JP2000085043A - Synthetic resin laminate and sleeper - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve mechanical strength and to reduce costs by being a laminate having at least two synthetic resin layers in which the modulus of compressive elasticity and the strain of the compressive yield point in the longitudinal direction to the laminate are decided in a specified range. SOLUTION: In a synthetic resin laminate 1, a synthetic resin A-layer containing a filler a synthetic resin layer B-layer fiber-reinforced in the longitudinal direction are laminated/integrated. In the synthetic resin laminate comprising at least two layers, the modulus of compressive elasticity in the longitudinal direction to the laminate and the strain of the compressive yield point are decided to be 1,000-25,000 MPa and at least 0.7%, respectively. The filler of the A-layer occupies 30-80% of the volume of the A-layer. The synthetic resin layer of the A-layer or the B-layer is constituted from a foamed layer. In this way, mechanical strength such as flexural properties is excellent, the reduction of costs is possible, and nailing properties and nail extracting strength are excellent. Corresponding to the characteristics of the filler, for example, the reduction of costs, the decrease of weight, high strength, and others can be attained surely.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a synthetic resin laminate and sleepers which are suitably used as building materials and the like.

[0002]

2. Description of the Related Art In general, a molded product made of a synthetic resin is sometimes used as a structural material such as a building material. It is widely known that the molded article is reinforced with fibers in order to strengthen the molded article. It is also widely known that a filler is filled to reduce the cost of a molded product.

[0003] As an example of combining these, a laminate composed of a thermosetting resin foam layer containing a filler as a core material layer and a thermosetting resin foam layer reinforced with fibers in the longitudinal direction as a surface layer is known. Has been proposed (JP-A-5-1387).
No. 97), the laminate is capable of exhibiting excellent properties such as waterproofness, heat insulation and rigidity.

[0004]

However, in many cases, structural materials such as building materials need to be fixedly joined to each other or to other structural materials by using a material such as nails. The laminate can also be nailed.

However, when actually used as a building material, according to the study of the present inventor, not only is it possible to drive nails but also the nail pull-out strength when nailing has reached a certain level. If not, stable joining and fixing cannot be achieved, and if lateral pressure is applied to the nail, the deformation of the nail hole becomes unnecessarily large, but the laminate described in the above publication has a nail pulling strength. Further improvement is desired.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a synthetic resin laminate and a sleeper which are excellent in nailing performance and nail pull-out strength while solving the problems of the above-mentioned conventional laminate used for building materials and the like. .

[0007]

According to the present invention, there is provided a laminated body having a synthetic resin layer (A) containing a filler and a synthetic resin layer (B) reinforced with fibers in the longitudinal direction. The compression elastic modulus in the longitudinal direction with respect to the laminate is 1000-2500
It is a synthetic resin laminate comprising at least two layers and having a strain of 0 MPa and a compression yield point of 0.7% or more.

The present invention according to claim 2 is the synthetic resin laminate according to claim 1, wherein the filler of the layer (A) occupies 30 to 80% by volume of the layer (A). According to a third aspect of the present invention, there is provided the synthetic resin laminate according to the first or second aspect, wherein the (A) layer or the (B) layer is a foam layer.

According to a fourth aspect of the present invention, there is provided a sleeper comprising the synthetic resin laminate according to any one of the first to third aspects.
Hereinafter, the present invention will be described in more detail.

The synthetic resin used in the layer (A) or the layer (B) in the present invention may be a thermosetting resin such as polyurethane, unsaturated polyester, phenolic resin, epoxy resin, etc., which is curable under heating or normal temperature. , Polyethylene, polypropylene, polyvinyl chloride, thermoplastic resins showing heat plasticity such as polyester and the like, in particular,
Polyurethane is preferably used from a comprehensive viewpoint such as strength, moldability, and cost.

The synthetic resins of the layers (A) and (B) may be of the same type or of different types, but the same type of synthetic resin is desirable in consideration of the adhesiveness between the layers. The synthetic resin of the layer (A) or the layer (B) may be a foam, and this enables weight reduction and reduction of material cost.

The filler for the layer (A) is, for example, an inorganic solid filler such as glass beads, silica sand, silica beads, needle-like silica, fly ash, talc, calcium carbonate, magnesium carbonate, mica, magnesia, and glass. Inorganic hollow fillers such as balloons, shirasu balloons, fly ash balloons, mesalite, perlite, foam glass,
Organic solid fillers such as synthetic resin powder, pulverized thermosetting resin molded articles, etc., organic hollow fillers such as thermosetting resin hollow bodies, thermoplastic resin hollow bodies, and wood chips are exemplified. These may be used alone or as a mixture of two or more.

The proportion of the filler used is preferably 30 to 80% by volume of the layer (A). If it is less than 30% by volume, cost reduction and weight reduction,
Not only is the effect of the filler such as high strength small,
Mixing with the synthetic resin tends to be uneven. 80% by volume
If the amount is larger, problems such as a decrease in strength, a decrease in mixing uniformity with a resin, and a decrease in fluidity during molding may occur.
Therefore, it is more preferably 35 to 65% by volume of the layer (A). The layer (A) may contain various additives and reinforcing fibers as long as the physical properties are not impaired, other than the above-mentioned filler.

The reinforcing fiber of the layer (B) in the present invention may be, for example, a roving such as glass roving, carbon roving, polyester roving or nylon roving, or a short fiber such as glass short fiber, carbon short fiber, polyester short fiber or nylon short fiber. Examples thereof include fibers, mats for reinforcing two-dimensionally and three-dimensionally, and nonwoven fabrics. These can be used alone or 2
Used in more than species. Among them, glass roving is preferable in terms of moldability, reinforcing effect, cost, and the like. In this case, the diameter of the monofilament is usually about 1 to 100 µm, preferably about 5 to 30 µm.

The layer (B) may contain various additives and fillers other than the reinforcing fibers as long as the physical properties are not impaired. The synthetic resin laminate of the present invention needs to have a compression modulus in the longitudinal direction of 1000 to 25000 MPa and a strain at the compression yield point of 0.7% or more.

If the compression modulus is less than 1000 MPa, the resistance to nail pulling will be low, and if lateral pressure is applied to the nail, the deformation of the nail hole will increase. This is because the resistance is so large that it is difficult for the nail to be driven. More preferably, it is 3000 to 20000 MPa.
It is. Furthermore, even if the compression modulus satisfies the above range,
If the strain at the compression yield point is less than 0.7%, cracks occur at the time of nailing, so it is necessary to be 0.7% or more, and preferably 1.0% or more. Although the upper limit of the strain at the compression yield point is not particularly defined, the larger the strain at the compression yield point is, the smaller the compression modulus usually becomes.
%.

Further, the synthetic resin laminate of the present invention has bending properties,
From the viewpoint of symmetry and the like, a sandwich structure in which the layer (A) is used as the core material layer and the layer (B) is laminated on both surface layers of the core material is preferable, and the periphery of the layer (A) is surrounded by the layer (B) including the side surfaces. Preferred structure. The thickness ratio of each layer of the laminate may be appropriately selected depending on desired physical properties.

The method for producing the laminate of the present invention is not particularly limited, but may be a method in which one of the layers is formed first, and then the other layer is formed in a laminated manner. Known methods such as a method of laminating and a method of simultaneously laminating and shaping each layer are appropriately adopted. The production may be continuous molding or batch molding. The laminate of the present invention can be used for a structural material such as a building material, a scaffold plate, a frame plate of a civil engineering work site, a railroad railroad sleeper, and the like.

(Operation) When driving a nail into a certain structural material,
If the strain at the compression yield point of the structural material is too small, it will crack, and the nail pull-out strength after driving depends on the frictional resistance between the nail and the structural material, but when the structural material is of synthetic resin type Usually depends greatly on the compression modulus of the structural material.

The synthetic resin laminate of the present invention is a laminate having a synthetic resin layer (A) containing a filler and a synthetic resin layer (B) reinforced with fibers in the longitudinal direction. Since the compression modulus in the longitudinal direction of the body is 1000 to 25000 MPa and the strain at the compression yield point is 0.7% or more, it is excellent in mechanical strength such as bending physical properties, and can realize cost reduction.
It is excellent in nail pulling strength as well as nailing performance, and is useful as a structural material such as a building material, a railroad railroad sleeper, and the like.

[0021]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Non-limiting embodiments of the present invention will be described below. (Example 1) 50% by volume of polyurethane and 50% by volume of silica sand 3
(A) a synthetic resin foam (expansion ratio 2.4 times) consisting of
85% by volume of polyurethane on both sides of this (A) layer
And a synthetic resin foam comprising a layer (B) of 15% by volume of glass roving and a synthetic resin foam (expansion ratio 2.7 times) was obtained by the following method using the following raw materials.

Raw material for layer (A) Ethylenediamine polyether polyol (OH value 380) 100 parts by weight Polymeric diphenylmethane diisocyanate (NCO% 31.5) 110 parts by weight Dibutyltin dilaurate (catalyst) 0.07 parts by weight Silicone foam stabilizer 0.6 Part by weight Water (foaming agent) 0.6 part by weight The mixed solution for polyurethane having the above composition was added to silica sand No. 3 and mixed with a mixer to obtain a composition for layer (A).

Raw material of layer (B) Sugar-based polyether polyol (OH value: 480) 100 parts by weight Polymeric diphenylmethane diisocyanate (NCO% 31.5) 140 parts by weight Dibutyltin dilaurate (catalyst) 0.17 parts by weight Silicone foam stabilizer 0.6 Part by weight Water (foaming agent) 0.8 part by weight A mixed solution for polyurethane obtained by stirring and mixing these was impregnated with glass roving (diameter of monofilament: 12 μm) to obtain a composition for layer (B).

Preparation of Synthetic Resin Laminate First, the composition for layer (A) was placed in a mold and heat-cured and shaped. Next, after putting the obtained excipient into another mold, setting the composition for (B) layer thereon and performing laminating and extruding, (A)
The layer (B) was similarly laminated and formed on the other surface of the layer.
The dimensions of the finally obtained laminate are 200 mm in width and 2100 in length
mm, the thickness was 140 mm, the thickness of the surface layer was 20 mm, and the thickness of the core layer was 100 mm.

Using this laminate as a test body, the compression modulus in the longitudinal direction, the strain at the compression yield point, the pull-out strength of the dog nail, and the like were evaluated according to the following evaluation methods. The results are shown in Table 1.

<Evaluation Method> The compression test was performed in accordance with the longitudinal compression test described in JISZ2101, and the values of the compression modulus and the strain at the compression yield point were measured. Compression speed: Thickness of test specimen (mm) x 0.1 (mm / min) 16 x 145 m as specified in JISE1108 as a dog nail pull-out test dog nail
m. Drill a pilot hole from the surface side of the specimen with a drill.
Open 15.5mm and hammer a dog nail at the site with a hammer
I typed it in. The maximum stress when the hammered dog nail was pulled out at a speed of 2 mm / min was measured. In addition, according to JISZ2101, flexural strength and flexural modulus were measured at a bending speed of 10 m.
When measured under the conditions of m / min and a distance between spans of 1960 mm, the bending strength of the test specimen was 90 MPa and the flexural modulus was 6.3 GPa.
Met.

(Example 2) A synthetic resin layer composed of 80% by volume of polyurethane and 20% by volume of silica sand No. 3 was used as an (A) layer, and 85% by volume of polyurethane and 15% by volume of glass roving were provided on both sides of the (A) layer. A synthetic resin laminate having a three-layer structure obtained by laminating and integrating the synthetic resin layer (B) was formed in the same manner as in Example 1 using the following raw materials.

(A) Layer Raw Material Glycerin-based polyether polyol (OH value 35) 100 parts by weight Polymeric diphenylmethane diisocyanate (NCO% 31.5) 30 parts by weight Dibutyltin dilaurate (catalyst) 0.07 parts by weight It was added to silica sand No. 3 and mixed with a mixer to obtain a composition for layer (A).

Raw material of layer (B) Sugar-based polyether polyol (OH value 480) 50 parts by weight Glycerin-based polyether polyol (OH value 35) 50 parts by weight Polymeric diphenylmethane diisocyanate (NCO% 31.5) 85 parts by weight Dibutyltin dilaurate ( Catalyst) 0.17 parts by weight A mixture for polyurethane obtained by stirring and mixing these was impregnated with glass roving (diameter of monofilament: 12 μm) to obtain a composition for layer (B). Next, the compression modulus, the strain at the compression yield point, and the pull-out strength of the dog nail were evaluated in the same manner as in Example 1, and the results are shown in Table 1.

(Example 3) A synthetic resin layer composed of 50% by volume of polyurethane and 50% by volume of silica sand No. 3 was used as a layer (A). On both sides of the layer (A), 85% by volume of polyurethane and 15% by volume of glass roving were used. A synthetic resin laminate having a three-layer structure obtained by laminating and integrating the synthetic resin layer (B) was formed in the same manner as in Example 1 using the following raw materials.

(A) Layer Raw Material Glycerin-based polyether polyol (OH value 35) 100 parts by weight Polymeric diphenylmethane diisocyanate (NCO% 31.5) 30 parts by weight Dibutyltin dilaurate (catalyst) 0.07 parts by weight It was added to silica sand No. 3 and mixed with a mixer to obtain a composition for layer (A).

(B) Raw Material Sugar Polyether Polyol (OH Value 480) 50 parts by weight Glycerin Polyether Polyol (OH Value 35) 50 parts by weight Polymeric diphenylmethane diisocyanate (NCO% 31.5) 85 parts by weight Dibutyltin dilaurate ( Catalyst) 0.17 parts by weight A mixture for polyurethane obtained by stirring and mixing these was impregnated with glass roving (diameter of monofilament: 12 μm) to obtain a composition for layer (B). Next, the compression modulus, the strain at the compression yield point, and the pull-out strength of the dog nail were evaluated in the same manner as in Example 1, and the results are shown in Table 1.

Example 4 A synthetic resin foam comprising 50% by volume of polyurethane and 50% by volume of silica sand No. 3 (expansion ratio: 2.4)
Times) as the (A) layer, 85% by volume of polyurethane and 15% by volume of glass roving on both sides and both sides of the (A) layer.
A synthetic resin laminate 1 in which the layer (B), which is a synthetic resin foam (expansion ratio 2.7 times) composed of the following, was laminated and integrated, was obtained by the following method using the following raw materials.

Raw material of layer (A) Ethylenediamine-based polyether polyol (OH value: 380) 100 parts by weight Polymeric diphenylmethane diisocyanate (NCO% 31.5) 110 parts by weight Dibutyltin dilaurate (catalyst) 0.07 parts by weight Silicon-based foam stabilizer 0.6 Part by weight Water (foaming agent) 0.6 part by weight The mixed solution for polyurethane having the above composition was added to silica sand No. 3 and mixed with a mixer to obtain a composition for layer (A).

Raw material for layer (B) Sugar-based polyether polyol (OH value: 480) 100 parts by weight Polymeric diphenylmethane diisocyanate (NCO% 31.5) 140 parts by weight Dibutyltin dilaurate (catalyst) 0.17 parts by weight Silicone foam stabilizer 0.6 Part by weight Water (foaming agent) 0.8 part by weight A mixed solution for polyurethane obtained by stirring and mixing these was impregnated with glass roving (diameter of monofilament: 12 μm) to obtain a composition for layer (B).

Preparation of Synthetic Resin Laminate First, the composition for layer (A) was put into a mold, and the width W in FIG.
A 180mm, length L2100mm, thickness tA 100m
It was heat-cured into a size of m. Next, the obtained excipient A is put into another mold, the composition for the (B) layer is set on and on both sides thereof, and the laminate is extruded. Then, the whole is taken out and put into another mold (B). Put the layer on the lower side and the (A) layer on the upper side,
On the layer (A), the composition for the layer (B) was set and laminated and formed.

The dimensions of the finally obtained laminate are the width W2
00mm, length L2100mm, thickness T140mm,
The thickness of the surface layer in the width direction was 10 mm, and the thickness of the surface layer in the thickness direction was 20 mm. Next, the physical properties and the like were evaluated in the same manner as in Example 1. Table 1 shows the compression modulus, the strain at the compression yield point, and the pull-out strength of the dog nail. The bending strength is 120MP
a, The flexural modulus is 8.0 GPa, and (A) is higher than that of Example 1 which is a three-layer structure in which the (A) layer and the (B) are simply laminated.
The article having the present shape in which the four sides of the layer were covered with the layer (B) was superior.

Comparative Example 1 A synthetic resin foam comprising 60% by volume of polyurethane and 40% by volume of silica sand No. 3 (expansion ratio: 4.0)
Times) as the (A) layer, and on both sides of the (A) layer, a (B) layer which is a synthetic resin foam (foaming ratio 4.0 times) composed of 95% by volume of polyurethane and 5% by volume of glass roving is laminated. Using the following raw materials, an integrated synthetic resin laminate was obtained in the same manner as in Example 1 to obtain a laminate composed of three layers (A), (B), and (A). Then, the compression elastic modulus, the strain at the compression yield point, and the pull-out strength of the dog nail were evaluated in the same manner as in Example 1,
The results are shown in Table 1.

Raw material for layer (A) Glycerin-based polyether polyol (OH value 35) 100 parts by weight Polymeric diphenylmethane diisocyanate (NCO% 31.5) 30 parts by weight Dibutyltin dilaurate (catalyst) 0.25 parts by weight Silicone foam stabilizer 0.6 Parts by weight Water (foaming agent) 1.3 parts by weight The mixed solution for polyurethane having the above composition was added to silica sand No. 3 and mixed with a mixer to obtain a composition for layer (A).

Raw material of layer (B) Sugar polyether polyol (OH value: 480) 100 parts by weight Polymeric diphenylmethane diisocyanate (NCO% 31.5) 160 parts by weight Dibutyltin dilaurate (catalyst) 0.25 parts by weight Silicone foam stabilizer 0.6 Part by weight Water (foaming agent) 1.8 parts by weight A mixed solution for polyurethane obtained by stirring and mixing these was impregnated with glass roving (diameter of monofilament: 12 μm) to obtain a composition for layer (B).

(Comparative Example 2) A synthetic resin layer composed of 40% by volume of polyurethane and 60% by volume of silica sand No. 3 was used as an (A) layer, and 85% by volume of polyurethane and 15% by volume of glass roving were provided on both sides of the (A) layer. (Foaming ratio 2.
(7 times) was obtained in the same manner as in Example 1 using the following raw materials to form a three-layer synthetic resin laminate in which the layer (B) was laminated and integrated. Then, in the same manner as in Example 1,
The distortion of the compression yield point and the pull-out strength of the dog nail were evaluated, and the results are shown in Table 1.

Raw material of layer (A) Ethylenediamine-based polyether polyol (OH value: 380) 100 parts by weight Polymeric diphenylmethane diisocyanate (NCO% 31.5) 110 parts by weight Dibutyltin dilaurate (catalyst) 0.07 parts by weight It was added to silica sand No. 3 and mixed with a mixer to obtain a composition for layer (A).

Raw material of layer (B) Sugar-based polyether polyol (OH value: 480) 100 parts by weight Polymeric diphenylmethane diisocyanate (NCO% 31.5) 140 parts by weight Dibutyltin dilaurate (catalyst) 0.17 parts by weight Silicone foam stabilizer 0.6 Part by weight Water (foaming agent) 0.8 part by weight A mixed solution for polyurethane obtained by stirring and mixing these was impregnated with glass roving (diameter of monofilament: 12 μm) to obtain a composition for layer (B).

Comparative Example 3 50% by volume of unsaturated polyester
And a synthetic resin layer composed of 50% by volume of silica sand No. 7 as layer (A). On both sides of this layer (A), a synthetic resin foam composed of 95% by volume of polyurethane and 5% by volume of glass roving (expansion ratio 3.3) Example 1 was prepared by using the following raw materials to prepare a synthetic resin laminate composed of three layers obtained by laminating (B) the layer (B).
Was obtained in the same manner as described above. Next, the compression modulus, the strain at the compression yield point, and the pull-out strength of the dog nail were evaluated in the same manner as in Example 1, and the results are shown in Table 1.

[0045](A) Raw material of layer 100 parts by weight of unsaturated polyester (Yupika 7015, manufactured by Yupika Japan Co., Ltd.) 2 parts by weight of Kayaester O-50 (catalyst) manufactured by Kayaku Akzo (B) Layer raw material Sugar polyether polyol (OH value 480) 100 parts by weight Polymeric diphenylmethane diisocyanate (NCO% 31.5) 160 parts by weight Dibutyltin dilaurate (catalyst) 0.25 parts by weight Silicone foam stabilizer 0.6 parts by weight Water (foaming agent) 8 parts by weight The mixture for polyurethane obtained by stirring and mixing these was added
Includes last roving (monofilament diameter 12 μm)
It was immersed to obtain a composition for layer (B).

[0046]

[Table 1]

[0047]

The synthetic resin laminate of the present invention is a laminate having a synthetic resin layer (A) containing a filler and a synthetic resin layer (B) reinforced with fibers in the longitudinal direction. , The compression modulus in the longitudinal direction with respect to the laminate is 1000-25000 MPa,
Since the strain at the compression yield point is 0.7% or more, it is excellent in mechanical strength such as bending physical properties, cost reduction can be realized, and it has excellent nail pulling strength as well as nailing property. Therefore, it has a practically high effect as a structural material such as a building material.

In the synthetic resin laminate according to the second aspect of the present invention, the filler in the layer (A) occupies 30 to 80% by volume of the layer (A). Reduction, weight reduction, high strength, etc. are reliably achieved. Claim 3
The synthetic resin laminate of the present invention described above may be a layer (A) or a layer (B).
Since the synthetic resin layer of the layer is a foam layer, a lightweight laminate is provided.

The sleeper according to the fourth aspect of the present invention has excellent nailing properties and nail pull-out strength while exhibiting excellent properties that are practically important as a sleeper, while being high in strength and lightweight.

[Brief description of the drawings]

FIG. 1 is a perspective view of a synthetic resin laminate of the present invention obtained in Example 4.

[Explanation of symbols]

 1: synthetic resin laminate

Claims (4)

[Claims] 1. A laminate comprising a synthetic resin layer (A) containing a filler and a synthetic resin layer (B) reinforced in the longitudinal direction with a fiber, and the compression elasticity in the longitudinal direction with respect to the laminate. Rate is 1000 ～ 25000MPa, strain of compression yield point is 0.7%
A synthetic resin laminate comprising at least two layers as described above. 2. The filler of the layer (A) is 30 to 80 of the layer (A).
2. The synthetic resin laminate according to claim 1, occupying a volume%. 3. The synthetic resin laminate according to claim 1, wherein the (A) layer or the (B) layer is a foam layer. 4. A sleeper comprising the synthetic resin laminate according to any one of claims 1 to 3.