JP4187806B2 - Method for producing granular thermosetting resin molding material - Google Patents
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Description
【発明の属する技術分野】
【0001】
本発明は粒状熱硬化性樹脂成形材料に関する。特に、粉塵の発生が少なく、計量性に優れ、射出成形などの成形加工性に優れた粒状の熱硬化性樹脂成形材料、及びその製造方法に関する。
【従来の技術】
【0002】
熱硬化性樹脂、例えばフェノール系樹脂の成形材料は、機械的強度等の特性、電気的性質、耐熱性等に優れており、従来から、自動車、電気、機械、或いは一般成形品の分野などの幅広い産業分野における樹脂製品に用いられている。このような製品に用いられる原材料としてのフェノール系樹脂成形材料(熱硬化性樹脂成形材料)は、原料樹脂に、ガラス繊維、炭素繊維、木粉、布チップ等の補強材、充填材、硬化剤、離型剤、着色剤等を配合した配合物を混合し、混練ロール、ニーダ又はスクリュ押出機などの混練装置で混練し、この混練物を粉砕あるいはペレット化等を行うことによって製造されたものである。
【0003】
そのようなフェノール系樹脂成形材料の製造方法として、上記のような配合物を混練してなる混練物を押出機に取り付けたダイスから押出し、そして押出されたストランドをカッタによって所定の長さに切断し、粒状物とする押出造粒方法が知られている。例えば、特開平3−246011号公報では、熱硬化性樹脂及びガラス繊維を主配合成分とする材料を混合し、これを押出機で押出造粒するフェノール系樹脂成形材料の製造方法が提案されている。特開平6−192435号公報では、ガラス繊維を必須成分として含有するフェノール樹脂成形材料配合物に、水を添加して混練し、押出造粒するフェノール系樹脂成形材料の製造方法が提案されている。特開平7−80829号や特開平7−80830号公報では、フェノール樹脂に特定の長さのチョップドストランドガラス繊維および溶剤を添加し、高速ミキサで混練した後、特定のL/Dを有する押出機で押出造粒するフェノール系樹脂成形材料の製造方法が提案されている。
上記のような押出造粒方法は、押出機に取り付けられたダイスから押出されたストランドをカッタで所定の長さに切断して粒状物とするものである。ところが、対象となっているものが熱硬化性樹脂材料であるが故に、押出機のダイスには目詰まりが起き易い。そして、熱硬化性樹脂を対象としているが故に、目詰まりが、一度、起きると、その回復作業が非常に厄介で、生産性は悪い。更には、ガラス繊維などに細断が起き易く、成形品の物性低下が引き起こされる。
【0004】
又、上記のような配合物をヘンシェルミキサのような高速攪拌混合機で粒状化する造粒方法が知られている。例えば、特開平2−169206号では、ミキシングロール又は押出混練機等により混練後粉砕したフェノール樹脂成形材料に沸点100℃以下の低沸点溶剤を添加して高速攪拌混合機で造粒するフェノール系樹脂成形材料の製造方法が提案されている。
しかしながら、ヘンシェルミキサのような高速攪拌混合機による粒状化は、ガラス繊維などが細断され易く、機械的強度の低下などの物性に悪影響を与える。又、微粉が付き易い問題も有る。
【0005】
又、上記のような配合物を加熱下で加圧ニーダ等により混練し、そしてシート状あるいはストランド状とし、これを乾燥した後、粉砕機などで粉砕し、そして篩分けして粒状物とする方法も有る。
しかしながら、この方法は、得られる粒子の形状が不揃いなことを意味しており、このことは射出成形などの場合には、計量性が悪く、成形加工性に大きな問題を引き起こす。尚、粒状物の形状を揃えようとして篩分けを厳密にしようとすると、生産性が極度に低下する。
又、上記方法は、シートを粉砕して粒状物とする際に、微粉が発生して粒状物表面に付着し易い問題が有る。尚、この微粉末が混じっていると、これを用いて成形するに際して、粒状物と微粉末とでは溶融温度が大きく異なる為に、成形品の品質劣化が大きく、好ましいものではない。かつ、微粉の発生は、環境汚染を招き、又、生産性も低下させる。更に、使用時にも微粉が飛散する恐れが有り、取扱上も好ましく無い。
【発明が解決しようする課題】
【0006】
従って、本発明が解決しようとする課題は、前記の従来技術が抱える問題点を解決することである。
【0007】
すなわち、本発明が解決しようとする第1の課題は、押出機を用いないで、フェノール系樹脂成形材料や不飽和ポリエステル樹脂成形材料などの粒状熱硬化性樹脂成形材料を製造できる技術を提供することである。すなわち、ダイス目詰まりの問題が起きず、生産性の難点とか、ガラス繊維などに細断が起きることから成形品の物性低下と言った問題が起き難い技術を提供することである。
【0008】
本発明が解決しようとする第2の課題は、ヘンシェルミキサのような高速攪拌混合機を用いないで、粒状熱硬化性樹脂成形材料を製造できる技術を提供することである。すなわち、ヘンシェルミキサのような高速攪拌混合機を用いないで済むことから、ガラス繊維などが細断され難く、成形品の物性低下と言った問題が起き難い技術を提供することである。
【0009】
本発明が解決しようとする第3の課題は、粉砕機を用いないで、粒状熱硬化性樹脂成形材料を製造できる技術を提供することである。すなわち、粉砕機を用いないことから、得られる粒子の形状は揃っており、従って計量性が良く、成形加工性が良くなり、かつ、生産性も良く、更には微粉が発生し難く、そして粒状物表面に付着する等して混じり込むことが少なく、成形品の品質劣化が起き難く、成形加工性の低下の恐れも改善される射出成形用材料として好適な粒状熱硬化性樹脂成形材料を提供することである。
【課題を解決するための手段】
【0010】
前記の課題を解決する為、本発明者は、粉塵の発生が少ない粒状熱硬化性樹脂成形材料の製造方法について種々検討を重ねた。その結果、これまでの高速攪拌混合機による方法や押出造粒方法とは全く異なり、しかしながら極めて簡単な手法に気付くに至った。しかも、この手法によれば、均質な形状を有し、かつ、粉塵の発生が少ない粒状の熱硬化性樹脂成形材料が得られるものであった。
【0011】
すなわち、前記の課題は、フェノール系樹脂または不飽和ポリエステル樹脂に、ガラス繊維、充填材、硬化剤、離型剤、着色剤を添加し、混合、混練する混練工程と、
前記混練工程で得られた混練物を、加熱ロールにより、1〜5mm厚のシート状物にするシート化工程と、
前記シート化工程で得られたシート状物を45〜55℃の温度に制御し、該温度制御されたシート状物を30℃以下の温度に制御された裁断刃によって1〜5mm幅の紐状物に裁断する裁断工程と、
前記裁断工程で得られた紐状物を45〜55℃の温度に制御し、該温度制御された紐状物を30℃以下の温度に制御された切断刃によって1〜5mm長の粒状物に切断する切断工程
とを具備することを特徴とする粒状熱硬化性樹脂成形材料の製造方法によって解決される。
【0013】
本発明は、押出機やヘンシェルミキサのような高速攪拌混合機や破砕機を用いないで済むことから、これらの装置を用いて粒状熱硬化性樹脂成形材料を製造する場合に起きていた諸々の問題が解決される。すなわち、ダイス目詰まりの問題や、生産性低下の問題や、ガラス繊維細断による成形品の物性低下の問題が改善される。更には、微粉発生の問題が起き難く、粒状熱硬化性樹脂成形材料中に微粉が混入している場合に起きる成形時の溶融温度のバラツキに起因した成形加工性の低下や成形品の品質低下の問題が改善される。
更には、例えば加熱ロールによるシート化、そしてこれを裁断・切断するのみであるから、極めて簡単に得られる。
【0015】
又、前記の課題は、上記粒状熱硬化性樹脂成形材料の製造方法によって得られてなることを特徴とする粒状熱硬化性樹脂成形材料によって解決される。
【発明の実施の形態】
【0016】
本発明の粒状熱硬化性樹脂成形材料の製造方法は、熱硬化性樹脂に充填材、補強剤、硬化剤、その他添加剤を添加し、混合、混練する混練工程と、前記混練工程で得られた混練物をシート状物にするシート化工程と、前記シート化工程で得られたシート状物を紐状物に裁断する裁断工程と、前記裁断工程で得られた紐状物を所定の長さに切断して粒状物にする切断工程とを具備する。裁断工程におけるシート状物の温度は25〜100℃に制御される。裁断刃の温度は85℃以下の温度に制御される。切断工程における紐状物の温度は25〜100℃に制御される。切断刃の温度は85℃以下の温度に制御される。シート状物の厚さは1〜5mmであり、裁断幅は1〜5mmであり、切断長さは1〜5mmである。特に、熱硬化性樹脂に充填材、補強剤、硬化剤、その他添加剤を添加し、混合、混練した後、該混練物を1〜5mmの厚さにシート化し、該シートを幅1〜5mmの紐状に裁断し、該紐状物を1〜5mmの長さに切断する方法である。又、熱硬化性樹脂に充填材、補強剤、硬化剤、その他添加剤を添加し、混合、混練した後、加熱ロールで厚さ1〜5mmのシート状とし、該シートを幅1〜5mmの紐状に裁断すると共に紐状物の長手方向に対して直角方向に長さ1〜5mmに切断する方法である。又、粉末状または液状のフェノール系樹脂あるいは不飽和ポリエステル樹脂等に充填材、補強剤、硬化剤、その他の添加剤を添加・混合し、混練後、1〜5mmの厚さにシート化し、該シートを幅1〜5mmの紐状に裁断し、該紐状物を1〜5mmの長さに切断する方法である。又、粉末状または液状のフェノール樹脂あるいは不飽和ポリエステル樹脂などの熱硬化性樹脂に充填材、補強剤、硬化剤、その他の添加剤を添加・混合し、混練後、加熱ロールで1〜5mmの厚さのシート状とし、該シートを回転刃を備えた裁断装置で連続的に幅1〜5mmの紐状に裁断すると共に該紐状物の長手方向に対して垂直方向に長さ1〜5mmに切断する方法である。
【0017】
以下に詳細に説明する。
本発明において、シート状物を裁断や切断する際、シート状物の温度と裁断刃や切断刃の温度とを一定の温度範囲に制御して裁断や切断することが好ましい。この際のシート状物の温度は、使用される樹脂の性状、補強材、充填材、その他の添加剤の種類や量により設定されるが、一般的には、常温(通常、25℃程度)〜100℃の範囲に設定されることが好ましい。更に好ましくは45〜55℃である。裁断刃や切断刃の温度は、一般的には85℃以下の温度に設定されることが好ましい。更に好ましくは30℃以下の温度である。すなわち、シート状物の温度が上記の温度範囲より低すぎる場合は、切断や裁断時に微粉が大量に発生し易く、逆に、高すぎる場合は、切断刃や裁断刃にシートが付着し易くなり、良好な切断・裁断が行われ難い。かつ、裁断・切断後の物同士が付着する恐れが有り、生産性が低下する。裁断刃や切断刃の温度が上記の温度範囲よりも高すぎる場合は、裁断刃や切断刃にシートが付着し易くなり、良好な切断が行われ難く、生産性が低下する。
【0018】
尚、本発明のシート状物を裁断・切断して得られた方形粒状物を、例えばマルメライザのような整粒機により処理することも良い。このような場合には、方形状の鋭角な角部がやや丸められ、作業性、計量性が良好になり、又、取扱中の微粉の発生が抑制される。
【0019】
本発明の粒状熱硬化性樹脂成形材料の形状は、通常、厚さ1〜5mm、幅1〜5mm、長さ1〜5mmの範囲のほぼ直方体である。このものは、射出成形における計量性に優れている。更に好ましくは厚さ2〜3mm、幅2〜3mm、長さ2〜3mmである。すなわち、このような場合には、より安定した計量が行え、連続射出成形をより効率的に実施できる。粒状熱硬化性樹脂成形材料の形状を上記の範囲内にするには、裁断刃や切断刃の形状、裁断刃や切断刃の間隔、裁断・切断温度などの調整により可能である。
【0020】
本発明における熱硬化性樹脂は、ノボラック型あるいはレゾール型フェノール系樹脂、不飽和ポリエステル樹脂、ジアリールフタレート樹脂などが例示される。これらの樹脂は成形材料用に使用される合成樹脂であり、固形状あるいは液状いずれでも使用されるが、他の充填材、補強材やその他の添加剤と混合する際の分散性が良好な固形状(粉末状)のものが好ましい。
本発明に使用される切断刃や裁断刃を備えた装置は、シートを連続的に切断および裁断することが出来る装置が使用できる。例えば、回転刃を備えた市販のシートペレタイザなどの装置が使用される。
以下、本発明を実施例により具体的に説明する。尚、「部」は重量部を表す。
【実施例】
【0021】
[実施例1]
粉末状フェノール樹脂100部にガラス繊維(繊維長:6mm、径:13μm)70部、炭酸カルシウム70部、硬化剤(ヘキサメチレンテトラミン)15部、その他の添加剤(離型剤、着色剤)を所望量配合し、混練機により加熱下で混練し、そして50℃の加熱ロールで厚さ3mm、幅300mmのシートを作製した。
このシートを、シート温度55℃で、刃の間隔を3mmに設定した円盤状の回転刃で3mm幅の紐状に裁断した。そして、紐状物をロタリーカッタで長さ3mmに切断した。尚、裁断刃やロータリーカッタの刃は25℃に制御された。
このようにして製造されたフェノール樹脂成形材料は、縦3mm、横3mm、高さ3mmの直方体形状であった。そして、この粒状フェノール樹脂成形材料は、微粉の発生が少なくて取扱い易く、又、射出成形時の計量バラツキは殆ど無く、更には成形加工性が良好で、良好な成形品が得られた。
【0022】
[実施例2]
実施例1において、シート温度を53℃、刃の間隔を4mmに設定して4mm幅の紐状に裁断し、そして該紐状物をロタリーカッタで長さ5mmに切断し、3mm×4mm×5mmの直方体形状のフェノール樹脂成形材料を得た。
この粒状フェノール樹脂成形材料は、微粉の発生が少なくて取扱い易く、又、射出成形時の計量バラツキは殆ど無く、更には成形加工性が良好で、良好な成形品が得られた。
【0023】
[実施例3]
不飽和ポリエステル樹脂100部に、ガラス繊維80部、充填材(炭酸カルシウム)150部、及びジアリルフタレートプレポリマ30部、その他の添加剤を配合・混合し、加熱下で混練し、そして50℃の加熱ロールで厚さ3mm、幅300mmのシートを作製した。
このシートを、シート温度52℃で、刃の間隔を3mmに設定した円盤状の回転刃で3mm幅の紐状に裁断した。そして、該紐状物をロタリーカッタで長さ3mmに切断した。尚、裁断刃やロータリーカッタの刃は25℃に制御された。
このようにして製造された不飽和ポリエステル樹脂成形材料は、縦3mm、横3mm、高さ3mmの直方体形状であった。そして、この粒状不飽和ポリエステル樹脂成形材料は、微粉の発生が少なくて取扱い易く、又、射出成形時の計量バラツキは殆ど無く、更には成形加工性が良好で、良好な成形品が得られた。
【0024】
[比較例1]
実施例1と同様な配合物を混練してシートを得、このシートを室温まで冷却した後、3mmのスクリーンを備えた衝撃式粉砕機で粉砕し、顆粒状フェノール樹脂成形材料を得た。
このようにして得られた顆粒状フェノール樹脂成形材料は、取扱時に微粉の発生が多く、取扱い難く、かつ、射出成形時の計量バラツキが大きく、良好な成形加工が出来ないものであった。
【0025】
[比較例2]
実施例3と同様な配合物を混練してシートを得、このシートを室温まで冷却した後、3mmのスクリーンを備えた衝撃式粉砕機で粉砕し、不飽和ポリエステル樹脂成形材料を得た。
このようにして得られた不飽和ポリエステル樹脂成形材料は、取扱時に微粉の発生が多く、取扱い難く、かつ、射出成形時の計量バラツキが大きく、良好な成形加工が出来ないものであった。
【発明の効果】
【0026】
本発明の粒状熱硬化性樹脂成形材料は、粉塵の発生を殆ど伴わず、生産性が良く、しかも取扱い易い。そして、この粒状物は形状が均質で、計量性が良好であり、射出成形用材料として好適な成形材料である。BACKGROUND OF THE INVENTION
[0001]
The present invention relates to a granular thermosetting resin molding material. In particular, the present invention relates to a granular thermosetting resin molding material that generates less dust, has excellent meterability, and has excellent molding processability such as injection molding, and a manufacturing method thereof.
[Prior art]
[0002]
Thermosetting resins, such as phenolic resin molding materials, are excellent in properties such as mechanical strength, electrical properties, heat resistance, etc., and have been conventionally used in the fields of automobiles, electricity, machinery, or general molded products. Used for resin products in a wide range of industrial fields. The phenolic resin molding material (thermosetting resin molding material) used as a raw material for such products is made of raw material resin, reinforcing material such as glass fiber, carbon fiber, wood powder, cloth chip, filler, curing agent. , Manufactured by mixing a mixture containing a release agent, a colorant, etc., kneading with a kneading apparatus such as a kneading roll, kneader or screw extruder, and pulverizing or pelletizing the kneaded product It is.
[0003]
As a method for producing such a phenolic resin molding material, a kneaded product obtained by kneading the above compound is extruded from a die attached to an extruder, and the extruded strand is cut into a predetermined length by a cutter. However, an extrusion granulation method for forming a granular material is known. For example, Japanese Patent Laid-Open No. 3-246011 proposes a method for producing a phenol-based resin molding material in which materials containing a thermosetting resin and glass fiber as main blending components are mixed and extruded and granulated with an extruder. Yes. Japanese Patent Laid-Open No. 6-192435 proposes a method for producing a phenolic resin molding material in which water is added to a phenolic resin molding material composition containing glass fiber as an essential component, kneaded, and extrusion granulated. . In JP-A-7-80829 and JP-A-7-80830, an extruder having a specific L / D after adding a chopped strand glass fiber of a specific length and a solvent to a phenol resin, kneading with a high-speed mixer A method for producing a phenolic resin molding material by extrusion granulation has been proposed.
In the extrusion granulation method as described above, a strand extruded from a die attached to an extruder is cut into a predetermined length with a cutter to form a granular material. However, since the target is a thermosetting resin material, the extruder die is likely to be clogged. And since it is intended for thermosetting resins, once clogging occurs, the recovery operation is very troublesome and productivity is poor. Furthermore, shredding is likely to occur in glass fibers and the like, resulting in a decrease in physical properties of the molded product.
[0004]
In addition, a granulation method is known in which the above-mentioned compound is granulated with a high-speed stirring mixer such as a Henschel mixer. For example, in JP-A-2-169206, a phenolic resin that is granulated with a high-speed stirring mixer by adding a low-boiling solvent having a boiling point of 100 ° C. or lower to a phenolic resin molding material kneaded and pulverized by a mixing roll or an extrusion kneader. A method for producing a molding material has been proposed.
However, granulation with a high-speed stirring mixer such as a Henschel mixer tends to shatter glass fibers and the like, which adversely affects physical properties such as a decrease in mechanical strength. There is also a problem that fine powder is easily attached.
[0005]
Further, the above-mentioned compound is kneaded with a pressure kneader or the like under heating, and is formed into a sheet or strand, dried, pulverized with a pulverizer, and sieved to obtain a granular material. There is also a method.
However, this method means that the shapes of the obtained particles are not uniform. This means that in the case of injection molding or the like, the meterability is poor, which causes a serious problem in molding processability. Note that if the sieving is strictly performed in order to make the shape of the granular material uniform, the productivity is extremely lowered.
Further, the above method has a problem that when the sheet is pulverized into a granular material, fine powder is generated and easily adheres to the surface of the granular material. If this fine powder is mixed, since the melting temperature differs greatly between the granular material and the fine powder when molding using this, the quality of the molded product is greatly deteriorated, which is not preferable. And generation | occurrence | production of fine powder causes environmental pollution, and also reduces productivity. Furthermore, there is a possibility that fine powder will be scattered during use, which is undesirable in handling.
[Problems to be solved by the invention]
[0006]
Therefore, the problem to be solved by the present invention is to solve the problems of the above-described conventional technology.
[0007]
That is, the first problem to be solved by the present invention is to provide a technique capable of producing granular thermosetting resin molding materials such as phenolic resin molding materials and unsaturated polyester resin molding materials without using an extruder. That is. That is, it is to provide a technique that does not cause the problem of die clogging and is difficult to cause the problem of productivity and the problem that the physical properties of the molded product are deteriorated because the glass fiber is shredded.
[0008]
The second problem to be solved by the present invention is to provide a technique capable of producing a granular thermosetting resin molding material without using a high-speed stirring mixer such as a Henschel mixer. That is, it is not necessary to use a high-speed agitation mixer such as a Henschel mixer, and therefore, it is to provide a technique in which glass fibers and the like are not easily shredded and problems such as deterioration of physical properties of a molded product hardly occur.
[0009]
The third problem to be solved by the present invention is to provide a technique capable of producing a granular thermosetting resin molding material without using a pulverizer. That is, since the pulverizer is not used, the shape of the obtained particles is uniform, and therefore, the meterability is good, the moldability is good, the productivity is good, and the fine powder is not easily generated. Providing a granular thermosetting resin molding material suitable as an injection molding material that is less likely to mix due to adhesion to the surface of the object, hardly deteriorates in the quality of the molded product, and also improves the risk of deterioration in molding processability It is to be.
[Means for Solving the Problems]
[0010]
In order to solve the above-mentioned problems, the present inventor has made various studies on a method for producing a granular thermosetting resin molding material with less generation of dust. As a result, the conventional high-speed stirring mixer and extrusion granulation method are completely different from each other, but an extremely simple method has been realized. Moreover, according to this method, a granular thermosetting resin molding material having a uniform shape and generating less dust can be obtained.
[0011]
That is, the above-mentioned problems include a kneading step of adding glass fiber , filler, curing agent, mold release agent, and colorant to a phenolic resin or unsaturated polyester resin , and mixing and kneading.
The kneaded product obtained in the kneading step is made into a sheet-like product having a thickness of 1 to 5 mm by a heating roll ,
The sheet-like material obtained in the sheet forming step is controlled to a temperature of 45 to 55 ° C., and the temperature-controlled sheet material is 1 to 5 mm wide by a cutting blade controlled to a temperature of 30 ° C. or less. A cutting process of cutting into objects,
The string-like material obtained in the cutting step is controlled to a temperature of 45 to 55 ° C, and the temperature-controlled string-like material is formed into a granular material having a length of 1 to 5 mm by a cutting blade controlled to a temperature of 30 ° C or less. It solves by the manufacturing method of the granular thermosetting resin molding material characterized by comprising the cutting process cut | disconnected.
[0013]
The present invention eliminates the need to use a high-speed agitating mixer or crusher such as an extruder or a Henschel mixer, and therefore, various kinds of problems that have occurred in the production of granular thermosetting resin molding materials using these apparatuses. The problem is solved. That is, the problem of die clogging, the problem of lowering the productivity, and the problem of lowering the physical properties of the molded product due to glass fiber shredding are improved. Furthermore, the problem of generation of fine powder is unlikely to occur, and deterioration of molding processability and quality of molded products due to variations in melting temperature during molding that occurs when fine powder is mixed in the granular thermosetting resin molding material. The problem is improved.
Furthermore, since it is only made into a sheet by, for example, a heating roll and then cut and cut, it can be obtained very easily.
[0015]
Moreover, the said subject is solved by the granular thermosetting resin molding material characterized by being obtained by the manufacturing method of the said granular thermosetting resin molding material.
DETAILED DESCRIPTION OF THE INVENTION
[0016]
The method for producing a granular thermosetting resin molding material of the present invention is obtained by a kneading step of adding a filler, a reinforcing agent, a curing agent, and other additives to a thermosetting resin, mixing and kneading, and the kneading step. The kneaded product into a sheet-like material, a cutting step for cutting the sheet-like material obtained in the sheet-forming step into a string-like material, and the string-like material obtained in the cutting step with a predetermined length And a cutting step of cutting into a granular material. The temperature of the sheet-like material in the cutting process is controlled to 25 to 100 ° C. The temperature of the cutting blade is controlled to a temperature of 85 ° C. or lower. The temperature of the string-like object in the cutting step is controlled to 25 to 100 ° C. The temperature of the cutting blade is controlled to a temperature of 85 ° C. or lower. The sheet-like material has a thickness of 1 to 5 mm, a cutting width of 1 to 5 mm, and a cutting length of 1 to 5 mm. In particular, after adding a filler, reinforcing agent, curing agent, and other additives to the thermosetting resin, mixing and kneading, the kneaded product is sheeted to a thickness of 1 to 5 mm, and the sheet is 1 to 5 mm in width. This is a method of cutting the string-like material into a length of 1 to 5 mm. Further, a filler, a reinforcing agent, a curing agent, and other additives are added to the thermosetting resin, mixed and kneaded, and then formed into a sheet shape having a thickness of 1 to 5 mm with a heating roll, and the sheet has a width of 1 to 5 mm. This is a method of cutting into a string shape and cutting it to a length of 1 to 5 mm in a direction perpendicular to the longitudinal direction of the string-like object. In addition, a filler, a reinforcing agent, a curing agent, and other additives are added to and mixed with powdered or liquid phenolic resin or unsaturated polyester resin, kneaded, and then sheeted to a thickness of 1 to 5 mm. In this method, the sheet is cut into a string having a width of 1 to 5 mm, and the string is cut into a length of 1 to 5 mm. In addition, fillers, reinforcing agents, curing agents, and other additives are added to and mixed with thermosetting resins such as powdered or liquid phenolic resins or unsaturated polyester resins, and after kneading, 1-5 mm with a heating roll. The sheet is formed into a thickness, and the sheet is continuously cut into a string having a width of 1 to 5 mm by a cutting device equipped with a rotary blade, and the length is 1 to 5 mm in a direction perpendicular to the longitudinal direction of the string. It is a method of cutting.
[0017]
This will be described in detail below.
In the present invention, when cutting or cutting a sheet-like material, it is preferable to cut or cut the sheet-like material by controlling the temperature of the sheet-like material and the temperature of the cutting blade or the cutting blade within a certain temperature range. The temperature of the sheet-like material at this time is set depending on the properties of the resin used, the reinforcing material, the filler, and the type and amount of other additives, but generally room temperature (usually about 25 ° C.) It is preferable to be set in a range of ˜100 ° C. More preferably, it is 45-55 degreeC. In general, the temperature of the cutting blade or the cutting blade is preferably set to a temperature of 85 ° C. or lower. More preferably, the temperature is 30 ° C. or lower. That is, if the temperature of the sheet-like material is too lower than the above temperature range, a large amount of fine powder is likely to be generated at the time of cutting or cutting, and conversely, if it is too high, the sheet tends to adhere to the cutting blade or cutting blade. Good cutting / cutting is difficult. In addition, there is a possibility that the objects after cutting and cutting adhere to each other, and the productivity is lowered. When the temperature of the cutting blade or the cutting blade is too higher than the above temperature range, the sheet is likely to adhere to the cutting blade or the cutting blade, and it is difficult to perform good cutting, and productivity is lowered.
[0018]
In addition, the rectangular granular material obtained by cutting and cutting the sheet-like material of the present invention may be processed by a granulator such as a Malmerizer. In such a case, the sharp corners of the square shape are slightly rounded, the workability and the meterability are improved, and the generation of fine powder during handling is suppressed.
[0019]
The shape of the granular thermosetting resin molding material of the present invention is generally a rectangular parallelepiped having a thickness of 1 to 5 mm, a width of 1 to 5 mm, and a length of 1 to 5 mm. This thing is excellent in the meterability in injection molding. More preferably, the thickness is 2 to 3 mm, the width is 2 to 3 mm, and the length is 2 to 3 mm. That is, in such a case, more stable weighing can be performed, and continuous injection molding can be performed more efficiently. In order to bring the shape of the granular thermosetting resin molding material into the above range, it is possible to adjust the shape of the cutting blade and the cutting blade, the interval between the cutting blade and the cutting blade, the cutting / cutting temperature, and the like.
[0020]
Examples of the thermosetting resin in the present invention include novolak-type or resol-type phenolic resins, unsaturated polyester resins, and diaryl phthalate resins. These resins are synthetic resins used for molding materials and are used in solid or liquid form, but they are solid resins with good dispersibility when mixed with other fillers, reinforcing materials and other additives. A shape (powder) is preferred.
The apparatus provided with the cutting blade and the cutting blade used in the present invention can use an apparatus capable of continuously cutting and cutting a sheet. For example, an apparatus such as a commercially available sheet pelletizer equipped with a rotary blade is used.
Hereinafter, the present invention will be specifically described by way of examples. “Parts” represents parts by weight.
【Example】
[0021]
[Example 1]
Glass fiber 100 parts powdery phenolic resin (fiber length: 6 mm, diameter: 13μ m) 70 parts, 70 parts of calcium carbonate, a curing agent (hexamethylene tetramine) 15 parts, other additives (release agents, coloring agents) Was blended in a desired amount, kneaded under heating with a kneader, and a sheet having a thickness of 3 mm and a width of 300 mm was produced with a heating roll at 50 ° C.
The sheet was cut into a 3 mm wide string with a disk-shaped rotary blade with a sheet temperature of 55 ° C. and a blade interval of 3 mm. The string-like material was cut to a length of 3 mm with a rotary cutter. The cutting blade and the blade of the rotary cutter were controlled at 25 ° C.
The phenol resin molding material thus produced was a rectangular parallelepiped shape having a length of 3 mm, a width of 3 mm, and a height of 3 mm. The granular phenolic resin molding material was easy to handle with little generation of fine powder, there was almost no variation in measurement during injection molding, and the molding processability was good, and a good molded product was obtained.
[0022]
[Example 2]
In Example 1, the sheet temperature was set to 53 ° C., the blade interval was set to 4 mm, and cut into a 4 mm wide string, and the string was cut into a length of 5 mm with a rotary cutter, and 3 mm × 4 mm × 5 mm. A rectangular resin-shaped phenolic resin molding material was obtained.
This granular phenolic resin molding material is easy to handle with little generation of fine powder, has almost no variation in measurement at the time of injection molding, and has good molding processability, and a good molded product was obtained.
[0023]
[Example 3]
100 parts of unsaturated polyester resin, 80 parts of glass fiber, 150 parts of filler (calcium carbonate), 30 parts of diallyl phthalate prepolymer, and other additives are blended and mixed, kneaded under heating, and 50 ° C. A sheet having a thickness of 3 mm and a width of 300 mm was produced with a heating roll.
The sheet was cut into a 3 mm wide string with a disk-shaped rotary blade with a sheet temperature of 52 ° C. and a blade interval of 3 mm. Then, the string-like material was cut into a length of 3 mm with a rotary cutter. The cutting blade and the blade of the rotary cutter were controlled at 25 ° C.
The unsaturated polyester resin molding material produced in this way was a rectangular parallelepiped shape having a length of 3 mm, a width of 3 mm, and a height of 3 mm. And this granular unsaturated polyester resin molding material is easy to handle with little generation of fine powder, there is almost no measurement variation at the time of injection molding, and the molding processability is good, and a good molded product was obtained. .
[0024]
[Comparative Example 1]
The same formulation as in Example 1 was kneaded to obtain a sheet. The sheet was cooled to room temperature, and then pulverized with an impact pulverizer equipped with a 3 mm screen to obtain a granular phenol resin molding material.
The granular phenolic resin molding material obtained in this way has a large amount of fine powder generated during handling, is difficult to handle, has a large measurement variation during injection molding, and cannot be molded satisfactorily.
[0025]
[Comparative Example 2]
The same formulation as in Example 3 was kneaded to obtain a sheet. The sheet was cooled to room temperature, and then pulverized with an impact pulverizer equipped with a 3 mm screen to obtain an unsaturated polyester resin molding material.
The unsaturated polyester resin molding material obtained in this manner has a large amount of fine powder generated during handling, is difficult to handle, has a large measurement variation during injection molding, and cannot be molded satisfactorily.
【The invention's effect】
[0026]
The granular thermosetting resin molding material of the present invention is hardly accompanied by generation of dust, has good productivity, and is easy to handle. The granular material has a uniform shape and good meterability, and is a molding material suitable as an injection molding material.
Claims (1)
前記混練工程で得られた混練物を、加熱ロールにより、1〜5mm厚のシート状物にするシート化工程と、
前記シート化工程で得られたシート状物を45〜55℃の温度に制御し、該温度制御されたシート状物を30℃以下の温度に制御された裁断刃によって1〜5mm幅の紐状物に裁断する裁断工程と、
前記裁断工程で得られた紐状物を45〜55℃の温度に制御し、該温度制御された紐状物を30℃以下の温度に制御された切断刃によって1〜5mm長の粒状物に切断する切断工程
とを具備することを特徴とする粒状熱硬化性樹脂成形材料の製造方法。A kneading step of adding glass fiber , filler, curing agent, mold release agent, colorant to the phenolic resin or unsaturated polyester resin , and mixing and kneading;
The kneaded product obtained in the kneading step is made into a sheet-like product having a thickness of 1 to 5 mm by a heating roll ,
The sheet-like material obtained in the sheet forming step is controlled to a temperature of 45 to 55 ° C., and the temperature-controlled sheet material is 1 to 5 mm wide by a cutting blade controlled to a temperature of 30 ° C. or less. A cutting process for cutting into objects,
The string-like material obtained in the cutting step is controlled to a temperature of 45 to 55 ° C, and the temperature-controlled string-like material is formed into a granular material having a length of 1 to 5 mm by a cutting blade controlled to a temperature of 30 ° C or less. The manufacturing method of the granular thermosetting resin molding material characterized by including the cutting process cut | disconnected.
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JP14473197A JP4187806B2 (en) | 1997-05-19 | 1997-05-19 | Method for producing granular thermosetting resin molding material |
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JP14473197A JP4187806B2 (en) | 1997-05-19 | 1997-05-19 | Method for producing granular thermosetting resin molding material |
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