JP3779192B2 - Method and apparatus for producing long fiber reinforced resin foam - Google Patents

Description

表１から明らかなように、比較例で得られた成形品では、比重分布が０．７４±０．１８であるのに対し、実施例１〜３では、比重分布の幅がこれより狭く、特に、内型を含浸型１の中心軸から傾けて回転させた実施例１及び３では、比重分布範囲のむらがより一層小さくなっていることがわかる。また、実施例１〜３では、３日以上の連続操業を行った場合でも、熱硬化性樹脂の堆積による操業の停止を行う必要がなかった。
【００５７】
【発明の効果】
本発明に係る製造方法では、樹脂原液含浸型内において、樹脂原液吐出口から径方向外側に向かって樹脂原液吐出されるので、また内型及び外型に樹脂原液溜まり部を設ける必要がないため、発泡性熱硬化性樹脂原液が樹脂原液含浸型内に滞溜し難い。従って、長期間に渡り連続操業を行うことができ、長繊維強化樹脂発泡体の生産性を高めることができる。加えて、樹脂原液吐出口よりも上流側において、内型の外周面及び外型の内周面の少なくとも一方に環状突起が形成されており、それによって長繊維束が環状突起を通過する際に開繊される。よって、樹脂原液が開繊された長繊維束に確実に含浸され、長繊維束が均一に分散された長繊維強化樹脂発泡体を確実に得ることが可能となる。
【００５８】
また、本発明に係る繊維補強樹脂成形品の製造方法及び製造装置では、発泡性熱硬化性樹脂原液は、吐出口から径方向外側に吐出されるものであるため、樹脂原液含浸型は、縦方向に配置されてもよく、横方向に配置されてもよい。従って、長繊維強化樹脂発泡体の製造スペースの低減を図ることができる。
【図面の簡単な説明】
【図１】本発明の一実施形態に係る長繊維強化樹脂発泡体の製造装置の用具を示す縦断面図。
【図２】図１のＸ−Ｘ線に沿う略図的断面図。
【図３】本発明の一実施形態に係る長繊維強化樹脂発泡体の製造装置の概略構成図。
【図４】本発明の一実施形態で用いられる可動金型を説明するための略図的斜視図。
【図５】本発明の一実施形態に係る長繊維強化樹脂発泡体の樹脂原液含浸型内型の回転方法を説明するための略図的部分断面斜視図。
【図６】図５のＢ−Ｂ線に沿う部分の略図的断面図。
【図７】実施例１で用いられる内型を示す縦断面図。
【図８】実施例１で用いられる樹脂原液含浸型を示す縦断面図。
【図９】実施例２で用いられる内型を示す縦断面図。
【図１０】実施例２で用いられる樹脂原液含浸型を説明するための縦断面図。
【図１１】比較例で用いられる内型を示す縦断面図。
【図１２】比較例で用いられる樹脂原液含浸型を説明するための縦断面図。
【図１３】従来の繊維補強樹脂成形品の製造装置の要部を示す縦断面図。
【図１４】従来の繊維補強樹脂成形品の製造装置で用いられる配列板を示す平面図。
【符号の説明】
１…樹脂原液含浸型
２…可動金型
３…長繊維束
３Ａ…合流された長繊維束
４…外型
５…内型
６…環状突起
７…樹脂原液吐出口
８…樹脂原液流路
１１…エンドレスベルト
１２…引取機
１３…繊維補強樹脂成形品
２１…回転駆動源[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method and an apparatus for manufacturing a fiber-reinforced resin molded article in which a foamable thermosetting resin stock solution is attached to and merged with a plurality of long fiber bundles and then foamed and cured.
[0002]
[Prior art]
In order to increase the bending strength and the like of the thermosetting resin foam, molded products obtained by reinforcing the thermoplastic resin foam with long fiber bundles have been used for various purposes.
[0003]
An example of a method for producing such a reinforced resin molded product is disclosed in Japanese Patent Laid-Open No. 10-119141.
FIG. 13: is a longitudinal cross-sectional view which shows the principal part of the fiber reinforced resin molded product manufacturing apparatus currently disclosed by this prior art.
[0004]
A resin stock solution impregnation region A and a resin stock solution impregnated fiber convergence region B connected to the lower part of the resin stock solution impregnation region A are provided. These two regions A and B are constituted by a gap between a cylindrical portion, an inner die 91 having a conical portion below it, and an outer die 92 around the inner die 91.
[0005]
In the region A, a ring-shaped fiber introduction port 93 at the upper end of the gap between the molds, a cylindrical gap 94 for sending the fibers below the lower part, and a resin stock solution reservoir and a resin stock solution impregnation at the lower part of the cylindrical gap 94 An annular gap 95, an injection pipe 96 for sending the resin stock solution to the gap 95, and an annular resin stock solution reservoir outlet 97 for sending the resin stock solution-impregnated fiber from the gap 95 to the lower region B are provided. On the other hand, in the region B, a gap 98 is provided so that the thickness gradually increases in the direction of the tip 99 of the conical portion of the inner mold 91.
[0006]
Using this apparatus, a plurality of fibers F are fed into the fiber introduction port 93 in a ring shape. When the fiber F is guided into the annular gap 95 through the cylindrical gap 94, the fiber F is impregnated with the resin stock solution L stored in the annular gap 95. Next, the resin stock solution-impregnated fiber F / L is drawn out from the annular resin stock solution accumulation outlet 97 and converged, and the fiber bundle impregnated with the resin stock solution is drawn out. By curing the resin stock solution of the fiber bundle impregnated with this resin stock solution, a long fiber reinforced resin molded product is obtained.
[0007]
However, the apparatus described in the above prior art has the following problems. (1) A thermosetting resin composition is usually used as the resin stock solution L. However, when a manufacturing apparatus is used for a long period of time, the resin adhering to the gap 95 is cured and deposited, and the gap 95 is blocked. There was a thing. Therefore, the operation has to be stopped in a relatively short period of time and the inside of the gap 95 has to be cleaned. However, cleaning is difficult only by stopping the operation, and the inner mold 91, the outer mold 92, and the injection pipe must be disassembled each time, and the cleaning work is very complicated.
[0008]
Moreover, immediately before introducing a plurality of long fiber bundles into the apparatus, the plurality of long fiber bundles must be arranged in a ring shape. For this purpose, an array plate 151 as shown in FIG. 14 must be used. In the array plate 151, a plurality of holes 152 are dispersedly arranged along the circumferential direction. Long fiber bundles are introduced into the plurality of holes 152, respectively. However, when a long fiber bundle that is easy to open is used, there is a risk that the fibers fluff when arranged using the array plate 151, and the array plate 151 may be clogged or cut. Therefore, as the long fiber bundle to be used, it was necessary to use a bundle having a certain degree of convergence.
[0009]
However, when molding is performed using the fiber-reinforced resin molded product manufacturing apparatus described in the above-mentioned prior art using a strongly bundled long fiber bundle, the resin is not easily penetrated into the long fiber bundle due to insufficient opening. Therefore, the amount of the resin that can be held by the long fiber bundle is reduced, and there is a possibility that the resin drips in the foaming mold, the drooping resin abnormally foams, and flows back to the inlet side of the mold.
[0010]
Moreover, in the fiber reinforced resin molded product manufacturing apparatus described in the above prior art, the impregnation mold shown in FIG. 13 must be arranged and used in the vertical direction. That is, when the impregnation mold is disposed sideways, the resin moves downward due to its own weight, and the resin stock solution does not easily accumulate in the annular gap. Therefore, the dispersibility of the resin stock solution is lowered, and the long fiber bundle cannot be uniformly impregnated with the resin stock solution.
[0011]
[Problems to be solved by the invention]
The present invention eliminates the disadvantages of the prior art described above, and even when a strongly bundled long fiber bundle is used, the foamed resin stock solution is sufficiently and uniformly impregnated while the long fiber bundle is opened. Provided is a method and apparatus for producing a fiber-reinforced resin molded product that can be molded continuously over a long period of time, and further can be provided with a resin stock solution-impregnated mold in either a vertical orientation or a horizontal orientation. There is to do.
[0012]
[Means for Solving the Problems]
The method for producing a fiber-reinforced resin molded article according to the present invention includes impregnating a plurality of long fiber bundles with a thermosetting foamed resin stock solution, bundling the plurality of long fiber bundles, and foaming and curing the fiber reinforced resin molding. A plurality of long fiber bundles are introduced into a ring-shaped gap formed between a resin stock solution-impregnated inner mold and a cylindrical outer mold, and the plurality of long fiber bundles are formed into a ring shape. An annular protrusion extending in the circumferential direction on the outer peripheral surface of the inner mold and / or the inner peripheral surface of the outer mold, and opening the long fiber bundle by the annular protrusion; and the annular protrusion A step of discharging the resin stock solution from a plurality of resin stock solution discharge ports provided on the outer peripheral wall surface of the inner mold downstream, and attaching the resin stock solution to a plurality of long fiber bundles, and a plurality of the resin stock solutions attached A step of joining the long fiber bundles in the resin stock solution impregnation mold or outside, and the inner mold It is arranged downstream of the resin stock solution impregnation mold consisting of the outer mold, and is led to a cylindrical movable molding die that moves in the same direction as the plurality of joined long fiber bundles, and the resin stock solution is foamed and cured And forming a long fiber reinforced resin foam.
[0013]
In a specific aspect of the manufacturing method according to the present invention, the inner mold and / or the outer mold is rotated around the central axis of the outer mold and the inner mold, thereby more reliably opening the long fiber bundle in the fiber opening process. The long fiber bundle is more reliably impregnated with the fine fiber and the foamable resin stock solution.
[0014]
In still another specific aspect of the manufacturing method according to the present invention, the inner mold is rotated in a state where the central axis of the inner mold is inclined with respect to the central axis of the resin-impregnated mold. In this case, the size of the ring-shaped gap changes along the circumferential direction, and the fiber bundles are further opened and the resin stock solution is impregnated more effectively.
[0015]
An apparatus for producing a long fiber reinforced resin foam according to the present invention has an inner mold and a cylindrical outer mold, and a plurality of long fiber bundles are introduced into a ring-shaped gap between the inner mold and the outer mold. The resin stock solution impregnated mold and the resin stock solution impregnated mold are disposed downstream of the resin stock solution impregnated mold so as to move in the same direction at substantially the same speed as the movement speed of the plurality of long fiber bundles to which the resin stock solution is adhered and joined. And a movable molding die having a cylindrical molding space, and an outer peripheral surface of the inner die and / or an inner circumference of the outer die on the upstream portion of the annular gap of the resin stock solution-impregnated die A plurality of annular protrusions for opening in the circumferential direction are formed on the surface, and the foaming resin stock solution is discharged to the outer peripheral surface of the inner mold on the downstream side of the portion where the annular protrusions are provided. The resin stock solution discharge port is formed.
[0016]
On the specific situation with the manufacturing apparatus which concerns on this invention, the rotational drive source for rotating the inner mold | type and / or outer mold | type of the said resin stock solution impregnation type | mold is further provided. Thereby, the long fiber bundle is more reliably opened in the fiber opening process, and the foamable resin stock solution is more reliably impregnated into the long fiber bundle.
[0017]
In still another specific aspect of the manufacturing apparatus according to the present invention, the rotational drive source is turned into an inner mold so that the inner mold is rotated with the central axis of the inner mold tilted with respect to the central axis of the resin stock solution-impregnated mold. It is connected. In this case, the size of the ring-shaped gap changes along the circumferential direction, and the fiber bundles are further opened and the resin stock solution is impregnated more effectively.
[0018]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, specific embodiments of the present invention will be described with reference to the drawings.
With reference to FIGS. 1-3, the manufacturing apparatus and manufacturing method of the fiber reinforced resin molded product which concern on one Embodiment of this invention are demonstrated.
[0019]
The manufacturing apparatus of this embodiment includes a resin stock solution impregnation mold 1 schematically shown in FIG. 3 and a movable mold 2 disposed downstream of the resin stock solution impregnation mold 1.
A plurality of long fiber bundles 3 are supplied to the resin stock solution impregnation mold 1, and a plurality of long fiber bundles impregnated with the thermosetting foamable resin stock solution and impregnated with the resin stock solution in the resin stock solution impregnation die 1. Are merged in the resin stock solution impregnation mold 1 or in the region discharged from the resin stock solution impregnation die 1. Further, a movable metal configured such that a plurality of long fiber bundles impregnated and joined with a resin stock solution can move in the same direction as the plurality of long fiber bundles at the same speed as the plurality of long fiber bundles. Guided into the mold 2. In the movable mold 2, a plurality of long fiber bundles impregnated and joined with the resin stock solution are molded and foamed / cured so as to have a predetermined cross-sectional shape.
[0020]
The resin stock solution impregnation mold 1 will be described with reference to FIGS. 1 and 2. As shown in a longitudinal sectional view in FIG. 1, the resin stock solution-impregnated mold 1 has a cylindrical outer mold 4 and an inner mold 5 disposed in the outer mold 4. In the present embodiment, the outer mold 4 has a substantially cylindrical shape whose diameter decreases as it goes downstream. An annular gap A is formed between the outer mold 4 and the inner mold 5. A plurality of long fiber bundles 3 are guided into the annular gap A. That is, in FIG. 1, a plurality of long fiber bundles 3 are inserted from the upper end side of the annular gap A. For guiding the plurality of long fiber bundles 3 to the gap A, for example, an array plate 151 as shown in FIG. However, a plurality of long fiber bundles 3 may be inserted into the gap A while being uniformly distributed along the circumferential direction of the gap A without using the array plate 151.
[0021]
In the upstream portion of the gap A, an annular protrusion 6 is formed on the outer peripheral surface of the inner mold 5. The annular protrusion 6 is provided in order to reduce the size of the gap A in the portion where the annular protrusion 6 is provided. When passing through the portion where the annular protrusion 6 is provided, a force is applied to the long fiber bundle 3 in a direction perpendicular to the direction in which the long fiber bundle 3 extends, whereby the long fiber bundle 3 is opened. .
[0022]
That is, since the annular protrusion 6 is provided to perform the opening action, the protrusion amount of the annular protrusion 6 is larger than the gap A in the portion where the annular protrusion 6 is provided rather than the diameter of the long fiber bundle 3 to be inserted. Is selected to be small. However, when the inner mold 5 is rotated while the central axis of the inner mold 5 is inclined, the size of the gap A is not necessarily smaller than the diameter of the long fiber bundle 3.
[0023]
In the present embodiment, one annular protrusion 6 is provided on the outer peripheral surface of the inner mold 5, but a plurality of annular protrusions may be provided on the outer peripheral surface of the inner mold 5. Further, an annular protrusion may be provided on the inner peripheral surface of the outer mold 4 instead of the outer peripheral surface of the inner mold 5, and the annular protrusion is provided on both the outer peripheral surface of the inner mold 5 and the inner peripheral surface of the outer mold 4. May be.
[0024]
Next, a plurality of resin stock solution discharge ports 7 are provided on the outer peripheral surface of the inner mold 5 on the downstream side of the portion where the annular protrusion 6 is provided. The resin stock solution discharge ports 7 are uniformly distributed on the outer peripheral surface of the inner mold 5 in the circumferential direction. Further, the plurality of resin stock solution discharge ports 7 are connected to a resin stock solution flow path 8 formed in the inner mold 5. The resin stock solution flow path 8 is formed so as to reach the upper surface of the inner mold 5 and is connected to a resin stock solution injection device disposed outside the inner mold 5. That is, the foamable thermosetting resin stock solution L flows from the resin stock solution injection device into the resin stock solution flow path 8 of the inner mold 5 and is discharged from the resin stock solution discharge port 7.
[0025]
The resin stock solution flow path 8 includes a vertical flow path portion 8a extending downward from the upper surface of the inner mold 5 and a horizontal flow path portion 8b extending horizontally from the lower end of the vertical flow path portion 8a and leading to the resin stock solution discharge port 7. Have Therefore, the resin stock solution L is discharged from the resin stock solution discharge port 7 toward the radially outer side of the inner mold 5.
[0026]
Therefore, the foamable thermosetting resin stock solution L is discharged and impregnated into the long fiber bundle 3 opened by passing through the portion where the annular protrusions 6 are formed. In this case, neither the inner mold 5 nor the outer mold 4 is formed with the resin stock solution reservoir, so that the foamable thermosetting resin stock solution L is hardly deposited in the gap A.
[0027]
On the downstream side of the portion where the resin stock solution discharge port 7 is provided, the outer diameter of the inner mold 5 and the inner diameter of the outer mold 4, that is, the diameter of the ring-shaped gap gradually decrease toward the downstream. It is configured. Accordingly, the plurality of long fiber bundles 3 impregnated with the foamable thermosetting resin stock solution L are brought closer to each other toward the downstream side. In the present embodiment, a plurality of adjacent long fiber bundles 3 are discharged from the resin stock solution impregnation mold 1 and then merged as shown in FIG. 1 to form a long fiber bundle 3A. A plurality of long fiber bundles 3 may be joined in the resin stock solution impregnation mold. Further, the diameter of the annular gap in the resin stock solution impregnation mold does not necessarily have to be reduced toward the downstream side, and may be cylindrical. In that case, what is necessary is just to make a long fiber bundle adjoin and merge outside an impregnation type | mold.
[0028]
Since the resin stock solution L is discharged from the resin stock solution discharge port 7, it does not stay on the outer peripheral surface of the inner mold 5 and the inner peripheral surface of the outer mold 4, but is impregnated into the long fiber bundle 3 and downstream with the long fiber bundle 3. Move to the side.
[0029]
FIG. 4 shows the details of the movable mold 2 for foam-molding the long fiber bundle 3A obtained as described above. A movable mold 2 including a plurality of endless belts 11 is disposed downstream of the resin stock solution impregnation mold 1. In the movable mold 2, a molding space having a rectangular cross section is constituted by a plurality of endless belts 11 so that a finally obtained molded body has a rectangular cross section. The endless belt 11 is provided to constitute the molding space, and the fiber reinforced resin molded product 13 finally obtained by the take-up machine 12 disposed downstream of the movable mold 2 is used as the endless belt 11. It is moved at approximately the same speed as the take-off speed.
[0030]
The movable mold 2 is heated by a heating source (not shown). Therefore, when the long fiber bundle 3A passes through the movable mold 2, the foamable thermosetting resin stock solution impregnated in the long fiber bundle is foamed. Then, it is cured and molded so as to have a cross-sectional shape of a molding space constituted by the endless belt 11. As a result, a fiber-reinforced resin molded product 13 having a rectangular cross section is obtained and taken up by the take-up machine 12.
[0031]
As described above, in the manufacturing apparatus and the manufacturing method of the present embodiment, the long fiber bundle is reliably opened by providing the annular protrusion 6 in the impregnation mold 1. Therefore, when the foamable thermosetting resin stock solution L is discharged from the resin stock solution discharge port 7, the long fiber bundle is reliably impregnated with the resin stock solution. Further, since the resin stock solution L is discharged from the resin stock solution discharge port toward the radially outer side of the cross section of the inner mold 5, the resin stock solution L is stagnated on the outer peripheral surface of the inner mold 5 and the inner peripheral surface of the outer mold 4. It is hard to collect. Therefore, since the foamable thermosetting resin is difficult to deposit, continuous operation can be performed for a long period of time.
[0032]
5 and 6 are schematic partially cutaway sectional perspective views for explaining the main part of the present embodiment and schematic sectional views taken along the line BB in FIG. 5 except that the long fiber bundle 3 is omitted. is there. For easy understanding, the inner mold 5 is schematically shown in a vertically divided state.
[0033]
In the manufacturing apparatus of this embodiment, the rotational drive source 21 of the inner mold 5 is connected. As shown in the figure, the rotational drive source 21 is rotated with a larger diameter at the upper end compared to the lower end of the inner mold 5 with the central axis of the inner mold 5 inclined with respect to the central axis of the impregnation mold 1. It is configured. In this way, by rotating the inner mold 5, as shown in a schematic cross-sectional view in FIG. 6, a portion where the size of the gap A becomes thinner moves in the circumferential direction. Therefore, a greater opening effect is exhibited. Further, since the long fiber bundle impregnated with the resin stock solution L is swallowed, the resin stock solution L can be more reliably impregnated into the long fiber bundle 3A.
[0034]
In the apparatus shown in FIG. 5, the inner mold 5 is rotated in a state where the central axis of the inner mold 5 is inclined with respect to the central axis of the impregnation mold 1 by the rotation drive source 21. It may be rotated around the central axis of the impregnation mold 1, and even in that case, by the rotation of the inner mold 5, the opening effect by the annular protrusion 6 and the long fiber bundle impregnated with the resin stock solution are swallowed. An impregnation effect is obtained. However, it is preferable to rotate the inner mold 5 with the central axis of the inner mold 5 tilted as described above.
[0035]
Moreover, in the said embodiment, although the inner mold | type 5 was rotated, it is not necessary to rotate either the inner mold | type 5 and the outer mold | type 4, and even in that case, a long fiber bundle is opened by presence of the annular protrusion 6. The effects of the present invention can be obtained.
[0036]
In the above embodiment, the inner mold 5 is connected to the rotation drive source 21 and rotated. Conversely, the outer mold 4 is connected to the rotation drive source, the inner mold is fixed, and the outer mold 4 is rotated. Alternatively, both the inner mold 5 and the outer mold 4 may be rotated in the circumferential direction or the reverse direction. When the inner mold 5 and the outer mold 4 are rotated while being inclined from the central axis of the impregnation mold 1, the portion where the space ratio of the gap A is the smallest is 10% or more, and the portion having the highest space ratio is 90%. % Should not be exceeded. The space ratio is a ratio of the volume excluding the total accumulation of the long fiber bundles inserted from the accumulation of the gap A and the accumulation of the discharged foamable thermosetting resin stock solution to the accumulation of the gap A. Say it.
[0037]
Further, when the inner side 5 or the outer die 4 is tilted from the central axis of the impregnation die 1 and rotated, the above-mentioned space factor means an average space factor in a cross section perpendicular to the extending direction of the long fiber bundle.
[0038]
Preferably, the cross-sectional area of the gap A is configured to become smaller toward the downstream side downstream of the resin stock solution discharge port. As a result, the flow of the resin stock solution toward the outlet side of the impregnation mold 1 can be suppressed. Therefore, the resin stock solution discharge port is provided so that the cross-sectional area of the gap A at the outlet of the impregnation mold 1 is 25 to 95% of the cross-sectional area of the gap A in the portion where the resin stock solution discharge port is provided. It is desirable that the sectional view of the gap A gradually decreases from the portion toward the downstream. However, at the outlet of the impregnation mold 1, if the average space ratio of the cross section perpendicular to the fiber direction of the long fiber bundle 3 is less than 0, the resin may flow back upstream. Therefore, at the outlet of the impregnation mold 1, it is desirable that the space ratio does not fall below zero.
[0039]
The annular protrusion 6 is provided to open the long fiber bundle. Accordingly, it is desirable that the annular protrusion 6 is configured such that the space ratio in the gap A is 5% or less. Further, when the inner mold 5 or the outer mold 4 is eccentrically rotated, it is desirable that the annular protrusion 6 is configured so that the space ratio in the portion where the gap A is the thinnest is 5% or less.
[0040]
However, in the portion where the annular protrusion 6 is provided, it is necessary that the accumulation of the annular protrusion 6 is not included in the accumulation of the gap A when determining the space ratio.
The material constituting the annular protrusion 6 is not particularly limited, and may be made of the same material as the inner mold 5 or the outer mold 4. However, in order to exhibit the fiber opening effect more effectively, it is preferable that the annular protrusion 6 is made of a material having excellent friction such as natural rubber or elastomer. Also, the shape of the annular protrusion 6 can be various shapes such as a lattice shape depending on the type of the long fiber bundle.
[0041]
The space ratio of the gap A in the portion where the resin stock solution discharge port 7 is provided is 0 to 40%. When the inner mold 5 or the outer mold 4 is inclined and rotated from the central axis of the impregnation mold 1 as described above, 0 to 80% is preferable.
[0042]
The rotational speed when rotating the inner mold 5 or the outer mold 4 varies depending on the shape and size of the annular protrusion 6, the type of the long fiber bundle 3 and the foamable resin stock solution, and is preferably about 10 to 600 rpm. .
[0043]
The discharge rate of the resin stock solution from the resin stock solution discharge port 7 is not particularly limited as long as the long-fiber bundle 3 can be reliably impregnated with the resin stock solution, but preferably a method of increasing the discharge rate and reliably impregnating, or the resin stock solution A method of reducing the thickness of the gap A in the portion where the discharge port 7 is provided and providing a large number of resin stock solution discharge ports is suitably provided. In the former case, the resin stock solution discharge speed may be about 5 to 200 m / second, and in the latter case, it may be about 0.3 to 200 m / second.
[0044]
The movable mold 2 is not limited to the one using the endless belt 11 but may be one using a slat. Further, the heating device is not necessarily provided in the movable mold 2. That is, foaming and curing may be performed by the amount of heat held by the molten resin stock solution.
[0045]
In addition, as the foamable thermosetting resin stock solution used in the present invention, an appropriate foamable thermosetting resin stock solution containing a thermosetting resin and a foaming agent that are liquid before the reaction can be used. For example, thermosetting resins such as urethane resins, unsaturated polyester resins, epoxy resins, diallyl phthalate resins, phenol resins, etc. can be used, and well-known thermal decomposition type foaming agents should be used as foaming agents. Can do. However, when the viscosity of the foamable thermosetting resin stock solution is too high, it is difficult to impregnate the long fiber bundle. Therefore, the viscosity of the foamable thermosetting resin stock solution is preferably 10,000 cps or less, more preferably 3000 cps or less at the temperature at the time of impregnation. It is.
[0046]
The long fiber bundle used in the present invention is not particularly limited, and a bundle of various fibers such as monofilaments, fibrils (fibers protruding in a hook shape), and woven yarns are used. Moreover, as for the material of the long fiber bundle constituting the long fiber bundle, appropriate materials such as glass, carbon, and organic fiber are used. Preferably, a fiber made of glass or carbon is suitable for enhancing the reinforcing effect.
[0047]
Next, specific examples will be described.
[0048]
Example 1
As a long fiber bundle, twisted and weakly wound E glass fiber of 13800 count was used (Central Glass Co., Ltd., glass roving ERS13800-811).
Moreover, the following materials were prepared as foaming resin stock solution so that it might become the following assembly formulas.
[0049]
(1) Polyol premix solution
Made by Sumika Bayern, product number: Sumifen 1703 ... 100 parts by weight
Made by Toray Dow Silicone Co., Ltd., product number: SRX295 ... 2 parts by weight
Sansha Co., Ltd., product number: SCAT-31A 0.175 parts by weight
Water: 0.6 parts by weight
[0050]
(2) MDI
Product number: Sumidur 44v20 manufactured by Sumika Bayern
[0051]
A resin stock solution-impregnated mold having the same configuration as that of the impregnation mold 1 of the embodiment shown in FIG. 1 and having the inner and outer molds as shown in FIGS. 7 and 8 was used. 300 long fiber bundles were fed into the resin stock solution impregnated mold, and a foamable thermosetting resin stock solution prepared by mixing the MDI and the premix solution at a weight ratio of 1.1 to 1 was injected by an injector. . The inner mold 5 was rotated at 300 rpm and its central axis was tilted from the central axis of the resin stock solution-impregnated mold 1. The long fiber bundle and the resin stock solution are supplied into the resin stock solution impregnation mold 1 so that the weight ratio is 1: 1, taken up at a speed of 3 m / min, and disposed downstream of the resin stock solution impregnation die 1. Foaming / curing molding was performed with a movable mold set at a temperature of 0 ° C., and a long fiber bundle reinforced resin molded product having a rectangular cross section of 200 mm width × 56 mm thickness and a specific gravity of 0.74 was obtained.
[0052]
(Example 2)
Except that the dimensions of the inner and outer molds of the resin stock solution impregnation mold were changed to FIGS. 9 and 10, and the inner mold 5 was rotated around the central axis of the impregnation mold 1. Molding was performed.
[0053]
Example 3
Molding was performed in the same manner as in Example 1 except that the supply ratio of the resin stock solution and the long fiber bundle was changed to 8 to 2 in terms of weight ratio.
[0054]
(Comparative example)
As shown in FIGS. 11 to 12, molding was performed in the same manner as in Example 1 except that an impregnation mold without an annular protrusion was used on the inner mold and the inner mold was not rotated. .
[0055]
A test piece having a width of 25 mm, a thickness of 28 mm, and a length of 50 mm was cut from each molded body obtained in Examples 1 to 3 and Comparative Example, and the specific gravity distribution in the cross-sectional direction of the molded body was measured. The results are shown in Table 1 below.
[0056]
[Table 1]

As is clear from Table 1, in the molded product obtained in the comparative example, the specific gravity distribution is 0.74 ± 0.18, whereas in Examples 1 to 3, the specific gravity distribution is narrower than this, In particular, in Examples 1 and 3 in which the inner mold is rotated while being tilted from the central axis of the impregnation mold 1, it can be seen that the unevenness of the specific gravity distribution range is further reduced. In Examples 1 to 3, even when continuous operation was performed for 3 days or more, it was not necessary to stop the operation by depositing a thermosetting resin.
[0057]
【The invention's effect】
In the production method according to the present invention, since the resin stock solution is discharged from the resin stock solution discharge port toward the radially outer side in the resin stock solution impregnation mold, it is not necessary to provide a resin stock solution reservoir in the inner mold and the outer mold. The foamable thermosetting resin stock solution is less likely to stay in the resin stock solution-impregnated mold. Therefore, continuous operation can be performed over a long period of time, and the productivity of the long fiber reinforced resin foam can be increased. In addition, an annular protrusion is formed on at least one of the outer peripheral surface of the inner mold and the inner peripheral surface of the outer mold on the upstream side of the resin stock solution discharge port, whereby the long fiber bundle passes through the annular protrusion. Opened. Therefore, it is possible to surely obtain a long fiber reinforced resin foam in which the long fiber bundle with the resin stock solution spread is reliably impregnated and the long fiber bundle is uniformly dispersed.
[0058]
In the method and apparatus for producing a fiber-reinforced resin molded product according to the present invention, the foamable thermosetting resin stock solution is discharged radially outward from the discharge port. You may arrange | position in a direction and may arrange | position in a horizontal direction. Therefore, the manufacturing space of the long fiber reinforced resin foam can be reduced.
[Brief description of the drawings]
FIG. 1 is a longitudinal sectional view showing a tool of an apparatus for producing a long fiber reinforced resin foam according to an embodiment of the present invention.
2 is a schematic cross-sectional view taken along line XX of FIG.
FIG. 3 is a schematic configuration diagram of an apparatus for producing a long fiber reinforced resin foam according to an embodiment of the present invention.
FIG. 4 is a schematic perspective view for explaining a movable mold used in one embodiment of the present invention.
FIG. 5 is a schematic partial cross-sectional perspective view for explaining a method for rotating a resin stock solution-impregnated inner mold of a long fiber reinforced resin foam according to an embodiment of the present invention.
6 is a schematic cross-sectional view of a portion along line BB in FIG.
7 is a longitudinal sectional view showing an inner mold used in Example 1. FIG.
8 is a longitudinal sectional view showing a resin stock solution impregnation mold used in Example 1. FIG.
9 is a longitudinal sectional view showing an inner mold used in Example 2. FIG.
10 is a longitudinal sectional view for explaining a resin stock solution-impregnated mold used in Example 2. FIG.
FIG. 11 is a longitudinal sectional view showing an inner mold used in a comparative example.
FIG. 12 is a longitudinal sectional view for explaining a resin stock solution-impregnated mold used in a comparative example.
FIG. 13 is a longitudinal sectional view showing a main part of a conventional apparatus for producing a fiber-reinforced resin molded product.
FIG. 14 is a plan view showing an array plate used in a conventional apparatus for producing a fiber-reinforced resin molded product.
[Explanation of symbols]
1 ... Resin stock solution impregnation type
2 ... Moveable mold
3 ... Long fiber bundle
3A ... long fiber bundles joined together
4 ... Outer mold
5 ... Inner type
6 ... Annular projection
7. Resin stock solution outlet
8 ... Resin stock solution flow path
11 ... Endless belt
12 ... take-up machine
13 ... Fiber-reinforced resin molded product
21 ... Rotation drive source

Claims (6)

A method for producing a fiber reinforced resin molded article by impregnating a plurality of long fiber bundles with a thermosetting foamed resin stock solution, bundling the plurality of long fiber bundles, and foaming and curing the bundle.
Introducing a plurality of long fiber bundles into a ring-shaped gap formed between a resin stock solution-impregnated inner mold and a cylindrical outer mold, and arranging the plurality of long fiber bundles in a ring shape;
An annular protrusion extending in the circumferential direction is formed on the outer peripheral surface of the inner mold and / or the inner peripheral surface of the outer mold, and the step of opening the long fiber bundle with the annular protrusion;
A step of discharging the resin stock solution from a plurality of resin stock solution discharge ports provided on the outer peripheral wall surface of the inner mold downstream of the annular protrusion, and attaching the resin stock solution to the plurality of long fiber bundles;
A step of merging a plurality of long fiber bundles to which the resin stock solution is adhered in or outside the resin stock solution impregnation mold; and
The resin stock solution is arranged downstream of the resin stock solution impregnated mold composed of the inner mold and the outer mold, and is guided to a cylindrical movable molding mold that is moved in the same direction as the plurality of joined long fiber bundles. And a step of molding a long fiber reinforced resin foam, and a method for producing a fiber reinforced resin molded article. The method for producing a fiber-reinforced resin molded article according to claim 1, wherein the inner mold and / or the outer mold is rotated around a central axis of the resin stock solution-impregnated mold. The method for producing a fiber-reinforced resin molded article according to claim 2, wherein the inner mold is rotated in a state in which the central axis of the inner mold is inclined with respect to the central axis of the resin-impregnated mold. An apparatus for manufacturing a fiber reinforced resin molded article by impregnating and joining a plurality of long fiber bundles with a thermosetting foamable resin stock solution, joining them, and then foaming and curing the thermosetting foamable resin stock solution. ,
A resin stock solution-impregnated mold having an inner mold and a cylindrical outer mold, in which a plurality of long fiber bundles are guided into a ring-shaped gap between the inner mold and the outer mold;
Arranged downstream of the resin stock solution impregnation mold, configured to move in the same direction at substantially the same speed as the movement speed of the plurality of long fiber bundles to which the resin stock solution is adhered and joined, and A movable mold having a cylindrical molding space;
An annular protrusion for opening in the circumferential direction is formed on the outer peripheral surface of the inner mold and / or the inner peripheral surface of the outer mold on the upstream portion of the annular gap of the resin stock solution-impregnated mold,
Long fiber reinforcement characterized in that a plurality of resin stock solution discharge ports for discharging a foamable resin stock solution are formed on the outer peripheral surface of the inner mold on the downstream side of the portion where the annular protrusion is provided. Production equipment for resin foam. The apparatus for producing a long fiber reinforced resin foam according to claim 4, further comprising a rotation drive source for rotating the inner mold and / or the outer mold of the resin stock solution-impregnated mold. 6. The rotary drive source is connected to the inner mold so that the inner mold is rotated with the central axis of the inner mold inclined with respect to the central axis of the resin stock solution-impregnated mold. Manufacturing equipment for long fiber reinforced resin foam.

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