JPH0437521A - Manufacture of laminated molded item - Google Patents

Abstract

PURPOSE:To reinforce the lug part near the terminal edge part of reinforced core material by a method wherein the core material, which is prepared by infiltrating synthetic resin in reinforcing fiber material, is formed at the lug part in tubular loop and the terminal edge part of the core material at the lug part is bonded to the core material at the main body part under heat and pressure in a mold and the reinforced core material is extrusion- coated with molten thermoplastic resin. CONSTITUTION:Band-like reinforced core material 10, which is prepared by infiltrating thermoplastic resin in long fibers, is shaped into the reinforced core material 10 consisting of the core material 10a at the lug part, which is formed in hollow square loop with a heat forming device 60, and the groove-shaped core material 10b at the main body part. The reinforced core material 10 is introduced in a crossheat mold 70 under the condition that the terminal edge part 10c of the core material 10a at the lug part is brought into contact with the core material 10b at the main body part. The terminal edge part 10c of the core material 10a at the lug part is softened and fused by the heat given from the heated mold 70 to the core material 10b at the main body part at the core material introducing slit part 7a of the mold and the whole surface of the reinforced core material 10 excluding the inside of the core material 10a at the lug part is covered by melt-extruded thermoplastic resin 20 at the resin covering slit part 70b of the mold, resulting in obtaining an eave gutter-like laminated molded item, in which the terminal edge part 10c of the core material 10a at the lug part is bonded under heat and pressure to the core material 10b at the main body part by the pressure of the thermoplastic resin 20.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for manufacturing a laminate molded product made of fiber-reinforced synthetic resin with excellent durability.

(Prior Art) A molded product provided with an edge, such as an eave gutter, generally consists of a main body part and an ear part, and is extruded into a long length from thermoplastic resin such as vinyl chloride resin and is widely used. However, such thermoplastic resin molded articles have large thermal expansion and contraction and low rigidity, and therefore have the disadvantage that they are easily deformed due to seasonal changes and temperature changes between day and night, and are prone to cracking.

As a molded product that improves on these drawbacks, a laminate molded product in the shape of an eave gutter has been proposed, as shown in FIG. ing. This type of laminated molded product generally uses a strip-shaped core material impregnated with a reinforcing core material to make a reinforcing core material 1 in the shape of an eave gutter. It is manufactured by introducing the core material into the core introduction slit section 6 of the Rosshend mold 5 and melting and extruding the thermoplastic resin 2 to cover the resin coating slit section 6' following the core introduction slit section 6.

In this case, as shown in FIG. 6, the reinforcing core material 1 is generally extended not only to the gutter-shaped main body part 3 but also to the ear part 4 to strengthen this part. The ear part core material 1'' is formed in a substantially cylindrical shape t-a to the ear part 4, and its edge 1'' is in contact with the main body part core material 1'' or is slightly separated from it, and is connected to the inside thereof. A thermoplastic resin 2 is extrusion coated on the outside.

(Problem to be Solved by the Invention) However, in the case of a laminated molded product using such a conventional reinforcing core material, especially the edge 1'' of the reinforcing core material.

The reinforcement of the nearby ears 4 is insufficient. Therefore, when a laminated molded product is used as an eaves gutter, when the eaves gutter is exposed to direct sunlight and becomes high temperature, the ear portion 4 near the edge 1゛°' of the reinforcing core material 1 deforms, causing the ear portion 4 to deform. In some cases, the ear part 4 may open or the mounting bracket may come off, and the function of the ear part 4 may not be fully demonstrated.

Further, when introducing the reinforcing core material 1 into the core material introduction slit section 6 of the crosshead mold 5 and melt-extruding the thermoplastic resin 2 to cover the resin coating slit section 6' following the core material introduction slit section 6, As shown in Figure 8, the edge 1 and the main body core 1
If the distance between the core material introduction slit portion 6 and the core material introduction slit portion 6 is too wide, a gap e will be created near the edge of the core material introduction slit portion 6 by 1°. When this gap e occurs, a so-called backflow phenomenon occurs in which the molten resin flows back from the resin coating slit section 6'' to the core material introduction slit section 6, as shown in Fig. 7, and the backflow occurs during continuous molding. The resin clogs the core material introduction slit 6, making it difficult to extrude and cover the reinforcing core material 1.

The present invention solves the above-mentioned problems, and its purpose is to sufficiently strengthen the ears near the terminal edge of the reinforcing core material so that the ears do not deform even when used in high-temperature environments. It is an object of the present invention to provide a method for producing a laminate molded product, which does not cause the occurrence of huck flow phenomenon when melt extrusion coating a thermoplastic resin in a crosshead mold.

(Means for Solving the Problems) The method for manufacturing a laminate molded product of the present invention uses a belt-shaped reinforcing core material made of reinforcing fiber material impregnated with synthetic resin, and transforms the ear core material into a loop-shaped cylindrical shape. The end edge is bent to bring it close to or in contact with the main body core material, and in this state it is introduced into the crosshead mold of the extruder, and the end edge of the ear core material is bent in the crosshead mold. The present invention is characterized in that it is thermocompression bonded to the main body core material and that the entire surface of the reinforcing core material is melt-extruded coated with a thermoplastic resin and integrated, thereby achieving the above object.

The present invention will be described below with reference to the drawings.

FIGS. 1 and 2 are schematic diagrams of an example of manufacturing eaves gutters as an example of the method of manufacturing the laminated molded product of the present invention.

In FIG. 1, the fibers 11 are a large number of continuous long fibers, and as the long fibers 11, rovings made of glass fibers, carbon fibers, alumina fibers, aramid fibers, etc. are preferably used.

A large number of long fibers 11 are fed out from a bobbin and arranged in a strip in the longitudinal direction, and are placed in a fluidized bed 3 equipped with a porous bottom plate 31.
0 is introduced. The long fibers 11 are usually defibrated by a defibrator 32 before being introduced into the fluidized bed 30 or in the fluidized bed 30 as shown in the figure.

In the fluidized bed 30, a powdered thermoplastic resin 12 is blown up by air pressure above a porous bottom plate 31 and maintained in a floating state. The particle size of the powdered thermoplastic resin 12 is generally about 10 to 200 μm. Then, a large number of long fibers 11 introduced into the fluidized bed 30 are impregnated with powdered thermoplastic resin 12 in a suspended state.

As the thermoplastic resin 12, engineering resins such as vinyl chloride resin, chlorinated vinyl chloride resin, polyethylene, polypropylene, acrylic resin, nylon resin, polyphenylene sulfide, and polyether sulfone are used.

The long fibers 11 can theoretically be contained up to 90% by volume of the thermoplastic resin 12, but it is usually preferably used in a range of 60% by volume or less.

When long fiber]1 exceeds 60% by volume relative to thermoplastic resin2, cracks are likely to occur due to impact.

The long fibers 11 impregnated with powdered thermoplastic resin 12 are
The thermoplastic resin 12 is passed through a heating furnace 40 and impregnated therein.
is heated and fused with molten metal, which is further thermocompressed by a pair of heated pinch rolls 41 to uniformly impregnate the inside and adjust the thickness. Then, it is taken up by a pair of take-up pinch rolls 50. In this case, the pair of heating pinch rolls 41 may be arranged in one set or in plural sets. In FIG. 0, two sets are arranged.

The above arrangement of the pair of heating pinch rolls 41 and the heating furnace 40 may be reversed, and the pair of heating pinch rolls 41 may be used to first perform thermocompression bonding, followed by heating in the heating furnace 40. In this way, the belt-shaped reinforcement may be Core material 10 is formed. Band-shaped reinforcing core material 10
may be wound up once as shown in the figure, but may be continued to the next step without being wound up.

Next, as shown in FIG. 2, the strip-shaped reinforcing core material 10 is
The heating forming device 60 heats and softens the thermoplastic resin 12 to a temperature higher than the softening temperature, and as shown in FIG.
A reinforcing core material 10 in the shape of an eave gutter is formed, which includes a main body portion 10b formed in the shape of a groove. At this time, the ear core material 10a
The terminal edge 10c is bent to be close to or in contact with the main body core 10b.

The reinforcing core material 10 shaped in this way is the ear core material 10a.
is introduced into the crosshead mold 70 of the extruder 71 with the end edge 10c of the main body core 10b in contact with the main body core material 10b. In the crosshead mold 70, when the reinforcing core material 10 is introduced into the core material introduction slit 70a of the crosshead mold 70 shown in FIG.
The terminal edge 10c of the main body core 10b is softened or melted by the heating of the mold 70. Subsequently, the thermoplastic resin 20 melted and extruded from the extruder 71 at the resin coating slit section 70b following the core introduction slit section 70a shown in FIG. The entire surface is coated, and a gutter-shaped laminated product as shown in FIG. 5 is obtained. At this time, the thermoplastic resin 2 to be melt extruded
The terminal edge 10c of the ear core 10a is thermocompression bonded to the main body core 10b by a resin pressure of 0. In addition, in Figure 4, 7
0c is a core material that supports the ear core material 10a of the reinforcing core material 10, and is extended from the heating forming device 60 side and inserted into the crosshead mold 70.

As the thermoplastic resin 20 for coating, vinyl chloride resin,
Resins with good weather resistance such as chlorinated vinyl chloride resins, acrylic resins, and nylon resins are used. Further, the slit gap and the length of the land portion of the crosshead mold 70 are appropriately determined depending on the product thickness, the thermoplastic resin for coating, the extrusion temperature, the extrusion speed, and the like.

Thereafter, the surface is finished by a sizing device 80 such as a cooling mold, cooled, and taken up by a tensioning device 90 such as a caterpillar tensioning machine to form an eaves gutter consisting of a main body portion 21 and an ear portion 22 as shown in FIG. A laminated molded product is produced.

The shape of the ears of the eaves gutter to be manufactured may be square, round, triangular, or other loop-shaped tubes as shown in FIG. 3.

In addition, in the above example, a large number of continuous long fibers 11 were used as the reinforcing fiber material, but instead of this large number of long fibers 11, a band-shaped woven fabric or non-woven fabric may be used.
If woven or non-woven fabrics are used, defibration is not necessary. In addition, on the upper side, powdered thermoplastic resin 12
However, instead of the powdered thermoplastic resin 12, a liquid thermosetting resin such as an unsaturated polyester resin liquid or a photocurable resin may be used. When using a curable resin, the fluidized bed 3
0, an impregnation tank containing liquid thermosetting resin or photocuring resin is used, and in this case, the strip core material 10 is B.
It is a staged semi-cured prepreg.

(Function) According to the method of the present invention, the ear core material is formed into a loop-shaped tube shape, and the end edge thereof is bent and brought into close proximity to or in contact with the main body core material, and then molded into the crosshead mold of the extruder. introduced in
When the end edge of the ear core material is thermocompressed to the main body core material in the crosshead mold, the synthetic resin of the reinforcing core material melts, and the end edge of the ear core material is heated to the main body core material. Since it is glued and fixed, the reinforcing core material at the end edge becomes integrally continuous with the main body part and the ear part, and the end of the reinforcing core material, which was weak in conventional laminated molded products reinforced with reinforcing core material, is removed. The ears near the edges are fully reinforced, as is the body.

In addition, since the end edge is bent and introduced into the crosshead mold of the extruder while being close to or in contact with the main body core material, the end edge does not separate from the main body core material, and the thermoplastic resin When the is extrusion coated, the reinforcing core material of the coated part is pressed and fixed from both sides by the coated thermoplastic resin, and even during the extrusion coating of the thermoplastic resin. There is no possibility that the molten resin flows back toward the core introduction side from the vicinity of the final edge in the crosshead mold.

(Example) Examples and comparative examples of the present invention are shown below.

First of all, glass roving (Jt4400: manufactured by Nittobo)
11 are arranged in a longitudinal direction and introduced into a fluidized bed 30, where they are defibrated and blown up by air to be fluidized and impregnated with vinyl chloride resin blended powder (TX-400: manufactured by Shin-Etsu Chemical) 12 which is in a floating state. This was passed through a heating furnace 40 to heat the resin blended powder to 190°C, and then passed through a pair of heated pinch rolls with a surface temperature of 200°C to be thermocompressed and completely melted, resulting in a thickness of 0.6 m. , width 300 mm,
A strip-shaped reinforcing core material work 0 with a glass roving content of 30% by volume was created.

This reinforcing core material 10 is formed into 8
The material is softened by heating to 0°C, and as shown in FIG. 3, an eaves gutter-like shape is formed, which is composed of an ear core material 10a formed in a loop-shaped cylindrical shape and a bridge body core material 10b formed in a groove shape. The reinforcing core material 10 was shaped. At this time, the terminal edge 10c of the ear core 10a is bent downward and is in contact with the main body core 10b.

Subsequently, the shaped reinforcing core material 10 is formed into an ear core material 10.
The terminal edge 10c of the main body core material 10b is introduced into the crosshead mold 70 of the extruder, and the ear core material 1
0a and the main body core material 10b were coated with a vinyl chloride resin compound having an average degree of polymerization of 1050 by melt extrusion at 185°C to a thickness of 0.5a+n+.

Next, a sizing device 80 performs surface finishing,
It was cooled and taken out by a tensioning device 90, to produce a long eaves gutter with a thickness of 1.5 mm as shown in FIG.

This eaves gutter was cut to a length of 4s+ to make a test piece, and after leaving it in an oven at 80°C for 5 hours, the deformation of the ears was observed, and it was found that the deformation of the ears was very small. Met.

Construction ±1 Example 1 except that the end edge of the ear core material was molded so that it was slightly separated within the ear as shown in FIG.
I did the same thing. In this case, the deformation of the ears of the obtained laminate molded product was extremely large. Further, in the crosshead mold 70 of the extruder, the molten resin for extrusion coating flowed back into the introduction side of the reinforcing core material 10, making it difficult to take off the reinforcing core material 10 and making continuous molding impossible.

(Effects of the Invention) As described above, according to the method for manufacturing a laminate molded product of the present invention, a belt-shaped reinforcing core material made of a reinforcing fiber material impregnated with a synthetic resin is used, and the ear core material is formed into a loop-shaped tube. The end edge is bent to bring it close to or in contact with the main body core material, and in this state, it is introduced into the crosshead mold of the extruder, and the end of the ear core material is formed in the crosshead mold. The edges are heat-pressed to the main body core material, and the entire surface of the reinforcing core material is melt-extruded and coated with thermoplastic resin, so the reinforcing core material at the end edge is integrated with the main body part and the ear part. It becomes a continuous state, and the conventional #
The ear portion near the end edge of the reinforcing core material, which was weak in the No. 11 molded product, is sufficiently strengthened like the main body portion.

Therefore, even if the laminate molded product obtained by the manufacturing method of the present invention is used in a high-temperature environment exposed to direct sunlight, the ears will not deform, and the ears will not open or the mounting hardware will come off, and the laminate molded product The functions of the ears are fully demonstrated.

In addition, since the end edge is bent and introduced into the crosshead mold of the extruder while being close to or in contact with the main body core material, the end edge does not separate from the main body core material, and the thermoplastic resin When the is extrusion coated, the reinforcing core material of the coated part is pressed and fixed from both sides by the coated thermoplastic resin, and even during the extrusion coating of the thermoplastic resin. There is no possibility that the molten resin flows back toward the core introduction side from the vicinity of the final edge in the crosshead mold.

Therefore, when melt extrusion coating a thermoplastic resin in a crosshead mold, the molten resin for extrusion coating is unlikely to flow back into the crosshead mold of the extruder to the introduction side of the reinforcing core material. As a result, the occurrence of backflow phenomenon can be gradually reduced, and long-term continuous operation is possible.

[Brief explanation of drawings]

1 and 2 are schematic diagrams showing an example of the method of the present invention, FIG. 3 is a partially cutaway cross-sectional view showing an example of the reinforcing core material used in the method of the present invention, and FIG. 4 is a schematic diagram showing an example of the reinforcing core material used in the method of the present invention. FIG. 5 is a partially cutaway cross-sectional view showing an example of a crosshead mold used, FIG. 5 is a partially cutaway cross-sectional view showing an example of an eave gutter of a laminated molded product obtained by the method of the present invention, and FIG. Fig. 7 is a partially cutaway cross-sectional view showing an example of a conventional laminate molded product; Fig. 8 is a partially cutaway cross-sectional view showing a crosshead mold for producing a conventional laminate molded product; ■It is a sectional view taken along the line and viewed in the direction of the arrow. Explanation of symbols 10...Reinforcement core material, 10a...Ear portion core material, 10
b...Main body core material, 10c...Terminal edge of ear core material, 11...Reinforcing fiber material, 12...Resin for impregnation, 2
0... Thermoplastic resin for coating, 21... Main body, 21
・・Ear part, 30・・Fluidized bed, 40・・Heating furnace, 41・
・・Heating pinch roll, 5o・Takeover pinch roll,
60... Heating forming device, 70... Cross head mold, 70a... Core material introduction slit part, 70
b...Resin coated slit portion, 80...Sizing device, 9o...Tension device.

Claims (1)

[Claims] 1. Using a belt-shaped reinforcing core material made of reinforcing fiber material impregnated with synthetic resin, form the ear core material into a loop-shaped cylinder, and bend the end edge of the core material to close to the main body core material. In this state, the end edge of the ear core material is thermocompressed to the main body core material, and thermoplastic resin is applied to the entire surface of the reinforcing core material. A method for manufacturing a laminate molded product, characterized by melt extrusion coating and integrating.