JPS5949907B2 - Manufacturing method of lightweight plate-like synthetic material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a lightweight plate-shaped synthetic material made of synthetic resin foam and fibers.

Various synthetic materials using synthetic resin foams have been proposed in the past, such as those in which the surface of synthetic resin foams is covered with asbestos slate or metal plates, and those in which fiber materials are dispersed in the foams. BACKGROUND OF THE INVENTION Synthetic resin foams reinforced with fibers are known. However, when asbestos slate is used in the former VC, it is weak against impact and has poor workability when cutting with a saw, etc. When a metal plate is used, workability is poor, and even in the case of 0, it is insufficient. It is not possible to achieve significant weight reduction. Furthermore, even if the surface of the synthetic resin foam is covered with a synthetic resin plate reinforced with fibers, the surface is hard, so the impact resistance is not sufficient, and furthermore, in any of the above cases, the compressive strength is not sufficient. In addition, in the case of synthetic resin foam reinforced with fiber materials dispersed therein, even if it has excellent impact resistance, workability, strength, etc., when the foaming ratio is increased, the interface with the fibers contained therein will deteriorate. The bubbles become open and absorb water easily, which increases the weight and impairs the insulation properties, so the foaming ratio 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 impact strength and compressive strength, and are also excellent in workability. It was developed with the aim of providing a sheet with a cross-sectional shape perpendicular to the direction of travel, and the gist is that a large number of continuous long fibers are arranged so that the cross-sectional shape perpendicular to the direction of travel is a sheet cross-sectional shape, and the fibers continuously travel in one direction. Then, between the continuous long fiber material layers impregnated with the foamed curable resin liquid, the foamed curable resin liquid was held in the voids of the one-Nicum structure...Nicum material was inserted and these were combined. The light-weight plate-shaped composite is led to a molding passage having an inlet and an outlet and having a plate-like cross-sectional shape, in which the foamed curable resin liquid is foamed and cured. It depends on the manufacturing method of the material.

The foamed curable resin used in the present invention refers to a synthetic resin liquid that can be foamed and hardened in a short time, such as hard polyurethane, unsaturated polyester-phenolic resin, urea resin, melamine resin, and epoxy resin. The liquid is given foaming and hardening properties before being used.

Among these resin liquids, hard polyurethane is particularly suitable. Further, the resin liquid applied to the continuous filaments and the resin liquid applied to the honeycomb material may be of the same type (although they may be of different types).Next, as the continuous filaments, , the type is not particularly limited,
For example, inorganic fibers such as glass fibers, carbon fibers, and asbestos fibers, organic fibers such as vinylon fibers, and polypropylene fibers can be used, but glass fibers are particularly preferred from the viewpoint of strength, elastic modulus, and economical efficiency. .

Since the fibers are drawn in one direction and made to advance continuously, they need to be continuous long fibers. Furthermore, the type of the honeycomb material used in the present invention and the shape of the honeycomb structure are not particularly limited, and the honeycomb core material conventionally used as a material for sanderch structure materials may be used. Rice, such as paper honeycomb, resin-impregnated paper honeycomb, plastic honeycomb, etc., can be suitably used.

Furthermore, the molding passage used in the present invention has an inlet and an outlet, and is surrounded by walls so that its cross-sectional shape is a plate material, and the foam hardening process is carried out within the passage. This completes the foaming and curing of the resin liquid.

In the present invention, it is preferable to use a molding passage whose surrounding wall surface is constituted by an endless belt because the resistance when passing through the passage is small. The method of the present invention will be explained below with reference to the drawings. FIG. 1 is an explanatory diagram showing an embodiment of the method of the present invention, and 11 in the figure is a continuous long fiber.

A large number of these continuous long fibers 11 are arranged in the width direction,
The sheets are arranged by guides 12 so that the cross-sectional shape perpendicular to the traveling direction becomes the sheet cross-sectional shape, and are continuously advanced in one direction.
A foamed curable resin liquid is supplied from 3 and passed through an impregnating device 14 consisting of two rubbing plates, so that the resin liquid is uniformly impregnated between the fibers to form a resin liquid-impregnated continuous long fiber material layer. It will be done. Two material layers as described above are prepared,
A honeycomb material 21 is inserted between these layers. The honeycomb material retains the foamed curable resin liquid supplied from the foamed curable resin liquid supply device 22 and the aggregate supplied from the aggregate supply device 23 in the voids of its one-nicomb structure. Note that the above aggregate may be omitted in the method of the present invention. In this embodiment, the resin liquid and the like are retained in the voids of the one-nicomb structure by placing a sheet-like material 31 made of fibers on the lower surface of the honeycomb material 21. 34 is a conveyor for transporting the one-nicum material 21.

Note that the sheet-like material 31 is not an essential requirement in the present invention, but is an example for retaining the resin liquid in the voids of the honeycomb structure. 32 is a sheet-like material 3 applied to the upper surface of the honeycomb material as necessary in the present invention.
These are sheet-like materials similar to 1, and 33 is a card roll for these sheet-like materials 31 and 32. Next, the above-mentioned two layers of resin liquid impregnated continuous long fiber material layer...Nicum material 21. The sheet-like materials 31, 32, etc. are overlapped and combined and guided to the molding path 4.

The molding passage 4 has an inlet and an outlet, and has a plate-like cross section, and the surrounding wall surface is constituted by endless belts 41, 41.
, 41 are held and rotated by rolls 42, 42. The foaming and curing of the foamed curable resin liquid added to the long fibers 11 and the honeycomb material 21 in the molding passage 4 is completed, and the plate-shaped synthetic material 5 is taken out as the molding passage 4. Note that the molding passage 4 may be appropriately provided with a heating device for promoting foaming and hardening of the resin liquid, and a cooling device for lowering the temperature after foaming and hardening. FIG. 2 is a cross-sectional view of the molding passage 4 shown in FIG. 1 at the time when foaming of the resin liquid is completed. Among them, a foam layer 111 containing long fibers 11, a sheet-like material 31, a honeycomb material 2L sheet-like material 32 filled with foam and aggregate 231, and long fibers 11.
A plate-shaped synthetic material is formed in which the foam layers 111 including the foamed layers 111 are laminated in this order.

Since the method for manufacturing the lightweight plate-like synthetic material of the present invention is as described above, the surface layer is made of long fiber-reinforced synthetic resin foam and has excellent impact resistance, mechanical strength in the longitudinal direction, rigidity, etc. Not only is it excellent, but the middle layer is filled with foam.
-Made of Nicum material, it has excellent compressive strength and bending strength in the width direction, and is lightweight, such as insulating wall materials for houses, flooring materials, materials for benches and balconies, truck loading materials, materials for land and sea containers, etc. It is possible to continuously produce a plate-shaped synthetic material suitable for use in core materials for FRP ships and the like.

In particular, when the aggregate is applied to the honeycomb material together with the foamed curable resin liquid, the compressive strength becomes even better, and it can also be advantageous in terms of cost.

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram showing one embodiment of the method of the present invention, and FIG. 2 is a sectional view at the time when foaming of the resin liquid in the molding passage 4 shown in FIG. 1 is completed. 11... Continuous long fibers, 13, 22... Foaming curable resin liquid supply device, 14... Impregnation device, 21... Honeycomb material, 31, 32... Sheet-like material made from fibers , 4... Molding passage, 41... Endless belt,
42...Roll, 5...Plate-shaped synthetic material.

Claims (1)

[Claims] 1. A large number of continuous long fibers are arranged so that the cross-sectional shape perpendicular to the direction of travel is a sheet cross-sectional shape, and continuously travel in one direction, and is impregnated with a foamed curable resin liquid. A honeycomb material holding a foamed curable resin liquid is inserted into the voids of the honeycomb structure between the continuous long fiber material layers, and these are combined to have an inlet and an outlet, and the cross-sectional shape is a plate. A method for producing a lightweight plate-shaped synthetic material, characterized in that the foamed curable resin liquid is guided into a molding channel shaped like a molding channel, and the foamed curable resin liquid is foamed and cured therein. 2. The manufacturing method according to claim 1, wherein the foamed curable resin liquid held in the voids of the honeycomb structure contains aggregate. 3. The manufacturing method according to claim 1, wherein the forming passage is constituted by an endless belt. 4. The manufacturing method according to claim 1, wherein the long fibers are glass long fibers. 5. The foamed curable resin liquid is retained in the voids of the honeycomb structure by a sheet-like material placed on the lower surface of the honeycomb material, and this sheet-like material is made of fibers.Claim 1 Manufacturing method described.