JP2006198809A - Recycled molding material and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a recycled molding material enhanced in bending strength while enhanced in productivity, and its manufacturing method. <P>SOLUTION: The manufacturing method of the recycled molding material 17 comprises a process for crushing a structure produced from a fiber reinforced molding material, a process for bonding a binder to the obtained crushed matter 10, a process for shaping an aggregate of the crushed matter to which the binder is bonded to form a core material 15, a process for laminating and arranging a reinforcing fiber material 16 on one side or both sides of the formed core material 15, and a process for subjecting the laminated reinforcing fiber material 16 and the core material 15 to press molding to successively compactify and integrate them. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a recycled molding material manufactured by recycling a waste structure made of a fiber reinforced molding material, and a method for manufacturing the same.

Research has been progressing on reclaimed molding materials in which crushed pieces obtained by crushing structures made of fiber-reinforced molding materials are pressed into a predetermined shape using a binder and reused.
The present applicant has already proposed such a regenerated molded material in Japanese Patent Application No. 2002-257959 (unpublished).

  Such reclaimed molding material is obtained by selecting elongated chip-shaped fragments from the crushed fragments, attaching a binder to these fragments, and pressing them in a state of being aligned in the longitudinal direction. Manufactured.

By the way, in order to improve the bending strength (bending elastic modulus) of the above-mentioned regenerated molded material, it was necessary to press and compact the crushed pieces that function as aggregates inside the regenerated molded material. This is because if the compaction is low, the joint area between the crushed pieces decreases and the strength of the recycled molding material decreases, and by consolidating the crushed pieces by pressurization, the joint area between the crushed pieces is increased. Therefore, it was necessary to ensure the bending strength of the recycled molding material.
However, in order to promote the consolidation of the crushed pieces, a high pressure must be applied, and a large press machine is required as the molding material becomes larger. .

Further, in a regenerated molded material obtained by molding a crushed piece obtained by pulverizing a structure made of a fiber reinforced molded material using a binder, the maximum length of the crushed piece is large when trying to increase the bending strength of the regenerated molded material. Is more advantageous. This is because the long crushed pieces function as aggregates and contribute to the improvement of the bending strength of the regenerated molded material.
Here, when the fiber-reinforced molding material is pulverized, the crushing conditions are set such that the crushed pieces are in the form of elongated chips. For example, the pulverization conditions are set so that the maximum length of the crushed pieces exceeds 10 mm and reaches 200 mm. However, even if such pulverization conditions are set, the crushed pieces obtained by pulverization include, for example, many crushed pieces having a maximum length of less than 10 mm, in addition to those having the target maximum length.

  However, when an aggregate in which short crushed pieces are mixed with long crushed pieces is hardened with a binder and molded, the bending strength is lowered for the reasons described above. On the other hand, in order to remove short crushed pieces, it is necessary to add a process, and there is a conflicting problem that the short crushed pieces are discharged as waste as well as time and effort.

  The present invention is proposed in view of the above-described circumstances, and provides a reclaimed molded material having improved bending strength while improving manufacturability by improving the tensile strength of one side of the reclaimed molded material. It is aimed. Another object of the present invention proposed at the same time is to provide a method for producing the regenerated molded material.

In order to achieve the above object, the present inventors have taken the following technical means.
In other words, the invention described in claim 1 includes a step of crushing a structure made of fiber-reinforced molding material, a step of attaching a binder to the obtained crushed material, and a crushed material to which a binder is attached. Forming a core material by shaping the aggregate of the substrate, a step of laminating and arranging reinforcing fiber materials on one or both sides of the formed core material, and a laminated reinforcing fiber material and core material A method of manufacturing a regenerated molded material comprising a step of pressing and integrating while consolidation.

  The step of attaching the binder to the crushed material is, for example, a method in which the crushed material is put in a rotating tank having a substantially horizontal rotating shaft, and the binder is sprayed toward the inside of the tank while rotating the rotating tank. A method of spraying the binder toward the inside of the tank while putting the crushed material into the equipped stirring tank and rotating the stirring blade to move the crushed material can be adopted.

As the binder, a resin adhesive such as MDI (Methylene Diphenyl Isocyanate) can be used. Although the viscosity of MDI is not specifically limited, The viscosity which can be sprayed is preferable.
MDI reacts with moisture to develop adhesive force while curing. For this reason, it is necessary to add moisture to the crushed material, to add moisture to the MDI, or to supply moisture at the time of curing. The method of replenishing water for curing MDI can be performed simultaneously with the spraying of MDI, or the method in which only water is attached to the crushed material in advance.

  The amount of MDI attached to the crushed material depends on the total surface area of the crushed material, but is preferably 3 to 50% by weight with respect to the weight of the recycled molding material. When the amount of the binder is less than 3% by weight, the crushed materials are not sufficiently joined to each other, and the strength of the regenerated molded material is lowered. When the amount of the binder exceeds 50% by weight, the binder overflows and looks bad and uneconomical.

The step of forming the core material by shaping the aggregate of the crushed material with the binder attached thereto, and the step of laminating and arranging the reinforcing fiber material on one or both sides of the core material facing each other include a continuous molding method or It can be performed by a batch molding method.
In the continuous molding method, a method is used in which a crushed material to which MDI is attached is continuously supplied in a constant amount while guiding a reinforcing fiber material continuously. Further, in the batch molding method, a method is used in which a reinforcing fiber material cut into a predetermined shape is placed on a molding die and a crushed material in which MDI is adhered on the reinforcing fiber material is evenly spread.

  In the batch molding method, the process of integrating the laminated reinforcing fiber material with the core material by press molding is performed by pressing the reinforcing fiber material and the core material arranged in a laminated state on the mold with a press machine. Done. Further, in the case of the continuous molding method, a configuration in which pressure molding is continuously performed by a pressure roller or the like while the reinforcing fiber material and the core material are stacked and moved by an endless belt or the like is employed.

In addition, in the case of adopting either a continuous molding method or a batch molding method, it is necessary to heat in order to promote the hardening of MDI during press molding. The heating temperature during press molding is desirably in the range of 80 to 220 ° C. When the heating temperature is less than 80 ° C., the effect of accelerating the curing of MDI is low, and when the heating temperature exceeds 220 ° C., the regenerated molded material and the MDI are deteriorated and deteriorated.
As the heating method, a method in which the mold is heated to a high temperature in advance, or a method in which the mold is heated by steam or electromagnetic waves when press-molding can be employed.

  According to the manufacturing method of the present invention, during press molding, the binder (MDI) adhered to the crushed material oozes out and is cured and integrated while adhering to the reinforcing fiber material. As a result, it is possible to produce a recycled molding material without unnecessarily adhering the binder.

  Invention of Claim 2 is a manufacturing method of the recycle molding material which further has the process of classifying a slender chip-like fragment from the crushed material obtained by crushing a structure in the invention of Claim 1. .

According to the present invention, a crushed material having a short maximum length or a crushed material in powder form is removed by a process of selecting elongated chip-shaped fragments from the crushed material. In other words, by removing fine crushed material and powdered crushed material and using only elongated chip-shaped crushed pieces, the crushed pieces function as aggregates inside the core material and bend the recycled molding material. Strength can be improved.
In addition, according to the present invention, when sorting the elongated chip-shaped fragments, it is not necessary to classify according to the length of the fragments, and only fine fragments and powdered fragments need to be removed. Therefore, the sorting process can be simplified, and the residual waste material is small.

  Invention of Claim 3 is a manufacturing method of the recycle molding material which further has the process of making the reinforcing fiber material impregnate a binder in the invention of Claim 1 or 2.

According to the present invention, the reinforcing fiber material can be impregnated with the binder in advance, and the smoothness of the surface of the recycled molded material can be improved.
In order to impregnate the reinforcing fiber material with the binder, for example, after immersing the reinforcing fiber material in a storage tank of the binder (MDI), the reinforcing fiber material is passed through the pressure roller, and the binder that has adhered extra is added. By adopting a squeezing configuration or the like, the reinforcing fiber material can be uniformly impregnated with the binder.

  According to a fourth aspect of the present invention, there is provided a core material in which a chip-shaped crushed piece obtained by crushing a fiber-reinforced molding material is formed into a predetermined plate shape composed of an aggregate of crushed pieces using a binder, and the core It is a regenerated molded material formed integrally with a reinforcing fiber material impregnated with a binder that is laminated on one or both sides of the material.

  According to the present invention, in the recycled molded material in which the reinforcing fiber material is laminated on one surface of the core material, when a bending load is applied to the surface opposite to the side on which the reinforcing fiber material is laminated, the recycled molded material is It tries to bend so that the surface on which the reinforcing fiber material is laminated becomes convex. For this reason, a large tensile force acts on the surface on which the reinforcing fiber material is laminated, but the tensile strength of the reinforcing fiber material prevents the bending while preventing the bending, and the bending strength and bending elastic modulus of the recycled molded material. Can be improved.

  The reclaimed molding material of the present invention can be applied to, for example, railway sleepers, water tanks, and water channel cover lids. When using the regenerated molding material of the present invention in which the reinforcing fiber material is laminated on only one side, by arranging the bending load to be applied to the surface opposite to the side on which the reinforcing fiber material is laminated, As described above, it is possible to improve the bending strength and the flexural modulus.

In the present invention, the material of the fiber reinforced molding material (FRP) to be crushed and reused is not particularly limited. However, when the recycled molding material is used as a structural material requiring strength, a thermosetting hard resin is preferable.
Specific examples include polyurethane resins, phenol resins, unsaturated polyester resins, diallyl phthalate resins, vinyl ester resins, epoxy resins, urea resins, melamine resins, polyimide resins, polyamideimide resins, acrylic resins, and the like. May be foamed using an auxiliary agent. In particular, in order to obtain a light-weight and high-strength recycled molded material, a rigid polyurethane resin foam is preferred.

In addition, the shape of the fiber contained in the fiber-reinforced molding material to be crushed is not limited as long as it has a function as a reinforcing fiber. For example, monofilaments and fibrillated fiber elements (those protruding from cocoon-like fibers) And weaving yarns. Further, the reinforcing fiber may be, for example, only glass fiber, or may be a composite of glass fiber and reinforcing fiber such as carbon fiber or synthetic fiber.

  As a fiber-reinforced molding material to be crushed, for example, when a waste material made of glass fiber-reinforced hard synthetic resin foam reinforced with glass fiber is reused, the glass fiber content is preferably 20 to 80% by weight. When the glass fiber content is lower than 20% by weight, the strength of the crushed pieces is reduced, the strength of the recycled molded material is insufficient, and the recycling rate of the waste material is reduced. When the glass fiber content exceeds 80% by weight, the surface of the crushed pieces is not sufficiently covered with the hard synthetic resin material, and a large amount of binder is used to smooth the surface of the recycled molding material. Cost.

  As the reinforcing fiber material laminated on the core material, any form of fiber material such as glass roving reinforced with glass fiber, glass mat, glass cloth or glass chop may be used. Further, a composite mat or composite cloth of glass fiber and organic fiber can be used. Furthermore, it is possible to use a mat or cloth made of only organic fibers.

According to a fifth aspect of the present invention, in the fourth aspect of the present invention, the average value of the maximum lengths of the crushed pieces contained in the core material is 10 to 200 mm.
When the average maximum length of the crushed pieces is less than 10 mm, as described above, the crushed pieces do not function as aggregates inside the core material, and the compressive strength as well as the tensile strength of the core material is insufficient. . Moreover, when the average value of the maximum length of the crushed pieces exceeds 200 mm, handling of the crushed pieces becomes difficult during production, and the production efficiency is remarkably lowered. It is desirable to use a crushed piece used for the core material having an average maximum length of 10 to 200 mm.

  In the present invention, the average value of the maximum width of the crushed pieces is desirably 3 to 50 mm, and the average value of the maximum height of the crushed pieces is desirably 1 to 20 mm. If the average value of the maximum width or maximum height of the crushed pieces is shorter than the above-mentioned value, the total surface area of the crushed pieces increases and the required amount of binder increases. When the average value of the maximum width or the maximum height of the crushed pieces exceeds the above-described value, the total joint area between the crushed pieces is reduced and the strength of the regenerated molded material is lowered.

According to a sixth aspect of the present invention, in the invention according to the fourth or fifth aspect, the weight of the reinforcing fiber material contained in the recycled molded material is 0.3 to 10% by weight.
When the weight of the reinforcing fiber material contained in the regenerated molded material is less than 0.3% by weight, the tensile strength is not significantly improved by the reinforcing fiber material, and the bending strength is not improved. Moreover, when the weight of the reinforcing fiber material included in the regenerated molded material exceeds 10% by weight, the bending strength is improved with an increase in the tensile strength, but the cost is increased.

In the invention according to any one of claims 3 to 5, the specific gravity of the core material is desirably 0.8 to 1.8.
When the specific gravity of the core material is lower than 0.8, the degree of compaction of the crushed pieces becomes low, the joint area between the crushed pieces is reduced, and the strength of the recycled molded material is lowered.
Moreover, when the specific gravity of the core material exceeds 1.8, consolidation of the crushed pieces is promoted and the strength is improved, but a large pressing force is required, so that the equipment cost increases. That is, press molding is performed in a state where the core material and the reinforcing fiber material are laminated, and consolidation is performed. However, as the recycled molding material is increased in size, a large and high press machine is required, resulting in an increase in equipment costs.

The invention according to claim 7 is a step of crushing a structure made of fiber reinforced molding material, a step of attaching a binder to the obtained crushed material, and applying vibration to the aggregate of crushed materials, While the crushed material is moved and distributed in the height direction of the aggregate according to the maximum length and the longitudinal direction of the crushed material is oriented in substantially the same direction, the aggregate of the crushed material is long in the orientation direction. And a step of press-molding a compacted aggregate of the crushed material and compacting the compacted material.

  In the present invention, the step of adhering the binder to the crushed material is a method of spraying the binder into the tank while rotating the rotating tank containing the crushed material, as in the invention of claim 1, and stirring. A method of spraying the binder into the tank while stirring the crushed material in the tank with a stirring blade can be employed.

As the binder, a resin adhesive such as MDI (Methylene Diphenyl Isocyanate) can be used. Although the viscosity of MDI is not specifically limited, The viscosity which can be sprayed is preferable.
Since MDI develops adhesive force while curing by reacting with moisture, it is necessary to contain moisture in the crushed material, to contain moisture in MDI, or to supply moisture at the time of curing. The method of replenishing water for curing MDI can be performed simultaneously with the spraying of MDI, or the method in which only water is attached to the crushed material in advance.

  The amount of MDI attached to the crushed material depends on the total surface area of the crushed material, but is preferably 3 to 50% by weight with respect to the weight of the regenerated molded material. When the amount of the binder is less than 3% by weight, the crushed materials are not sufficiently joined to each other and the strength of the molded product is lowered. When the amount of the binder exceeds 50% by weight, the binder overflows and looks bad and uneconomical.

In the present invention, the method of applying vibration to the crushed material can take various forms. For example, a method of vibrating the entire mold for accommodating and molding the aggregate of crushed materials, a method of arranging a vibration device inside the mold, and vibrating the crushed material by the vibration device can be employed.
By applying vibration to the crushed material, the small crushed material moves downward through the gaps of the larger crushed material. Thereby, it is possible to distribute many crushed materials having a short maximum length below the aggregate of crushed materials and to distribute many crushed materials having a long maximum length upward.
In addition, by applying vibration to the crushed material, it is possible to simultaneously align the longitudinal direction of the crushed material with the longitudinal direction of the recycled molded material.

  In the present invention, the frequency of vibration applied to the crushed material is preferably in the range of 0.1 Hz to 30 Hz. If the frequency of vibration applied to the crushed material is less than 0.1 Hz or exceeds 30 Hz, there is little effect of moving the crushed material in the height direction due to vibration, and the crushed material having a different maximum length can be effectively moved. Can not. The frequency of vibration applied to the crushed material is preferably in the range of 0.1 Hz to 30 Hz, and the range of 1 Hz to 10 Hz is optimal.

  In the batch molding method, the step of pressing and compacting the shaped crushed material aggregate is configured to press the crushed material aggregate placed in the mold with a press. In the case of the continuous molding method, a configuration is adopted in which the aggregate of crushed materials is moved by an endless belt and is continuously pressurized by a pressure roller or the like.

In addition, in the case of adopting either a continuous molding method or a batch molding method, it is necessary to promote the curing of MDI by heating at the time of press molding. The heating temperature for press molding is desirably in the range of 80 to 220 ° C. When the heating temperature is less than 80 ° C., the effect of accelerating the curing of MDI is low. When the heating temperature exceeds 220 ° C., the recycled molded material is altered or deteriorated.
As a heating method, a method of heating a molding die to a high temperature in advance, or a method of heating by steam or electromagnetic waves when press molding can be adopted.

  The invention according to claim 8 is the method for producing a regenerated molding material further comprising the step of selecting elongated chip-shaped fragments from the crushed material obtained by crushing the structure in the invention according to claim 7. .

According to the present invention, the powdered crushed material and the shortest crushed material of the maximum length are removed by the process of selecting elongated chip-shaped crushed pieces from the crushed material. In other words, by removing fine crushed material and powdered crushed material and using only elongated chip-shaped crushed pieces, the crushed pieces function as aggregates in the core material, and the bending strength of the recycled molded material is increased. Can be improved.
Further, according to the present invention, it is not necessary to classify according to the length of the crushed pieces when sorting the elongated chip-shaped crushed pieces. Thereby, it is only necessary to remove fine crushed material and powdered crushed material, and it is possible to reduce the residual waste while simplifying the sorting process.

  The invention according to claim 9 is a regenerated molding material in which elongated chip-shaped crushed pieces obtained by pulverizing a fiber reinforced molding material are molded into a predetermined plate body composed of aggregates of crushed pieces using a binder. Each piece is composed of a set of short crushed pieces belonging to the shortest maximum length and a set of long crushed pieces belonging to the longest maximum length, and the crushed pieces are pulled in the longitudinal direction of the recycled molding material. A structure in which a large number of short crushed pieces are distributed in a region close to one surface of the regenerated molded material and a small amount of short crushed pieces are distributed in a region close to the other surface of the regenerated molded material. It is said that.

Here, when an excessive bending load is applied to the molding material in which the crushed pieces are hardened with a binder, the fracture occurs due to the tensile stress on the surface opposite to the surface to which the load is applied.
Recycled molded material obtained by pressure-molding an assembly of long crushed pieces has a higher tensile stress due to the function of the crushed pieces as an aggregate than when short crushed pieces are used. The elastic modulus and tensile strength at break are large.
On the other hand, there is no significant difference between the elastic modulus of compression accompanying the bending load and the fracture strength of compression, regardless of whether short shredded pieces or long shredded pieces are used.

According to the present invention, a large amount of short crushed pieces are distributed on one surface side of the regenerated molded material, and a small amount of short crushed pieces are distributed on the other surface side.
As a result, a large tensile elastic modulus and tensile breaking strength are exhibited on the surface where the long crushed pieces of the regenerated molded material are distributed, and a compression elastic modulus and a compressive force are exhibited on the surface where many of the short crushed pieces of the regenerated molded material are distributed. The breaking strength of can be maintained.
As a result, it is possible to improve the bending elastic modulus and bending fracture strength of the recycled molded material by laying and using the recycled molded material of the present invention so that a bending load is applied to the surface where many short fragments are distributed. It becomes.

In the present invention, as the waste material of the fiber-reinforced molding material to be crushed, a fiber-reinforced hard synthetic resin foam can be used as in the invention described in claim 4. The hard synthetic resin material is not particularly limited. For example, waste materials using urethane resin, polyester resin, vinyl ester resin, etc. can be reused.
When the waste material made of glass fiber reinforced rigid synthetic resin foam is reused, the glass fiber content is preferably 20 to 80% by weight.
When the glass fiber content is less than 20% by weight, the strength of the crushed pieces is reduced, the strength of the recycled molded material is reduced, and the degree of reuse of the waste material is reduced. If the glass fiber content exceeds 80% by weight, a large amount of binder is required because the surface of the crushed pieces is not sufficiently covered with the hard synthetic resin.

  According to a tenth aspect of the present invention, in the recycled molded material according to the ninth aspect, the short crushed piece has an average value of the maximum length of 1 to 10 mm, and the long crushed piece has an average value of the maximum length exceeding 10 mm and 200 mm. In the region from the approximate center of the thickness of the regenerated molded material to one side, the distribution amount of the short crushed pieces is 30% by weight or more with respect to the total crushed pieces, The region extending from the approximate center to the other surface is configured such that the distribution amount of the short crushed pieces is 10% by weight or less with respect to the entire crushed pieces.

In the present invention, in the region from the approximate center of the thickness of the regenerated molded material to one surface, the distribution amount of the short crushed pieces is 30% by weight or more based on the total crushed pieces. This is because the compressive strength associated with the bending load is reduced when the amount is less than 30% by weight.
In addition, in the region from the approximate center of the thickness of the regenerated molded material to the other surface, the distribution amount of the short crushed pieces is 10% by weight or less with respect to the total crushed pieces. This is because if the amount exceeds 10% by weight, the amount of long crushed pieces decreases accordingly, and the tensile modulus and tensile breaking strength associated with the bending load decrease accordingly. The lower the amount of short fragments in this region, the better and may be 0%.

Here, it is desirable that the region in the thickness direction that regulates the distribution amount of the short crushed pieces in the recycled molded material is a region of 5 to 25% in the thickness direction from each surface.
By restricting the amount of short shredded pieces in this region to the above-mentioned amount, a large amount (short in weight) of short shredded pieces are distributed on one side, and conversely, long shredded pieces are placed on the other side. Can be distributed in a large amount (by weight). This prevents the fragments from being located on the surface of the regenerated molded material, maintains the smoothness of the surface, and distributes the fragments at a position as far as possible from the center in the thickness direction of the regenerated molded material. It is possible to effectively increase the cross-sectional second moment and the bending rigidity of the regenerated molded material.

  When using the reclaimed molding material of the present invention for, for example, a water tank cover or a railroad sleeper or a walking board, a surface containing a large amount of short shredded pieces becomes a side to which a load is applied, that is, a short It is arranged and used so that the surface containing a lot of fragments is the upper surface. Thereby, a tensile elasticity modulus and a tensile breaking strength increase, and the bending strength and bending elastic modulus of a regenerated molding material can be improved.

  In the present invention, when the above-mentioned MDI is used as a binder, the amount of MDI attached to the crushed pieces depends on the surface area of the crushed pieces, but is preferably 3 to 50% by weight with respect to the weight of the crushed pieces. When the amount of MDI is less than 3% by weight, the adhesion is insufficient and the strength of the recycled molding material is lowered, and when the amount of MDI exceeds 50% by weight, it overflows and is uneconomical.

  In the present invention, the average value of the maximum length of the short crushed pieces is set to 1 to 10 mm. When the average value of the maximum length of the short crushed pieces is less than 1 mm, the surface area of the chip becomes too large, and the binder (MDI ) Is required more. Moreover, the reason why the average value of the maximum length of the long crushed pieces exceeds 200 mm and is up to 200 mm is that when the average value of the maximum length of the long crushed pieces is 10 mm or less, the tensile stress associated with the bending load is insufficient. This is because if the average value of the maximum lengths of the long crushed pieces exceeds 200 mm, handling of the crushed pieces becomes difficult and the production efficiency decreases.

In the present invention, for both the short crushed pieces and the long crushed pieces, the average value of the maximum width of the crushed pieces is preferably 0.5 to 50 mm, and the average value of the maximum height (thickness) of the crushed pieces is 0.00. 5 to 20 mm is desirable.
When the average value of the maximum width and maximum height of the crushed pieces becomes shorter than the above-described values, the surface area of the crushed pieces increases and the required amount of binder increases. When the average value of the maximum width and the maximum height of the crushed pieces is longer than the above-described values, the joint area between the crushed pieces is reduced, and the strength of the recycled molded material is reduced.

In the invention according to claim 9 or 10, the specific gravity of the recycled molded material is preferably 0.8 to 1.8.
When the specific gravity of the recycled molded material is lower than 0.8, the degree of consolidation of the crushed pieces is reduced, the bonding area between the crushed pieces is reduced, and the strength of the recycled molded material is lowered.
Further, when the specific gravity of the regenerated molded material exceeds 1.8, consolidation of the crushed pieces is promoted and the strength is improved, but a large pressing force is required, so that the equipment cost increases. In other words, a large pressing machine is required in order to require a large pressing force when pressing and compacting an aggregate of crushed pieces, which increases equipment costs.

The invention described in claim 11 is a recycled molded material obtained by bonding the recycled molded materials according to claim 9 or 10, and is formed by bonding surfaces close to a region where a lot of short crushed pieces are distributed. Recycled molding material.
That is, this invention joins the reclaimed molding materials of Claim 9 or 10, and uses them as a new recycle molding material.

According to the present invention, by sticking together the surfaces with a large amount of distribution of short crushed pieces, the surface of the new recycled molded material with a large amount of distribution of long crushed pieces is located outward. Therefore, the new regenerated molded material has an increased tensile elastic modulus and tensile breaking strength in a region close to both opposing sides, and can improve the bending strength and the flexural modulus of the new regenerated molded material.
Although it does not specifically limit as an adhesive agent which bonds reproduction | regeneration molding materials together, For example, an above-described MDI, an epoxy-type adhesive agent, a urethane type adhesive agent, etc. are mentioned, for example.

According to the first to third aspects of the present invention, it is possible to efficiently produce a recycled molded material with improved bending strength without performing classification and orientation of the crushed pieces and consolidation by high pressure.
According to the inventions described in claims 4 to 6, it is possible to form a regenerated molded material having remarkably improved bending strength and bending elastic modulus simply by laminating reinforcing fiber materials.
According to the seventh and eighth aspects of the present invention, it is possible to efficiently manufacture a regenerated molded material with improved bending strength by adjusting the distribution and orientation direction of the crushed pieces by vibration.
According to the ninth and tenth aspects of the present invention, it is possible to improve the tensile strength by distributing a large number of long crushed pieces on one surface of the recycled molded material, and to improve the bending strength and the bending elastic modulus. It becomes possible to provide a molding material.
According to the eleventh aspect of the present invention, it is possible to obtain a reclaimed molding material having a further improved bending strength by simply joining the reclaimed molding materials of the ninth and tenth aspects.

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

(First embodiment)
FIG. 1 is an explanatory view showing a manufacturing process of the regenerated molded material 17 according to the first embodiment of the present invention, and FIG. 2 is an explanatory view showing a state in which a load is applied to the regenerated molded material 17. In the present embodiment, the regenerated molded material is manufactured by a batch molding method, and the manufacturing method will be described with reference to FIGS.

  In this embodiment, as a waste material of a fiber-reinforced molding material to be reused, synthetic wood (Sekisui Chemical Co., Ltd., made by Sekisui Chemical Co., Ltd.) made of a long glass fiber reinforced rigid urethane resin foam obtained by reinforcing a urethane resin foam with glass long fibers. Neo Lumber FFU 74) was used. The ratio between the synthetic resin urethane resin foam and the long glass fiber is 50% by weight.

  First, in the step of crushing the waste material of the fiber reinforced molding material, the synthetic wood was crushed using a biaxial crusher. Then, the crushed material is put into a wave roller type classifier and classified, and as shown in FIG. 1 (a), the maximum length is 10 to 80 mm, the maximum width is 3 to 10 mm, and the maximum height is 1 to 5 mm. The elongated chip-shaped fragments 10 were selected. The density of the crushed pieces 10 thus selected was 0.5 g / cm 3 to 0.8 g / cm 3.

Next, in the step of attaching the binder to the crushed pieces 10, water is preliminarily included in the crushed pieces 10, and as shown in FIG. 1B, the binder (MDI: Methylen) together with the crushed pieces 10 in the drum blender 11.
e Diphenyl Isocyanate. “Sumijour 44V10” manufactured by Sumika Bayer Urethane Co., Ltd. was sprayed at 20 wt% with respect to the total amount of the crushed pieces, and the mixture was uniformly applied to the surface of the crushed pieces 10 by rotating and stirring. The amount of water previously contained in the crushed pieces 10 was 50% by weight of the weight of the binder.

  In the step of forming the core material, as shown in FIG. 1 (c), the crushed pieces 10 with the binder attached thereto were supplied to the mold 12 using the belt conveyor 13 and spread uniformly. The crushed pieces 10 spread on the mold 12 were random without being oriented in a specific direction. And as shown in FIG.1 (d), the aggregate | assembly of the crushing piece 10 spread | laid on the metal mold | die 12 was inserted in the press apparatus 14, and it pressurized while heating at 150 degreeC and the pressure of 10 kg / cm2 for 15 minutes. . And as shown in FIG.1 (e), the core material 15 which preformed the aggregate | assembly of the crushing piece 10 was obtained. Thereafter, the preformed core material 15 was removed from the mold 12.

Next, in the step of attaching the binder to the reinforcing fiber material 16, after the reinforcing fiber material 16 is immersed in a binder storage tank (not shown), the excess binder is squeezed out by a squeezing roller (not shown). It was. The reinforcing fiber material 16 used was a continuous strand mat having a basis weight of 450 g / m ² .

  The step of laminating and arranging the reinforcing fiber material 16 impregnated with the binder on the core material 15 was performed as follows. That is, as shown in FIG. 1E, in the configuration in which the reinforcing fiber material 16 is laminated only on one surface of the core material 15, the reinforcing fiber material 16 impregnated with the binder is placed on the upper surface of the core material 15. . Further, in the configuration in which the reinforcing fiber material 16 is laminated on both surfaces of the core material 15, the core material 15 is placed on the reinforcing fiber material 16 impregnated with the binder, and further the binder is put on the core material 15. The impregnated reinforcing fiber material 16 was placed in a sandwich shape.

Next, as shown in FIG. 1 (f), the one in which the reinforcing fiber material 16 is laminated on one or both sides of the core material 15 is inserted into the press device 14 and pressurized while being heated. As shown, a regenerated molded material 17 was obtained by laminating a reinforcing fiber material 16 on the core material 15 and integrating them.
At the time of molding, each of the reinforcing fiber materials 16 laminated on one side and both sides of the core material 15 is produced by changing the pressing force of the pressing device and changing the specific gravity to 1.0 and 1.2. Got. The dimensions of the obtained recycled molding material 17 were 1000 mm in length, 200 mm in width, and 30 mm in thickness.
Further, as comparative examples, comparative examples 1 and 2 were obtained by molding a regenerated molded material not laminated with the reinforcing fiber material 16 so that the specific gravity was 1.0 and 1.2.

  Evaluation of the prototype of the regenerated molded material 17 was carried out by cutting out a test piece having a length of 500 mm, a width of 50 mm, and a thickness of 30 mm from the regenerated molded material 17 by a three-point bending test. As shown in FIG. 2 (a), the three-point bending test includes a regenerated molding material 17 in which a reinforcing fiber material 16 is laminated on one surface of the core material 15, and a core material 15 as shown in FIG. 2 (b). The reproduction forming material 17 in which the reinforcing fiber material 16 was laminated on both sides was performed. Further, as shown in FIGS. 2A and 2B, the span between the fulcrums S and S in the three-point bending test was 420 mm, and the load F was applied at a speed of 15 mm / min. In the test of the regenerated material 17 in which the reinforcing fiber material 16 is laminated only on one surface of the core material 15, as shown in FIG. 2 (a), the surface on which the reinforcing fiber material 16 is laminated has a load. The surface to be applied was reversed. The test results are as shown in Table 1.

In the regenerated molded material 17 in which the reinforcing fiber material 16 is laminated on the lower surface of the core material 15, as can be seen from Table 1 and FIG. 2A, the regenerated material 17 tries to bend due to the load F applied to the upper surface. A large pulling force F1 is generated. However, as can be seen from Prototype Examples 1 and 2 in Table 1, bending and breaking are prevented by the tensile stress F1 of the reinforcing fiber material 16 laminated on the lower surface side, and the bending elastic modulus compared to Comparative Examples 1 and 2, Bending strength is improved by about 15% or more.
Similarly, in the recycled molding material 17 in which the reinforcing fiber material 16 is laminated on both surfaces of the core material 15, as can be seen from the prototype examples 3 and 4 in FIG. By the tensile resistance F2, the bending elastic modulus and bending strength are improved by about 20% or more compared to Comparative Examples 1 and 2.

  Thus, according to the regenerated molding material 17 of the present embodiment, by laminating the reinforcing fiber material 16, the bending elastic modulus can be obtained without orienting the crushed pieces 10 and without increasing the pressing force during press molding. And it is possible to effectively increase the bending strength. As a result, it is possible to manufacture a recycled molded material having improved strength while improving manufacturability and reducing equipment costs.

(Second Embodiment)
FIG. 3 is an explanatory view showing the production process of the regenerated molding material of the second embodiment according to the present invention, FIG. 4A is a partially enlarged view of the regenerated molding material 19 produced by the production process of FIG. (B) is an explanatory view showing a state in which a load is applied to the recycled molding material 19. In the present embodiment, the recycled molding material is manufactured by a batch molding method, and the manufacturing method will be described with reference to FIGS.

  In this embodiment, as a waste material of a fiber-reinforced molding material to be reused, synthetic wood (Sekisui Chemical Co., Ltd., ESLON) made of a long glass fiber reinforced rigid urethane resin foam obtained by reinforcing a urethane resin foam with glass long fibers. Neo Lumber FFU 74) was used. The ratio between the urethane resin foam and the long glass fiber is 50% by weight.

First, in the step of crushing the waste material of the fiber reinforced molding material, the synthetic wood was crushed using a biaxial crusher. And as shown to Fig.3 (a), the crushed material was thrown into the classifier of a wave roller system, and was classified into the long crushed piece 10 with the longest maximum length, and the short crushed piece 10 with the shortest maximum length. The long crushed pieces 10 have an average maximum length of about 80 mm, an average maximum width of about 10 mm, and an average maximum height of about 5 mm. The short crushed pieces 10 have an average maximum length of about 8 mm. The average value of the maximum width was about 5 mm, and the average value of the maximum height was about 5 mm.
Of the obtained crushed pieces 10, the long crushed pieces 10 were 60% by weight, and the short crushed pieces 10 were 40% by weight. The density of the crushed pieces 10 selected was 0.5 g / cm 3 to 0.8 g / cm 3.

  Next, in the step of attaching the binder to the crushed pieces 10, water is preliminarily included in the crushed pieces 10, and as shown in FIG. 3B, the binder (MDI: Methylene: together with the crushed pieces 10 in the drum blender 11. 10% by weight of “Sumijoule 44V10” manufactured by Sumika Bayer Urethane Co., Ltd. was added to the total amount of the crushed pieces 10, and the mixture was uniformly applied to the surface of the crushed pieces 10 by rotating and stirring. The amount of water previously contained in 10 was 50% of the weight of the binder.

In the step of shaping the aggregate of the crushed pieces into a plate shape, as shown in FIGS. 3 (c) and 3 (d), the vibration device 18 is inserted into the molding die 12 and fed from the belt conveyor 13. The piece 10 was dropped into the mold 12 through the vibration device 18.
Here, the vibration device 18 is a plurality of long thin plate-like alignment plates 18a fixed vertically to the side plate 18b with the longitudinal direction thereof aligned with the longitudinal direction of the mold 12, and the vibration device 18 is It is detachable from the mold 12.

Then, with the crushed pieces 10 dropped between the orientation plates 18a, the vibration device 18 was vibrated at a predetermined frequency f as shown in FIG. As a result, as shown in FIG. 4A, the short crushing piece 10c of the crushing pieces 10 receives the vibration of the orientation plate 18a and moves below the mold 12 through the gap between the long crushing pieces 10a and 10b. However, the shredded pieces 10 are further aligned and oriented along the longitudinal direction of the orientation plate 18a. And it shape | molded in plate shape so that the aggregate | assembly by the crushing piece 10 might become long in an orientation direction.
In the present embodiment, in the step of shaping the aggregate of crushed pieces into a plate shape, the vibration frequency f by the vibration device 18 and the shape of the crushed pieces 10 are changed, and the following prototype example 5, prototype example 6, and comparative example are shown. 3 and Comparative Example 4 were produced.

(Prototype example 5)
By applying vibration of 1 Hz by the vibration device 18, the short crushed piece on the lower surface side of the recycled molded material is 50 wt%, the long crushed piece is 50 wt%, the short crushed piece on the upper surface side is 5 wt%, and the long crushed piece is long. An aggregate of 95% by weight pieces was formed.
(Prototype example 6)
By applying vibration of 10 Hz by the vibration device 18, the short crushed piece on the lower surface side of the recycled molded material is 80 wt%, the long crushed piece is 20 wt%, the short crushed piece on the upper surface side is 3 wt%, and the long crushed piece is long. An aggregate of 97% by weight pieces was formed.

(Comparative Example 3)
Without giving vibration, an aggregate of 60% by weight of long crushed pieces and 40% by weight of short crushed pieces was formed on the upper and lower surfaces of the regenerated molded material.
(Comparative Example 4)
The assembly was shaped using all long fragments without applying vibration.

Next, as shown in FIG. 3 (f), the vibration device 18 is extracted from the mold 12, and the crushed pieces spread on the mold 12 are inserted into the press device 14, and the temperature is 150 ° C. and the pressure is 10 kg / cm 2. Pressurizing while heating for a minute, a regenerated molding material 19 shown in FIG.
The dimensions of the obtained recycled molded material 19 were 1000 mm in length, 200 mm in width, and 30 mm in thickness, and the specific gravity of the molded product was 1.1.

Evaluation of the manufactured regenerated molding material 19 was carried out by cutting a test piece having a length of 500 mm, a width of 50 mm, and a thickness of 30 mm from the regenerated molding material 19 by a three-point bending test. The three-point bending test is shown in FIG.
As shown in (b), the surface where the short crushed pieces 10c of the regenerated molding material 19 are distributed is arranged as the side to which the load F is applied (upper surface side), the span between the fulcrums S and S is 420 mm, and the load F The application speed was 15 mm / min.
The test results are as shown in Table 2.

According to the regenerated molding material 19 of the present embodiment, as shown in FIG. 4 (b), the long crushing pieces 10 a are distributed on the lower surface side of the regenerated molding material 19, thereby pulling the lower surface side of the regenerated molding material 19. The stress can be increased. Therefore, the bending and breaking when the bending load F is applied to the regenerated molding material 19 are prevented, and the bending elastic modulus and bending strength can be improved.
In particular, in Prototype Examples 5 and 6 of this embodiment shown in Table 2, regeneration using only the long crushed pieces shown in Comparative Example 4 is performed by appropriately setting the distribution amount of the short crushed pieces and the long crushed pieces. It turns out that the bending elastic modulus and bending strength equivalent to a molding material are expressed.

  Thus, according to the reclaimed molding material 19 of the present embodiment, the bending strength and the flexural modulus of the regenerated molding material 19 are obtained by efficiently distributing the fragment 10 by applying vibration of 1 to 10 Hz. It is possible to improve the strength of the recycled molded material while improving the productivity.

(Third embodiment)
Further, as shown in FIG. 5, prototype example 7 of recycled molding material 20 in which the recycled molding materials 19 of prototype examples 5 and 6 and comparative examples 3 and 4 prototyped in the second embodiment are bonded together with an adhesive, respectively. And Comparative Examples 5 and 6 were made and strength evaluation was performed. An epoxy adhesive was used as the adhesive. In the prototype examples 7 to 10, the upper surface refers to a surface close to a portion where a large number of short fragments 10c are distributed.

  The prototype of the regenerated molded material 20 was evaluated by cutting a test piece having a length of 1000 mm, a width of 50 mm, and a thickness of 60 mm from the regenerated molded material and performing a three-point bending test. As shown in FIG. 5, the three-point bending test was performed at a span between the fulcrums S and S of 840 mm and an application speed of the load F of 30 mm / min. The test results are as shown in Table 3.

  According to the regenerated molding material 20 of the present embodiment, as can be seen from Prototype examples 7 and 9 in Table 3 and FIG. 5, long shredded pieces 10a and 10b are formed on the upper and lower surfaces of the regenerated molding material 20 newly produced by joining. It is possible to obtain a reinforced molded material 20 that has an extremely high bending strength and bending elastic modulus equivalent to those of Comparative Example 6 using only long crushed pieces.

  In the first and second embodiments, the recycle molding materials 17 and 19 have been described as being configured using a batch molding method, but can be manufactured using a continuous molding method.

(A)-(g) is explanatory drawing which shows the manufacturing process of the reproduction | regeneration molding material of 1st Embodiment which concerns on this invention. (A) is explanatory drawing of the drag which acts with respect to the bending load applied to the reproduction | regeneration molding material which laminated | stacked the reinforcement fiber material on one side of the core material, (b) is a reinforcement fiber material on both surfaces of a core material. It is explanatory drawing of the drag which acts with respect to the bending load applied to the laminated | stacked reproduction | regeneration molding material. (A)-(g) is explanatory drawing which shows the manufacturing process of the reproduction | regeneration molding material of 2nd Embodiment which concerns on this invention. (A) is the elements on larger scale of the reproduction | regeneration molding material manufactured by the manufacturing method shown in FIG. 3, (b) is explanatory drawing of the drag which acts with respect to the bending load applied to a reproduction | regeneration molding material. It is explanatory drawing of the regenerated molding material newly manufactured by joining the regenerated molding materials shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Crush piece 10a, 10b Long crush piece 10c Short crush piece 15 Core material 16 Reinforcement fiber material 17, 19, 20 Recycled molding material

Claims (11)

A step of crushing a structure made of fiber-reinforced molding material, a step of attaching a binder to the obtained crushed material, and a crushed material aggregate to which the binder is attached is shaped into a plate shape to form a core material Forming a reinforcing fiber material on one or both sides of the formed core material facing each other, and integrating the laminated reinforcing fiber material and the core material while pressing and compacting them. A method for producing a regenerated molding material comprising: The method for producing a regenerated molded material according to claim 1, further comprising a step of selecting elongated chip-shaped fragments from a crushed material obtained by crushing the structure. The method for producing a regenerated molded material according to claim 1, further comprising a step of impregnating the reinforcing fiber material with a binder. A chip-shaped crushed piece obtained by crushing a fiber-reinforced molding material is laminated on one or both sides of the core material, which is formed into a predetermined plate shape made of an aggregate of crushed pieces using a binder. A regenerated molded material formed by integrating a reinforcing fiber material impregnated with a binder to be disposed. The regenerated molded material according to claim 4, wherein the crushed pieces contained in the core material have an average maximum length of 10 to 200 mm. The regenerated molded material according to claim 4 or 5, wherein the weight of the reinforcing fiber material contained in the regenerated molded material is 0.3 to 10% by weight. A step of crushing a structure made of fiber reinforced molding material, a step of attaching a binder to the obtained crushed material, and applying vibration to the crushed material aggregate to collect the crushed material according to the maximum length A process of shaping the aggregate of the crushed material into a plate shape so as to be elongated in the orientation direction while orienting the longitudinal direction of the crushed material in substantially the same direction while moving and distributing in the height direction of the body, and shaping A method for producing a regenerated molding material comprising a step of pressing and compacting an aggregate of crushed materials. The method for producing a recycled molded material according to claim 7, further comprising a step of selecting elongated chip-shaped fragments from a crushed material obtained by crushing the structure. Recycled molding material obtained by molding elongated chip-shaped fragments obtained by crushing fiber-reinforced molding materials into a predetermined plate made of aggregates of fragments using a binder, and the fragments have a short maximum length. It is composed of a set of short shredded pieces and a set of long shredded pieces belonging to a long maximum length, and the shredded pieces are oriented with their longitudinal directions aligned in the longitudinal direction of the reclaimed molding material. A regenerated molded material characterized in that a large amount of short crushed pieces are distributed in a region close to one surface of the material, and a short crushed piece is distributed in a region close to the other surface of the regenerated molded material. The regenerated molded material according to claim 9, wherein the short crushed pieces have an average value of a maximum length of 1 to 10 mm, and the long crushed pieces have an average value of a maximum length of more than 10 mm and up to 200 mm. The region from the approximate center of the thickness to one surface has a distribution amount of the short crushed pieces of 30% by weight or more based on the total crushed pieces, and the other surface from the approximate center of the thickness of the regenerated molded material. In the re-formed material, the distribution amount of the short crushed pieces is 10% by weight or less based on the total crushed pieces. A reclaimed molding material obtained by joining the reclaimed molding materials according to claim 9 or 10, wherein the surfaces near the region where the short crushed pieces are distributed are joined to each other. Wood.

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