JPH059929U - Multipurpose panel made of synthetic resin - Google Patents

Abstract

(57) [Abstract] [Purpose] Despite the fact that the properties of the panel body are fully utilized, the fluff of glass fibers does not appear on the surface even if the panel body is formed of a glass fiber reinforced resin plate. [Constitution] A fluffy cloth 2 is laminated and integrated on the outer surface of a panel body 1 in which glass single fibers are uniformly mixed in a thermoplastic synthetic resin layer such as PP. The resin 2 seeps inside the cloth 2, the fluff of the cloth 2 is entangled with the glass fibers, and the fluff of the cloth 2 is embedded in the resin layer for anchoring. Firmly bond to. Since the cloth 2 has breathability and water permeability,
The cloth 2 does not impair the air permeability and water permeability of the panel body 1, and can be used for concrete formwork, interior materials, floorboards and the like.

Description

[Detailed description of the device]

[0001]

[Industrial applications]

 The present invention relates to a multipurpose panel made of synthetic resin, which is formed by laminating a panel body mainly made of thermoplastic synthetic resin and cloth.

[0002]

[Prior Art]

 Recently, attempts have been made to use synthetic resin panels for various applications such as concrete formwork, floorboards, and automobile interior panels. Panels used for this type of application are required to have various properties such as moldability, toughness, rigidity, light weight, and abrasion resistance that are suitable for the application. A glass fiber reinforced resin plate in which glass fibers are mixed is often used. However, the glass fiber reinforced resin plate has an essential problem that the glass fibers are fluffed on the surface and the fluff comes into contact with the skin and itches when carrying it, which makes it difficult to use. Therefore, conventionally, a measure has been taken to form a gel coat layer on the outer surface of the glass fiber reinforced resin plate and suppress the fuzz of the glass fiber by the gel coat layer.

[0003]

[Problems to be solved by the device]

 However, since the gel coat layer does not have air permeability or water permeability in the panel having the gel coat layer, even if the panel body made of the glass fiber reinforced resin plate has air permeability or water permeability, those properties are not affected by the gel coat layer. As a result, the panel is not air-permeable or water-permeable and cannot be used for applications requiring air-permeability or water-permeability.

The present invention has been made in view of the above problems, and when the panel body has properties such as air permeability and water permeability, those properties are fully utilized, and regardless of that, It is an object of the present invention to provide a synthetic resin multi-purpose panel in which glass fiber fluff does not appear on the surface even when the panel body is formed of a glass fiber reinforced resin plate.

[0005]

[Means for Solving the Problems]

 The synthetic resin multipurpose panel of the present invention has a fluffy cloth laminated and integrated on the outer surface of the panel body in which reinforcing fibers such as glass fibers are mixed in a thermoplastic synthetic resin layer.

[0006]

[Action]

 According to the present invention, the cloth helps suppress the fluffing of the reinforcing fibers on the outer surface of the panel body. Also, the resin content of the panel body oozes out inside the cloth, the fluff of the cloth entangles with the glass fibers exposed on the outer surface of the panel body, and the fluff of the cloth is embedded in the resin layer of the panel body and anchored. However, this helps increase the bonding strength between the panel body and the cloth. Further, since the cloth is a material having air permeability and water permeability, when the panel body has air permeability and water permeability, the air permeability and water permeability of the panel body are provided as properties of the panel itself. In addition, the soft feel of the cloth is provided as a property of the panel itself.

[0007]

【Example】

 The multipurpose panel P made of synthetic resin according to the embodiment of FIG. 1 has a fluffy cloth 2 laminated and integrated on the outer surface of a panel body 1 in which glass fibers are mixed in a thermoplastic synthetic resin layer. The fluffing of the cloth 2 is provided in advance on the cloth 2 before the cloth 2 is laminated and integrated on the panel body 1. In the figure, the cloth 2 is laminated and integrated on both the front and back outer surfaces of the panel body 1, but the cloth 2 is laminated and integrated only on the outer surface of either the front surface or the back surface is also included in the scope of the present invention. Which one should be selected should be appropriately selected in view of the use of the panel P.

In the panel body 1, for example, a single sheet body manufactured by the method described in Japanese Patent Laid-Open No. 60-158227 is used alone, or is laminated by heat fusion so as to have a predetermined thickness. It is possible to use the integrated one. That is, in the sheet body produced by the method described in this publication, glass single fibers as reinforcing fibers are mixed in a uniform density throughout the thermoplastic resin synthetic resin layer. This sheet body is non-porous and has neither air permeability nor water permeability because the resin on its surface is fused when it is hot pressed. The manufacturing method described in this publication is the method described below. That is, a powdered or granular thermoplastic resin, glass single fibers, a foaming agent, and water are mixed to prepare a foaming dispersion in which fine bubbles are dispersed, and the foaming dispersion is used in the papermaking field. Paper is made on a porous support such as a net as in papermaking, dehydrated, and the resulting sheet is dried and continuously heat-solidified to disperse the glass single fibers in a uniform density throughout. Is.

As the panel body 1, an open-celled porous sheet body is obtained by expansion-molding the above-mentioned sheet body (raw sheet) by the method described in JP-A-60-179234. It is also possible to do so. In the expansion molding described in JP-A-60-179234, the non-porous raw fabric is reheated to be softened, and the stress accumulated in the glass single fiber during the above-mentioned hot pressing during the production of the raw fabric causes This is a method in which the glass single fibers are restored to some extent and then compressed again to obtain a sheet body thicker than the original fabric. In this method, when the original fabric is reheated and softened, the resin layer of the original fabric apparently expands due to the force when the glass single fibers are restored, and continuous cells are formed in the resin layer. The continuous bubbles formed in this way remain as they are even after the raw material after expansion has hardened. In addition, re-compression of the original fabric after expansion ensures that the original fabric after expansion is placed in the mold consisting of the lower mold and the upper mold either individually or in a stack of the required number to ensure a predetermined thickness. However, it is re-compressed with a compression device such as a hot press so that it becomes thicker than the original thickness before hot pressing and thinner than the thickness after expansion. A porous porous sheet body is obtained. This sheet has air permeability and water permeability, and further has high rigidity due to its porous structure, which has high rigidity.

The thermoplastic synthetic resin forming the main body of the above-mentioned raw fabric or panel body includes polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polycarbonate (PC). , Nylon, and other synthetic resins, among which PP and PE are preferably used. Further, it is possible to use carbon fibers, metal fibers, or other fibers that serve to reinforce, instead of the glass single fibers. When glass monofilaments are used, if 20-60% by weight of monofilaments having a thickness of 5 to 20 μm and a length of 7 to 50 mm and the remainder being a thermoplastic resin, the glass monofilaments are recompressed during expansion. The fibers are evenly distributed around the entire resin layer, and the reinforcing action, the toughness promoting action and the abrasion resistance action of the single glass fiber are evenly distributed over the entire sheet material.

The cloth 2 laminated and integrated with the panel body 1 includes a woven cloth made by weaving twisted yarns made by twisting synthetic fiber filaments such as PP, PE and PET, and natural fibers such as cotton, wool and flannel. It is possible to use a woven fabric made of, a non-woven fabric made of synthetic fiber such as polyester, or a natural fiber. The cloth 2 is extremely fine so that weaves and gaps between fibers cannot be seen through, and in that sense, it is distinguished from nets and nets through which the mesh can be seen. Further, the cloth 2 is required to have fuzz. The degree of fluffing is that the fluffed filaments or fibers exert an anchoring action (described later) on the resin layer of the panel body 1 or a entanglement action (described below) with respect to the glass single fiber of the panel body 1. It has been found that it is desirable to obtain such an amount, and even if the fluffing length of one filament or fiber is about several μ, it is known that the fluffing as a whole effectively exerts these effects. Therefore, it is necessary to forcibly fluff the cloth 2 that does not have such fluff, and as a means for that, scratch the surface of the above-mentioned woven cloth, non-woven cloth, or the like with a comb or a brush, or any other known method. It is possible to employ means.

In order to laminate and integrate the panel body 1 and the cloth 2, the following method can be preferably adopted.

That is, in the panel P used for applications where air permeability or water permeability is not required, or applications where air permeability or water impermeability is required, the method described in JP-A-60-158227 described above is used. The non-perforated raw fabric manufactured in 1. is expanded by heating, the cloth 2 is superposed on this, and it is compressed and hot pressed without increasing the thickness of the raw fabric. By doing so, the resin component of the resin layer of the panel body 1 enters the inside of the cloth 2, and at the same time, the fluff of the cloth 2 is embedded in the resin layer and anchored, and the fluff of the cloth 2 is further attached to the surface of the panel body 1. Exhibits the entanglement action of being entangled with the exposed glass single fibers or the glass single fibers in the resin layer to make it difficult to separate. The resin invasion into the cloth 2, the anchoring action, the entanglement action, and the like may occur independently or in combination, and by these actions, the fabric 2 is extremely hard to peel off from the panel body 1 and is strong. To be joined to. There are various modes of resin penetration into the cloth 2. That is, a state in which less than half the thickness of the cloth 2 is embedded in the surface layer portion, a state in which about half the thickness of the cloth 2 is embedded in the surface layer portion of the panel body 1, There is a state in which almost the entire surface is embedded in the surface layer portion, and these modes are formed when the mold clamping pressure is increased in this order. The joining force between the panel body 1 and the cloth 2 becomes stronger in this order. In the panel P used for applications that do not require air permeability or water permeability or for applications that do not require air permeability or water permeability, a cloth may be laminated on the glass fiber reinforced resin plate described in the conventional example.

In the panel P used for applications requiring air permeability and water permeability, the panel body obtained by the expansion molding described in JP-A-60-179234 can be used as the panel body 1. In this case, before performing expansion molding, that is, when laminating a required number of non-perforated original fabrics in a mold composed of a lower mold and an upper mold, at the same time, superposing the cloth 2 on or below the cloth 2, Expansion molding is performed in that state. Then, the cloth 2 is laminated and integrated on the outer surface of the panel body 1 at the same time when the panel body 1 having air permeability and water permeability is formed. Even in this case, the above-mentioned invasion of resin into the cloth 2, anchoring action, entanglement, etc. occur independently or in combination, and the cloth 2 is firmly bonded to the panel body 1 in a state in which peeling is less likely to occur. To be done.

When the cloth 2 is laminated and integrated on the outer surface of the panel body 1 as described above, the glass single fibers exposed on the surface of the panel body 1 are pressed by the cloth 2. Therefore, the single glass fibers do not fluff on the outer surface of the panel P, that is, the outer surface of the cloth 2.

In the panel P manufactured as described above, the panel body 1 is a thermoplastic synthetic resin, and the cloth 2 is a soft and flexible material, so that it is possible to perform the above-mentioned laminated integration. Depending on the shape of the mold, it can be molded into a shape suitable for various uses. Further, since the panel body 1 is made of glass fiber reinforced resin, it has excellent strength and abrasion resistance. Furthermore, by appropriately selecting the blending ratio of glass monofilament and synthetic resin, its flexibility and rigidity can be adjusted appropriately according to the purpose of use, and it should also have excellent lightness. Is also possible. The panel P is a material suitable for a concrete formwork, a floorboard, a core material of a backrest portion of a chair or a seat portion, an interior material for an automobile, and the like.

As a suitable material for forming the panel body 1, there is KP sheet (trade name) manufactured by Capela Sheet Co., Ltd., which is a material corresponding to the above-mentioned raw material, and is 70% by weight of PP. It is a sheet material having a thickness of about 0.4 to 5 mm and containing 30% by weight of glass single fiber. Therefore, this KP sheet may be used alone as the panel body 1, or may be formed by compressing and molding the KP sheets by stacking them in a required number of sheets, or by providing them with air permeability and water permeability obtained by expansion molding. It is also possible to use another panel body for the panel body 1. When the KP sheet is expansion-molded, the expansion rate can be set to 1.2 to 3 times, and the panel body 1 having a thickness of 0.5 to 15 mm can be obtained.

FIG. 2 shows an example in which the expansion-molded product is used as a concrete form. Since the conventional plywood formwork does not have air permeability and water permeability, an air layer or water layer is formed on the surface of the cast concrete layer, and the concrete layer forms the plywood formwork at the place where these layers are formed. There was a portion commonly called a dull avatar that did not touch and was dull. On the other hand, since this cloth-equipped formwork 3 has air permeability and water permeability, the above-mentioned avatar is generated due to the formation of an air layer or water layer on the surface of the casting concrete layer. Not only does it have no edge, but because of the air permeability and water permeability, the air and water in the cast concrete 4 can properly pass through the cloth-equipped formwork 3 and / or the cloth 2 to drop the water, so that concrete curing can be performed smoothly. .. As the cloth 2 used for the cloth-formed form 3, only one surface of the woven cloth made of twisted yarn such as PP that is superposed on the panel body 1 is fluffed, and the other surface facing the cast concrete layer is fluff-free woven cloth. It is preferable to use the cloth as it is. By doing so, the cloth 2 is easily integrated with the panel body 1 and easily peeled off from the cast concrete 4.

When the panel P having water permeability in the panel body 1 is used as a floor plate installed on a veranda or the like, the water permeability causes the floor plate-like rainwater to naturally escape downward to the floor plate. There is an advantage that it is difficult for the accumulated water to remain. Further, when the panel P having the air permeability of the panel body 1 is used as the core material for the chair, the air permeability can be effectively utilized and the comfort of the user is improved.

The KP sheet before expansion can be formed by press forming, vacuum forming, pressure forming, and vacuum pressure forming, and when forming, the KP sheet is expanded by heating prior to forming, and the expansion causes open cells. It can also be formed to have breathability and water permeability. When each of the above-mentioned moldings is carried out, the heating can be carried out at a high temperature of 170 to 230 ° C., and the pressing force can be set in the range of 1 to 50 kg / cm ² . It is considered that the reason why heating at a high temperature of 170 to 230 ° C. is possible is that the glass single fibers have a sufficient role of retaining the shape of the melted PP layer. If the content of the glass single fibers is too small, the panel shape may not be maintained. As a result of the experiment, when the heating temperature is set to 170 to 230 ° C, sufficient flexibility and fluidity required in the molding process are satisfied, and particularly when heated in the range of 190 to 210 ° C, it can be molded into a considerably complicated shape. I have confirmed. If the heating temperature is lower than 170 ° C, it will be difficult to heat the entire thickness of the layer uniformly in a short time, so that the fluidity will be insufficient and the glass single fibers will be unevenly distributed in the molded product, resulting in uneven distribution in each part. It may be difficult to obtain strength. Further, if the heating temperature is higher than 230 ° C, a phenomenon that smoke is emitted from the molding material A appears, and the hue is apt to deteriorate due to heat deterioration or surface burning. The smoke is considered to be due to overheating of the additive. If the applied pressure is less than 1 kg / cm ² , the cloth 2 and the panel body 1 may not be reliably integrated, and if the applied pressure is more than 50 kg / cm ² , the resin layer oozes out onto the surface of the cloth 2 and the air permeability is improved. There is a risk of forming an outer skin-like film having no water permeability.

[0021]

[Effect of the device]

 The synthetic resin multi-purpose panel of the present invention provides a multi-purpose panel in which fluffing of reinforcing fibers such as glass fiber, which is useful for enhancing the toughness, abrasion resistance, and high rigidity of the panel body, does not appear on the outer surface. be able to. In the present invention, the panel body and the cloth are prevented from invading resin into the cloth, anchoring due to the fluffing of the cloth, entanglement of the glass fibers exposed on the surface of the panel body with the fluffing of the cloth, etc. When the panel itself is breathable or water permeable, the properties of the panel itself are as it is because the panels themselves are more firmly integrated and less likely to separate from each other, and the cloth itself is breathable and water permeable. It is equipped as a property of. Further, the synthetic resin multipurpose panel of the present invention has the effect that the moldability of the panel body is not impaired by the cloth, so that the molding suitable for the moldability of the panel body can be performed satisfactorily. In addition, there are other effects such as the softness of the touch due to the action of the cloth, and the fact that the cloth suppresses the deterioration of the panel body due to ultraviolet rays. Therefore, the synthetic resin multipurpose panel of the present invention can be suitably used for both indoor and outdoor use. Specific applications include concrete formwork, floorboards, automobile interior materials, chair backs and seat core materials. It becomes possible to adapt to a wide range of applications such as.

[Brief description of drawings]

FIG. 1 is an explanatory view showing a cross section of a synthetic resin multipurpose panel according to an embodiment of the present invention.

FIG. 2 is a sectional view of a synthetic resin multipurpose panel according to an embodiment of the present invention when used as a concrete formwork.

[Explanation of symbols]

 P panel 1 panel body 2 cloth

Claims (1)

[Claims for utility model registration] [Claim 1] A fluffy cloth is laminated and integrated on the outer surface of a panel body in which reinforcing fibers such as glass fibers are mixed in a thermoplastic synthetic resin layer. Multipurpose panel made of synthetic resin.