JP3590526B2 - Composite - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a composite material in which a thermoplastic resin is extrusion-coated around a reinforcing core material. In particular, it relates to a composite material suitable for an eaves gutter.
[0002]
[Prior art]
The present invention relates to an extruded product excellent in low elasticity and heat resistance. Here, taking a rain gutter as an example, conventionally, a rain gutter is generally formed by extrusion molding using hard vinyl chloride resin. However, rain gutters are particularly required to have low elasticity and heat resistance because they are attached to the eaves.The above-mentioned rain gutters have large thermal expansion and contraction and thermal deformation, and cracks due to deformation also occur. There is a possibility that the function of the above will not be achieved. Therefore, by forming a core material formed by molding a thermoplastic resin and a fiber reinforced composite sheet made of glass fibers oriented in one direction or a plurality of directions into the shape of a rain gutter, by extrusion-coating the surface with the thermoplastic resin, Attempts have been made to solve the above problems (for example, Japanese Patent Publication No. Hei 6-98691 and Japanese Patent Publication No. Hei 7-110514).
[0003]
[Problems to be solved by the invention]
However, when a porosity close to 0 is used as the composite sheet, cracks or breaks occur at the bent portion when the fiber reinforced composite sheet is formed into a rain gutter shape to form a core material, In addition, there is a problem that the obtained gutter has low impact resistance.
[0004]
Therefore, an object of the present invention is to solve the conventional problems as described above, and the fiber in the reinforcing core material is not cracked or broken when the fiber-reinforced composite sheet is formed into an irregular cross-section, and the impact strength is improved. It is to provide an excellent composite material.
[0005]
[Means for Solving the Problems]
In the composite material of the present invention described in claim 1, a composite thermoplastic resin is formed by extrusion coated around the reinforcing core, the reinforcing core material, randomly oriented thermoplastic resin unfoamed A fiber-reinforced composite sheet having a porosity of 10 to 60%, which is made of a carbon fiber prepared as described above, and formed into an irregular cross-sectional shape.
[0006]
The fiber reinforced composite sheet used in the present invention needs to have a porosity of 10 to 60%. In the present invention, when a material having a porosity of less than 10% and a material having a porosity of more than 60% are formed into a modified cross-sectional shape to form a reinforcing core material, cracks and breaks occur in the bent portion of the fiber-reinforced composite sheet.
The porosity indicates the occupancy of voids in the fiber-reinforced composite sheet, and is the ratio of the volume of voids formed therein to the total volume of the fiber-reinforced composite sheet.
As the fibers constituting the fiber-reinforced composite sheet used in the present invention, carbon fibers are used, and those having a fiber length of 100 μm to 100 mm and a fiber diameter of 5 to 50 μm are preferable. As the thermoplastic resin constituting the fiber-reinforced composite sheet used in the present invention, various thermoplastic resins can be used. For example, vinyl chloride resin, acrylic resin, polyethylene terephthalate, vinyl chloride and other monomers And a copolymer of an acrylic monomer and another monomer. The thermoplastic resin to be coated on the reinforcing core material is appropriately selected from the fusing property with the reinforcing core material and moldability. Examples thereof include vinyl chloride resin, acrylic resin, polyethylene terephthalate (PET) resin, and polyethylene. (PE) resin, polyethylene (PE) resin, nylon resin and the like.
[0007]
(Action)
In the composite material of the present invention, the reinforcing core material is formed of a non-foamed thermoplastic resin and randomly oriented carbon fibers, and a porosity of 10 to 60% is formed into a fiber-reinforced composite sheet having an irregular cross-sectional shape. The carbon fibers are uniformly oriented in any direction in the fiber reinforced composite sheet and reinforced in the fiber reinforced composite sheet, and because there are many voids, they are not fixed by the thermoplastic resin and are free to deform. Since the degree is large, when forming the fiber reinforced composite sheet into an irregular cross-sectional shape, the carbon fiber is not cracked or broken at a portion bent in an irregular shape, and the molding stability of the reinforcing core material is excellent.
[0008]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, examples of the present invention will be described.
1 and 2 show a part of an example of the composite material of the present invention. FIG. 1A is a partially cutaway perspective view of the composite material, and FIG. FIG. 2 is a perspective view showing a part of the fiber-reinforced composite sheet of FIG. 2, and FIG. 2 is an explanatory view showing a cross section of an example of the composite material of the present invention.
[0009]
1 and 2, reference numeral 1 denotes a composite material. The composite material 1 is composed of a reinforcing core material 2 and a thermoplastic resin 3 covering the periphery of the reinforcing core material 2.
The fiber-reinforced composite sheet 20 serving as the base material of the reinforcing core material 2 is formed into a fibrous carbon fiber 21 and a thermoplastic resin 22 by a method of powder impregnation, and is blown by air to be deposited in a layer form, or is impregnated with a liquid. In the method (2), the mixture is mixed by stirring or the like, and then heated and pressurized to be integrally formed into a sheet. The fiber-reinforced composite sheet 20, as shown in FIG. 1 (b), the carbon fibers 21 are oriented randomly in the unfoamed thermoplastic resin 22, so as to have 10 to 60% voids, formed in a strip Have been.
[0010]
The size and arrangement of the voids 50 are randomly formed. The void 50 is a bubble that is taken in during the process of producing the fiber-reinforced composite sheet 20 by a method such as powder impregnation or liquid impregnation of the carbon fiber 21 and the thermoplastic resin 22. The content of the voids depends on the pressure at the time of heating and pressing. Therefore, when the pressure is increased, the porosity of the fiber-reinforced composite sheet 20 in the void 50 is reduced, and the fiber-reinforced composite sheet 20 having a high density is generated. On the other hand, when the pressure is reduced, the porosity of the fiber-reinforced composite sheet 20 in the void 50 increases, and the fiber-reinforced composite sheet 20 having a low density is generated.
[0011]
As shown in FIG. 2, the reinforcing core material 2 is formed in an eaves gutter shape (irregular sectional shape). The composite material 1 has a reinforcing core 2 covered with a thermoplastic resin 3 and molded into an eaves gutter shape.
[0012]
Hereinafter, an example of the method for producing a composite material of the present invention will be described with reference to FIGS .
[0013]
As shown in FIG. 3, reference numeral 6 denotes a preforming device for forming the fiber-reinforced composite sheet 20 into the reinforcing core material 2.
The extruder 5 includes a hopper 51, a barrel, and a screw provided in the barrel. Reference numeral 7 denotes a mold composed of a crosshead die. The mold 7 is attached to the tip of the extruder 5. The mold 7 has a gap 71 having substantially the same shape as the eaves gutter 1.
[0014]
As shown in FIG. 4, reference numeral 65 denotes a sizing device for cooling the composite material 1 extruded from the mold 7 into a substantially eaves gutter shape.
Reference numeral 8 denotes a take-up device provided with upper and lower caterpillars 81, 81, and is configured to pick up the composite material 1 between the upper and lower caterpillars 81, 81.
[0015]
The fiber reinforced composite sheet 20 is formed into a substantially eaves gutter shape by the preforming device 6 to obtain a reinforcing core material, and the reinforcing core material is passed through the gap 71 of the mold 7.
On the other hand, the thermoplastic resin 3 is put into the hopper 51 of the extruder 5, and the extruder 5 is operated. Then, the rotation of the screw causes the thermoplastic resin 3 in the hopper 51 to move in the barrel toward the mold 7.
[0016]
The thermoplastic resin 3 is melted by a heater attached around the barrel while traveling through the barrel, and is extruded from above and below the reinforcing core 2 through a resin passage 72 in the mold 7 to reinforce the thermoplastic resin. The periphery of the core material 2 is covered. As a result, the periphery of the reinforcing core material 2 is covered with the thermoplastic resin 3, and is extruded as a composite material 1 formed into a substantially eaves gutter shape.
[0017]
In the composite material 1 extruded in this manner, the reinforcing core material 2 is composed of an unfoamed thermoplastic resin 22 and randomly oriented carbon fibers 21, and the carbon fibers 21 are uniform in any direction. Orientation to reinforce the core material. Furthermore, since the fiber reinforced composite sheet 20 having a porosity of 10 to 60% is formed into an irregular cross-sectional shape, the fiber reinforced composite sheet 20 is not fixed by the thermoplastic resin 22 due to the presence of many voids. Large degree of freedom of deformation. Therefore, when the fiber reinforced composite sheet 20 is formed into an irregular cross-sectional shape, the carbon fiber 21 does not crack or break at the irregularly bent portion, and the molding stability of the reinforcing core material 2 is excellent. I have.
[0018]
EXAMPLE A fiber reinforced composite sheet 20 made of polyethylene terephthalate and randomly oriented carbon fibers and having a porosity of 40% as shown in FIG. 1B was reinforced by the process described with reference to FIG. A core material 2 was formed, and a polyethylene resin was extrusion-coated on both surfaces thereof to obtain a composite material 1 as shown in FIG.
Comparative Example 1 A composite material 1 was obtained in the same manner as in Example except that a fiber reinforced composite sheet having a porosity of 50% was used.
The composite materials obtained in the examples and comparative examples were subjected to a DuPont impact test to compare the stability and impact strength of the composite material 1.
As a result, in the DuPont impact test (23 ° C., weight 200 g) of the composite material, the drop distance was 380 mm in the example and the drop distance was 150 mm in the comparative example.
In addition, the molding stability of the reinforcing core material 2 at the time of molding in Examples and Comparative Examples was evaluated. As a result, the carbon fibers 21 were not cracked or torn in the example, but torn in the comparative example.
[0019]
【The invention's effect】
In the composite material according to the first aspect of the present invention, when the fiber-reinforced composite sheet is formed into an irregular cross-sectional shape to form a reinforcing core material, carbon is formed at an irregularly bent portion. No cracking or breakage of the fiber occurs, and the molding stability of the reinforcing core material is excellent, and carbon fibers are uniformly oriented in the reinforcing core material without any directionality. It has excellent impact resistance because it exists in the middle.
[Brief description of the drawings]
FIG. 1 shows a part of an example of a composite material of the present invention, (a) is a partially cutaway perspective view of the composite material, and (b) is a fiber-reinforced composite sheet serving as a base material of a reinforcing core material. It is a perspective view which shows a part.
FIG. 2 is a cross-sectional view of one embodiment of the composite material of the present invention.
FIG. 3 is an explanatory view illustrating a process of the composite material of the present invention.
FIG. 4 is a cross-sectional view of a crosshead die portion.
[Explanation of symbols]
1 Composite material (eave gutter)
2 Reinforcement core material 3 Thermoplastic resin 20 Fiber reinforced composite sheet 21 Carbon fiber 22 Thermoplastic resin 5 Extruder 6 Preforming device 65 Sizing device 7 Crosshead die 8 Take-off device

Claims (1)

A composite material obtained by extrusion-coating a thermoplastic resin around a reinforcing core material, wherein the reinforcing core material is made of an unfoamed thermoplastic resin and randomly oriented carbon fibers, and has a porosity of 10 to 60. % Of a fiber-reinforced composite sheet formed into an irregular cross-sectional shape.

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