JP3456853B2 - Composite - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite material comprising a core material and a thermoplastic resin covering the periphery of the core material. In particular, it relates to a composite material suitable for an eaves gutter. 2. Description of the Related Art Conventionally, a composite material comprising a core material such as a metal plate and a sheet and a thermoplastic resin covering the periphery of the core material has been widely used for eaves gutters and the like. For example, Japanese Unexamined Patent Publication No.
No. 33660, Japanese Utility Model Publication No. 61-43873,
Japanese Utility Model Publication No. Sho 61-27397 describes an eaves gutter manufactured from a composite material comprising a metal plate and a thermoplastic resin covering the periphery of the metal plate. The method for producing such a composite material generally uses a crosshead mold to extrude the molten thermoplastic resin around the core material passing through the mold, and to apply the thermoplastic resin around the core material. It is to be coated. [0003] For example, Japanese Patent Publication No. Hei 6-98691 discloses that a core material is a prepreg sheet in which many parallel long fibers are fixed with a thermoplastic resin (thermoplastic fixing material), and the same kind of thermoplastic fixing material is used. A method for producing a composite material in which a core material is coated with a thermoplastic resin is described. Also, Tokuho 7-1
No. 10514 discloses a method for manufacturing an eaves gutter in which a prepreg sheet is used as a core material, and a composite material in which the core material is coated with a thermoplastic resin of the same type as the thermoplastic fixing material is formed into an eaves gutter shape. I have. On the other hand, a normal eaves gutter is disclosed in Japanese Utility Model Publication No. 60-800.
As described in Japanese Patent Publication No. 4 (1994), a thermoplastic resin such as a vinyl chloride resin or a metal molded into an eaves gutter shape is often used. [0005] However, the eaves gutter obtained by molding the above thermoplastic resin into an eaves gutter shape is directly irradiated with sunlight when the eaves gutter is attached to the eaves gutter. When the temperature rises, the eaves are softened or expanded, which causes a problem that the eaves gutter is deformed such as being bent or bent or cracks occur. For example, a typical rigid vinyl chloride resin among thermoplastic resins is most often used as an eaves gutter because of its excellent water resistance, flame retardancy, and good mechanical strength. Is 60-70 ° C,
It is easily softened by heat such as direct sunlight. Further, the coefficient of linear expansion is as large as 7.0 × 10 ⁻⁵ (1 / ° C.). As a result, the two often overlap, crack, bend or break. [0006] An eaves gutter formed of metal in the shape of an eaves gutter does not deform but has a problem that it is easily rusted. Also, an eaves gutter made of a composite material comprising a core material made of a metal plate and a thermoplastic resin covering the periphery of the core material has good heat resistance, has a small expansion and contraction, and is hardly rusted. Since the metal is exposed on the surface, there is a problem that the exposed portion rusts. Further, a prepreg sheet in which long fibers are fixed with a thermoplastic resin (thermoplastic fixing material) is used as a core material, and the core is coated with a thermoplastic resin of the same kind as the thermoplastic fixing material to manufacture a composite material. Eaves gutters are extremely preferred because they have good heat resistance, little expansion and contraction, and are less likely to rust, but they are expensive. Therefore, if the present inventor replaces the prepreg sheet in which long fibers are fixed with a thermoplastic resin and uses a sheet in which inexpensive short fibers are fixed with a thermoplastic resin (thermoplastic fixing material) as a core material, the cost becomes low. I noticed that when the core material with the short fibers fixed with a thermoplastic fixing material was coated with a thermoplastic resin of the same type as the thermoplastic fixing material using a crosshead die, the short fibers fell apart. Become
A good composite having good heat resistance could not be produced. Further, as a result of further studies by the present inventors, a composite material having good heat resistance was invented using a core material in which inexpensive short fibers were fixed with a thermoplastic fixing material. That is, an object of the present invention is to provide a composite material having good heat resistance using a core in which short fibers are fixed with a thermoplastic fixing material. SUMMARY OF THE INVENTION The present invention has been made to achieve the above object, and comprises a composite comprising a core material and a thermoplastic resin covering the periphery of the core material. The core material is a belt-like body in which short fibers are randomly oriented and the short fibers are fixed with a thermoplastic fixing material, and the thermoplastic fixing material can be fused with a thermoplastic resin, It has a melting point higher than the molding temperature of the plastic resin. As the short fibers used in the present invention, any fibers can be used as long as they can withstand the molding temperature of the thermoplastic resin, but inorganic fibers such as carbon fiber, metal fiber, glass fiber, Kepler, cotton fiber and the like can be used. Organic fibers and the like can be suitably used. The diameter and length of the short fiber are appropriately selected according to the required performance of the core material.
１００100 mm and a diameter of 5５０50 μm are often used. Although various thermoplastic resins can be used as the thermoplastic resin used in the present invention, vinyl chloride resins, acrylic resins, and copolymers of vinyl chloride and other monomers, copolymers of acrylic monomers and other monomers can be used. Copolymers and the like are preferred. As the thermoplastic fixing material used in the present invention, any material can be used as long as it can be fused with a thermoplastic resin and has a melting point higher than the molding temperature of the thermoplastic resin. Therefore, although different depending on the type of the thermoplastic resin used, acrylic resin, polyethylene terephthalate (PET), polyethylene (PE), nylon, and the like are often used. (Function) The core material used in the composite material of the present invention is:
It is a belt-like body in which short fibers are fixed with a thermoplastic fixing material, and since this thermoplastic fixing material can be fused with a thermoplastic resin and has a melting point higher than the molding temperature of the thermoplastic resin, for example, a crosshead Even when the composite material is manufactured by passing the core material through the die and extruding the molten thermoplastic resin heated to the molding temperature around this core material, the short fibers fixed with the thermoplastic fixing material are separated. In addition, the composite material is obtained by fusing the thermoplastic resin to the thermoplastic fixing material. Further, the composite material of the present invention comprises a core material and a thermoplastic resin covering the periphery of the core material, and since the short fibers are not dispersed as described above, this composite material is used. When used with eaves gutters, it has good heat resistance and expands and contracts as well as eaves gutters made of a composite material in which a conventional prepreg sheet is used as the core material and this core material is coated with the same type of thermoplastic resin as the thermoplastic fixing material Is very preferable because it is small and hard to rust. Therefore, forming this composite material into an eaves gutter shape results in an ideal eaves gutter. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described. 1 to 4 show one embodiment of the present invention.
FIG. 1A is a partially cutaway perspective view of the composite material, FIG. 1B is a perspective view showing a part of the core material, FIG. 2 is an explanatory view showing a state in which an eaves gutter made of the composite material is manufactured, and FIG. FIG. 4 is a cross-sectional view of the crosshead die when the eaves gutter is manufactured. FIG. 4 is an explanatory diagram showing a cross-section of the eaves gutter manufactured by the manufacturing method of FIG. 1 to 4, reference numeral 1 denotes a composite material,
The composite material 1 is composed of a core material 2 and a thermoplastic resin 3 covering the periphery of the core material 2. The core material 2 is a carbon fiber short fiber (fiber length 1 to 40 mm, fiber diameter 1).
0 μm) 21 and a thermoplastic fixing material 22 in which PET fibers have been shortened are blown off with air to be deposited in a layer, and heated and pressed at a temperature equal to or higher than the softening temperature of the PET fibers, and the short fibers 21 are thermoplastically fixed. The core material 2 is manufactured by fixing and integrally forming a sheet shape. As shown in FIG. 1B, the short fibers 21 are randomly oriented, and
Is a belt-shaped body fixed with a thermoplastic fixing material. The thermoplastic resin 3 is a vinyl chloride resin.
The melting point of PET as the thermoplastic fixing material 22 is 25.
The temperature is 6 ° C., which is higher than the molding temperature (die temperature) of the thermoplastic resin 3 of about 180 ° C., and is well fused to the vinyl chloride resin. Reference numeral 4 denotes an eaves gutter. As shown in FIG. 4, the eaves gutter 4 is formed by forming the composite material 1 into an eaves gutter shape. Reference numeral 5 denotes an extruder. The extruder 5 includes a hopper 51, a barrel, and a screw provided in the barrel. Reference numeral 6 denotes a preforming device for forming the core material 2 into the eaves gutter 4 shape. Reference numeral 7 denotes a mold composed of a crosshead die. The mold 7 is attached to the tip of the extruder 5. This mold 7 has a gap 7 having substantially the same shape as the eaves gutter 4.
There is one. The method of using the mold 7 is to pass the core material 2 formed into the same shape as that of the eaves gutter 4 by the preforming device 6 through the gap 71, and to form upper and lower resin passages 72, 72.
The core material 2 is covered with the thermoplastic resin 3 by extruding the melted thermoplastic resin 3 from the plastic material 3, and the composite material 1 in which the thermoplastic resin 3 and the thermoplastic fixing material 22 are fused together is substantially eaves trough 4. And extruded. Reference numeral 65 denotes a sizing device for forming the composite material 1 extruded from the mold 7 into a substantially eaves trough 4 shape into a substantially accurate eaves trough 4 shape. 8 is a vertical caterpillar 81, 81
In the take-off device 5, the composite material 1, which comes out of the mold 7 and is formed into a substantially accurate shape of the eaves gutter 4 by the sizing device 65, is provided by the upper and lower capillaries 51, 51. It is designed to be picked up and picked up. Next, a manufacturing method and an operation for manufacturing the eaves gutter 4 from the composite material 1 will be described. The core material 2 is formed into the shape of the eaves gutter 4 by the preforming device 6 and passed through the gap 71 of the mold 7. On the other hand, the hopper 5 of the extruder 5
The extruder 5 is operated by putting the thermoplastic resin 3 into 1. Then, the rotation of the screw causes the thermoplastic resin 3 in the hopper 51 to advance in the barrel toward the mold 7. The thermoplastic resin 3 is melted by a heater attached around the barrel while traveling through the barrel, and passes through the resin passage 72 in the mold 7 to form the core material 3.
To cover the periphery of the core material 3. As a result, the core material 2 is covered with the thermoplastic resin 3, and is extruded into a composite material 1 formed into a substantially eaves gutter 4 shape. The composite material 1 thus extruded is
The core material 2 is a belt-like body in which the short fibers 21 are fixed by a thermoplastic fixing material 22, and the thermoplastic fixing material 22 can be fused to the thermoplastic resin 3. Since it has a high melting point, even if the composite material 1 is manufactured by passing the core material 2 through the mold 7 and extruding the molten thermoplastic resin 3 around the core material 2, the thermoplastic material is fixed. The short fibers 21 fixed by the material 22 do not fall apart,
In addition, the thermoplastic resin 3 is fused to the thermoplastic fixing material 22 to form the composite material 1 formed into the eaves gutter 4 shape. The composite material 1 is made of a thermoplastic resin 3 covering the periphery of the core material 2 and, since the short fibers of the core material 2 are not separated, the heat resistance is good and the expansion and contraction is small. It is a very preferable eaves gutter because it is small and hard to rust.
Moreover, since the core material 2 of the composite material 1 is a belt-like body in which inexpensive short fibers 21 randomly oriented and fixed by a thermoplastic fixing material 22, the core material 2 is made of a conventional prepreg sheet using expensive long fibers. It is inexpensive, and thus the eaves gutter is inexpensive. The composite material 1 extruded in this manner is formed into a substantially accurate shape of the eaves gutter 4 by the sizing device 65, and is taken out by being sandwiched between the upper and lower capillaries 51, 51, and cut into a fixed length to be cut into a fixed length. Becomes (Comparative Example) Next, an eaves gutter having the same shape as that of the example was extruded and formed only with a vinyl chloride resin.
The eaves gutter manufactured in the example and the eaves gutter manufactured in the comparative example were attached to the eaves, and the presence or absence of deformation after one month in summer was examined. The eaves gutter produced in the example had no deformation at all,
The eaves gutter produced in the comparative example was deformed such that the outdoor side wall fell outward. As a result of examining the degree of deformation, it was found that it fell outward more than 5% of the height. Also, warping and cracking due to thermal expansion and contraction occurred. As can be seen from the results, it can be seen that the examples using the thermoplastic fixing material which can be fused to the thermoplastic resin and have a melting point higher than the molding temperature of the thermoplastic resin have extremely excellent heat resistance. The core material used in the composite material of the present invention is a band in which short fibers are fixed with a thermoplastic fixing material, and this thermoplastic fixing material can be fused with a thermoplastic resin. Since it has a melting point higher than the molding temperature of the thermoplastic resin, the short fibers fixed by the thermoplastic fixing material do not fall apart, and the thermoplastic resin has good heat resistance fused to the thermoplastic fixing material. Composite material. Therefore, when this composite material is formed into an eaves gutter and used as an eaves gutter, it is a very valuable eaves gutter because it has excellent heat resistance, small expansion and contraction, and does not easily rust. Moreover, the core material of the composite material of the present invention is a belt-like body in which randomly oriented short fibers are fixed with a thermoplastic fixing material, and thus is less expensive than a conventional prepreg sheet. Therefore, eaves gutters formed from this composite material into eaves gutters are less expensive.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows an embodiment of the present invention, wherein (a) is a partially cutaway perspective view of a composite material, and (b) is a perspective view showing a part of a core material. . FIG. 2 is an explanatory diagram showing a state in which an eaves gutter made of a composite material is being manufactured. FIG. 3 is a cross-sectional view of a crosshead die. FIG. 4 is an explanatory view showing an eaves gutter manufactured by the manufacturing method of FIG. 2; [Description of Signs] 1 Composite material 2 Core material 21 Short fiber 22 Thermoplastic fixing material 3 Thermoplastic resin 4 Eaves 5 Extruder 6 Preforming device 65 Sizing device 7 Crosshead die 8 Take-off device

──────────────────────────────────────────────────続 き Continued on the front page (58) Fields surveyed (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 B29C 47/02 E04D 13/064

Claims (1)

(57) [Claim 1] A composite material comprising a core material and a thermoplastic resin covering the periphery of the core material, wherein the core material randomly orients short fibers. A belt-like body in which the short fibers are fixed with a thermoplastic fixing material, wherein the thermoplastic fixing material is capable of being fused with a thermoplastic resin and has a melting point higher than a molding temperature of the thermoplastic resin. And composite material.