JP4351879B2 - Method for manufacturing anchor pressure plate - Google Patents

Description

The present invention relates to a method for manufacturing an anchor pressure receiving plate in which plastic waste can be suitably used .

  Conventionally, as an anchor pressure receiving plate, for example, from our company, a plate made of fiber reinforced plastic is used, and a ground anchor pressure receiving plate for fixing a ground anchor inserted into a drilling hole on a ground slope to the ground surface is used. (Hereinafter simply referred to as “anchor pressure receiving plate”) is disclosed (see Patent Document 1).

  The anchor pressure plate is superior to the conventional concrete pressure plate in that the weight is reduced and the workability is improved. However, since all the constituent materials are fiber reinforced plastics, the manufacturing method is not always easy. In addition, there is a problem that the cost is high because the material is expensive.

  On the other hand, the strength of the anchor pressure plate is appropriately selected depending on the conditions of the ground slope used, and therefore does not necessarily require a high strength. The recyclability and the There is a demand for formability that makes it difficult to produce waste materials, or for further lightness and economy.

Japanese Patent Laid-Open No. 06-108465

An object of the present invention, the light of the conventional problems, can be a plastic waste material in a large amount, provided with a light weight and economy, that the manufacturing process is to provide a method of manufacturing easy anchor receiving plate is there.

The method for producing an anchor pressure receiving plate according to claim 1 is made of a resin material containing a pulverized product of plastic waste material, the upper surface and the lower surface are reinforced with FRP, and the outer surface is covered with an elastic resin material. The plate is manufactured using a press mold having a lower mold having a mold surface corresponding to the upper surface and the side surface of the anchor pressure receiving plate, a cylindrical mold, and an upper mold having a mold surface corresponding to the lower surface of the anchor pressure receiving plate. The FRP is laminated on a portion corresponding to the upper surface of the lower mold anchor pressure receiving plate, and then filled with a resin material containing a pulverized product of the plastic waste material, and the upper mold is placed in the cylinder mold. It is characterized by being pressed down and press-molded, integrated with FRP and demolded, FRP is laminated on the lower surface, and then the outer surface is coated with an elastic resin.

The method for manufacturing the anchor pressure receiving plate according to claim 2 is the method for manufacturing the anchor pressure receiving plate according to claim 1, wherein a heater is provided in a portion corresponding to the upper surface of the lower die and in the upper die. It is characterized by.

The method for manufacturing the anchor pressure plate according to claim 3 is the method for manufacturing the anchor pressure plate according to claim 1, wherein when the upper die is press-molded, the cylindrical die is located on the inner side of the side surface of the lower die. It is characterized in that it is installed on the lower mold so as to protrude by an amount corresponding to the thickness of the FRP.

Hereinafter, the present invention will be described in detail.
In the present invention, the plastic waste means a plastic material composed of general waste or industrial waste, and the general waste is a material or product discarded after being used. This refers to materials or defective products generated from the disposal route in the manufacturing process.

The plastic waste material used in the present invention is not particularly limited, and examples thereof include polyolefin plastic waste material, polyester plastic waste material, polyurethane plastic waste material and the like. Moreover, it is preferable that the plastic waste material contains a fiber-reinforced plastic because it is easy to improve the strength, and if the plastic waste material contains a polyurethane-reinforced plastic foam that is further fiber-reinforced, the balance between lightness and strength is improved. More preferable in terms.

  When the pulverized product of the plastic waste material contains a polyurethane-based plastic foam reinforced with fiber, it is particularly preferable that the urethane resin is mixed with the pulverized product as a binder to improve moldability.

The FRP that is used in the present invention is not particularly limited such as by, if so-called fiber-reinforced plastic SMC (sheet molding compound) or BMC (bulk molding compound), mainly comprising normal unsaturated polyester resins and epoxy resins The thermosetting resin is hand laid up in a plurality of layers together with a glass fiber mat and the like and cured and cured.

May be a metal plate is used in the present invention, the metal plate that is used is not particularly limited, iron, stainless steel plates, aluminum plates, and various alloy plate and the like. These may be used alone or in combination of two or more. Among these, an iron plate is preferable in terms of strength and economy.

And an elastic resin used in the present invention is not particularly limited, for example, rubber or thermoplastic elastomer, and the like thereof foam like. Examples of the rubber include butyl, urethane, acrylic, silicone, ethylene-propylene copolymer, and ethylene-propylene-diene terpolymer rubbers. These rubbers may be unvulcanized or vulcanized. Examples of the thermoplastic elastomer include isoprene-based elastomers, olefin-based elastomers, ester-based elastomers, and urethane-based elastomers. Among them , urethane-based resins such as elastic urethane resins are preferably used.

Hereinafter, the manufacturing method of the anchor pressure receiving plate of this invention is demonstrated, referring drawings.
FIGS. 1-7 is explanatory drawing which illustrates a series of processes about the manufacturing method of the anchor pressure receiving plate which concerns on this invention. In the figure, reference numeral 1 is a lower mold of the press mold, reference numeral 2 is a cylinder of the press mold, reference numeral 3 is an upper mold of the press mold, reference numeral 4 is a resin material containing a pulverized plastic waste, and reference numeral 5 is FRP, code 6 is an ejector.
Since the press die is formed by turning the anchor pressure plate upside down, the lower die 1 corresponds to the upper surface and the inclined surface of the anchor pressure plate, and the portion 11 corresponding to the upper surface and the portion corresponding to the inclined surface. 12 and 12. The upper die 3 corresponds to the lower surface of the anchor pressure receiving plate.

Hereinafter, an example of a method for manufacturing an anchor pressure receiving plate according to the present invention will be described in the order of steps.
First, as a first step, three plies (three layers by hand layup) of FRP 5 are formed on a portion 11 corresponding to the upper surface shown in FIG. 1, and a metal plate (not shown) is laminated as necessary. In this case, it is preferable that the FRP 5 is formed not only in the portion 11 corresponding to the upper surface as shown in the figure but also in the portions corresponding to the inclined surface 12 and the side surface 15 in that the strength of the obtained anchor pressure receiving plate is improved. Further, it is preferable to apply a gel coat to the surface in the lower mold in advance before the hand laying up of the FRP 5 in terms of improving the appearance of the surface.

  As the shape of the metal plate, for example, an appropriate shape such as the shape of the ribbed iron plate 20 or the flat iron plate 21 as exemplified in the anchor pressure receiving plate of FIGS.

  Next, as a second step, as shown in FIG. 2, the resin material 4 containing the pulverized plastic waste material is filled and press-molded using the upper die 3 as shown in FIG. 3 to be integrated with the FRP. To do. In this case, the press pressure is not particularly limited, but is usually 2 to 5 MPa. Further, as shown in FIG. 8, the size of the press plate 16 used for pressing the upper die 3 during pressing is not necessarily the same as that of the upper die 3, and may be smaller than the upper die 3. In this case, it is preferable to use the presser 17 during curing after pressing because the upper mold 3 can be fixed and stably cured.

  The curing conditions after the pressing are not particularly limited. However, when the resin material 4 contains a thermosetting material such as a urethane resin, the curing reaction is promoted, for example, as illustrated in FIG. As described above, it is preferable to provide the heater 18 in the portion 11 corresponding to the upper surface of the lower die 1, the portion corresponding to the inclined surface 12, and the upper die 3.

  Further, as shown in FIG. 8B, when the cylindrical mold 2 is installed so as to protrude from the surface of the side surface portion 15 of the lower mold 1 by an amount corresponding to the thickness of the FRP 5, the upper mold 3 is pushed down. At this time, it is preferable in that FRP 5 can be prevented from being caught.

  Next, as a third step, as shown in FIG. 4, the molded product in which the portion corresponding to the upper surface of the resin material 4 is reinforced with FRP 5 is removed, and as shown in FIG. 5, it corresponds to the lower surface of the molded product. 3 layers of FRP13 (3 layers by hand layup) are laminated on the part to be processed. At the time of demolding, in order to facilitate demolding, it is preferable to use ejectors 6 and 6 as shown in FIG.

As shown in FIG. 6, the obtained molded product has an anchor insertion hole 19 having an appropriate shape to obtain an anchor pressure receiving plate. In the present invention, as shown in FIG. 7, if necessary, the foam 14 may be further adhered and laminated in contact with the FRP 13 on the side corresponding to the lower surface portion. By doing in this way, it is preferable at the point which the lightweight property of the anchor pressure-receiving plate obtained improves.

Further, in order to reinforce the strength of the upper surface portion, for example, as shown in FIG. 9 may be reinforced with an upper surface 26 with the supporting steel plate 23.

Furthermore, in the present invention, as illustrated in FIG. 12, since the outer surface of the anchor pressure receiving plate is covered with an elastic resin 24 such as urethane resin, the elastic resin 24 easily follows deformation during construction. Depression on the outer surface such as the upper surface and the slope is less likely to occur, and the appearance can be improved.

According to the manufacturing method of the present invention as set forth in claim 1, it is possible to use a large amount of plastic waste material, and it is possible to provide an anchor pressure receiving plate having both light weight and economy, and further, formed by press molding. Therefore , it is possible to provide a manufacturing method in which waste materials are hardly generated during molding and molding is easy.

  For this reason, it becomes easy to recycle waste, and it can contribute to the reduction of the burden on the environment.

And since the outer surface of the anchor pressure plate is covered with an elastic resin such as urethane resin , the elastic resin can easily follow the deformation during construction, and it is difficult for dents on the outer surface such as the upper surface and the slope to occur. Can be improved.

According to the manufacturing method of the present invention described in claim 2, since the heater is provided in the portion corresponding to the upper surface of the lower mold and the inside of the upper mold, the resin material is heated by heating with the heater. When the thermosetting material is contained, the curing reaction can be promoted in the curing process after pressing, and the production capacity can be improved even when the ambient temperature is low, such as in winter.

According to the manufacturing method of the present invention as set forth in claim 3, when the upper mold is press-molded, the cylindrical mold is protruded by an amount corresponding to the thickness of the FRP inside the side surface of the lower mold. Since it is installed on the lower mold, when the upper mold is pushed down, it is possible to prevent the tip periphery of the upper mold from being caught by the FRP layer formed by being laminated on the surface of the side surface of the lower mold. Can be produced, no defective products are produced, and production efficiency is improved.

The present invention will be specifically described below by showing examples.
In addition, this invention is not limited only to the following Example.
(Example)
As a resin material, 75 parts by weight of an industrial waste pulverized product of synthetic wood (“Neo Lumber FFU” manufactured by Sekisui Chemical Co., Ltd.) containing a fiber-reinforced polyurethane plastic foam was mixed with 25 parts by weight of a urethane resin. Resin material was used.

  As a first step, a gel coat is applied in advance to the surface in the lower mold 1 shown in FIG. 1, and 3 portions of FRP 5 made of unsaturated polyester resin and glass mat are applied to a portion corresponding to the portion 11 corresponding to the upper surface of the lower mold 1. A ply (three layers by hand layup, thickness 2 mm) was formed, and a flat iron plate 21 as shown in FIG.

  Next, as a second step, the resin material 4 is filled as shown in FIG. 2 and the upper die 3 is used as shown in FIG. 3 at a press pressure of 3 MPa, as shown in FIG. The upper die 3 was pushed down with a small-sized press plate 16, and the upper die was fixed with a presser 17 and cured for 12 hours. In addition, as shown in FIG.8 (b), the heater 11 was provided in the part 11 equivalent to the upper surface of the lower mold | type 1, the part of the inclined surface 12, and the upper mold | type 3, and the curing temperature was 50 degreeC. Further, as shown in FIG. 8 (b), the cylindrical mold 2 was installed so as to protrude 2 mm inward from the surface of the side surface portion 15 of the lower mold 1.

  Next, as a third step, as shown in FIG. 4, the molded product is demolded using ejectors 6 and 6, and an unsaturated polyester resin and a portion corresponding to the lower surface of the molded product are formed as shown in FIG. Three plies (three layers by hand layup, thickness 2 mm) of FRP13 made of glass mat were laminated.

  Further, as shown in FIG. 7, the foam insertion hole 19 having a diameter of 100 mm was drilled after the foamed polystyrene was adhered and laminated in contact with the FRP 13.

Subsequently, the upper and lower sides were inverted, and the elastic urethane resin 24 was spray-coated on the upper surface 26 and the slope 25 as shown in FIG. 12, and the support iron plate 23 was attached to the upper surface 26 to obtain an anchor pressure receiving plate.

  The plastic waste material usage rate of the anchor pressure plate obtained as described above is 70%, which is about 60% lighter than the conventional concrete pressure plate, and from the plate molded with the conventional fiber reinforced plastic. The cost can be reduced by 30 to 40% compared to the anchor pressure receiving plate.

It is the 1st explanatory view which illustrates the process of the manufacturing method of the anchor receiving plate concerning the present invention. It is the 2nd explanatory view which illustrates the process of the manufacturing method of the anchor receiving plate concerning the present invention. It is the 3rd explanatory view which illustrates the process of the manufacturing method of the anchor receiving plate concerning the present invention. It is the 4th explanatory view which illustrates the process of the manufacturing method of the anchor receiving plate concerning the present invention. It is a 5th explanatory view which illustrates the process of the manufacturing method of the anchor receiving plate concerning the present invention. It is the 6th explanatory view which illustrates the process of the manufacturing method of the anchor receiving plate concerning the present invention. It is a 7th explanatory view which illustrates the process of the manufacturing method of the anchor pressure plate concerning the present invention. It is explanatory drawing which illustrates the curing method in the manufacturing method of the anchor pressure receiving plate which concerns on this invention. It is a schematic cross section which shows an example of the anchor pressure receiving plate obtained by this invention. It is a schematic cross section which shows the other example of the anchor pressure receiving plate obtained by this invention. It is a schematic cross section which shows the other example of the anchor pressure receiving plate obtained by this invention. It is a schematic cross section which shows the other example of the anchor pressure receiving plate obtained by this invention.

Explanation of symbols

1 Lower mold 2 Cylinder 3 Upper mold 4 Resin material 5 FRP
6 Ejector 11 Portion corresponding to the upper surface 12 Portion corresponding to the slope 13 FRP
DESCRIPTION OF SYMBOLS 14 Foam 15 Side part 16 Press plate 17 Press 18 Heater 20 Ribbed iron plate 21 Flat iron plate 23 Support iron plate 24 Elastic resin 25 Slope 26 Upper surface

Claims (3)

An anchor pressure receiving plate made of a resin material containing a pulverized waste plastic waste, whose upper and lower surfaces are reinforced with FRP, and whose outer surface is coated with an elastic resin material, corresponds to the upper and side surfaces of the anchor pressure receiving plate. A method of manufacturing using a press mold having a lower mold having a mold surface, a cylindrical mold, and an upper mold having a mold surface corresponding to the lower surface of the anchor pressure plate,
FRP is laminated on a portion corresponding to the upper surface of the lower mold anchor pressure plate, and then filled with a resin material containing a pulverized product of the plastic waste material, and the upper mold is pushed down along the cylinder mold and press molded. Then, after demolding integrally with FRP, FRP is laminated on the lower surface, and then the outer surface is covered with an elastic resin, and the method for producing an anchor pressure receiving plate is characterized.
2. The method for manufacturing an anchor pressure receiving plate according to claim 1, wherein a heater is provided in a portion corresponding to the upper surface of the lower mold and in the upper mold. When press-molding with the upper die, the cylindrical die is placed on the lower die so as to protrude from the side surface of the lower die by an amount corresponding to the thickness of the FRP. A method for manufacturing an anchor pressure receiving plate according to claim 1.

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