JP3253232B2 - Multilayer sheet material and resin-impregnated multilayer sheet material, method for producing the same, and concrete panel comprising the resin-impregnated sheet material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a multilayer sheet material useful as a sound absorbing material, a heat insulating material, a shock absorbing material, and a core material of a composite resin sheet, and a resin obtained by impregnating the multilayer sheet material with a resin. The present invention relates to an impregnated multilayer sheet material, a method for producing the same, and a concrete panel comprising the resin-impregnated multilayer sheet material, which is excellent in handleability and has high deformation resistance and dimensional accuracy.

[0002]

2. Description of the Related Art As a sheet material for sound absorption, heat insulation, impact mitigation, etc., a non-woven fabric mainly composed of glass fiber or the like has been widely used, but recently, a foamed resin having a large number of voids therein has been used. Seats are also used in various fields. Further, a fiber reinforced composite resin material in which a fiber such as a glass fiber is used as a reinforcing material and a resin is impregnated with the reinforcing material is also widely used as an FRP material.

[0003] However, glass fiber nonwoven fabrics currently most widely used as sound absorbing and heat insulating materials have a problem in that glass fibers and small fragments thereof penetrate the skin in the handling process and cause irritation and health problems. Moreover, since it itself lacks shape retention, it must be combined with some kind of supporting material in order to put it into practical use for sound absorption, heat insulation and the like.

[0004] Further, the FRP material in which the reinforcing fiber and the resin are composited is very excellent in terms of cost and strength, but is often required to be lightweight depending on its use. For example, there has been a movement to use FRP material as an alternative to wood concrete panels that have traditionally used Lauan wood and the like imported from South Sea countries, but FRP material still has a higher cost than natural wood. Not only does it stick to wood, but it is very heavy compared to wood, making it difficult to handle and transport.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and has as its object to improve the disadvantages pointed out by conventional glass fiber non-woven fabrics and the like and to provide them at a low cost. An object of the present invention is to provide a multi-layer sheet material which is made possible, is lightweight, and is excellent in handleability and shape retention, and a method for producing the same. Another object of the present invention is to provide a resin-impregnated multilayer sheet material which is useful as various panel materials, floor materials, wall materials, partition materials, outer panel materials and the like by using the above-mentioned multilayer sheet material as a reinforcing material. Is to establish. Still another object of the present invention is to provide a concrete panel which is excellent in deformation resistance, dimensional accuracy, etc. and can be economically manufactured at a low cost by using the above resin-impregnated multilayer sheet material. Things.

[0006]

Means for Solving the Problems The structure of the multilayer sheet material according to the present invention which can solve the above-mentioned problems has a plurality of small holes which have a large number of discontinuous independent fine spaces and penetrate in the thickness direction. A first layer having a plurality of layers and a second layer having a large number of voids communicating in a three-dimensional direction are laminated at least two layers adjacent to each other, and the first layer and the second layer Are alternately laminated, and the outermost surface has an odd-numbered laminated structure formed on both sides by the first layer, and at least in the thickness direction of the first layer, a see-through hole larger than the small hole is provided. The gist is that a large number are formed. In this way, by making the outermost surface of the sheet have an odd-numbered laminated structure in which both surfaces are constituted by the first layer, it is possible to further improve the appearance, structural characteristics, and handleability of the sheet material. it can. The first-layer component constituting the multilayer sheet is preferably a closed-cell resin, and the second-layer component is preferably a nonwoven fabric.
It is recommended that a part of the fibers of the nonwoven fabric constituting the second layer penetrate into the pores of the first layer in the multi-layer sheet material, as that the integration of both layers is enhanced by a simpler configuration. You.

Since a large number of see-through holes are formed in the thickness direction of at least the first layer in the multilayer sheet material as described above, it is possible to obtain an advantage that the obtained multilayer sheet material has a further enhanced sound absorbing effect and the like. In addition to the above, an effect of improving the transparency of the resin-impregnated multilayer sheet material obtained by impregnating and solidifying the resin into the multilayer sheet material can be enjoyed. It is preferable that the see-through hole is larger than the small hole, or the diameter of the small hole is 0.1 mm.
5 to 3 mm, and the size of the see-through hole is preferably 1.5 to 15 mm.

The resin-impregnated multilayer sheet according to the present invention has a structure in which a resin is impregnated and solidified in the small holes of the first layer and the large number of voids of the second layer in the multilayer sheet having the above structure. Has a gist where it is. In this resin-impregnated multilayer sheet material, a large number of see-through holes are formed penetrating in the thickness direction of the first layer component, and the small holes and the see-through holes of the first layer and the numerous voids of the second layer are formed. It is preferable that the light-transmitting resin is impregnated and solidified therein, because the resin-impregnated multilayer sheet material can be provided with transparency. Further, the resin-impregnated multilayer sheet material in which both surfaces are reinforced with a fiber-reinforced resin layer is extremely useful as a material having further excellent strength characteristics.

[0009] The resin-impregnated multilayer sheet material, particularly a double-sided reinforced resin-impregnated multilayer sheet, wherein the intermediate layer of the multilayer sheet material constituting the sheet material is constituted by a second layer, and both sides thereof are reinforced by a fiber-reinforced resin layer. A sheet material, especially a double-sided reinforced resin-impregnated multilayer sheet material in which a transparent hole is formed in the first layer and a light-transmitting resin is impregnated and solidified to give transparency in the thickness direction of the laminate, and is extremely useful as a synthetic concrete panel. It is.

[0010] Further, the method for producing a multilayer sheet material according to the present invention is as follows.
A first layer having a large number of discontinuous independent fine spaces and a second layer made of a nonwoven fabric are superimposed at least two layers adjacent to each other, and needle-punching is performed from at least one side of the superimposed body. A large number of small holes penetrating in the thickness direction are formed in the first layer, and a part of the fibers of the nonwoven fabric constituting the second layer is made to penetrate into the small holes, and the first layer and the second layer are integrated. There is a gist in enhancing the character.

Further, the resin-impregnated multilayer sheet material according to the present invention is superposed on both surfaces of the multilayer sheet material in a state where a resin liquid is applied to reinforcing fibers constituting a fiber-reinforced resin layer, and the resin liquid is subjected to the reinforcement. It can be easily manufactured by infiltrating and solidifying the fibers and the small holes of the first layer in the multilayer sheet material or the transparent holes and the voids of the second layer.

[0012]

Under the circumstances described above, the present inventors have solved the difficulties pointed out by ordinary glass fiber non-woven fabric sheets and provided an inexpensive sheet material exhibiting a performance exceeding that. In addition, a high-performance resin-impregnated sheet material using the sheet material, and furthermore, as a result of intensive research aimed at developing a method capable of industrially producing the sheet material, the present invention described above resulted in the present invention. That is what I imagined.

Hereinafter, the multilayer sheet material and the resin-impregnated multilayer sheet material according to the present invention, the method for producing them, and the concrete panel made of the resin-impregnated multilayer sheet material will be described in detail.

The multilayer sheet material according to the first invention of the present invention comprises:
For example, as shown in FIG. 1 schematically showing the cross-sectional structure, a structure in which a first layer A and a second layer B are basically stacked adjacent to each other at least two layers or more (three layers in the illustrated example) The first layer A has a large number of discontinuous independent fine spaces dP formed therein, and has a plurality of small holes sP penetrating in the thickness direction, while the second layer B has It has a number of voids communicating in three dimensions.

That is, the first layer A is lightened by the formation of a large number of discontinuous voids therein due to the large number of independent fine spaces dP formed therein, and the presence of the independent fine spaces dP. Demonstrates various functions such as heat insulation and impact mitigation, and also forms a resin non-impregnated portion when used as a constituent material of a resin-impregnated multilayer sheet material described later, and maintains a constant thickness and shape as a whole layer. . There are various materials constituting such a layer, such as a resin sheet of independent foaming type, a balsa material, cork, etc., but the cost and availability, the number and size of the independent fine space dP Well,
The most preferred in view of the overall stability and quality, including physical properties, is most preferably a closed cell type resin, specifically a closed cell type polyurethane resin, polystyrene resin,
Examples thereof include a polyvinyl chloride resin, a polyethylene resin, and a polypropylene resin. Among these, foamed polyethylene resins and foamed polypropylene resins are more common.

These closed-cell type resins have a porosity of 10 to 80 from the standpoint of more effectively exhibiting various functions such as heat-insulating and shock-absorbing effects due to the independent fine space dP present therein. % By volume, more preferably 30%
It is preferable to use one in the range of ５０50% by volume.

The first layer A has a plurality of small holes s penetrating in the thickness direction in addition to the large number of independent fine spaces dP.
This small hole sP mainly exerts a sound absorbing effect, and also acts as a resin impregnating void when used as a constituent material of a resin-impregnated multilayer sheet material described later, and is integrated with the second layer B. Plays an important function in enhancing The size and number of the small holes sP are not particularly limited, but from the viewpoint of effectively exhibiting the above effects, a hole diameter of about 0.5 to 3 mm,
More preferably, a small hole sP of about 1 to 2.5 mm
1,000,000 pieces / m ² or so, more preferably those having at 50,000 to 500,000 pieces / m ² or so. The thickness of the first layer A cannot be uniformly defined because it varies depending on the use and required characteristics, and furthermore, the total number of layers including the second layer B, but it is usually 1 to 50 mm, preferably 1 to 50 mm. It is selected from the range of 5 to 10 mm.

In the first layer A, it is effective to form a see-through hole slightly larger than the small holes sP in addition to the large number of small holes sP. The see-through hole H will be described later in detail, but its function is to enhance the sound absorption characteristics of the multilayer sheet material itself, and to impregnate the multilayer sheet material with a resin as described later to form a concrete panel or the like. When used as a material, it has the effect of increasing the transparency in the thickness direction of the laminate.

On the other hand, the second layer B has a large number of three-dimensionally communicating voids existing therein to form continuous voids therein, thereby reducing the weight and having various functions such as sound absorption, heat insulation, impact mitigation, and the like. The resin-impregnated portion forms a resin-impregnated portion when used as a constituent material of a resin-impregnated multilayer sheet material described later, and the resin-impregnated portion exhibits an effect of increasing structural strength.
There are various materials that constitute such a layer,
A continuous foam type resin sheet, a fibrous nonwoven fabric, a woven fabric, a knitted fabric, and the like are exemplified, and among them, the most common is a fibrous nonwoven fabric. The constituent material of the fibrous non-woven fabric can be used irrespective of whether it is organic or inorganic, natural or synthetic, and may be appropriately selected and determined according to the characteristics required for the multilayer sheet material from these materials. In addition to ensuring the layer thickness of the above and effectively exhibiting the above functions, the most preferable in consideration of handleability, cost, etc., is a fiber non-woven fabric made of synthetic fibers such as polyester fibers, acrylic fibers, and polyamide fibers. Is the most common. In addition, by using a carbon fiber or a metal fiber to impart conductivity to the multilayer sheet material, or by using a hygroscopic fiber (including a nonwoven fabric mixed with a water-absorbing resin powder). Obtaining a moisture-absorbing and water-absorbing multilayer sheet material is also recommended as a preferred embodiment.

The form of the fibrous nonwoven fabric used as the constituent material of the second layer B is not limited at all, and may be appropriately determined in consideration of various functions such as light weight, sound absorption, heat insulation, and impact mitigation required for the intended multilayer sheet material. What is necessary is just to select and decide. The second layer B
Can not be uniformly defined because it varies depending on the use and required properties, and furthermore, the total number of layers including the first layer A, but is usually 0.5 to 20 mm, preferably 2 to 10 mm. Is selected from the range.

The first layer A and the second layer B have the simplest two-layer laminated structure of the first layer and the second layer, and the first layer and the second layer B have the first and second layers.
A three-layer structure of layer-first layer (laminated structure of FIG. 1), or 4
It includes a multi-layered structure with more than two layers, but the most practical one is a two- to five-layer structure in consideration of laminating workability and the like. In order to increase the number of layers, a three-layer or five-layer odd-number laminated structure in which both sides are the first-layer constituent material and the second-layer constituent material is interposed therebetween.

The method of laminating and integrating the first layer A and the second layer B is not particularly limited, and for example, a method of bonding the entire surface or a spot using an appropriate adhesive may be employed. However, as a method for easily integrating both layers without deteriorating the characteristics of the respective constituent materials, the following method can be mentioned. That is, for example, as shown in FIG.
First layer A by selecting fiber nonwoven fabric as second layer B constituent material
After being superimposed on the constituent material, for example, it is penetrated in the thickness direction of the laminated body using a needle punch N (1 is a needle main body, 2 is a fiber hook portion) having a cross-sectional structure as shown in FIG. Needle punching [Fig. 2 (B), (C)
And a small hole sP is formed in the first layer A, and a part of the non-woven fabric fiber 3 forming the second layer B is removed by the needle punch N.
In the small holes sP formed in the first layer A to allow a part of the nonwoven fabric fibers 3 to enter the small holes sP formed in the first layer A. Then, by appropriately adjusting the size of the needle body 1 and the hook portion 2 constituting the needle punch N at this time, the size of the small hole sP and the nonwoven fabric fiber 3
Of the small holes sP can be freely controlled by changing the interval and the number of the needle punching, whereby the first layer A and the first layer A can be freely controlled. The degree of integration of the two layers B can be arbitrarily controlled.

Therefore, this method constitutes one of the methods of the present invention as the most effective method for producing a multilayer sheet material, and the first layer A obtained by such a method.
The multilayer sheet material having a structure in which a part of the nonwoven fabric fiber 3 constituting the second layer B has penetrated into the small holes sP of the first layer A and the second layer B
This is one of the aspects of the present invention as a multilayered sheet material having a unique structure in which is integrated without using an adhesive or the like. The nonwoven fabric fiber 3 penetrated into the small holes sP of the first layer by the needle punching treatment is, for example, as shown in FIG.
As shown in (C), when it is pulled out to the outside of the small holes sP, the integrity as a laminate is increased, and the surface irregularities of the first layer A formed by the perforations are reduced, and furthermore, Is preferable in terms of enhancing the surface smoothness when the resin is impregnated and solidified as described later.

FIG. 4 is a partial perspective view illustrating a multilayer sheet material manufactured by the above method, and sandwiches first layers A, A having a large number of independent fine spaces dP (not shown in the drawing). In the meantime, a second layer B made of a nonwoven fabric is laminated, and a large number of small holes sP are formed in the first layers A, A by penetrating the laminate in the thickness direction and performing the needle punching treatment as described above. This shows a state in which a part of the nonwoven fabric fiber 3 is formed and penetrates into the small holes sP.

H shown in FIG. 4 is a see-through hole that may be formed in the multilayer sheet material, and the see-through hole H is a small hole s
It can be formed slightly larger than P, and can be formed at any density according to the purpose, and has the effect of enhancing the sound absorption characteristics of the multilayer sheet material, and impregnated with resin as described later. When used as a concrete panel or the like, it has the effect of increasing the transparency in the thickness direction of the laminate. The size and formation density of the see-through hole H are not particularly limited, but are preferably 1.5 to 15 mm, more preferably 2 to 15 mm in order to effectively exert the above-described functions.
The formation density is about ^{2 to} 20 pieces, and more preferably about 4 to 15 pieces per 1 m ² .

The multi-layer sheet material thus obtained can be used, for example, as a heat insulating material, a sound absorbing material, a shock absorbing material and the like, as well as building materials such as wall materials, floor materials and ceiling materials, packing materials for packing, speakers and the like. It can be widely used as an acoustic lining material, a lining material of a heat insulating container such as a cooler box, and can be effectively used as a core material of a resin-impregnated sheet material as described in detail below.

Next, the resin-impregnated sheet material according to the present invention will be described. The resin-impregnated sheet material of the present invention has a configuration in which the resin is impregnated and solidified in the small holes sP (and the transparent holes H) in the first layer A and the voids in the second layer B in the above-described multilayer sheet material. For example, as shown in FIG. 5, the resin is impregnated and solidified in the small holes sP (and the holes H and the see-through holes H) and the gaps in the second layer B, so that the first layer A and the second layer B are solidified. The two layers B are joined and integrated to form a resin-impregnated multilayer sheet material having a strong laminated structure. The lamination structure of the resin-impregnated multilayer sheet material can be freely changed by changing the lamination structure of the multilayer sheet material used as the core material.
When a multi-layer sheet material in which the first and second layers B are laminated one by one is used, a resin-impregnated multi-layer sheet material having a structure in which resin is impregnated and solidified in a two-layer laminated structure is obtained.
When a multilayer sheet material in which two layers B are alternately laminated is used, a resin-impregnated multilayer sheet material having a structure in which resin is impregnated and solidified in a four-layer laminated structure is obtained.

In this resin-impregnated multilayer sheet material, the independent fine space dP in the first layer A serves as a non-resin-impregnated portion to increase the lightness, so that it is smaller than conventional fiber-reinforced resin panels and the like. The second layer B, which is lightweight and has three-dimensionally communicating voids, penetrates into the resin layer impregnated and solidified in the voids, and further penetrates into small holes (and see-through holes H) in the first layer A. Combined with the pillar effect of the solidified resin, the resin has both excellent structural strength and light weight.

As a preferred configuration of the above-mentioned multilayer sheet material, for example, as shown in FIG. 1, an odd-number laminated structure in which both sides are constituted by a first layer A is described as being preferable.
Even in the case of a resin-impregnated multilayer sheet material, such an odd-number laminated structure is preferable. However, in the case of the odd-number laminated structure, the intermediate layer portion of the laminated structure is necessarily constituted by the second layer B, and the second layer B is formed in the three-dimensional direction as in the case of the fiber non-woven fabric as described above. The second layer B, which has an open space and is impregnated and solidified with a resin, constitutes an intermediate layer.
The resin is impregnated and solidified therein to form a reinforced core, and a resin-impregnated multilayer sheet material having high structural strength as a whole and hardly causing warpage or the like is obtained.

As another preferred laminated structure of the resin-impregnated multilayer sheet material, for example, as shown in FIG. 6, an intermediate layer and both outer side layers of the laminate are both constituted by a second layer B. However, with such a laminated structure, in a state where the resin is impregnated and solidified, the resin is impregnated and solidified in the gaps of the second layers B on both outer surfaces, and as a result, both outer surfaces are fiber-reinforced. This is because a resin-impregnated multilayer sheet material having excellent surface strength characteristics can be obtained by being composed of a resin layer.

When the first layer A having a transparent hole H as shown in FIG. 4 is used, the transparent hole H serves as a thick pillar connecting the first layer A and the second layer B. When the light transmitting resin is used as the impregnating resin, the thick transparent hole H
Part of the panel works as a light transmitting part, and exhibits excellent effects when used as a paneling material for ceiling, ceiling material, wall material, etc., and when used as a concrete panel material, etc. This is also preferable because it can be used for confirming the filling position of the concrete material to be filled from the outside.

As another preferred structure of the resin-impregnated multilayer sheet material according to the present invention, for example, as shown in FIG. 7, a fiber-reinforced resin layer FRP is formed on both sides of the resin-impregnated multilayer sheet material to reinforce both sides. A double-sided resin-impregnated multilayer sheet material may be used. That is, as shown in FIG. 5, in the resin-impregnated multilayer sheet material having both surfaces formed of the first layer A, the resin is not substantially impregnated except for the small holes sP (or see-through holes H) on both surfaces. The surface is exposed, and there is a possibility that the surface strength tends to be insufficient. However, if it is a structure in which the fiber reinforced resin layer FRP is laminated on both sides, a very excellent surface strength can be obtained. Because it can be obtained.

As the reinforcing fibers used in the fiber-reinforced resin, nonwoven fabrics made of glass fibers, chopped strands, roving cloths and the like are most commonly used in order to more effectively utilize the purpose of surface reinforcement. Of course, it can be used in combination with metal fibers and organic fibers.
The preferred thickness of the fiber reinforced resin layer FRP is arbitrarily determined according to the required surface strength and cannot be uniformly defined, but is usually 0.5 to 10 m.
It is better to select from a range of about m, more generally about 1 to 5 mm.

The surface-reinforced resin-impregnated multilayer sheet material thus obtained exhibits excellent effects for synthetic concrete panels due to its excellent surface strength characteristics. In particular,
In the case where the intermediate layer of the laminated structure is constituted by the second layer B, warping and bending are significantly suppressed by the effect of strengthening the intermediate portion by the resin impregnated and solidified second layer B, and the first through hole H is formed. The use of the layer A is preferable because the practical value as a concrete panel can be further enhanced, for example, as described above, the filled amount of the concrete inside can be confirmed from the outside through the transparent hole H.

There are no particular restrictions on the type of impregnating resin used in the production of the above resin-impregnated multilayer sheet material, and unsaturated polyester resins, epoxy resins, vinyl ester resins, polyurethane resins, alkyd resins , Phenolic resin, furan resin, melamine resin, urea resin and other thermosetting resins; acrylic resin, polystyrene resin, polyolefin resin (polyethylene and polypropylene etc.), polyvinyl chloride resin, vinylidene chloride Resin, polyamide resin, saturated polyester resin,
A thermoplastic resin such as an acetal-based resin can be used, and the type of the impregnated resin may be appropriately selected and determined according to the use and required characteristics of the resin-impregnated multilayer sheet material. It is a thermosetting resin such as a saturated polyester resin, an epoxy resin, and a vinyl ester resin.

Next, a preferred method for producing the multilayer sheet material and the resin-impregnated multilayer sheet material according to the present invention will be described.
FIG. 8 is a schematic process explanatory view illustrating a method for manufacturing a multilayer sheet material according to the present invention, and the materials used, that is, the constituent materials of the first layer A and the second layer B are as described above. In FIG. 8, a three-layer structure is described as an example of a laminated structure. However, as described above, the present invention can be applied to a two-layer structure or a multilayer structure having four or more layers. The method of the present invention can also be applied to such different laminated structures with appropriate modifications according to the following method.

In producing a multilayer sheet material having a three-layer laminated structure, two raw material windings A obtained by winding the constituent material of the first layer A are used.
₁ , A ₂ and one raw material winding B _{1 obtained} by winding the constituent material of the second layer B
After each material is fed out, the first layer A is overlapped on both surfaces thereof with the second layer B interposed therebetween, and needle punching is performed by the needle punching device 8 on the downstream side to penetrate the first layers A, A. A large number of small holes are formed. In this needle punching step, as shown in FIG.
Using a needle punch N provided with a fiber hooking portion 2, a part of the nonwoven fabric fiber constituting the second layer B is made to penetrate into the small holes at the same time as the small holes are formed [FIGS. C)
reference]. After that, if necessary, it may be wound through the pressure shaping unit 9 before shaping. The size and number of small holes formed in the raw material windings A ₁ and A ₂ can be freely changed by changing the interval between the needle punches and the needle size.

In the case where the transparent holes H are formed in the first layer A as shown in FIG. 4, the raw materials in which the transparent holes H are formed in advance are wound up as raw material windings A ₁ and A _2. 8, a method of forming a see-through hole H by performing a punching process on the upstream side before laminating with the second layer in FIG. 8, or a method of forming the second layer B on the upstream or downstream side of the needle punching device 8. A method of performing a punching process in the thickness direction of the laminated body to form a transparent hole penetrating in the entire thickness direction of the laminated body, or the like can be adopted. The multilayer sheet material thus obtained is a multilayer sheet material according to a preferred embodiment of the present invention, in which a part of the nonwoven fabric fiber constituting the second layer B has penetrated into the small holes formed in the raw material windings A ₁ and A _2. Become.

Next, a method for producing a double-sided reinforcing resin-impregnated multilayer sheet material according to the present invention will be described with reference to FIG. In carrying out the method shown in FIG. 9, the first upstream side of a production line provided with a device (not shown) for moving a releasable film made of, for example, a polyester-based or polyvinyl alcohol-based material is preferably used. A resin liquid Ra for impregnation is supplied on the film Fa, and a reinforcing fiber material (nonwoven fabric, woven / knitted or chopped strand, etc.) Ga is supplied thereon, and the resin liquid Ra is further increased on top of it. After the supply, the multilayer sheet material S manufactured by the above method is overlaid thereon. Next, on the downstream side, the same reinforcing fiber material Ga as described above is supplied onto the multilayer sheet material S, and the impregnating resin liquid Ra is supplied.
By laminating the films Fb and pressing them with a moderate pressure using a belt, a roll or the like, the resin liquid Ra is applied to the small holes of the first layer or the transparent holes and the holes of the second layer in the multilayer sheet material S. The impregnated resin is infiltrated into the gap and sent to the heating and solidifying chamber 10 to solidify and shape the impregnated resin. At this time, cooling is performed by passing through the air cooling chamber 11 on the downstream side as necessary. Thereafter, the first and second films Fa and Fb on the front and back surfaces of the molded body having undergone the surface shaping are peeled and removed, or cut to a predetermined size by the cutter 12 without removal, as described with reference to FIG. A resin-impregnated multilayer sheet material 13 with a double-sided structure having a double-layered structure is obtained. The first and second films Fa and Fb used here have a function of holding the reinforcing fiber materials Ga and Ga in an unsolidified or semi-solid state to prevent leakage of the impregnated resin and perform a surface shaping function. As the film, for example, cellophane, vinylon, tetron, etc. are used. These may be peeled after solidification of the impregnated resin and used circulatingly as described above, or may be cut as it is adhered to both surfaces of the product. It can also be used as a protective film for panels.

In the above description, a method for manufacturing a double-sided reinforced resin-impregnated multilayer sheet material has been described. In the case of manufacturing a resin-impregnated multilayer sheet material having a laminated structure as shown in FIG. Reinforcing fiber materials Ga, Ga in production example
May be omitted, and the following may be performed exactly as described above.

However, the production example shown in FIG. 9 shows a preferable method for continuously producing the resin-impregnated multilayer sheet material of the present invention or a double-sided reinforcing body thereof. The method is not limited to the above, and in addition to the above-described methods, it is also possible to adopt a method of impregnating the resin liquid by an impregnation pultrusion method, a hand lay-up molding method, a spray-up molding method, or the like. In the case of manufacturing a product having a relatively small size, a so-called resin injection impregnation molding method in which the above-described multilayer sheet material is charged into a sealed mold and a resin liquid for impregnation is injected, a vacuum bag impregnation molding method It is also possible to adopt such as.

[0042]

The present invention is constituted as described above, and its use and characteristics are summarized as follows. Multilayer sheet material: For example, heat insulation, moisture proof,
It can be effectively used as a wall material or floor material for soundproofing or interior use, and can also be effectively used as a core material for producing a resin-impregnated multilayer sheet material as described below.

Resin-impregnated multi-layer sheet material: The presence of the first layer having a large number of independent fine spaces makes it possible to maintain lightness even after resin impregnation, and the strength of the resin to the second layer having three-dimensional voids Impregnation and solidification and bridging (pillars) of resin that has penetrated and solidified into small holes (and see-through holes) formed in the first layer
It is a composite resin sheet that is secured by the effect and is lightweight and has high structural strength. It can be applied to various applications by utilizing its own characteristics, and it can be secondarily formed into any shape by heating and pressing afterwards It can be applied to various uses as a preformed sheet material or the like.

Double-sided reinforced resin-impregnated multilayer sheet material: Both sides of the above-mentioned resin-impregnated multilayer sheet material are reinforced with a fiber-reinforced resin. The surface strength of the resin-impregnated multilayer sheet material is reinforced and the structural strength as a whole is also improved. Widely used as various large and small molding materials, such as bathtubs, domes, vehicle panels and spoilers, tanks, boats, etc., which require higher structural strength and surface strength than the above. be able to.

Concrete panel: made of the above-mentioned double-sided resin-impregnated multilayer sheet material, having a large number of independent fine spaces, most of which constitute the resin non-impregnated portion.
While the weight is reduced by laminating the layers, the intermediate layer is constituted by the second layer constituting the resin-impregnated portion, and the structural strength is also increased by bridging the solidified resin into the small holes (and the see-through holes) of the first layer. Since it is enhanced, and furthermore, both sides are reinforced by a fiber reinforced resin layer, it becomes a concrete panel with excellent performance that can withstand repeated use many times. In addition, when a transparent hole is formed in the first layer and a light transmissive resin is used as the impregnating resin, the amount of concrete filled inside through the transparent hole can be checked from the outside. You can enjoy great advantages. Further, according to the production method of the present invention, a multilayer sheet material and a resin-impregnated multilayer sheet material or a double-sided reinforcing body thereof can be produced with a relatively simple method with high productivity.

[Brief description of the drawings]

FIG. 1 is a partial cross-sectional explanatory view illustrating the configuration of a multilayer sheet material according to the present invention.

FIG. 2 is an explanatory view illustrating a method for producing a multilayer sheet material according to the present invention.

FIG. 3 is an explanatory view showing a structure of a needle punch N used in the present invention.

FIG. 4 is a partially sectional explanatory view illustrating the structure of another multilayer sheet material according to the present invention.

FIG. 5 is a partially sectional explanatory view illustrating the structure of a resin-impregnated multilayer sheet material according to the present invention.

FIG. 6 is a partially sectional explanatory view illustrating the structure of another resin-impregnated multilayer sheet material according to the present invention.

FIG. 7 is a partial cross-sectional explanatory view illustrating the structure of a multilayer sheet impregnated with a double-sided reinforcing resin according to the present invention.

FIG. 8 is an explanatory view illustrating a method for producing a multilayer sheet material according to the present invention.

FIG. 9 is an explanatory view illustrating a method for producing a resin-impregnated multilayer sheet material and a double-sided reinforcing body thereof according to the present invention.

[Explanation of symbols]

 A first layer B second layer sP small hole dP independent fine space H see-through hole 1 needle body 2 fiber hooking projection 4 needle punching device S multilayer sheet material Ra impregnating resin liquid Ga reinforcing fiber Fa, Fb first, first 2 film 10 heating solidification room 12 cutter

Continued on the front page (72) Inventor Hiroshi Taruki 8-1 Techno Park, Mita City, Hyogo Japan Polyester Co., Ltd. Mita Plant (72) Inventor Masatake Fujiwara 2-5-25 Tenjinbashi, Kita-ku, Osaka City Sansho Trading Co., Ltd. In-house (56) References Japanese Utility Model Sho 59-50721 (JP, U) Japanese Utility Model Sho 59-48831 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 1/00- 35/00

Claims (9)

(57) [Claims] (1) a plurality of discontinuous independent fine spaces;
A first layer having small holes penetrating in the thickness direction, and a three-dimensional
A second layer having voids communicating in the directions
At least two or more layers, wherein the first layer and the second layer are alternately stacked, and
Odd number product composed of the first layer on both sides on the front side
Are those having a layered structure, the thickness direction of at least the first layer, to wherein in which the larger perspective holes than the small hole formed many
Multi-layer sheet material that. Wherein in the thickness direction of at least the first layer, before
Be those whose serial number perspective holes are formed, the pore size of pores is 0.5 to 3 mm, the multilayer sheet of claim 1 the size of the perspective hole is 1.5~15mm Wood. 3. A process according to claim 1 or the multi-layer sheet material as described in 2, wherein the stoma or its prior to the first layer
Serial fluoroscopic bore and said second layer within said plurality of voids, the resin-impregnated multilayered sheet material resin is characterized in that the impregnated and solidified. 4. The resin-impregnated multilayer sheet according to claim 3 , wherein the multilayer sheet is impregnated with a light-transmitting resin. 5. A double-sided, resin-impregnated multilayer sheet material comprising a resin-impregnated multilayer sheet material according to claim 3 and a fiber-reinforced resin laminated on both surfaces. 6. A concrete panel comprising the reinforced resin-impregnated multilayer sheet material on both sides according to claim 5 , wherein an intermediate layer of the multilayer sheet material is constituted by the second layer. 7. A method of manufacturing a multi-layer sheet material according to claim 1 or 2, the first and second layers made of nonwoven fabric having a large number of non-contiguous independent fine space, adjacent to each other By laminating at least two or more layers and performing needle punching from at least one side of the laminated body, a large number of small holes penetrating in the thickness direction are formed in the first layer, and the second layer is formed. A method for producing a multilayer sheet material, characterized in that a part of the fibers of a nonwoven fabric is caused to penetrate into the small holes. 8. A multilayer sheet material according to claim 1 or 2 , wherein a resin liquid is applied to said multilayer sheet material, and
The small hole or between this and the perspective hole layer in the gap of the second layer, production method of the resin-impregnated multilayered sheet, wherein the solidified impregnated with the resin solution. 9. A multilayer sheet material according to claim 1 or 2 , which is superimposed on both surfaces of the multilayer sheet material in a state in which a resin liquid is applied to reinforcing fibers constituting a fiber-reinforced resin layer, and the resin liquid is combined with the reinforcing fibers. , preparation of the said first layer of the multilayer sheet material ostium or this and the perspective hole and both sides of the reinforced resin impregnated multilayered sheet, wherein the second layer is penetrating into the gap, characterized in that to solidify .