JPS598229B2 - Manufacturing method for composite structural materials - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a composite structural material reinforced with long fibers suitable for use in building materials and the like.

Recently, fiber-reinforced synthetic resin foams suitable for use in building materials, etc., are being foamed and hardened by continuously introducing long fiber bundles impregnated with resin liquid into a molding channel. A method of manufacturing the same is provided.

However, products manufactured by this method have drawbacks such as low surface strength and easy scratching, and low compressive strength, so that if pressure is applied locally, dents are likely to occur in that area. . It is also known to manufacture a sandwich structure by using a synthetic resin foam as a core and covering the core with an FRP board as a surface material, but such a manufacturing method complicates the manufacturing process and is not economical. Furthermore, it is difficult to continuously manufacture elongated bodies suitable for use as building materials.

In view of the drawbacks of the conventional methods as described above, the present invention has been made to provide a method for continuously producing a long fiber reinforced synthetic resin foam that has excellent surface strength and compressive strength and is suitable for use in building materials, etc. The gist of this is that long fiber bundles impregnated with a foaming resin liquid that foams and hardens in a relatively short period of time to produce a resin foam are continuously introduced into a molding channel. At the same time, a layer of aggregate is provided between at least two sheets of fibrous material so as to be sandwiched between at least one surface of the forming path and the long fiber bundle, and a layer of aggregate is provided between at least two sheets of fibrous material for a relatively short period of time. continuously introducing a composite sheet material containing a curable resin liquid that is cured in a molding passage to complete foaming and curing of the foamable resin liquid and curing of the curable resin liquid in the molding passage. The main feature lies in the manufacturing method of composite structural materials.

The foamable resin liquid used in the present invention is initially a liquid, but has the property of foaming and hardening in a relatively short period of time to produce a resin foam. Although any of these may be used, it is preferable to use a thermosetting resin for use as a building material. Further, in order to foam the resin, a foaming agent that reacts with heat, a catalyst, etc. and foams may be used. Specific examples of resins suitably used in the present invention include polyurethane resins, unsaturated polyester resins, phenol resins, urea resins, and the like. Next, the long fiber bundle impregnated with the foamable resin liquid is a bundle of many long fibers aligned in one direction, and the type thereof is not particularly limited, such as glass fiber, carbon fiber, etc. , metal fibers, natural fibers, synthetic fibers, rayon fibers, etc.

In particular, it is preferable to use glass fiber from both the physical properties and economic efficiency of the composite structural material obtained by the method of the present invention.
Next, the molding passage is a mold for molding that has a passage shaped according to the cross-sectional shape of the intended product, and is provided with an inlet and an outlet, and the length of the passage is continuous within this mold. The length is set such that the resin liquid impregnated into the moving long fiber bundle can complete foaming and curing. The molding passage may be appropriately provided with a heating device for starting or promoting foaming and hardening of the resin liquid, and a cooling device for cooling the molded product after foaming and hardening. Further, the molding passage may be a cylindrical body composed of a fixed wall surface, but in order to reduce friction with the molded body passing through the passage, the passage may be surrounded by a number of endless belts. In this case, it is necessary to support the endless belt constituting the molding path from the outside with a plate-shaped body, rollers, etc. so that it does not curve outward due to the foaming pressure. . In addition, a sheet-like fiber material is one in which the same types of fibers as mentioned above for long fiber bundles are formed into a sheet shape. This can be done by making it into a mat shape, by making it into a net shape, or by collecting short fibers into a mat shape.

In the present invention, at least two of the above-mentioned sheet-like fiber materials are used, and a layer of aggregate is provided between them. Silica sand, calcium carbonate, talc, shirasu balloons, perlite, glass balloons, etc. are used.

Further, in the present invention, the composite sheet material consisting of at least two sheet-like fibers and an aggregate layer interposed between them is made to contain a curable resin liquid that hardens in a relatively short time. However, the type of the curable resin liquid is not particularly limited as long as it cures in a relatively short time, and it may be the same type as the resin used for the foamable resin or a different type.

Examples of curable resins suitable for use in the present invention include unsaturated polyester resins, phenolic resins, and urea resins. Further, the above-mentioned curable resin may be contained in the entire composite sheet or in a part thereof, and when it is contained in one part, it is contained in the sheet-like fiber material on the side opposite to the one in contact with the long fiber bundle. Preferably, it is contained.
Next, the method of the present invention will be explained with reference to the drawings.
FIG. 1 is an explanatory diagram showing the steps of one embodiment of the present invention,
In the figure, reference numeral 1 is a long fiber bundle, which is traveling in the direction of the arrow.
0 and impregnated into the long fiber bundle 1.

31 and 32 are impregnated plates for uniformly dispersing the resin 2, and perform reciprocating motion in a direction perpendicular to the traveling direction of the long fiber bundle.

In the figure, reference numeral 4 denotes a molding passage, into which the long fiber bundle 1 impregnated with the resin liquid 2 is continuously introduced. The driving force required to move the long fiber bundle 1 is provided by a take-up roll (not shown) provided in front of the product 8 obtained by the method of the present invention. 51, 52, 53, 5 in the diagram
4 are sheet-like fibrous materials, which are supplied by winding bodies 510, 520, 530, 540 of the material.

Further, 71 and 72 are curable resin liquids that harden in a relatively short time, 710 and 720 are liquid tanks for the resin liquids, and 71
1 and 721 are press rolls to ensure impregnation. The sheet-like fibrous materials 52 and 54, which are positioned on the outside when introduced into the molding passage 4, pass through presser rolls 711 and 721, respectively, to form the curable resin liquid 7.
1,72 will be contained. Then, aggregates 61 and 6 are applied from aggregate supply devices 610 and 620 onto the surfaces of sheet-like fibrous materials 52 and 54 containing the curable resin liquid.
2 is dispersed quantitatively to form a layer, and other sheet-like fiber materials 51 and 53 are laminated thereon to form a composite sheet material. and sheet-like fibrous material 51,5
2 and aggregate 61 is formed into a molding passage 4.
A composite sheet material made of sheet-like fiber materials 53, 54 and aggregate 62 is sandwiched between the lower surface of the molding channel 4 and the long fiber bundle 1 so as to be sandwiched between the upper surface and the long fiber bundle 1. are respectively introduced into the passage 4. In this way, in this example, two types of composite sheet materials consisting of two sheet-like fiber materials and one aggregate layer were prepared and introduced into the upper and lower surfaces of the molding channel, but the present invention In this case, the composite sheet material may have more than two sheets of fibrous material and more than one aggregate layer, and the molding passage into which the composite sheet material is introduced may have one or more surfaces. Good. Then, in the forming passage 4, the foamable resin liquid 2 contained in the long fiber bundle 1 is foamed and cured, and the curable resin liquids 71 and 72 contained in the composite sheet material are cured, and the long fibers are The bundle 1 expands due to foaming and fills the passage 4, and is firmly bonded and integrated with the composite sheet material by hardening of the resin liquid to form a composite structural material, which is taken out from the passage 4 and cut into an appropriate length. It will be cut off right away.

FIG. 2 is a perspective view of a composite structural material obtained by the process shown in FIG. 51 has a sheet-like fibrous material 53 and an aggregate 62 on the lower surface.
and a sheet-like fiber material 54, respectively, and these are firmly integrated by hardened resin.

As described above, the composite structural material obtained by the method of the present invention has a surface layer on the surface of the long fiber reinforced foam having a structure in which an aggregate layer is interposed between at least two sheets of fibrous material. By providing this surface layer, the surface strength is improved and the surface becomes less likely to be scratched, and the bending rigidity and bending strength are also improved. Furthermore, the compressive strength is improved, and local This makes it difficult for dents to form even when subjected to compressive force.

Furthermore, if the fibers used in the sheet-like fiber material 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. This makes it possible to impart marble patterns, mosaic patterns, and other desirable patterns to the surface of the composite structural material. Next, FIG. 3 is a cross-sectional view showing an example of a forming passage preferably used in the method of the present invention.
2, 413, and 414 are endless belts, and these endless belts form a path for the long fiber bundle. and 421, 422, 423 and 4
24 are rollers, which form the outer frame and prevent the endless belt forming the molding path from curving outward due to internal foaming pressure, and also prevent the endless belt from curving outwards when the endless belt moves together with the long fiber bundle. It has the effect of reducing frictional resistance. In the method of the present invention, if a forming path formed by an endless belt as described above is used, the endless belt moves together with the molded object within the path, so there is less resistance when taking the product from the path. It is advantageous to continuously produce products of stable quality.
Since the method of the present invention is as described above, surface strength,
Composite structural materials with excellent bending strength, compressive strength, etc., and suitable for use in building materials, etc., can be manufactured continuously.
According to the present invention, the elongated body of the composite structural material described above can be obtained through a relatively simple process.

[Brief explanation of drawings]

Fig. 1 is an explanatory diagram showing the process of one embodiment of the heather invention, Fig. 2 is a perspective view of a composite structural material obtained by the process shown in Fig. 1, and Fig. 3 is a forming passage used in the present invention. It is a sectional view showing one example. 1... Long fiber bundle, 2... Foaming resin liquid, 4... Molding channel, 411, 412, 413
, 414... Endless belt, 51, 52,
53, 54... Sheet-like fiber material, 61, 62
... Aggregate, 71,72 ... Curing resin liquid, 8 ... Composite structural material.

Claims (1)

[Claims] 1. A long fiber bundle impregnated with a foamable resin liquid that foams and hardens in a relatively short period of time to produce a resin foam is continuously introduced into a molding passage, and A layer of aggregate is provided between at least two sheets of fibrous material so as to be sandwiched between at least one side of the passageway and the long fiber bundle, and a curable material that hardens in a relatively short time. A composite structure characterized in that a composite sheet material containing a resin liquid is continuously introduced to complete foaming and curing of the foamable resin liquid and curing of the curable resin liquid within a molding passage. Method of manufacturing wood. 2. The manufacturing method according to claim 1, wherein the forming passage is surrounded by a large number of endless belts. 3. The manufacturing method according to claim 1, wherein the long fiber bundle and the sheet-like fiber material are made of glass fiber.