JP3382736B2 - Continuous production method of fiber-reinforced foamed resin molded article - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for continuously producing a surface reinforced type fiber reinforced foamed resin molding used for various purposes such as truck carrier, sleepers and construction materials. is there.

[0002]

2. Description of the Related Art Conventionally, various proposals have been made on a continuous production method of a fiber-reinforced foamed resin molding (Japanese Patent Publication No. Sho 5).
2-2421, JP-A-3-81116, etc.), particularly in a continuous manufacturing method of integrally molding a surface laminated material and a foam synthetic resin body, as shown in FIG. 4 and FIG. After the surface laminated material (glass paper 44a, long glass fibers 44b and glass scrim 44c) on the belt 41 is impregnated with the semi-hard resin liquid 43 by the impregnation roll 42, the surface laminated material is applied to the endless belt 41.
Along with the continuous flow to the molding passage 45, the long fiber bundle 47 impregnated with the foam-curing resin liquid 46 is continuously guided to the molding passage 46, and the resin liquid 46 is formed in the molding passage 46.
Is foamed and cured to integrally mold the foamed resin body and the surface laminated material, and the width of the semi-hard resin liquid impregnated into the surface laminated material by the impregnation roll 42 is adjusted.
I was going to do it directly on 1.

However, the endless belt 41 has a seam where it is difficult to ensure smoothness. When this seam comes under the impregnating roll 42, the gap between the impregnating roll 42 and the endless belt 41 changes. It is difficult to keep the resin width of the semi-hard resin liquid constant, and even if the endless belt is warped due to long-term use, it becomes impossible to secure a stable resin width. There is also a problem that the impregnating roll is lifted up and the resin width is narrowed due to the seam and entanglement of the long glass fibers 44a constituting the laminated material 44, and defective products frequently occur (about 3%).

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above points, and an object of the present invention is to joint or warp an endless belt, and further to join or tangle a long glass fiber. It is an object of the present invention to provide a continuous method for producing a fiber-reinforced foamed resin molded article, which allows a surface-laminated material to be constantly impregnated with a semi-hard resin liquid with a constant resin width without being affected by.

[0005]

According to a first aspect of the present invention, there is provided a method for continuously producing a fiber-reinforced foamed resin molding, wherein a molding passage formed by an endless belt and a semi-hard resin for a surface laminated material located on the endless belt. Using a manufacturing apparatus equipped with an impregnating roll for impregnating the liquid, the surface laminated material impregnated with the semi-hard resin liquid with the impregnating roll on the endless belt is continuously guided to the molding passage along the endless belt,
A fiber-reinforced foamed resin molded body in which a long fiber bundle impregnated with a foaming curable resin liquid is continuously guided to a molding passage, and the resin liquid is foam-cured in the molding passage to integrally mold a foamed resin body and a surface laminated material. In the continuous manufacturing method, a supporting material is interposed between the endless belt and the surface laminated material, and the surface laminated material is supported by the supporting material, and the semi-hard resin liquid is impregnated into the surface laminated material by a roll. It is characterized by being impregnated.

According to a second aspect of the present invention, there is provided a method for continuously producing a fiber-reinforced foamed resin molded product, wherein the impregnating roll comprises a first impregnating roll and the first impregnating roll. And a second impregnating roll located near the entrance of the molding passage. First, the first impregnating roll impregnates the glass paper constituting the surface laminated material with the semi-hard resin liquid, and then the second impregnating roll. Is characterized in that the long glass fiber constituting the surface laminated material is impregnated with the semi-hard resin liquid and the glass paper and the long glass fiber are overlapped.

[0007]

According to the method for continuously producing a fiber-reinforced foamed resin molding according to claim 1, a supporting material is interposed between the endless belt and the surface laminated material, and a semi-hard resin liquid is applied to the surface laminated material on the supporting material. Is impregnated with the impregnating roll, the surface laminate does not come into contact with the endless belt when the surface laminate is impregnated with the semi-hard resin liquid.

[0008] Thus, without being affected by the joint portion and warping of the endless belt, it can be impregnated with the semi-rigid resin liquid to the surface laminate.

[0009] According to the continuous method for producing a fiber reinforced foam resin molded article according to claim 2, by the impregnation of the semi-rigid resin liquid glass paper at first impregnation roll, the resin impregnation and resin into glass paper spread width Then, the long glass fiber is impregnated with the semi-hard resin liquid by the second impregnating roll, and the glass paper and the long glass fiber are stacked. During this time, the glass paper and the long glass fibers are supported by the support material and do not come into contact with the endless belt.

[0010] Thus, without being affected by the joint portion and the entanglement of the long glass fibers when impregnating the semi-rigid resin liquid to the surface laminate, moreover, it will not be affected in the seam portion and warping of the endless belt.

[0011]

[Example] A continuous production method of a fiber-reinforced foamed resin molding is as follows.
A continuous production apparatus A for impregnating a long fiber bundle with a foam-curing resin liquid and foam-curing the resin liquid in a molding passage to integrally mold the long fiber bundle and the surface laminated material, and a semi-hard resin for the surface laminated material. It is carried out using an impregnating device B for impregnating the liquid.

FIG . 1 shows an apparatus for continuously producing a fiber-reinforced foamed resin molded body 1 of a surface lamination reinforced type. here,
The fiber-reinforced foamed resin molded body 1 is configured by integrally molding a foamed resin body 2 reinforced with a long fiber bundle and a surface laminated material 3. The surface laminated material 3 is composed of three kinds of laminated materials (glass paper 31, glass filament 32 and glass scrim 33) impregnated with the semi-hard resin 3a (FIG. 3), and the glass paper 31 serves as a protective layer. The long glass fiber 32 functions as a reinforcement for longitudinal strength, and the glass scrim 33 functions as a reinforcement for lateral strength.

The semi-rigid resin has a flexural or tensile elastic modulus of 70 to 700 MPa.

The continuous production apparatus A comprises a resin spouting device 5 for spraying a foam-curable urethane resin liquid (an example of a foam-curable resin liquid) 2a onto a glass fiber bundle (an example of a long fiber bundle) 4, and a glass fiber. A rubbing plate 6 for evenly dispersing the urethane resin liquid 2a between the glass fibers of the bundle 4, a molding passage 7 for continuously molding the glass fiber bundle 4 impregnated with the foam-curable urethane resin liquid 2a, and a back material 8 supply rolls 8a.

The molding passage 7 is formed by being surrounded by a pair of upper and lower endless belts 7a and 7b and a pair of left and right side belts (not shown).
b is a mold roller (not shown) rotatably supported by a mold (not shown), and endless belts 7a, 7b.
Of the glass fiber bundle 4 impregnated with the urethane resin liquid 2a is in contact with the endless belts 7a, 7b and the side belts of the molding passage 7, and the endless belts 7a, 7b and the side surfaces are supported. The urethane resin liquid 2a is foamed and cured while traveling with the belt.

The molding passage 7 may be formed by surrounding a pair of upper and lower endless belts and a pair of left and right endless belts.

The impregnator B surface laminate 3, there is impregnated with a semi-rigid urethane resin solution 3a on the surface laminate 3, and along a peripheral surface of the upper endless belt 7a flat (of the support An example) 10 is provided, and the flat plate 10 is provided with a resin jetting machine 9, a first impregnation roll 11 and a second impregnation roll 12 from the upstream side to the downstream side.

The flat plate 10 is the upper endless belt 7a.
It is held by a holding means (not shown) so as not to come into contact with.

Next, described molding method of a fiber reinforced foam resin molded article using the impregnation apparatus B is attached a continuous production apparatus A. (1) First, an embossed polyethylene film (an example of a peeling film) 30 is pulled out from the roll 13 onto the flat plate 10, and the polyethylene film 30 is pulled out from the resin ejector 9.
The semi-curable urethane resin 3a is sprinkled on. (2) Next, the glass paper 31 is pulled out from the roll 13 onto the flat plate 10, and the glass paper 31 is impregnated with the semi-hard urethane resin liquid 3a by the first impregnation roll 11. (3) Next, the long glass fiber 32 roll 13 configured by arranging a large number of long glass fibers is pulled out, and the long glass fiber 32 is impregnated with the semi-hard resin liquid 3a by the second impregnation roll 12 and the glass is used. Long fibers 32 and glass paper 3
Overlap with 1.

[0020] After that, superposed glass fiber 32 and scrim 33 in a glass paper 31. In this way, the surface laminated material 3 impregnated with the semi-hard resin liquid 3a on the flat plate 10 without contacting the upper endless belt 4a is guided to the forming passage 7 as the upper endless belt 7a advances. (4) On the other hand, in the continuous production apparatus A, the glass fiber bundles 4 are dispersed by an array plate (not shown) in a thin state and in a wide width state, and the glass fiber bundles 4 are foamed and cured with a urethane resin liquid. 2a is sprayed by the resin jetting machine 5. (5) Next, after the urethane resin liquid 2a is dispersed between the glass fibers of the glass fiber bundle 4 by the rubbing plate 6, the glass fiber bundle 4 is guided to the molding passage 7, while the backing material supply roll 8 is introduced.
The glass scrim (an example of the back surface material) 8 supplied from a is also guided to the molding passage 7.

At the inlet of the molding passage 7, the surface laminated material 3, the glass fiber bundle 4, and the glass scrim 8 are superposed and guided into the molding passage 7, and the urethane resin liquid 2 is introduced in the molding passage 7.
The surface laminated material 3, the glass fiber bundle 4, and the glass scrim 8 are integrally molded by foaming and hardening a. The glass fiber bundle 4, the surface laminate 3, and the glass scrim 8 are pulled by a tensioning machine (not shown) and guided into the molding passage 7. (6) The polyethylene film 30 is peeled off from the fiber-reinforced foamed resin molded body when the fiber-reinforced foamed resin molded body is pulled out from the outlet of the molding passage 7.

[0022] Thus, the seam portion and warping of the endless belt, even fiber-reinforced molded foamed resin body of good quality can be obtained without being affected by the seam portion or the entanglement of the long glass fibers.

The foam-hardening resin liquid is not limited to the foam-hardening urethane resin liquid, and the semi-hard resin liquid is not limited to the semi-hard urethane resin liquid. is there.

[0024] Of the Example 2 Example 1 above, forming a fiber reinforced foam resin molded article by using one support member 10 with impregnator having only impregnation roll B and continuous production apparatus A as in the prior art In this case, a good quality product can be obtained without being affected by the seam or warpage of the endless belt.

[0025]

As is apparent from the above description, according to the method for continuously producing a fiber-reinforced foamed resin molded article according to claim 1, the surface laminated material can be applied to the surface laminated material without being affected by the seam or warpage of the endless belt. Since the semi-hard resin liquid can be impregnated, the occurrence rate of defective products can be made extremely low.

Further , according to the method for continuously producing a fiber-reinforced foamed resin molded article according to claim 2 , when the surface laminated material is impregnated with the semi-hard resin liquid, it is not affected by the joints and entanglements of the long glass fibers, and Since the endless belt is not affected by the seam or warp, defective products can be surely suppressed.

[Brief description of drawings]

FIG. 1 is a perspective view showing a continuous manufacturing process of a fiber-reinforced foamed resin molding of the present invention.

FIG. 2 is a schematic view of the continuous manufacturing process.

FIG. 3 is a sectional view of a fiber-reinforced foamed resin molding.

FIG. 4 is a perspective view showing a continuous manufacturing process of a conventional fiber-reinforced foamed resin molding.

FIG. 5 is a schematic view showing the continuous manufacturing process.

[Explanation of Codes] 1 Fiber Reinforced Foamed Resin Molded Body 2 Foamed Resin Body 2a Foam-curable Urethane Resin Liquid (Foam-curable Resin Liquid) 3 Surface Laminated Material 31 Glass Paper 32 Glass Long Fiber 3a Semi-Hard Resin (Semi-curable Urethane) Resin) A Continuous manufacturing device 4 Glass fiber bundle (long fiber bundle) 7 Molding passage 7a Endless belt 10 Support material (flat plate)

─────────────────────────────────────────────────── ─── Continuation of the front page (56) Reference JP-A-3-81116 (JP, A) JP-A 63-166504 (JP, A) JP-A 62-140809 (JP, A) JP-A 54- 159475 (JP, A) JP 54-37172 (JP, A) JP 53-21267 (JP, A) JP 53-20547 (JP, Y1) (58) Fields investigated (Int.Cl. ⁷ , DB name) B29C 39/00-39/44 B29C 70/00-70/88 B29C 44/00-44/60

Claims (2)

(57) [Claims] 1. A manufacturing apparatus equipped with a molding passage formed by an endless belt and an impregnating roll located on the endless belt for impregnating a surface-laminated material with a semi-hard resin solution. The surface laminated material impregnated with the semi-hard resin liquid by the roll is guided along the endless belt to the molding passage continuously, while the long fiber bundle impregnated with the foam curable resin liquid is continuously guided to the molding passage. In a continuous manufacturing method of a fiber-reinforced foamed resin molded product in which a resin liquid is foamed and cured in a molding passage to integrally mold a foamed resin body and a surface laminated material, a support material is interposed between an endless belt and a surface laminated material. Then, while supporting the surface laminated material with this support material,
A continuous method for producing a fiber-reinforced foamed resin molded article, which comprises impregnating a surface-laminated material with a semi-rigid resin liquid using an impregnating roll. 2. An impregnating roll comprising a first impregnating roll and a first impregnating roll.
It is composed of a second impregnating roll located closer to the entrance of the molding passage than the impregnating roll. First, after supplying the semi-hard resin liquid to the glass paper, the first impregnating roll impregnates the glass paper with the semi-hard resin liquid. Then, the continuous glass fiber is impregnated with the semi-hard resin liquid in the second impregnating roll, and the glass paper and the continuous glass fiber are overlapped with each other, and the continuous fiber-reinforced foamed resin molded product according to claim 1. Production method.