JP2006264171A - Manufacturing method of fiber-reinforced resin molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To manufacture a regenerated fiber-reinforced resin molding which, uses a used fiber-reinforced molding material, excels in strength and rigidity and also allows nails and screws to be driven easily. <P>SOLUTION: The manufacturing method of the fiber-reinforced resin molding comprises the steps of fixedly installing a projection 11 on a predetermined position of the bottom plate 12 of a form 13 that has a bottom plate 12, fitting the projection 11 with a cylindrical insert 2, supplying into the form the slender crushed pieces of the fiber-reinforced molding material whose fiber direction is aligned in the direction of the major axis, with an adhesive attached thereon, while orientating so that the direction of the crushed strips becomes the same, and molding the supplied material under heat and pressure by a press. Although the hardness of the fiber-reinforced resin molding becomes high by the compaction of the crushed pieces by the press, since the cylindrical insert is embedded, by using an insert material easy to make a perforation, the nails and screws can easily be driven. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for producing a fiber reinforced resin molded article using a crushed piece of a fiber reinforced molded material.

Synthetic wood with excellent corrosion resistance and strength is used instead of wood for sleepers used in railway tracks, pressure plates used to prevent landslides, and cover plates used to cover water tanks and waterways. Many are used.
This synthetic wood is made of a hard synthetic resin foam reinforced with glass fibers or the like oriented in the longitudinal direction, and is lightweight, excellent in corrosion resistance and capable of withstanding long-term use.
However, it is difficult to develop the strength and rigidity of the synthetic wood before crushing, even if the new synthetic wood is regenerated using the used synthetic wood crush as it is. The reason is that most of the tissue of the synthetic wood is occupied by resin, so a large amount of pulverized material is produced by crushing the resin phase into powder during crushing, and these powder resins contribute as aggregates This is because the strength and rigidity of the recycled synthetic wood cannot be improved.
In particular, in synthetic wood having a fiber-reinforced hard synthetic resin foam structure, when crushed, the resin phase is a foam, so that it is more easily pulverized, and the strength and rigidity of regenerated synthetic wood are significantly reduced. Even if only the crushed material from which the resin powder is removed is used, it is difficult to expect the strength and rigidity of synthetic wood in which fibers are aligned in one direction as in the original structure.

Therefore, the present applicant crushes the used synthetic wood, removes the powder from the crushed material, selects only the slender crushed material, attaches the slender crushed material with an adhesive, and crushes the slender crushed material into the mold. It has already been proposed that a fiber-reinforced resin molded product is manufactured by supplying the materials while being oriented in the same direction, and heating and press-molding the supply material with a press (Patent Document 1).
JP 2004-148996 A

  According to this manufacturing method, it is possible to increase the density of crushed pieces by 1.5 times or more of that before pressing by heating and pressing with a press, and if such compaction is performed, excellent strength and rigidity are achieved. A recycled fiber reinforced resin molded article can be obtained.

When synthetic wood is used as a sleeper or the like, it is necessary to drive a nail or a screw for fastening the rail and the sleeper or the like. Usually, a pilot hole is drilled in the field, and the nail or screw is driven into the pilot hole.
However, in the method for producing a fiber reinforced resin molded article of Patent Document 1, if the density of the crushed pieces is increased to 1.5 times or more, the hardness of the obtained fiber reinforced resin molded article is considerably high. Thus, compared to ordinary synthetic wood (long fibers are glass fibers and resin is urethane foam), it is difficult to drill a pilot hole and drive nails and screws.

  An object of the present invention is to produce a recycled fiber reinforced resin molded product that is excellent in strength and rigidity by reusing a used fiber reinforced molded material and that can be easily driven with a nail or a screw.

The method for producing a fiber-reinforced resin molded product according to the present invention includes fixing a protrusion at a predetermined position on a bottom plate of a mold having a bottom plate, attaching a cylindrical insert to the protrusion, and a fiber direction being a major axis direction. The elongated crushed pieces of the fiber reinforced molding material arranged in the above are supplied while adhering the adhesive so that the orientation of the elongated crushed pieces is the same direction in the mold, and the supply material is heated by a press.・ It is characterized by pressure molding.

In the state where the cylindrical insert is attached to a protrusion fixed at a predetermined position on the bottom plate, an adhesive is attached to the elongated crushed piece of the fiber reinforced molding material in which the fiber direction is aligned in the long axis direction, and the above-mentioned formwork The elongated shredded pieces are supplied while being oriented in the same direction, and the supply material is heated and pressurized by a press, so that the cylindrical insert can be embedded at a predetermined position without deviation.
Since the density of the elongated crushed pieces of the fiber reinforced molding material can be increased by heating and pressing with a press, a fiber reinforced resin molded product having excellent strength and high rigidity can be obtained.
This compaction of the crushed pieces increases the hardness of the fiber-reinforced resin molded product, but it is a fiber that has a cylindrical insert embedded and can be easily driven into nails and screws by using an insert material that can be easily drilled. A reinforced resin molded product can be obtained.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 shows an example of a fiber-reinforced resin molded product produced according to the present invention.
In FIG. 1, A is a fiber reinforced resin molded product main body, 2 is a cylindrical insert embedded in a predetermined fastening position of the fiber reinforced resin molded product main body A, and has piercing properties and resistance to pulling out against nails and screws. It is possible to load the core material having the above or to process the female thread groove on the inner surface. As the material, nylon, epoxy resin, polyester, urethane resin, polyacetal, polyphenylene sulfide, or other synthetic resin, iron, SUS, or other metal can be used.
The top part of the cylindrical insert 2 is closed, and the top part is flush with the surface of the fiber reinforced resin molded product main body A or is embedded close to the surface.

FIG. 2 shows an example of a molding die B used in the present invention, and a mold 13 is attached around a bottom plate 12 in which a cylindrical insert fixing protrusion 11 is fixed at a predetermined position.
The mold 13 and the bottom plate 12 are preferably made of the same material, but may be made of different materials. In particular, in the bottom plate 12, it is preferable to use an iron plate, an aluminum plate, or a SUS plate in order to efficiently transfer heat from the press.
The protrusion 11 can be fixed to the bottom plate 12 by screwing or welding. The protrusion 11 is preferably made of the same material as the bottom plate 12. Different materials can be used.
Reference numeral 2 denotes a cylindrical insert attached to the protrusion 11, which is preferably provided with a taper for smooth removal. The height from the bottom plate to the top surface of the cylindrical insert is set to be smaller than the thickness of the fiber-reinforced resin molded product to be manufactured. In order to improve the binding between the cylindrical insert and the fiber reinforced resin molded product body, the outer surface of the cylindrical insert is made uneven, or the material of the cylindrical insert is made adhesive to the fiber reinforced resin molded product body. It is preferable to make it excellent.

The elongated crushed pieces of the fiber reinforced molding material used in the present invention can be obtained by crushing and selecting a used fiber reinforced molding material (synthetic wood). When the fiber reinforced molding material is crushed, slender crushed pieces in which the resin material is fixed around the fiber and powder of only the resin are generated. This resin powder is not used, but only the elongated crush pieces containing fibers are selected and reused. The fibers of the crushed pieces are aligned in the long and long axis direction.
The apparatus for crushing used fiber reinforced molding materials includes, for example, a uniaxial crusher that crushes with a roller having a rotary blade, and a material to be crushed between a pair of parallel rollers having a rotary blade. Thus, it is possible to use a biaxial crusher or the like that crushes both rotary blades by biting them into the object to be crushed.
For example, a wave roller type classifier can be used as an apparatus for sorting the elongated fragments. According to this classifier, it is possible to classify continuously based on the thickness and width of the crushed material, and it is possible to select elongated crushed pieces having a predetermined range of thickness, width and length from the crushed material.

The elongated shredded pieces thus selected are supplied while adhering an adhesive so that the elongated shredded pieces are oriented in the same direction in the mold.
In order to attach the adhesive to the selected crushed pieces, for example, the adhesive is sprayed on the crushed pieces put on the drum blender 3 or the conveyor as shown in FIG. Can be attached uniformly.
In order to supply the adhesive-attached elongated shredded pieces while orienting the elongated shredded pieces in the same direction so as to be in the same direction, for example, as shown in FIG. 4, the adhesive-attached elongated shredded pieces are transported by the upper conveyor 5, and the adhesive-attached shredded pieces are dropped toward the disc orienter 6 in which the discs are arranged at predetermined intervals, and are put into the molding die B. Alternatively, a method of aligning through a comb-like slit having a predetermined width and length can be used.
The cylindrical insert on the mold bottom plate is moved along with the running of the mold B by the conveyor 4 and is struck by the adhesive-attached elongated crush pieces supplied from above, but is attached to a protrusion fixed on the bottom plate. Therefore, it can be stably held at a predetermined position.

If the elongated shredded pieces selected in this way are attached to the mold with the adhesive attached and oriented so that the orientation of the elongated shredded pieces is the same direction, the material is shaped into a plate shape. After this supply, the plate-shaped supply material is heated and pressure-molded by a press 7 as shown in FIG. When compressed to a predetermined density by this pressurization, the press plate 71 receives a predetermined repulsive force. The pressing time is set according to the repulsive force relaxation time and the adhesive effect time. For heating, a method of heating the plate-shaped supply material by heating the press plate, a method of heating the plate-shaped supply material using steam or electromagnetic waves, and the like can be used.
Since the height of the cylindrical insert is greater than the final compressed thickness of the feed, it remains stably held in place despite the press.

As described above, the crushed pieces are oriented with the adhesive attached and shaped into a plate shape, and when this is press-shaped, if there is a large variation in the shape of the crushed pieces, the density of the crushed pieces in the plate shaped shaped product will be If the proportion of powdered crushed material is too large, a large amount of adhesive is required, or if the amount of adhesive is not increased, the amount of adhesive is insufficient and uniform adhesion becomes difficult. Variations in product strength will increase.
In the present invention, the crushed pieces are selected in order to use the crushed pieces with less variation in shape. However, as the amount of crushed pieces or crushed materials that are not used after being sorted is reduced, the use efficiency of the raw material is increased to increase the recycling efficiency. Can be increased. Thus, when the fiber reinforced molding material is crushed, it is difficult to make the shape of the crushed pieces constant because the fiber breaking positions vary, and a large amount of pulverized material is likely to be generated. Therefore, it is preferable to crush the fiber reinforced molding material after cutting it into 50 mm to 200 mm.

The used fiber-reinforced molding material used as a raw material in the present invention is obtained by impregnating a continuous long fiber with a thermosetting resin liquid and curing the impregnated resin while shaping it into a predetermined cross-sectional shape through a mold. Yes, for example, used as sleepers.
As the thermosetting resin of this fiber reinforced molding material, polyurethane resin, phenol resin, unsaturated polyester resin, diallyl phthalate resin, vinyl ester resin, epoxy resin, urea resin, melamine resin, polyimide resin, polyamideimide resin, acrylic resin These resins can be foamed with an auxiliary agent, for example, a hard polyurethane foam. The average density of this rigid polyurethane foam is 0.2 g / cm 3 or more.
Examples of the long fibers of the fiber-reinforced molding material include monofilaments, fibrillated fibers, and twisted yarns. Examples thereof include glass fibers alone, and composites of glass fibers and reinforcing fibers such as carbon fibers and synthetic fibers. be able to.

  The dimensions of the crushed pieces of the fiber-reinforced molding material used in the present invention are 0.5 mm to 10 mm in thickness and width, and 10 mm to 200 mm in length. If the thickness and width are less than 0.5 mm, the surface area of the crushed pieces becomes too large, and it becomes difficult to uniformly apply a small amount of adhesive to the surface of the crushed pieces. Large voids are generated at the locations, and the strength is likely to decrease due to stress concentration. Also, if the length is less than 10 mm, it is too short and orientation by alignment becomes difficult, and an effective reinforcing effect due to the fibers cannot be expected. It becomes easy to cross, and a big space | gap arises in a crossing location, and it becomes easy to generate | occur | produce the strength fall by stress concentration.

  As the adhesive used in the present invention, isocyanate, phenol, urea, urethane, epoxy and the like can be listed, and the blending amount is usually 1 to 20% by weight although it depends on the shape, surface property and density of the crushed pieces. . In order to reduce the weight, it is preferable to apply as little amount of adhesive as possible to the crushed pieces, and it is preferable to use a low-viscosity isocyanate.

The density of crushed pieces of the fiber-reinforced molding material used in the present invention is ^{0.3g / cm 3 ~0.9g / cm 3} , the density of the finally obtained fiber-reinforced resin moldings 0.9 g / ^cm 3 ~ The heating temperature and pressurizing force for press molding are set so as to be 1.6 g / cm ³ . The reason is that if it is less than 0.9 g / cm ³ , the strength is insufficient, and if it exceeds 1.6 g / cm ³ , crushing becomes difficult and recycling becomes difficult. For example, when using a glass fiber reinforced rigid urethane resin foam as a crushed piece of a fiber reinforced molding material, the heating temperature is 180 ° C.

  In the fiber reinforced resin molded product thus obtained, the crushed pieces are consolidated for press molding, and the strength thereof is comparable to that of a glass fiber reinforced rigid urethane resin foam. Due to press molding, the shredded pieces are consolidated and difficult to process, but a cylindrical insert is embedded in place, and nails and screws can be easily driven into this cylindrical insert. It can be easily fastened to the rail with nails or screws as sleepers.

  The fiber reinforced resin molded article produced by the present invention can be used by accommodating a freeze prevention heater or sensor in a cylindrical insert, in addition to being used as a sleeper by fastening with nails or screws. Moreover, it can also be fastened and used by a nail, a screw, etc. as a pressure receiving plate used in order to prevent a landslide, and a cover plate used in order to cover a water tank or a water channel.

A steel taper with a taper taper with a base diameter of 21 mmφ and a length of 80 mm is welded to four locations on a 6 mm thick bottom plate, and a formwork of width 200 x length 2100 mm x height 140 mm is formed around the bottom plate. A welded mold was used, and an embedded plug with a female thread groove made of polyester having a depth of 130 mm and a thickness of 23 mm was used for the cylindrical insert, and the embedded plug was attached to each of the protrusions.
As crushed pieces of fiber reinforced molding material, crushed chips of glass fiber reinforced foamed urethane synthetic wood (Eslon Neo Lumber FFU74 manufactured by Sekisui Chemical Co., Ltd.) having an average major axis length of 30 mm and an average minor axis length of 5 mm. Used as an adhesive, Isochanate (Sumijour 44V10 manufactured by MDI Sumika Bayer Urethane Co., Ltd.) was used.
As shown in FIG. 3 (a), the adhesive and the crushing tip are put into the drum blender 3 so that the amount of the adhesive is 15% by weight, and the adhesive is evenly distributed on the surface of the crushing tip by rotating and stirring. It was applied to.
Next, as shown in FIG. 3B, the adhesive-coated crushing tips are dropped from the upper belt conveyor 5 toward the disc orienter 6 in which the discs are arranged at intervals of 10 mm, and the longitudinal direction of the crushing tips is changed. While aligning in the molding line direction, the adhesive-coated crushing chip was put into the mold B and shaped into a plate shape.
Next, as shown in FIG. 3 (c), the plate-shaped shaped article is inserted into a press device and pressed while being heated at 180 ° C. × 1 hour, width 200 × length 2100 mm × thickness 135 mm, average density 0. A fiber reinforced resin molded product of 92 g / cm ³ was obtained.
About this fiber reinforced resin molded product, it was confirmed that the embedded plug with a female thread groove made of polyester was embedded in place without deviation and the strength was equal to or greater than the strength of long glass fiber reinforced urethane foam synthetic wood. .

It is drawing which shows the fiber reinforced resin molded product manufactured by this invention. It is drawing which shows the frame type | mold used in this invention. It is drawing which shows the manufacturing method of the fiber reinforced resin molded product which concerns on this invention.

Explanation of symbols

A Fiber reinforced resin molded body B Mold 11 Projection
DESCRIPTION OF SYMBOLS 12 Bottom plate 13 Frame type 2 Cylindrical insert 3 Drum blender 4 Conveyor 5 Conveyor 6 Disc orienter 7 Press 71 Press plate

Claims (1)

A protrusion is fixed at a predetermined position on the bottom plate of a mold having a bottom plate, a cylindrical insert is attached to the protrusion, and a long crushed piece of fiber reinforced molding material in which the fiber direction is aligned in the long axis direction is bonded. A fiber reinforced resin molding characterized in that an agent is attached and supplied into the mold so that the elongated shredded pieces are oriented in the same direction, and the supply material is heated and pressurized by a press. Product manufacturing method.

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