JP2003305742A - Foamed curable resin reinforced molded object and manufacturing method therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a foamed curable resin reinforced molded object having a fundamental capacity as a molding material for a lid or the like for water treatment, reducing a post-process and almost generating no warpage, and a manufacturing method therefor. <P>SOLUTION: The foamed curable resin reinforced molded object 19 is constituted so that a plate-shaped molded body 16 comprising a foamed curable resin 12 reinforced by long fibers 11 arranged in one direction and a mat-like reinforcing fibers 17 arranged in a direction vertical to long fibers 11 and reinforcing the upper and rear surfaces of the plate-shaped molded body 16 in a parallel direction. Further, a filler 22 is fixed on the surface of the foamed curable resin reinforced molded object 19 through a curable resin 21. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foam-curable resin reinforced molded body which is a material for forming a lid for water treatment and a method for manufacturing the same.

[0002]

2. Description of the Related Art In conventional lids for water treatment, a plate-shaped molded product reinforced with long fibers in which a foam-hardening resin is arranged in one direction is laminated in three layers at right angles to the long fibers. After that, a glass fiber mat impregnated with a curable resin was placed on the upper and lower surfaces of the laminated plate-shaped molded article, and further, silica sand was sown and adhered on the upper surface (JP-A-8-76189).
Issue).

[0003]

However, Japanese Patent Application Laid-Open No. 8-7.
In the conventional molded body 25 disclosed in Japanese Patent No. 6189, FIG.
As shown in FIG.
Was required and the step of impregnating it with the curable resin 27 was required. Further, on the upper and lower surfaces thereof, a reinforcing fiber mat 29,
It is necessary to stack 30.

That is, in the structure disclosed in Japanese Unexamined Patent Publication No. 8-76189, since a urethane foam, which is a curable resin 27, is laminated perpendicularly to the direction of the long fibers 28, a molded product is used. In addition to being excellent in corrosion resistance, bending strength in the direction of the long fibers 28 is also excellent. But,
The strength is insufficient in the direction perpendicular to the long fibers 28. In particular, products formed as lids for water treatment are usually
The rectangular plate is spanned so that its longitudinal direction serves as the fulcrum of bending.

The performance required therefor is that the bending deflection of the rectangular plate material in the longitudinal direction is less than the specified value and that the product does not warp in the direction perpendicular to the longitudinal direction. In order to prevent warping of this product, it is necessary to improve the bending strength in that direction. In order to obtain a bending strength that does not warp the product in a direction perpendicular to the longitudinal direction of this rectangular plate material, a laminated molded body is formed with the long fibers 28 oriented vertically, and this is formed into a laminated body for water treatment. It is necessary to use it as a forming material.

Further, it is preferable that the water treatment lid has some anti-slip so that a person can walk and inspect it. At that time, in order to obtain hardness and weather resistance of the surface of the water treatment lid, it is hardened. The resin 31 is applied, and silica sand or the like is fixed to the application surface. However, when the curable resin 31 is directly applied to the surface of the urethane foam reinforced with the reinforcing fiber mats 29 and 30 as in the case of the conventional forming material, the curable resin 31 expands and contracts due to heat and water to cure the resin. There is a defect that cracks are generated in the flexible resin 31. This is because the strength in the direction perpendicular to the reinforcing fiber mats 29 and 30 is low, so that the curable resin 31 expands and contracts a lot. Therefore, in the conventional lid for water treatment, the surface of the product is made by laying the reinforcing fiber mats 29 and 30 and impregnating the curable resin 27.

Further, the required performance can be achieved if only the upper surface side of the product is processed by non-slip processing by means such as sowing silica sand, but if the curable resin 31 is applied to the upper surface side, the curable resin 31 Due to curing shrinkage, the product warps in a concave shape on the upper surface side. Therefore, the lower surface side of the product is also coated with the same curable resin 31 as the upper surface side.

As described above, since the conventional forming material is manufactured through many post-processes, the manufacturing cost is high and a large number of manufacturing days are required. Further, the reinforcing fiber mats 29, 3 in the direction perpendicular to the longitudinal direction in the molded plate material.
Since 0 is located in the center of the product thickness, the force for suppressing the warp in the direction perpendicular to the longitudinal direction was weak.

Therefore, the present invention has a basic performance as a molding material such as a lid for water treatment, has a small number of post-processes, and has almost no warpage, and a foam-curable resin reinforced molded body, and the same. The purpose is to provide a manufacturing method.

[0010]

In order to achieve the above-mentioned object, the foam-hardening resin-reinforced molded product of the present invention comprises a plate-shaped molded product reinforced with long fibers in which the foam-hardening resin is arranged in one direction. It is characterized by

In the foam-hardening resin-reinforced molded product of the present invention, mat-shaped reinforcing fibers for reinforcing the vertical direction of the long fibers and the direction parallel to the upper and lower surfaces are arranged on the upper and lower surfaces of the above-mentioned plate-shaped molded product. Including configurations that consist of In this case, the mat-shaped reinforcing fiber includes a structure integrated with the above-mentioned plate-shaped molded body.

According to the above-mentioned structure in which the mat-shaped reinforcing fibers are arranged in the plate-shaped molded body, the bending strength in the direction perpendicular to the long fibers in the plate-shaped molded body is improved and the product warped in that direction. The effect of preventing the occurrence of is generated. This effect becomes greater when the plate-shaped molded body is formed integrally with the mat-shaped reinforcing fibers. Further, even if the curable resin is applied to the surface of the product, the effect of preventing the curable resin from cracking against the curing shrinkage is exhibited.

Furthermore, since it has resistance to the stress of curable shrinkage that occurs when the curable resin is applied to the upper surface of the product, it is not necessary to apply the curable resin to the back surface of the product. There is.

The foam-curable resin-reinforced molded product of the present invention may have a skin layer provided on the back side of the plate-shaped molded product. This skin layer can be formed by curing the surface layer and a curable resin in a mold that has been subjected to a release treatment.
The surface can be reinforced by this skin layer.

The foam-curable resin-reinforced molded article of the present invention comprises
The surface side of the plate-shaped molded body includes a configuration in which a curable resin mixed with a filler is applied.

The foam-hardening resin-reinforced molded product of the present invention is suitable as a forming material such as a lid for water treatment because of the performance based on each of the above-mentioned actions.

The production method for obtaining the above foam-hardening resin-reinforced molded article of the present invention is carried out after impregnating the continuously aligned long fibers with the foam-hardening resin or while impregnating the foam-hardening resin. The mat-shaped reinforcing fibers are continuously supplied to the upper and lower surfaces of the molded body in a direction perpendicular to the long fibers and in a direction parallel to the upper and lower surfaces, and then continuously guided to a mold and foamed in the mold, It is characterized by being cured to obtain a plate-shaped molded body.

In the above-mentioned method for producing a foam-curable resin-reinforced molded product of the present invention, a method of grinding only one surface of the obtained plate-shaped molded product, or a curable resin in which a filler is mixed on the ground surface side. A method of configuring as a lid for water treatment to which a resin is applied can also be adopted.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows an apparatus 10 for producing a foam-curable resin reinforced molded article of the present invention. In the process according to the flow of the manufacturing apparatus 10, first, the continuous long fibers 1 are aligned.
1 is impregnated with a foaming curable resin 12. Foam curable resin 1
2 is extruded from the resin nozzle 13 and further impregnated table 15
Is supplied through the impregnating plate 14 on the table surface of the plate, and thereby a plate-shaped molded body 16 is obtained.

The long fibers 11 are preferably glass fibers from the viewpoint of cost and reinforcing effect. The foam-hardening resin is not particularly limited in type, but it is preferable that foaming urethane or the like be relatively easy to control foaming. As the foaming agent for the foam curable resin, for example, water or an organic solvent having a low boiling point can be used. A solid or liquid filler may be mixed in the foam curable resin. Further, a catalyst for promoting the reaction, a foam stabilizer for smoothing foaming, a flame retardant, and a solid filler for adjusting specific gravity and improving compression strength may be mixed.

As for the size of the plate-shaped molded body, in the case of the single plate lid for water treatment specified in the standards of the Sewerage Agency, the thickness of the lid excluding the beams and packing is 33.5 mm. The preferred thickness in the invention is 10 mm to 40 mm.

Next, while impregnating the foaming curable resin 12, matt reinforcing fibers 17 are continuously supplied to the upper and lower surfaces of the molded body 16 in a direction perpendicular to the long fibers 11 and in a direction parallel to the upper and lower surfaces. The mat-shaped reinforcing fibers 17 are guided to the positions of the upper and lower surfaces of the forming body 16 by the tension rolls 18, respectively. The mat-shaped reinforcing fiber 17 may be of any type, but may be a continuous strand mat, a chop mat, a glass cloth, a glass scrim, or the like.

The foam-curable resin 16, the long fiber 11 and the mat-shaped reinforcing fiber 1 in the foam-curable resin molded product of the present invention.
The weight ratio with 7 is 45% by weight or more of the foam curable resin 6
It is preferable that the amount of long fibers is 25% by weight or more and 45% by weight or less, and the mat-like reinforcing fibers are 4% by weight or more and 15% by weight or less. If the amount of the foam-hardening resin is less than 45% by weight, impregnation into long fibers or mat-like reinforcing fibers will be insufficient, and the strength of the molded product may decrease.
If the amount of the foam-hardening resin exceeds 65% by weight, the amount of long fibers may decrease and the bending performance in the direction of the long fibers may deteriorate. When the amount of long fibers exceeds 45% by weight, impregnation of the foam-curable resin may be insufficient and the strength of the molded product may decrease. If the amount of the mat-like reinforcing fiber is less than 4% by weight, the bending performance in the direction perpendicular to the direction of the long fiber may be deteriorated. When the amount of the mat-like reinforcing fiber is more than 15% by weight, impregnation of the foam-curing resin becomes insufficient, the strength of the molded article is reduced, and the thickness of the mat-like reinforcing fiber is increased to increase the long fiber. The bending performance in the direction may deteriorate.

Thereafter, the molded body 16 in which the mat-shaped reinforcing fibers 17 are laminated is continuously introduced into the mold 20, and the foam-curable resin 12 is foamed and cured in the mold 20 to obtain a plate. A foam-curable resin molding 19 having a shape of a circle is obtained. The weight ratio on the upper surface side of the foam curable resin molded body 19 is preferably 25% by weight or less of the entire molded body. Further, the foam-hardening resin 12 impregnated in the mat-shaped reinforcing resin 17 in the foam-hardening resin molded body 19 may be the same as that impregnating the long fibers 11 or may be different. May be. In addition, in the above-described manufacturing process, the mat-shaped reinforcing fibers 17 are added to the long fibers 11 by the foamable resin 1
6 may be supplied during impregnation, or may be supplied after impregnating the long fiber 11 with the foaming curable resin 12.

As shown in FIG. 2, the foam-hardening resin molded body 19 has each long fiber 11 provided on the foam-hardening resin 12, and its upper and lower surfaces are integrally formed with the mat-shaped reinforcing fiber 17. Has been done. Therefore, each long fiber 11 can withstand the bending stress in the direction along the long fiber 11, and the mat-shaped reinforcing fibers 17 fixed to the upper and lower surfaces of the plate-shaped molded body 16 make it perpendicular to the long fiber 11. A force that resists the stress in the direction of is generated. Further, the surface of the foam curable resin molded body 19 is ground. This grinding thickness is 0.
It is preferably in the range of 1 mm or more and 1.0 mm or less. If the grinding is less than 0.1 mm, the skin layer partially remains, so that the adhesive strength becomes insufficient when the curable resin 21 is applied, causing the curable resin 21 to peel off. Becomes If the grinding exceeds 1.0 mm,
The mat-shaped reinforcing fibers 17 may be scraped off and the expected effect may not be obtained.

By applying the curable resin 21 to the ground surface, the polyester resin is strongly fixed to the ground surface. It is possible to sow the filler 22 on the surface of the polyester resin 21 and stably fix the non-slip filler 22 to the surface of the foam curable resin molded body 19. The filler 22 may be of any type, but silica sand, calcium carbonate, urethane foam grinding dust, or the like can be used. In the case of silica sand, its size is not limited, and silica sand No. 3, No. 5, No. 7, etc. can be used.

[0027]

EXAMPLES (Example 1 to 2) With the manufacturing apparatus of FIG.
A lid for water treatment made of a foam-curable resin molded body was formed under the following conditions. (A) Foam-curable resin: Water-foamable urethane resin (B) Long fiber: Glass long fiber (C) Mat-like reinforcing fiber: Continuous strand mat (D) Urethane resin, glass long fiber and continuous strand Weight ratio of mat: 56: 36: 8 in each of Examples 1 and 2 (E) Grinding thickness of the surface of the foam curable resin molding 18:
0.5 mm (F) Quartz sand: Quartz sand No. 5 was sown at a rate of about 0.1 g / cm ² . (G) Weight ratio of upper and lower surfaces of contour strand mat: 50:50 (H) Regarding the foam-curable resin molded body, the thickness was 0.59 mm and the width was 600 mm, respectively. (I) Specific gravity: 0.59 in Example 1, 0.65 in Example 2 (Comparative Examples 1 and 2) (a) Foam curable resin: Water-foamable urethane resin (b) Long fiber: Glass long fiber (C) The foam-curable resin molded article has a three-layer structure of a urethane resin foam having a thickness of 11.1 mm and long glass fibers,
Each of them was laminated so that the fibers were oriented in the vertical direction so that the thickness was 33.5 mm and the width was 600 mm. (D) The upper and lower surfaces of the three-layer molded body were ground by 0.5 mm, and the ground surfaces were chopped glass fibers (300 g /
m ² ) was laid and each was impregnated with a spolyester resin. Silica sand No. 5 was sown on the upper surface to prevent slipping. (E) The specific gravity is 0.5 for each of the three layers of Comparative Example 1,
In Comparative Example 2, the central layer was 0.5 and both outer layers were 0.74.

The products of the molded articles of Examples 1 and 2 and Comparative Examples 1 and 2 were evaluated for the following five test items, and the results are shown in Table 1.

[0029]

[Table 1]

The test items are bending breaking strength (longitudinal bending strength) at a span of 420 mm with the long fiber direction of the product as the long axis.
And the molded articles of Example 1 and Comparative Example 1 had a span of 1000 m.
m, Example 2 and Comparative Example 2 have a longitudinal bending elastic modulus calculated from bending deflection with the long fiber direction of the product as the long axis when the span is 1200 mm, and the span of 420 mm in the direction perpendicular to the long fiber direction of the product. Bending fracture strength (lateral bending strength),
The bending elastic modulus (horizontal bending elastic modulus) when the span is 420 mm in the direction perpendicular to the long fiber direction of the product and the warp in the direction perpendicular to the long fiber direction of the product.

In the warp test, the surface side of the molded product was 300 mm.
While irradiating 2000 W infrared rays from above, the back side of the molded body is heated from a distance of 300 mm with hot water at 60 ° C.
It was carried out by continuously heating for one month and measuring the generated warp.

From the results in Table 1, comparing the molded bodies of Example 1 and Comparative Example 1 and the molded bodies of Example 2 and Comparative Example 2, respectively, it is clear that the molded bodies of Examples 1 and 2 are You can see that the warp is small. Further, it can be seen that the molded products of Examples 1 and 2 are superior in longitudinal bending performance and lateral bending performance in comparison with the molded products of Comparative Examples 1 and 2.

[0033]

Since the present invention is constructed as described above, the following effects are exhibited. In the present invention, first,
The foam-curable resin-reinforced molded body is reinforced with long fibers in which plate-shaped molded bodies are arranged in one direction. In addition, mat-shaped reinforcing fibers are arranged on the upper and lower surfaces of the plate-shaped molded body to improve the bending strength in the direction perpendicular to the long fibers in the plate-shaped molded body, so that warpage occurs in that direction. Can be effectively prevented. This effect can be further enhanced by the configuration in which the plate-shaped molded body and the mat-shaped reinforcing fiber are integrated.

Further, in the foam-hardening resin-reinforced molded product of the present invention, as described above, it is reinforced not only in the direction parallel to the long fibers in the plate-shaped molded product but also in the direction perpendicular to the long fibers and parallel to the upper and lower surfaces. Therefore, even if the curable resin is applied to the surface, it is possible to prevent peeling or swelling due to cracks on the surface of the plate-shaped molded body when the curable resin is cured. Therefore, it is possible to apply a curable resin to the surface side of the foamed curable resin reinforced molded article of the present invention, and spread a filler, silica sand or the like on the coated surface to perform anti-slip processing. In this case, it is not necessary to apply a curable resin to the back surface side as in the conventional molded body.

According to the manufacturing method of the present invention, it is possible to mechanically continuously manufacture the above foam-hardening resin-reinforced molded product.

[Brief description of drawings]

FIG. 1 is a flow chart in an apparatus for producing a foam-curable resin reinforced molded body of the present invention.

FIG. 2 is a partial vertical cross-sectional view of a foam-curable resin reinforced molded body of the present invention.

FIG. 3 is a partial vertical sectional view of a conventional molded body.

[Explanation of symbols]

10 Manufacturing equipment 11 long fibers 12 Foam curable resin 16 Plate-shaped molded body 17 Matt-like reinforcing fiber 19 Foam-curable resin reinforced molding 21 Curable resin 22 Filler

   ─────────────────────────────────────────────────── ─── Continued front page    F-term (reference) 4F100 AG00 AK01A AK01C AK51                       BA03 BA07 BA10A BA10C                       BA22B BA22C CC002 DA20C                       DG01 DG01B DG04C DG20A                       DG20B DJ01C EJ08A EJ08C                       EJ81C GB07 JA20C JK12                       JL09                 4F204 AA36 AC03 AD16 AD20 AG01                       AG02 AG03 AG05 AG20 AH43                       AH46 FA01 FB01 FB11 FG02                       FG04 FG07 FG09 FW24 FW37

Claims (8)

[Claims] 1. A foam-curable resin-reinforced molded product comprising a plate-shaped molded product in which a foam-curable resin is arranged in one direction and reinforced with long fibers. 2. The foam-curable composition according to claim 1, wherein mat-shaped reinforcing fibers for reinforcing the vertical direction of the long fibers and the direction parallel to the upper and lower surfaces are arranged on the upper and lower surfaces of the plate-shaped molded product. Resin-reinforced molded product. 3. The foam-hardening resin-reinforced molded product according to claim 2, wherein the plate-shaped molded product is integrated with mat-shaped reinforcing fibers. 4. The foam curable resin reinforced molded article according to claim 1, wherein a curable resin mixed with a filler is applied to the surface side of the plate-shaped molded article. 5. The foam curable resin reinforced molded article according to claim 1, which is configured as a lid for water treatment. 6. A mat-like reinforcement in the direction perpendicular to the long fibers and in the direction parallel to the upper and lower surfaces after impregnating the continuously curled long fibers with the foam curable resin or during impregnation with the foam curable resin. Foaming and curing, characterized in that a fiber is continuously supplied to the upper and lower surfaces of a molded body, and then continuously guided to a mold to foam and cure in the mold to obtain a plate-shaped molded body. For producing a reinforced resin-reinforced molded article. 7. The method for producing a foam-curable resin-reinforced molded product according to claim 6, wherein only one surface of the obtained plate-shaped molded product is ground. 8. The method for producing a foam curable resin reinforced molded article according to claim 6, wherein a curable resin mixed with a filler is applied to the ground surface side.