JP2584880B2 - Manufacturing method of Kakuken gutter - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing a corner eaves gutter made of fiber-reinforced synthetic resin having excellent durability.

(Prior Art) A molded article provided with an edge such as an eaves gutter generally comprises a main body and an ear, and is widely extruded from a thermoplastic resin such as a vinyl chloride resin and is widely used. However, such a thermoplastic resin molded article has a disadvantage in that it has a large thermal expansion and contraction and a small rigidity, so that it is easily deformed due to a change in temperature during the four seasons or day and night, and cracks are easily generated.

As a molded product having improved such a defect, as shown in FIG. 6, an eaves gutter-shaped laminated molded product in which a reinforcing core material 1 is extrusion-coated with a thermoplastic resin 2 such as a vinyl chloride resin has been proposed. I have. In this type of laminated molded article, an eaves gutter-shaped reinforcing core 1 is generally made by using a strip-shaped core obtained by impregnating a reinforcing core, and the reinforcing core 1 is, for example, as shown in FIG. The core material introduction slit 6 of the crosshead mold 5 is introduced,
It is manufactured by melt-extruding and coating the thermoplastic resin 2 at the resin-coated slit portion 6 ′ following the core material introduction slit portion 6.

In this case, as shown in FIG. 6, the reinforcing core material 1 extends not only to the eaves gutter-shaped main body portion 3 but also to the ear portion 4 to reinforce this portion. The ear core 1 'is formed in a substantially cylindrical shape along the ear 4, and its edge 1 is in contact with or slightly apart from the body core 1 ", and a thermoplastic resin 2 is formed inside and outside thereof. Is extrusion coated.

(Problems to be Solved by the Invention) However, in such a laminated molded product using the conventional reinforcing core material, the reinforcement of the lug 4 near the edge 1 of the reinforcing core material is particularly insufficient. Therefore, when the laminated molded article is used as an eaves gutter, when the eaves gutter is exposed to direct sunlight and becomes high temperature, the ears 4 near the edge 1 of the reinforcing core 1 are deformed, and the opening of the ears 4 is reduced. In some cases, the mounting bracket may come off, and the function of the ears 4 may not be sufficiently exhibited.

Further, when the reinforcing core material 1 is introduced into the core material introducing slit portion 6 of the crosshead mold 5 and the thermoplastic resin 2 is melt-extruded and coated by the resin coating slit portion 6 ′ following the core material introducing slit portion 6, As shown in FIG. 8, the edge 1 and the body core 1 "
If the gap between them is too wide, a gap e is generated near the edge 1 of the core material introduction slit portion 6. When this gap e occurs, a so-called backflow phenomenon occurs in which the molten resin flows backward from the resin-coated slit portion 6 'to the core material introduction slit portion 6 as shown in FIG. The core material introduction slit 6 is clogged, and the reinforcing core material 1
Extrusion coating becomes difficult.

The present invention has been made to solve the above-mentioned problem, and an object of the present invention is to sufficiently strengthen the ear near the end edge of the reinforcing core so that the ear deforms even when used in a high-temperature environment. It is an object of the present invention to provide a method for manufacturing a corner eaves gutter in which no backflow phenomenon occurs when a thermoplastic resin is melt-extruded and coated in a crosshead mold.

(Means for Solving the Problems) In the method for manufacturing a corner eaves gutter according to the present invention, a band-shaped reinforcing core material obtained by impregnating a synthetic resin into a reinforcing fiber material is used, and the ear core material is formed into a loop-shaped cylindrical material. The end edge is bent and brought close to or in contact with the core material of the corner eaves gutter main body, and then introduced into the crosshead mold of the extruder in this state. The end of the core is thermocompression-bonded to the core of the main body, and the entire surface of the reinforcing core is melt-extruded and coated with a thermoplastic resin, thereby achieving the above object.

 Hereinafter, the present invention will be described with reference to the drawings.

FIG. 1 and FIG. 2 are schematic views of an example of the method for manufacturing a corner eaves gutter according to the present invention.

In FIG. 1, reference numeral 11 denotes a number of continuous long fibers. As the long fibers 11, rovings such as glass fibers, carbon fibers, alumina fibers, and aramid fibers are suitably used.

A large number of long fibers 11 are unwound from a bobbin, arranged in a strip shape in the longitudinal direction, and introduced into a fluidized bed 30 having a porous bottom plate 31. The long fibers 11 are usually defibrated by a defibrating device 32 before being introduced into the fluidized bed 30 or in the fluidized bed 30 as shown in the figure.

In the fluidized bed 30, the powdery thermoplastic resin 12 is blown up above the porous bottom plate 31 by air pressure and is kept in a floating state. The particle size of the powdery thermoplastic resin 12 is generally about 10 to 200 μm. The long fibers 11 introduced into the fluidized bed 30 are impregnated with the powdery thermoplastic resin 12 in a floating state.

As the thermoplastic resin 12, a vinyl chloride resin, a chlorinated vinyl chloride resin, polyethylene, polypropylene, an acrylic resin, a nylon resin, an engineering resin such as polyphenylene sulfide or polyether sulfone, or the like is used.

The above long fiber 11 is theoretically different from the thermoplastic resin 12.
Although it may be contained up to 90% by volume, it is usually preferable to use it in the range of 60% by volume or less. Long fiber 11 is thermoplastic resin 12
If it exceeds 60% by volume, cracks are likely to occur due to impact.

The long fiber 11 impregnated with the powdery thermoplastic resin 12 is passed through a heating furnace 40, where the impregnated thermoplastic resin 12 is heated and melt-bonded. And the thickness is adjusted. Then, it is picked up by a pair of pick-up pinch rolls 50. In this case, a pair of heating pinch rolls 41
May be arranged in one set or in plural sets. In the figure, two sets are arranged.

The arrangement of the above-mentioned pair of heating pinch rolls 41 and the heating furnace 40 may be reversed, and the pair of heating pinch rolls 41 may be thermocompression-bonded first and then heated in the heating furnace 40. Thus, the belt-shaped reinforcing core material 10 is formed. The belt-shaped reinforcing core material 10 may be wound up once as shown in the drawing, or may be continuously wound up without being wound up.

Next, as shown in FIG.
The heating and forming device 60 heats and softens the thermoplastic resin 12 to a temperature equal to or higher than the softening temperature of the thermoplastic resin 12, and as shown in FIG. It is shaped into an eaves gutter-shaped reinforcing core material 10 composed of a square eaves gutter main body 10b formed in a shape. At this time, it is bent to the end edge portion 10c of the ear core material 10a and is brought close to or in contact with the corner eaves gutter main body core material 10b.

The reinforcing core material 10 shaped in this manner is a crosshead mold of the extruder 71 in a state where the end edge portion 10c of the ear portion core material 10a is overlapped with, for example, the corner eaves gutter main body core material 10b and brought into contact therewith. Introduced in 70. In the crosshead mold 70, when the reinforcing core 10 is introduced into the core introduction slit 70a of the crosshead mold 70 shown in FIG. The terminal edge 10c is softened or melted by heating the mold 70 on the corner eaves gutter main body core 10b. Subsequently, the resin-coated slit portion 7 following the core material introduction slit portion 70a shown in FIG.
The thermoplastic resin 20 melt-extruded from the extruder 71 at 0b is coated on the entire surface of the reinforcing core material 10 excluding the inside of the ear core material 10a,
A laminated molded product which is a corner eaves gutter as shown in FIG. 5 is obtained. At this time, the end edge 10c of the ear core 10a is thermocompression-bonded to the main body core 10b by the resin pressure of the thermoplastic resin 20 that is melt-extruded. In FIG. 4, reference numeral 70c denotes a core material for supporting the ear core material 10a of the reinforcing core material 10, which extends from the heating forming device 60 side and is inserted into the crosshead mold 70.

As the thermoplastic resin 20 for coating, vinyl chloride resin,
A resin having good weather resistance such as a chlorinated vinyl chloride resin, an acrylic resin, and a nylon resin is used. Further, the slit gap and the length of the land portion of the crosshead mold 70 are appropriately determined by the product thickness, the thermoplastic resin for coating, the extrusion temperature, the extrusion speed, and the like.

After that, the surface is finished by a sizing device 80 such as a cooling mold and cooled, and a tension device such as a caterpillar type tension machine is used.
At 90, the eaves gutter comprising the eaves gutter main body 21 and the ears 22 as shown in FIG. 5 is manufactured.

As shown in FIG. 3, the shape of the ears of the eaves gutter to be manufactured can be formed not only in a square shape but also in a loop shape such as a round shape or a triangular shape.

Note that, in the above example, a large number of continuous long fibers 11 were used as the reinforcing fiber material, but a belt-like woven or nonwoven fabric may be used instead of the large number of long fibers 11. When using a woven or nonwoven fabric, defibration is not required. Further, in the above example, the powdery thermoplastic resin 12 was used, but instead of the powdery thermoplastic resin 12, a liquid thermosetting resin such as an unsaturated polyester resin liquid or a photocurable resin was used. May be used. When using a liquid thermosetting resin or a photocurable resin, instead of the fluidized bed 30, an impregnation tank containing a liquid thermosetting resin or a photocurable resin is used. The material 10 is a B-staged semi-cured prepreg.

(Operation) According to the method of the present invention, the ear core material is formed in a loop-shaped cylindrical shape, and the end edge thereof is bent so as to be close to or in contact with the corner eaves gutter main body core material. After being introduced into the crosshead mold of the extruder, and the end edge of the ear core material is thermocompressed to the core material of the gutter main body inside the crosshead mold, the synthetic resin of the reinforcing core material melts, The end edge of the core material is thermally bonded to the core of the eaves gutter main body and fixed, so the reinforcing core material of the end edge is integrally continuous with the gutter main body and ears The ears near the end edge of the reinforcing core material, which was weak in the conventional eaves gutter, which was a laminated molded product reinforced with the reinforcing core material,
Sufficiently reinforced as in the main part of the gutter.

In addition, since the end edge is bent and introduced into the crosshead mold of the extruder in a state of being brought close to or in contact with the core of the eaves gutter main body, the end is separated from the core of the eaves gutter main body Instead, when the thermoplastic resin is extrusion-coated on this, the reinforcing core material of the coated portion is fixed while being pressed from both sides by the coated thermoplastic resin, and the thermoplastic resin is During the extrusion coating, the molten resin does not flow back to the core material introduction side from near the end edge in the crosshead mold.

(Examples) Hereinafter, Examples and Comparative Examples of the present invention will be described.

Example 1 First, 20 glass rovings (# 4400: manufactured by Nitto Boshoku) 11 were arranged in a longitudinal direction and introduced into a fluidized bed 30 where a vinyl chloride resin blended in a floating state by being blown up by air while being defibrated. Powder (TK-400: Shin-Etsu Chemical Co., Ltd.) 12 is impregnated with a fluid, passed through a heating furnace 40, and the resin-blended powder is heated to 190 ° C.
And then passed through a pair of heating pinch rolls with a surface temperature of 200 ° C and thermocompressed to completely melt, and a thickness of 0.6 m
A belt-shaped reinforcing core material 10 having a width of 300 mm and a glass roving content of 30% by volume was prepared.

The reinforcing core material 10 is heated to 80 ° C. by the heating forming device 60.
As shown in FIG. 3, the heat-softening is performed to form a square eave gutter composed of a loop-shaped tubular core material 10a and a square eave gutter main body core material 10b. Formed reinforcing core 1
Shaped to 0. At this time, the end edge portion 10c of the ear core material 10a is bent downward and is in contact with the corner eaves gutter main body core material 10b in a superimposed state.

Subsequently, the shaped reinforcing core 10 is inserted into the ear core 10a.
The end edge 10c of the extruder is inserted into the crosshead mold 70 of the extruder in a state of being brought into contact with the core material of the gutter main body 10b while being superimposed on the core material of the gutter main body 10b. The surface of the material 10b was coated with a vinyl chloride resin composition having an average degree of polymerization of 1050 by melt extrusion at 185 ° C. to a thickness of 0.5 mm.

Next, surface finishing is performed by a sizing device 80,
After being cooled and taken up by a tensioning device 90, as shown in FIG.
A long eaves gutter with a thickness of 1.5 mm was manufactured.

This eaves gutter was cut into a length of 4 m to obtain a test piece, which was
After being left for 5 hours during opening at ℃, the deformation of the ears was observed, and the deformation of the ears was very small.

Comparative Example 1 The same procedure as in Example 1 was carried out except that the end edge of the ear core material was formed so as to be slightly separated in the ear as shown in FIG. In this case, the deformation of the ears of the obtained corner eaves gutter was very large. Further, in the crosshead mold 70 of the extruder, the molten resin for extrusion coating flowed back to the introduction side of the reinforcing core material 10, and it was difficult to take out the reinforcing core material 10, so that continuous molding could not be performed.

(Effect of the Invention) As described above, according to the method for producing a laminated molded product of the present invention,
Using a band-shaped reinforcing core material made by impregnating a synthetic resin into the reinforcing fiber material, the ear core material is formed into a loop-shaped cylindrical shape, the end edge of which is bent and superimposed on the square eaves gutter main body core material. As close as possible or in contact with each other, and in this state, it is introduced into the crosshead mold of the extruder, and the end edge of the ear core material is thermocompressed and reinforced in the crosshead mold to the core of the eaves gutter main body. Since the entire surface of the core material is melt-extruded and coated with a thermoplastic resin and integrated, the reinforcing core material at the end edge becomes a continuous state integrally with the gutter main body and ears, and the conventional gutter gutter The ear portion near the end edge of the reinforcing core material, which was weak in the above, is sufficiently reinforced similarly to the main body portion.

Therefore, the eaves gutter obtained by the production method of the present invention,
Even when used in a high-temperature environment exposed to direct sunlight, there is no deformation of the ears, the opening of the ears and the detachment of the mounting bracket are prevented, and the function of the ears of the corner eaves gutter is fully exhibited.

In addition, since the end edge is bent and introduced into the crosshead mold of the extruder in a state of being brought close to or in contact with the core of the eaves gutter main body, the end is separated from the core of the eaves gutter main body Instead, when the thermoplastic resin is extrusion-coated on this, the reinforcing core material of the coated portion is fixed while being pressed from both sides by the coated thermoplastic resin, and the thermoplastic resin is During the extrusion coating, the molten resin does not flow back to the core material introduction side from near the end edge in the crosshead mold. Therefore, when the thermoplastic resin is melt-extruded and coated in the crosshead mold, the molten resin for the extrusion coating is less likely to flow back to the reinforcing core material introduction side in the crosshead mold of the extruder. Therefore, the occurrence of the backflow phenomenon can be gradually reduced, and a long-time continuous operation can be performed.

[Brief description of the drawings]

1 and 2 are schematic views showing an example of the method of the present invention, FIG. 3 is a partially cutaway cross-sectional view showing an example of a reinforcing core used in the method of the present invention, and FIG. 4 is a method of the present invention. FIG. 5 is a partially cutaway cross-sectional view showing an example of a crosshead mold used in the present invention. FIG. 5 is a partially cutaway cross-sectional view showing an example of a corner eave gutter which is a laminated molded product obtained by the method of the present invention. FIG. 6 is a partially cutaway cross-sectional view showing an example of a conventional laminated molded product (eave gutter), and FIG. 7 is a partially cutaway sectional view showing a crosshead mold for manufacturing the conventional laminated molded product (eave gutter). 8 is a sectional view taken along line VIII-VIII in FIG. 7 and viewed in the direction of the arrow. Description of the reference numeral 10: reinforcing core material, 10a: ear core material, 10b: square eaves gutter main body core material, 10c: end edge of ear core material, 11: reinforcing fiber material, 12 ... ... impregnating resin, 20 ... thermoplastic resin for coating, 21
... body part, 21 ... ear part, 30 ... fluidized bed, 40 ... heating furnace, 41 ... heating pinch roll, 50 ... take-off pinch roll, 60 ... heating forming device, 70 ... crosshead metal Mold, 70a: core material introduction slit, 70b: resin-coated slit, 80: sizing device, 90: tension device.

Claims (1)

(57) [Claims] An ear core material is formed into a loop-shaped cylinder using a belt-shaped reinforcing core material in which a reinforcing fiber material is impregnated with a synthetic resin, and its end edge is bent to form a square eaves gutter main body. In this state, it is introduced into the crosshead mold of the extruder, and the end edge of the ear core material becomes the core material of the gutter main body in the crosshead mold. A method for manufacturing a square eaves gutter, which comprises performing thermocompression bonding and melt-extrusion coating a thermoplastic resin over the entire surface of a reinforcing core material to integrate them.