JP3483380B2 - Manufacturing method and manufacturing apparatus for long fiber reinforced foam 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 and an apparatus for continuously producing a foam-molded article reinforced with long fibers, and particularly suitable as a method and apparatus for producing a long-fiber-reinforced polyurethane foam-molded article. Is.

[0002]

2. Description of the Related Art A long-fiber-reinforced polyurethane foam molding is known as a material excellent in mechanical strength that can be used as a structural material such as a building material in place of wood. The long-fiber-reinforced polyurethane foam molding is a molding passage in which continuous fibers such as long-fiber bundles (for example, glass roving) are continuously impregnated with a polyurethane foaming resin liquid, and four surfaces are surrounded by the surface of a metal belt. It is produced by foaming and hardening it inside. That is, in the long-fiber-reinforced polyurethane foam-molded product, a process A of impregnating the long-fiber bundle 101 with the foamable resin liquid 102 as shown in FIG. 3, and a process of foaming the foamable resin liquid 102 to mold the molding intermediate structure 110. B, the molding intermediate structure 110 described above
With a take-up machine, a step D of finishing the surface of the molded intermediate structure 110 thus taken off, and finally, the molded intermediate structure 110 having the surface finished is cut into a predetermined size to obtain a molded body 1. Manufactured from process E.

In the step A in which the long fiber bundle 101 is impregnated with the foamable resin liquid 102, the fibers 100 supplied from the fiber bundle supply unit 120 are arranged in the width direction and the long fiber bundle 101 is aligned in one direction. It is formed. After the foaming resin liquid 102 such as urethane foam is discharged from the spraying device (mixing device) 121 to the long fiber bundle 101, the foaming resin liquid 102 is discharged.
Is kneaded into the long fiber bundle 101 by the kneading plate 122,
Distribute evenly. The long fiber bundle 101 impregnated with the foamable resin liquid 102 is sent to the subsequent step B.

In this step B, the long fiber bundle 101 impregnated with the foamable resin liquid 102 is introduced into the molding passage 130,
The foamable resin liquid 102 is foamed in the molding passage 130 and the liquid is cured, so that the molding intermediate structure 110 of the long fiber reinforced polyurethane foam molding is continuously manufactured in a strip shape.
As shown in FIG. 4, the molding passage 130 includes a pair of upper and lower endless belts 131 and 131 and a pair of left and right endless belts 1.
It is formed by a closed space whose four sides are surrounded by 33 and 33.

The inside of such a molding passage 130 is heated by the hot air sent from the hot air generator 132. Due to this heat, the reaction of the expandable resin liquid 102 with which the long fiber bundle 101 is impregnated in the molding passage 130 progresses, foaming is promoted and the resin is cured, and the molding passage 130 is formed.
The molding intermediate structure 110 is filled therein. Molding passage 130
When the foamable resin liquid 102 and the fibers 100 are uniformly filled therein and cured, the molding intermediate structure 110 having a specified dimension is continuously manufactured.

By the way, in the conventional method for producing a long-fiber-reinforced polyurethane foamed molded article, the method disclosed in JP-A-53-48866 is generally used as a raw material supplying means. That is, the method disclosed in JP-A-53-48866 discloses that a polyol, a foaming agent and a catalyst are mixed in a tank in advance to prepare a polyol component liquid and sprayed in order to produce a long fiber reinforced polyurethane foam molded product. Device 1
In 21, it is mixed with separately supplied isocyanate.

[0007]

However, the method of preliminarily mixing the polyol, the blowing agent and the catalyst in the tank is a batch process, and therefore is a wasteful manufacturing method in the continuous molding method. For example, in order to continuously supply the polyol component liquid, a separate mixing tank, service tank, etc. are required, resulting in waste of equipment cost and location, and when changing the raw material mix, It requires extraction work, which requires more man-hours and lowers the facility operation rate.

An object of the present invention is to continuously mix a polyol and a foaming resin liquid such as a foaming agent and a catalyst so that the polyol component liquid can be continuously supplied.
It is an object of the present invention to provide a method for producing a long fiber-reinforced foamed molded product, in which the amounts of the foaming agent and the catalyst mixed can be easily changed.

[0009]

SUMMARY OF THE INVENTION The invention for solving the above-mentioned problems is directed to a large number of filament bundles aligned in one direction and continuously advancing in the longitudinal direction, and a polyol is added to the advancing filament bundle. A foaming resin liquid prepared by mixing a polyol component liquid containing as a main component with an isocyanate component liquid containing an isocyanate as a main component immediately before is guided to a molding passage to foam the foaming resin liquid in the molding passage. And a method for producing a long-fiber-reinforced foamed molded article, wherein the polyol component liquid is prepared by continuously mixing a polyol, a foaming agent and a catalyst in the method for producing a long-fiber-reinforced polyurethane expanded molded article. Is the way.

According to the manufacturing method of the present invention, the foamable resin liquid is continuously mixed at the time of supplying the raw materials, and the mixed liquid is continuously supplied to the long fiber bundle. A mixing tank and a service tank for continuously supplying the mixed liquid are not required, and waste of equipment cost and space is eliminated.

Particularly, in the method of supplying the respective mixed components of the foamable resin liquid to an extruder and mixing them by the extruder to disperse them into long fibers, mixing of a foaming agent and a catalyst constituting the foamable resin liquid. The quantity can be changed instantaneously in the feed to this extruder. Further, when the extruder is a twin-screw co-rotating type, for example, the foaming agent, the catalyst, and the polyol can be uniformly mixed in the extruder while suppressing a temperature rise.

The basic concept of the present invention can also be applied to the case where a resin material other than polyurethane is used. That is, another invention in the case of using a material other than polyurethane is that a large number of filament bundles aligned in one direction are continuously advanced in the longitudinal direction, and the advancing filament bundles have different main components. A method for producing a long-fiber-reinforced foamed molded product, in which a foamable resin liquid prepared by mixing two or more raw material liquids immediately before is sprayed and guided to a molding passage to foam and cure the foamable resin liquid in the molding passage. In the above method, at least one raw material liquid is prepared by continuously mixing the main component thereof with a foaming agent and a catalyst, and is a method for producing a long fiber-reinforced foamed molded product.

Further, in the above-mentioned invention, it is desirable that the foaming agent and the catalyst are continuously supplied by a pump, and the mixing ratio of them can be adjusted.

Further, the invention of an apparatus for realizing these manufacturing methods is a molding passage, and an apparatus for continuously advancing a large number of long fiber bundles in the longitudinal direction into the molding passage. A mixing device for mixing two or more raw material liquids and discharging the mixed liquid into a long fiber bundle, and an apparatus for manufacturing a long fiber reinforced foamed molded article having a pump for supplying two or more raw material liquids to the mixing device, The premixing device includes a mixing device, a pump that supplies a foaming agent to the premixing device, and a pump that supplies a catalyst to the premixing device. In the premixing device, the foaming agent and the catalyst and the raw material liquid supplied from these pumps are included. One of the main components is mixed in advance, and this premixed raw material is supplied to the mixing device and mixed with the remaining raw material liquid.

An extruder is preferably used as the premixing device. The production apparatus of the present invention has a premixing device, and the catalyst supplied from each pump is introduced into this premixing device. For example, one main component of the raw material liquid such as the polyol component liquid and the blowing agent are introduced. And the catalyst is continuously premixed. That is, in the present invention, the premixing which is conventionally performed in a batch type by a mixing tank or the like is continuously performed by the premixing device. Then, this premixed raw material is supplied to the mixing device and finally mixed with the remaining raw material liquid such as an isocyanate component liquid.

[0016]

BEST MODE FOR CARRYING OUT THE INVENTION Specific preferred modes for carrying out the present invention will be sequentially described. The long fiber bundle used in the present invention is formed by aligning a large number of long fibers in one direction, and as the long fibers, natural fibers or synthetic fibers,
Of the inorganic fibers and the like, long fibers can be used, but glass fibers are most suitable from the viewpoint of producing one having a use as a structural material.

The foamable resin liquid means a liquid resin that foams and cures in a relatively short time, and for example, polyurethane resin, phenol resin, polyester resin and the like are preferably used.

FIG. 1 is a schematic view of an apparatus for explaining a method for producing a long fiber reinforced foam molded article. FIG. 1 shows only the raw material supply portion and the step portion of impregnating the long fiber bundle with the foamable resin liquid 102 in the step of producing the long fiber-reinforced foamed molded article. The steps and devices used that are not shown in FIG. 1 are the same as those in the prior art described with reference to FIGS. In the figure, 1 is a polyol, which is supplied to an extruder (premixing device) 5 by a pump 11. 2 is a foaming agent and 3 is a catalyst, which are similarly fed to the extruder 5 from pumps 21 and 31, respectively. The respective mixed components of the polyol 1, the foaming agent 2 and the catalyst 3 are mixed in the extruder 5 to become a polyol component liquid containing polyol as a main component, and transferred to the spraying device 6 (mixing device) by the pump 51. . Reference numeral 4 denotes diphenylmethane isocyanate, which is supplied to the spraying device 6 by the pump 41, is mixed with the polyol component liquid in the spraying device 6, and is sprayed from the spraying device 6 onto the long fiber bundle 7.

In the figure, 8 is a rubbing plate, which reciprocates in a direction at right angles to the traveling direction of the long fiber bundle 7 so that the long fiber bundle 7 sandwiched between the impregnating plate 9 and the rubbing plate 8 is reciprocated. It is made to rub. Reference numeral 10 denotes a molding passage in which the foamable resin liquid impregnated in the long fiber bundle 7 is foamed and hardened to be molded into the same shape as the cross-sectional shape of the molding passage 10. By driving a take-up machine (not shown) at a constant speed, the long fiber bundle 7 is given a forward motion at a constant speed.

In order to produce a long-fiber-reinforced foamed molded product by the method of the present invention, the foaming agent and the catalyst are quantitatively supplied by using an appropriate metering pump, and the foaming agent and the catalyst and the polyol are placed in the extruder 5. It is important to mix them uniformly while suppressing the temperature rise. To ensure uniform mixing, extruder 5
Is preferably a two-axis co-rotating type as shown in FIG. 2, and in order to suppress the temperature rise of the mixture, the screw 52 needs to have an appropriate shape. Since the screw rotation speed also affects both uniform mixing and temperature rise, it is preferable to set the rotation speed to an appropriate value and cool the cylinder 53 with cooling water. The polyol component liquid containing the foaming agent and the catalyst thus uniformly mixed in the extruder 5 is supplied to the pump 5
1 is transferred to the spraying device 6, mixed with diphenylmethane isocyanate and sprayed on the long fiber bundle 7, and is kneaded between the kneading plate 8 and the impregnating plate 9 to uniformly impregnate the long fiber bundle 7. Next, the long fiber bundles 7 are guided into the molding passage 10 where they are foamed and cured to form the molding passage 10
Is formed into a long foam according to the cross-sectional shape, and is cut to a fixed length when it exits the molding passage 10 and passes through the take-up machine.

By the method as described above, it is possible to continuously mix the foaming agent and the catalyst with the polyol. Regarding the uniformity of the mixing, the supply accuracy of the pumps 21 and 31 for supplying the foaming agent and the catalyst is ±. If it is about 1%, it is possible to obtain a better mixed state than the conventional batch process. Further, the pumps 11 and 41 and the pumps 21 and 31 are interlocked with each other by a proportional control method, and can be instantaneously changed by changing the discharge ratio of the pumps 11 and 41 and the pumps 21 and 31 when changing the raw material mixture.

[0022]

EXAMPLES As shown in Table 1 below, tests were conducted in three compounding ratio systems. The materials used in this example are as follows. Materials used Long fibers: 38 glass rovings having a weight of 9.26 g per 1 m were prepared by aligning a large number of monofilaments having a fiber diameter of 13 μ. Polyol: Propylene oxide-added polyether polyol foaming agent having 4 functional groups: Distilled water catalyst: Dibutyltin dilaurate isocyanate: Crude diphenylmethane diisocyanate

[0023]

[Table 1]

[0024]     (Product dimensions: width 10 cm, thickness 2 cm, specific gravity: 0.5)   * All molding methods were performed as shown in FIG.   * Extruder ・ Type: Two-axis rotating in the same direction                 ・ Screw outer diameter: φ50 mm                 ・ Screw length: 445 mm                 ・ Screw rotation speed: 90 rpm                 ・ Drive motor: DC motor 3.7kw

As a result, molded products of good quality were obtained in all three types.

[0026]

In the manufacturing method of the present invention, since the foaming agent and the catalyst are continuously mixed by the extruder (premixing device), the mixing tank and the service tank, which are required in the conventional method, are unnecessary. It saves space, and it is possible to easily change the raw material mix by adjusting the pumps connected to the tanks containing the respective materials. It also eliminates the work man-hours and increases the facility utilization rate.

Further, according to the manufacturing apparatus of the present invention, conventionally,
The premixing of the raw materials, which has been performed batchwise by the mixing tank or the like, can be continuously performed by the premixing device, and there is an effect that the mixing tank or the like is unnecessary.

[Brief description of drawings]

FIG. 1 is a schematic view of an apparatus for explaining a method for producing a long fiber-reinforced foamed molded product.

FIG. 2 is a sectional view of an extruder (premixing device).

FIG. 3 is a schematic view showing a manufacturing process of a long fiber-reinforced foamed molded product.

FIG. 4 is a cross-sectional view of a molding passage of an apparatus for manufacturing a long fiber reinforced foam molded article.

[Explanation of symbols]

1 polyol 2 foaming agent 3 catalyst 4 Isocyanate 5 Extruder (premixing device) 6 Dispersing device (mixing device) 7 long fibers 8 Rubbing board 9 Impregnation plate 10 Molding passage 11 pumps 21 pumps 31 pumps 41 pumps 51 pumps 52 screw 63 cylinders

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI B29K 105: 10 B29C 67/14 Z (58) Fields investigated (Int.Cl. ⁷ , DB name) B29C 44/00-44 / 60,67 / 20 B29C 39/14-39/24 B29C 70/00-70/54 B29B 7/30-7/56

Claims (4)

(57) [Claims] 1. A polyol component liquid containing a polyol as a main component, wherein a large number of long-fiber bundles aligned in one direction are continuously advanced in the longitudinal direction, and the advancing long-fiber bundle contains a polyol as a main component.
Long-fiber-reinforced foam molding in which a foamable resin liquid prepared by mixing an isocyanate component liquid containing isocyanate as a main component is sprayed immediately before being guided to a molding passage to foam and cure the foamable resin liquid in the molding passage. In the method for producing a body, the polyol component liquid is prepared by continuously mixing a polyol, a foaming agent, and a catalyst, and a method for producing a long fiber-reinforced foamed molded article. 2. A foaming process in which a large number of long fiber bundles aligned in one direction are continuously advanced in the longitudinal direction, and two or more raw material liquids having different main components are immediately mixed with the advancing long fiber bundles. In the method for producing a long-fiber-reinforced foamed molded product, in which a foamable resin liquid is sprayed and guided to a molding passage to foam and cure the foamable resin liquid in the molding passage, at least one raw material liquid is a main component thereof. And a foaming agent and a catalyst are continuously mixed to prepare a long-fiber-reinforced foamed molded article. 3. The method for producing a long fiber-reinforced foamed molded product according to claim 1, wherein the foaming agent and the catalyst are continuously supplied by a pump, and the mixing ratio of these is adjustable. . 4. A molding passage, an apparatus for continuously advancing a large number of long fiber bundles in the longitudinal direction thereof and introducing the bundle into the molding passage, and mixing two or more raw material liquids to obtain the mixed liquid. In a manufacturing apparatus for a long-fiber-reinforced foamed molded product, which has a mixing device for discharging a long fiber bundle and a pump for supplying two or more raw material liquids to the mixing device, a premixing device and a foaming agent are supplied to the premixing device. And a pump for supplying a catalyst to the premixing device, and the premixing device premixes the blowing agent and the catalyst supplied from these pumps with one main component of the raw material liquid. An apparatus for producing a long-fiber-reinforced foamed molded article, characterized in that a premixed raw material is supplied to the mixing device and mixed with the remaining raw material liquid.