches or balconies, corrosion-resistant structural materials for sewage treatment plants, chemical factories, etc., truck loading materials, land-based or Materials for marine containers,
It is suitable for use in core materials for FRP ships, etc.

Next, examples of the present invention will be described.

Example Using the apparatus as shown in FIG.
Using a polyfluorinated vinyl film with r1 and a thickness of 32μ,
As the porous sheets 14 to 14, a polypropylene fiber-wrapped nonwoven fabric (307/M2) with a width of 50 cm was used, and as the fiber materials 8, 8, 9, and 9, 200 single fibers with a thickness of 9 μ were collected into one strand. 60 strands of glass rope were used, and fiber materials 8 and 8 were cut into lengths of 1' inch using a fiber cutting machine.
was supplied without cutting.

The sheet was fed by a tensioner knob 37 so as to move at a speed of 1 TrL/Mln, and the amount of fiber materials 8 and 9 (or 8 and 9) fed was 675 t/Mln.

As the sheet materials 13 and 14 pass through the impregnation rolls 15 and 16 and the sheet materials 13 and 14 pass through the impregnation rolls 15
When passing through the torch 16r, the fiber material 8, 9 or 8,
9 is supplied between the sheet materials, and at the same time, a foamed curable resin liquid is supplied through supply pipes 7, 7.

This resin liquid consists of 100 parts of polyether polyol, 1 part of silicone oil, 1 part of water, and 2 parts of monofluorotrichloromethane.
8259/M with a mixture of 100 parts by weight of 0.3 parts by weight of dibutyltin dilaurate and 120 parts by weight of crude diphenylmethane diisocyanate.
The fiber material was uniformly impregnated into the fiber material and sandwiched between the sheet materials to form the surface layer material 20 (or 20).

Next, while the surface layer material is progressing, the supply pipe 2
7, 100 parts of polyether polyol, 1 part of silicone oil, 2 parts of water, 5 parts of monofluorotrichloromethane
8 parts by weight of a foamed curable resin liquid consisting of 100 parts by weight of a mixture of 0.5 parts by weight of dibutyltin dilaurate and 150 parts by weight of crude diphenylmethane diiricyanate.
At the same time, shirasu balloons were supplied as aggregates at a ratio of 1709/Mln, and then the surface layer material 20 was superimposed thereon and introduced into the molding path.

This molding passage has dimensions of 50 cm width, 2 cm thickness, and 9 m length, and the 3 m length from 3 m from the entrance to 6 m from the entrance is heated with 803C hot air, and then The 3m length was water-cooled. The resin liquid was foamed and hardened in the molding passage, and the resulting product was taken out by a tensioner 37. The resulting product has a width of 50Cr.
It is a plate-like object with a thickness of 2Crr1 and a surface layer of 5m thick made of glass fiber and urethane foam, and a center part with a thickness of about 10wr1fL made of urethane foam filled with shirasu balloons. The surface was covered with a smooth, completely bonded polyvinyl fluoride film.

In addition, the surface layer and the center were integrated and did not separate. Furthermore, in the surface layer, the long fibers were aligned in the longitudinal direction, but the short fibers were oriented in random directions. In addition, the physical properties of the product were as shown in Table 1 below.

[Brief explanation of the drawing]

Figure 1 is an explanatory diagram showing an example of the invention method, and Figure 2 is an explanatory diagram showing an example of the invention method.
FIG. 2 is a cross-sectional view showing a lightweight structural material obtained by the method shown in the figure. 1, 1, 2, 2, 21. 22... Storage tank for foaming curable resin liquid component, 7, 7,, 27... Supply pipe for resin liquid, 8, 8, 9 , 9... fiber material, 12
, 12... fiber cutting machine, 13, 13, 14, 1
4... Sheet material, 20, 20... Surface material, 30... Aggregate, 32, 33...
... Endless belt that constitutes the molding passage, 36...
...Lightweight structural material, 38, 38... Fiber-reinforced foam layer, 39... Foam layer in which aggregate is dispersed.

Claims (1)

[Scope of Claims] 1. A fibrous material impregnated with a foamed curable resin liquid is sandwiched between two layers of a surface layer material between sheet materials, and a foamed curable resin liquid is supplied between the two layers to form a mold. 1. A method for manufacturing a lightweight structural material, comprising: placing a foamed curable resin liquid in the mold and foaming and hardening the foamed curable resin liquid within the mold. 2. The manufacturing method according to claim 1, wherein the molding mold is a molding passage constituted by an endless belt, and foaming and curing is continuously performed within the passage. 3. The manufacturing method according to claim 1, wherein the foamed curable resin liquid supplied between the two layers of the surface layer material is mixed with an inorganic filler. 4. The manufacturing method according to claim 1, wherein the fiber material is made of glass fiber. 5. The manufacturing method according to claim 1, wherein the sheet material on the side that comes into contact with the foamed curable resin liquid supplied between the two layers of the surface layer material is a fibrous sheet-like material.