JP2013233681A - Traffic signal housing and road sign made by using high-strength fiber composite - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a high-strength fiber composite suitable as a base stock for a traffic signal housing or road sign to be used outdoors.SOLUTION: A high-strength fiber composite is made by covering the surface of a prepreg which is prepared by combining a sheet-shaped high-strength fiber with a thermoplastic resin, with a thermosetting resin. A traffic signal housing or road sign produced by using the high-strength fiber composite as the base stock exhibits high weather resistance against salt damage. The traffic signal housing or road sign produced thereby is lightweight and consequently, a support whose strength is made lower than that of the support of the conventional traffic signal housing or road sign using the conventional metallic plate, can be used. The traffic signal housing or road sign using the high-strength fiber composite as the base stock can be incinerated, and the incinerated residues can be used as a cement reinforcing material.

Description

  The present invention relates to a high-strength fiber composite, a traffic signal housing and a road sign using the high-strength fiber composite.

  Conventionally, a light bulb has been used as a light source of a traffic signal device installed on a road or a railroad track. However, in recent years, it has been converted into an LED having low power consumption and high brightness. And in exchanging traffic signals, parts other than a light source are combined again and reused.

The current traffic signal housing is usually made of a metal plate such as an iron plate or an aluminum plate (see, for example, Patent Document 1).
When a metal plate is used for the traffic signal housing, the weight is as large as 10 to 17 kg with a normal three-signal color traffic light. Further, when an arrow signal is added, its own weight increases. Need to increase. In addition, in the case of a metal plate, a problem of rust due to salt damage occurs particularly in the coastal area, so that there is a problem that maintenance cost is required, for example, it is necessary to periodically perform rust prevention coating. Furthermore, since the corroded metal plate is difficult to reuse and cannot be incinerated, it is landfilled as industrial waste.

On the other hand, a high-strength fiber composite obtained by combining a carbon fiber sheet and a resin is lightweight and highly durable, and is widely used in applications such as an aircraft casing.
There are a thermosetting resin and a thermoplastic resin as a resin to be combined with the carbon fiber sheet, but each has disadvantages.
Specifically, a thermosetting resin prepreg in which a carbon fiber sheet is hardened with a thermosetting resin is cured by heat-reacting an unreacted thermosetting resin. Once it is molded, it cannot be reused. Therefore, if a traffic signal housing or a road sign is produced using a thermosetting resin prepreg, it cannot be reused even if waste is generated during replacement.

  On the other hand, the thermoplastic resin prepreg can be deformed by applying heat of about 150 ° C., and various shapes can be easily formed. On the other hand, compared with the thermosetting resin prepreg, the strength and weather resistance are weak, and it was difficult to apply to a traffic signal frame or a road sign at a practical level.

Japanese Utility Model Publication No. 04-4396

  Under such circumstances, the present invention provides a high-strength and lightweight high-strength fiber composite using high-strength fibers that can be suitably used as a traffic signal frame or road sign material used outdoors. It is.

  The present inventor considered that a high-strength fiber composite that solves the above problems can be provided by simultaneously using a thermoplastic resin and a thermosetting resin for a high-strength fiber sheet such as carbon fiber. As a result of extensive research, it was surprisingly found that the properties of the prepreg obtained by the method of combining the thermoplastic resin with the high-strength fiber sheet are greatly changed, leading to the present invention.

That is, the present invention relates to the following inventions.
<1> A high-strength fiber composite obtained by coating the surface of a prepreg obtained by combining sheet-like high-strength fibers and a thermoplastic resin with a thermosetting resin.
<2> The high-strength fiber composite according to <1>, wherein the prepreg is obtained by heat-pressing a laminate in which a sheet-like thermoplastic resin and a high-strength fiber sheet are laminated in a sandwich structure.
<3> The high strength fiber composite according to <1> or <2>, wherein the high strength fiber is a carbon fiber or a basalt fiber.
<4> The thermoplastic resin is one selected from an acrylic resin, a vinyl chloride resin, a vinylidene chloride resin, a polyacrylonitrile resin, a polyamide resin, a polypropylene resin, a thermoplastic polyimide resin, a polyethylene terephthalate resin, and a polycarbonate resin. The high strength fiber composite according to any one of <1> to <3>.
<5> Any one of <1> to <4>, wherein the thermosetting resin is one selected from an epoxy resin, a phenol resin, a thermosetting polyimide resin, an unsaturated polyester resin, a urea resin, and a melanin resin. A high-strength fiber composite as described in 1.
<6> The high-strength fiber composite according to any one of <1> to <5>, wherein the number of high-strength fiber sheets is 5 to 100.
<7> A traffic signal housing comprising the high-strength fiber composite according to any one of <1> to <6>.
<8> A road sign comprising the high-strength fiber composite according to any one of <1> to <6>.

  According to the present invention, a high-strength fiber composite having high durability and light weight is provided. Traffic signal frames and road signs using the high-strength fiber composite as a material are highly weatherproof and durable, such as salt damage, and are lightweight, so traffic signal frames and roads using conventional metal plates Compared to a sign, a post with reduced strength can be used.

It is a figure which shows embodiment of a traffic signal. It is a figure which shows the manufacturing process of the prepreg which concerns on this invention. It is a figure which shows the state after coat | covering a thermosetting resin to a prepreg.

The present invention will be described in detail.
The present invention relates to a high-strength fiber composite formed by coating the surface of a prepreg composed of a sheet-like high-strength fiber and a thermoplastic resin with a thermosetting resin.
That is, the high-strength fiber composite is a prepreg in which a sheet-like high-strength fiber and a thermoplastic resin are composited, and a composite laminated structure in which a thermosetting resin film is formed on the surface.

A prepreg is a molded intermediate base material in which a matrix resin is combined with high-strength fibers.
Here, as a manufacturing method of a prepreg when a thermoplastic resin is used as a matrix resin, (a) a method in which a high strength fiber sheet is impregnated with a melted thermoplastic resin, and (b) direct heating on the high strength fiber sheet. A method of applying a plastic resin, (c) a method of heat-pressing a laminate in which a sheet-like thermoplastic resin and a high strength fiber sheet are laminated in a sandwich structure, and (d) a combination of a high strength fiber yarn and a thermoplastic resin yarn. For example, a method of twisting into a woven fabric and then laminating and heat-pressing may be mentioned.

Among these, in the high strength fiber composite of the present invention, it is preferable to use (c) a prepreg obtained by heat-pressing a laminate in which a sheet-like thermoplastic resin and a high strength fiber sheet are laminated in a sandwich structure. Here, the sandwich structure refers to a structure in which sheet-like thermoplastic resins and high-strength fiber sheets are alternately laminated.
At present, the detailed reason is not clear, but when a thermoplastic resin prepreg obtained by heat-pressing a laminate laminated in a sandwich structure is used, the final high-strength fiber compared to the thermoplastic resin prepreg produced by other methods. The strength of the composite tends to be improved stably.

  Hereinafter, the configuration of the high strength fiber composite of the present invention will be described in more detail.

(Prepreg)
(High strength fiber sheet)
As the high-strength fiber in the high-strength fiber sheet, for example, carbon fiber, basalt fiber, glass fiber, polyimide fiber, aramid fiber, polyarylate fiber, polyphenylene sulfide (PPS) fiber and the like can be used.
Among these, carbon fiber or basalt fiber is preferable because a high strength fiber composite having particularly high rigidity and mechanical strength can be obtained.

Carbon fiber has a good balance between weight and strength, and has high affinity regardless of the resin to be combined, and is particularly preferably used.
In addition, in the traffic signal housing, in order to allow the driver to accurately check the LED lighting, the housing is currently painted black, but if black carbon fiber is used as the high-strength fiber, it will remain as it is. There is also an advantage that it can be used and does not require painting.

Carbon fiber yarns are often referred to as 1k, 3k, 6k, 12k, and 24k. This represents how many carbon fiber filaments are assembled to form a yarn. For example, 12k is 12000 pieces. Filament assembly yarn.
Although depending on the number of laminated sheet-like carbon fibers in the prepreg, the carbon fiber yarn constituting the carbon fiber is preferably 6 k or more, and more preferably 12 k or more.

  In addition to mechanical strength such as tensile strength, basalt fiber, an inorganic mineral fiber, is particularly excellent in acid resistance and alkali resistance, making it suitable for use in harsh environments such as salt damage and acid rain. Yes. Moreover, since it has a thermal expansion coefficient similar to that of concrete, it is particularly suitable for reuse as a cement reinforcement after disposal.

When the high-strength fiber composite of the present invention is used for outdoor applications such as a traffic signal housing or a road sign, sufficient strength to withstand strong winds and snow is required.
In order to increase the mechanical strength of the high strength fiber composite of the present invention, the high strength fiber sheets constituting the prepreg are laminated. On the other hand, if the number of laminations is too large, the thickness of the high strength fiber composite is reduced. It becomes too large and molding becomes difficult.
Therefore, a range of 5 to 100 high-strength fiber sheets constituting the prepreg is preferable. If it is less than 5 sheets, the strength may be insufficient, and if the thickness is increased, the press pressure increases. Therefore, if it exceeds 100 sheets, molding becomes difficult.

  The thickness of one sheet of high strength fiber sheet is usually about 2 to 20 mm.

(Thermoplastic resin)
The thermoplastic resin is determined in consideration of compatibility with high-strength fibers that are combined as a prepreg. Preferred thermoplastic resins include, for example, acrylic resins, vinyl chloride resins, vinylidene chloride resins, polyacrylonitrile resins, polyamide resins, polypropylene resins, thermoplastic polyimide resins, polyethylene terephthalate resins, and polycarbonate resins.
Among these, acrylic resin is one of suitable resins because it has good compatibility with carbon fiber and basalt fiber.

  The thickness of the thermoplastic resin sheet is usually about 100 μm to 10 mm, although it depends on the thickness of the high-strength fiber sheet combined as a prepreg.

(Prepreg production)
The prepreg in the present invention can be manufactured by, for example, an apparatus having the configuration shown in FIG.
After a laminated body in which a sheet-like thermoplastic resin and a high-strength fiber sheet are laminated in a sandwich structure is heated by a preheating part (heater part), it is molded into a predetermined shape by a press part. A prepreg can be obtained.

For example, when the high-strength fiber composite of the present invention is used as a traffic signal housing, the thermoplastic resin prepreg may be coated with a thermosetting resin, which will be described later, after forming irregularities with a press.
In addition, there are a method of heating the mold as a preheating of the laminated prepreg and a method of not heating, either of which may be used, but when making an acute angle with a press die, it is easy to detach from the press die and is difficult to deform. A method without heating is preferred.

(Physical properties of prepreg)
The tensile strength of the prepreg is mainly determined by the tensile strength of the high strength fiber sheet. The strength is usually about 500 to 2000 kg / mm ^{2 although} it depends on the type of high-strength fiber sheet, fiber density, thickness, and the like.
As this strength, the theoretical value calculated from the number of yarns whose strength per yarn is presented in the yarn manufacturer catalog of high strength fibers used for high strength fiber sheets is often used. In the case of a woven fabric, unevenness occurs due to warp and weft crossing, and the strength decreases. Therefore, a numerical value obtained by multiplying 90% of this theoretical value by 70% is often used as an actual measurement value.

(Thermosetting resin)
The high-strength fiber composite of the present invention is formed by coating the surface of the prepreg with a thermosetting resin. A schematic diagram is shown in FIG.
By having a thermosetting resin film on the surface, the surface hardness and chemical durability of the high-strength fiber composite are significantly improved as compared to a prepreg without a film.

The thermosetting resin is not particularly limited as long as it undergoes a crosslinking reaction by heat and forms a three-dimensional crosslinked structure.
Examples of such a thermosetting resin include an epoxy resin, a phenol resin, a thermosetting polyimide resin, an unsaturated polyester resin, a urea resin, and a melamine resin, and these may be modified products. Two or more kinds of resins may be mixed and used.
In addition, these thermosetting resins may be cured by heating, or may be cured at a temperature of about room temperature by blending a curing agent or a curing accelerator.

  In particular, an epoxy resin and a thermosetting polyimide resin that are resistant to ultraviolet rays, have high weather resistance, have excellent mechanical properties, and have an excellent balance of adhesion to carbon fibers are preferably used.

  The method for applying the thermosetting resin to the prepreg surface is not particularly limited. For example, a known method such as a roll coating method, a spin coating method, a wire bar method, a dip coating method, an extrusion method, a curtain coating method, or a spray coating. A method, a casting film forming method, a bar coating method, a gravure coating method, a doctor blade method, a die coater method and the like can be appropriately employed. In particular, spray coating is preferable because the thermosetting resin can be uniformly coated on the surface even in a structure having irregularities.

The thickness of the thermosetting resin film formed on the surface of the prepreg varies depending on the intended use, but is usually about 100 μm to 10 mm, but is not limited thereto. For example, when used outdoors (particularly salt damage) If it is used on a coast where there is a strong wind, etc., it may be thicker.
The thermosetting resin may be cured at room temperature, but it is better to solidify by heating in a sealed oven in order to achieve uniformity. What is necessary is just to select the temperature suitable for the thermosetting resin to be used for heating temperature.

(Use of high strength fiber composites)
Since the high strength fiber composite of the present invention has high mechanical strength and high weather resistance, it can be suitably used as a material for a traffic signal frame or road sign used outdoors. And since it is lighter than the metal plate which is the conventional raw material, support | pillar strength can be reduced rather than using a metal plate.

When the high-strength fiber composite of the present invention formed into an appropriate shape is used as a traffic signal housing, both a light bulb and an LED can be used as a light emitting part. In contrast to the conventional traffic light that uses a light bulb, the shape of the housing used is complicated and difficult to form. On the other hand, the traffic light housing for LED as shown in FIG. Since it is inserted, the shape is simple, and the high strength fiber composite of the present invention can be suitably used.
In addition, as described above, in order to accurately confirm the LED lighting to the driver, the case for the traffic signal using the LED is painted black, but if a carbon fiber that is black as a high-strength fiber is used, it is used as it is. There is also an advantage that it is possible and does not require painting.

  In addition, when the high-strength fiber composite of the present invention molded into an appropriate shape is used as a road sign, in addition to the same features as the traffic signal housing, fluorine coating and vinyl chloride film lamination are possible. In addition, since an ink jet method or the like does not require a mold, there is an advantage that a single product can be manufactured at a lower cost than at present.

  In addition, traffic signal frames and road signs using the high-strength fiber composites can be separated by incineration or supercritical methods, and can be used as cement reinforcement after separation (after incineration). is there.

  According to the present invention, a high-strength fiber composite having high durability and light weight is provided. Traffic signal frames and road signs using the high-strength fiber composite as a material have high weather resistance such as salt damage and are lighter in weight, compared to conventional traffic signal frames and road signs using metal plates. Therefore, it is expected that it will be widely used because it is possible to use struts with reduced strength.

Claims (8)

  A high-strength fiber composite comprising a surface of a prepreg in which sheet-like high-strength fibers and a thermoplastic resin are combined with a thermosetting resin.   The high-strength fiber composite according to claim 1, wherein the prepreg is obtained by heat-pressing a laminate in which a sheet-like thermoplastic resin and a high-strength fiber sheet are laminated in a sandwich structure.   The high strength fiber composite according to claim 1 or 2, wherein the high strength fiber is a carbon fiber or a basalt fiber.   The thermoplastic resin is one selected from acrylic resin, vinyl chloride resin, vinylidene chloride resin, polyacrylonitrile resin, polyamide resin, polypropylene resin, thermoplastic polyimide resin, polyethylene terephthalate resin and polycarbonate resin. 4. The high strength fiber composite according to any one of 3.   The high-strength fiber according to any one of claims 1 to 4, wherein the thermosetting resin is one selected from an epoxy resin, a phenol resin, a thermosetting polyimide resin, an unsaturated polyester resin, a urea resin, and a melamine resin. Complex.   The high-strength fiber composite according to any one of claims 1 to 5, wherein the number of high-strength fiber sheets stacked is 5 to 100.   A traffic signal housing comprising the high-strength fiber composite according to any one of claims 1 to 6.   A road sign comprising the high-strength fiber composite according to any one of claims 1 to 6.

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