JP2624610B2 - Conveyor belt molding method and apparatus - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a conveyor belt molding method and an apparatus for carrying out the method.

[0002]

2. Description of the Related Art Conventionally, as one method of molding a fiber-reinforced thermosetting resin, a long fiber reinforcing material is prepared and the resin is impregnated by passing the same through a curing agent-mixed thermosetting resin impregnation tank. There is known a molding method in which an excess resin is squeezed and passed through a space between a pair of molds to be hardened and then continuously pulled out.

Now, this molding method will be described below with reference to the schematic diagram shown in FIG. 8 of the accompanying drawings. As shown in the figure, the fiber reinforcing material 1 in the form of a roving wound in a roll shape is passed through a curing agent-mixed thermosetting resin impregnation tank 2 while being rewound, so that the fiber reinforcing material is impregnated with a resin. After squeezing the resin (hereinafter, also referred to as “FRP prepreg”), the resin is hardened between a pair of upper and lower heating molds 4 and 5, and then continuously cured through an appropriate drawing device 30. By pulling out
This is a molded product PR.

In this case, the impregnated fiber reinforced material undergoes a step in this molding process, as shown in FIG. 8, in an impregnation zone extending between the resin impregnation tank 2 and the first half of the heating dies 4 and 5; And a curing zone in the latter half of the mold, respectively. In the first two steps of molding, the FRP prepreg is
As shown in the figure, the clogging resistance (R
-1), a viscous resistance (R-2) and a frictional resistance (R-3) due to hardening and thermal expansion are added. In order to overcome these resistances, the molded product PR is several hundred kg by the drawing device 30.
It is necessary to apply a pulling force T of up to several t. That is, the relationship between the resistance and the pulling force is expressed by the following equation. T = (R-1) + (R-2) + (R-3)

[0005] As described above, in the conventional pultrusion molding method, the frictional resistance between the mold surface and the uncured resin, the frictional resistance between the mold surface and the fiber reinforcement containing the gelled resin, and the like. Since pull-out resistance occurs due to frictional resistance between the mold surface and the surface of the molded product PR after curing, the pull-out force T of several hundred kg to several t is usually required. Therefore, due to the pulling force T, the molded product PR after curing is:
If there is no strength equal to or higher than the various resistance forces generated during the molding process, breakage, elongation, cracks, etc. will occur during the molding process. Therefore, in general, as a molded article,
The content of the fiber reinforcement must be 30% or more.
As described above, it is extremely difficult to form a molded product having a gel coat layer on the surface or having a low tensile strength, for example, a plate thickness of 2 mm or less, by a conventionally known pultrusion molding method.

[0006]

SUMMARY OF THE INVENTION Accordingly, the present invention provides a molded article having a gel coat layer on the surface, a molded article having a fiber reinforcing material content of about 30% or less, and a molded article containing a fiber having low strength. The object to be solved is to obtain a new conveyor belt type molding method capable of molding a product or a molded product having a thickness of, for example, 2 mm or less and a device for performing the method. It is.

[0007]

In order to solve this problem, in the method of the present invention, a fiber reinforced material is impregnated with a thermosetting resin mixed with a curing agent and the like, and then the fiber reinforced material is spaced at intervals. A pair of heating molds arranged opposite to each other ,
Each mold has a number of belt suction holes that penetrate the mold,
In addition, the pressure from the heating mold is passed through a clearance between a pair of conveyor belts that run continuously while being in contact with the heating mold through the belt suction hole due to the reduced pressure, and travel between the heating molds. The resin impregnated in the fiber reinforced material is sequentially gelled and cured through a conveyor belt heated by conduction, whereby a molded article is continuously formed. Further, the apparatus for carrying out the molding method according to the present invention includes a plurality of molds penetrating each mold.
A pair of endless conveyor belts having a pair of heating dies having a number of belt suction holes and running surfaces continuously running in the same direction at the same speed and facing each other at intervals. Inside, the mold surface of each heating mold is arranged so as to come into contact with each running surface of each conveyor belt facing each other through the belt suction hole .

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to FIGS. First, as shown in FIG. 1, a fiber reinforcing material 1 wound into a roll is placed in an impregnation tank 2 containing a thermosetting resin PL in which a curing agent, a curing accelerator, a pigment, a filler, and the like have been prepared. In the above, the fiber reinforcement 1
Is impregnated with a resin PL. Thus, the fiber reinforced material impregnated with the resin, that is, the FRP prepreg sheet P
S is guided below the liquid level of the resin reservoir 3 in which a certain amount of resin PL is stored, and the FRP prepreg sheet PS removes air pools and air bubbles therein while removing the upper and lower heating dies 4, The heating molds 4 and 5 have a pair of upper and lower endless conveyor belts which are installed so as to run at the same speed in the same direction, with their running surfaces facing each other. 6 and 7 (see also FIG. 5).

The belts of the endless conveyor belts 6 and 7 are made of a fiber reinforced rubber belt, a Teflon belt, or a metal, and are respectively driven by a belt guide roll (pulley, water cooling) 8 and a belt drive roll 9. , Forcibly and continuously at the same speed in the same direction indicated by the arrow X. These endless conveyor belts 6 and 7 may have steps or may have irregularities on the surface. In order to prevent the resin from leaking sideways from the FRP prepreg sheet PS on the running surfaces of the upper and lower endless conveyor belts 6 and 7 facing each other, as shown in FIG. on the surface of 7 of the belt, the silicone over down tube 10 several of longitudinally along its side edges, for example, is fixed by bonding or the like Teflon tape 11.

Further, in order to prevent the upper and lower endless conveyor belts 6, 7 from being deformed or sagged in the dies 4, 5, as shown in FIG.
A large number of belt suction holes 12 penetrating the upper and lower molds 4 and 5 are provided to penetrate vertically so as to open on the mold surfaces of the molds 4 and 5. A decompression chamber 13 is provided on the side surface, and each mold 4 of each suction hole 12 is provided.
5 opposite to the opening to the mold surface, these vacuum chambers 13
It is made to communicate with. These decompression chambers 13
Is connected to a blower 14 installed outside the conveyor belts 6 and 7, and the operation of the blower 14
, A negative pressure is generated inside.

The mold surfaces of the molds 4 and 5 which are in contact with the upper and lower endless conveyor belts 6 and 7 are finished smoothly, hard chrome plated, and have sliding friction or friction with the belts. Try to reduce wear. The molds 4 and 5 have a portion of each of the side walls in the longitudinal direction protruding laterally at appropriate intervals at at least two places, and between these protruding portions, the side walls of the upper and lower molds 4 and 5 are formed. The upper and lower molds 4 and 5 are provided with open portions in which the upper and lower molds 4 and 5 are formed with open portions.
By providing a clearance adjusting mechanism (not shown) having an appropriate configuration and adjusting the clearance adjusting mechanism, clearances at an inlet portion and an outlet portion through which a molded product passes between the upper and lower molds 4 and 5 are formed. Are adjustable (see in particular FIGS. 5 and 6).

Further, the upper and lower molds 4, 5 are each provided with a plurality of heating units 15 arranged at intervals in the horizontal direction, and the heating is performed by steam, heating oil, electric heating or the like. It has become.

On the outside near the exits of the endless conveyor belts 6, 7, a slitter 20 composed of a pair of upper and lower cutters for cutting each side edge portion of the molded product PR is provided.
Each of them is arranged, and a cutter 21 for transversely cutting the molded product PR is arranged in front of them.

The molding apparatus according to the present invention has the above-described configuration, and its operation is as follows. The fiber reinforcing material 1 wound in a roll is placed below the liquid level in an impregnation tank 2 containing a thermosetting resin PL in which a curing agent, a curing accelerator, a pigment, a filler and the like have been prepared. The FRP prepreg sheet PS impregnated with the resin by being guided to the above, and thus impregnated with the resin, is guided below the liquid level of the resin reservoir 3 in which a certain amount of the resin PL is stored, and
While removing air pockets and air bubbles in the RP prepreg sheet PS, the endless conveyor belt is moved in the direction of arrow X from the entrance of the upper and lower endless conveyor belts 6 and 7 from the entrance side of the running surface facing each other. With the continuous running of the belts 6 and 7, they enter between the belts. With the progress, FR
The P prepreg sheet PS reaches between the upper and lower molds 4 and 5. In this case, both belts are connected to the heating unit 15
For example, the FRP prepreg sheet PS is heated to a temperature of about 100 ° C. by the heat conduction due to the contact with the molds 4 and 5 being heated by the heat treatment.

The molded product PR thus hardened is extruded from the outlets of the dies 4 and 5 in the direction of arrow Y, and both edges are cut by the slitter 20 outside the outlets. The width direction is cut by the cutter 21,
A molded product PR having a predetermined length and width is obtained. In this case, the endless conveyor belts 6 and 7 are cooled by cooling air ejected from the forced air-cooled air nozzle 17 in the middle of the return stroke, and are cooled by the water-cooled belt guide rollers 8 on the inlet side. When entering the inlet, for example, the temperature will be 30 ° C. or less.

In the present invention, a molded article is continuously molded by the conveyor belt molding apparatus having the above-mentioned structure. FIG. 7 shows each step according to the present invention. It is as follows.

As described above, according to the method or apparatus of the present invention, the FRP prepreg sheet PS sandwiched between the upper and lower endless conveyor belts 6 and 7 is directly in contact with the mold surfaces of the dies 4 and 5. Without contact, it comes into contact with the upper and lower belts running continuously in the same direction at the same speed, so that frictional resistance is generated between the FRP prepreg sheet PS and the mold surfaces of the dies 4 and 5. Therefore, no tensile stress is generated in the molded product PR due to an external pulling force or the like as in the conventional method. FR by endless conveyor belts 6,7
No pressure is applied to the P prepreg sheet PS. The desired pattern can be formed on the surface of the molded product PR by attaching a pattern or the like to the belt surfaces of the endless conveyor belts 6 and 7 in advance.

The above description is based on the endless conveyor belts 6,7.
Is an example in the case of a device arranged horizontally,
Or I Ah in an apparatus disposed endless conveyor belts 6 and 7 vertically in the present invention.

Next, the results of experiments conducted to verify the effectiveness of the method of the present invention will be described. Experimental conditions : 1. Heating of molds 4 and 5: by electric heater (cartridge type) Set temperature of molds 4 and 5: 30 ° C at inlet, center-
Outlet 80-1000 ° C 3. 3. Conveyor belts 6,7: fiber reinforced silicone rubber belt, thickness 1.3mm; width 320mm 4. Belt cooling: forced air cooling 5. Adsorption of the belt to the upper and lower dies 4, 5: By reducing the pressure of a 150 mm water column (by suction with a blower). Molded product dimensions: wall thickness 1.6 mm, width 250 mm Experimental result : It was confirmed that a FRP flat plate-shaped molded product with a gel coat layer could be continuously molded.

Although the above description has been made on the assumption that one apparatus according to the present invention is used to carry out the conveyor belt molding, two apparatuses are used and only the gel coat layer is formed by the first apparatus. It is also possible to bond and form the fiber reinforced layer by the second device.

[0021]

The method of the present invention is carried out as described above, and since the apparatus of the present invention has the above-described structure and operation, a molded article having a gel coat layer on the surface is provided. Or a molded product having a fiber reinforcing material content of, for example, 30% or less, a molded product containing a low-strength fiber reinforcing material, or a molded product having a thickness of, for example, 2 mm or less, and a pattern on the surface. Molded articles, molded articles with irregularities on the surface, molded articles with uneven thickness, molded articles containing a hard filler that can damage the mold depending on the conventional pultrusion molding method, or letters It is possible to continuously mold a molded product or a sheet with a printed sheet attached. Since the molded product is continuously extruded by a pair of endless conveyor belts that are forcibly and continuously run, Conventional pultrusion molding method Definitive way, without the need for a separate withdrawal device, the entire device prices endless conveyor belt that is to be can reduce is heated, cured and the resin,
Functioning as a surface pattern mold by using a pair of endless conveyor belts,
Molded products with gel coat layer and low tensile strength and low tensile elasticity can be molded. No mold release film is used, so the molding cost can be reduced compared to conventional methods. It is effective.

[Brief description of the drawings]

FIG. 1 is an overall layout view showing one embodiment of the present invention.

FIG. 2 is a sectional view taken along line II-II of FIG.

FIG. 3 is a sectional view taken along line III-III in FIG. 1;

FIG. 4 is a sectional view taken along line IV-IV in FIG. 1;

FIG. 5 is a perspective view of the device according to FIG. 1;

6 is a cross-sectional view of the apparatus shown in FIG. 5 cut along a vertical cutting plane VI and viewed in a direction toward an outlet of a conveyor belt.

FIG. 7 is a diagram showing the apparatus shown in FIG. 1 divided into regions (zones) in which each step is performed.

FIG. 8 is a layout view showing an example of a conventional pultrusion molding apparatus.

[Explanation of symbols]

1 fiber reinforcement 2 resin impregnation vessel 3 resin reservoir 4 die (upper die) 5 die (lower die) 6 endless conveyor belt (upper) 7 endless conveyor belt (lower) 8 belt guide rolls 9-belt driving roller 10 silicone over Tube 11 Teflon tape 12 Belt suction hole 13 Decompression chamber 14 Blower 15 Heating unit 16 Insulation material 17 Forced air-cooled air nozzle 20 Slitter 21 Cutter

 ──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-2-128842 (JP, A) JP-A-59-106953 (JP, A) JP-A-63-267524 (JP, A) JP-A-63-267524 309397 (JP, A) JP-A-58-153652 (JP, A) JP-A-4-262320 (JP, A) JP-A-3-150160 (JP, A)

Claims (6)

(57) [Claims] 1. A pair of heating dies , in which a fiber-reinforced material is impregnated with a thermosetting resin mixed with a curing agent or the like, and which is disposed opposite to each other at intervals. Mold is mold
Has a number of holes for belt suction
The heat is transferred from the heating mold to the space between the pair of conveyor belts that run continuously while contacting the heating mold through the belt suction hole. A resin impregnated in the fiber reinforced material is sequentially gelled and cured through a conveyor belt heated by the method described above, whereby a molded product is continuously molded, thereby forming a molded product continuously. 2. A large number of belt suction holes penetrating each mold.
A pair of endless conveyor belts having a running surface that continuously runs in the same direction at the same speed with a pair of heating dies facing each other at an interval, and the belts are placed inside the pair of endless conveyor belts.
A conveyor belt-type forming apparatus , wherein a mold surface of each heating mold is arranged so as to come into contact with a mutually opposed running surface of each conveyor belt through a suction hole . 3. The conveyor belt-type forming apparatus according to claim 2, wherein each endless conveyor belt is made of a fiber reinforced rubber belt, a Teflon belt, or a metal. 4. The conveyor belt type molding apparatus according to claim 2, wherein the heating mold is heated by steam, heating oil, electric heat or the like. 5. The endless conveyor belts are arranged horizontally, each edge portion of the surface facing the endless conveyor belt upper part of the lower endless conveyor belts, silicone over to prevent the resin from leaking to the outside 5. The conveyor belt-type forming apparatus according to claim 2 , wherein a leakage preventing member formed of a tube or the like is fixed. 6. An endless conveyor belt is disposed vertically to prevent resin from leaking to the outside at each edge portion of one of the left and right endless conveyor belt surfaces of the left and right endless conveyor belts facing each other. formed by fixing the waterproof member made of a silicone chromatography emission tube according to claim 2, 3 or 4 of the conveyor belt type molding device.