JP4367994B2 - Method for producing composite material of pulp fiber panel and fiber reinforced plastic - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a composite material of a pulp fiber panel and a fiber reinforced plastic, and in particular, a composite material in which a pulp fiber panel having an open cell lattice on a panel surface and a fiber reinforced plastic are integrated without using an adhesive. It relates to a manufacturing method.
[0002]
[Prior art]
JP-A-9-195440 discloses a pulp fiber panel having an open cell lattice on the panel surface.
Such a pulp fiber panel is obtained by, for example, pulping raw materials such as wood fiber and recycled paper with a strong stirring force to obtain a pulp fiber-containing slurry having a moisture concentration of about 99%, and then the slurry is shown in FIG. A carrier 51 and a plurality of elastomer pads 52 geometrically arranged and fixed on the plate surface of the porous carrier 51 are placed on a mold 50, and the mold 50 is viewed from above and below. Is dehydrated by pressing with a flat plate (pre-press) and suction from the lower surface of the mold 50, and the slurry is made into a dehydrated cake with a moisture concentration of about 50%, and then the mold 50 is conveyed to a hot press and heated under the mold The dehydrated cake is heated and compression-molded by applying a vertical pressure to 50 to produce a molded product having a moisture concentration of about 8%.
[0003]
The pulp fiber panel thus manufactured has a turtle shell-shaped open cell lattice 61 constituted by a plurality of ribs as shown in FIG. 7 and a continuous flat plate 62 covering one opening of the lattice 61. And a flange 63 that covers a part of the other opening are formed into a panel integrally formed of dense compressed pulp fibers. The pulp fiber panel 60 is a lightweight and high-strength panel, and is a residential member. A wide range of uses such as joinery or furniture is conceivable, and it is expected to be a product that can effectively utilize recycled resources such as waste paper.
[0004]
On the other hand, fiber reinforced plastic is a glass fiber reinforced plastic reinforced with glass fiber developed around 1945, which is made by adding fibers to the advantages of plastic such as moldability, corrosion resistance and low cost. In recent years, fiber reinforced plastics using high-performance reinforcing fibers such as boron fibers, carbon fibers, aramid fibers, and silicon fibers having excellent specific elastic modulus and specific strength have also appeared.
[0005]
In glass fiber reinforced plastics, alkali-free borosilicate glass fibers mixed in a matrix such as unsaturated polyester or epoxy resin are used in bathtubs, helmets, and boats, and short fibers are used in so-called engineering plastics such as nylon, polycarbonate, and polyphenylene oxide. Mixed materials are used as structural materials. Further, in the construction field, there are those in which this fiber reinforced plastic product is bonded to the surface of various panels and boards using an adhesive or the like for the purpose of improving durability.
[0006]
Various methods such as a hand lay-up method, a spray-up method, a vacuum back method, a pressure back method, an autoclave method, a resin transfer method, and a compression molding method have been devised as methods for producing these fiber-reinforced plastic products. Basically, impregnation of the matrix into a reinforcing material such as glass fiber, shaping of the impregnated reinforcing material and the matrix into a predetermined shape, and hardening in order to stabilize this in some form It is made up of incorporated manufacturing methods.
[0007]
[Problems to be solved by the invention]
The problem to be solved by the present invention is to stimulate further demand for a pulp fiber panel having the above-described open cell lattice, and thus without using an adhesive that may be deteriorated or peeled off due to air bubbles. An object of the present invention is to provide a method for easily producing a new composite material that combines the above-mentioned advantages of a pulp fiber panel and the advantages of fiber-reinforced plastics by combining with existing fiber-reinforced plastics.
[0008]
[Means for Solving the Problems]
As a result of various tests and researches to achieve the above-mentioned object, the present inventors have found that the surface of the pulp fiber panel easily penetrates the matrix in the uncured fiber reinforced plastic, and after the fiber reinforced plastic is cured. In the case of air bubbles, both of them are firmly fixed and fixed, and bubbles due to poor impregnation of the matrix reinforcing material present in the uncured fiber reinforced plastic are not added nearby when pressed. The present invention has been completed by paying attention to the fact that there is a pressure portion, and there is no bubble hole formed in the pressure portion.
[0009]
That is, the present invention is a composite of a pulp fiber panel and a fiber reinforced plastic in which a pulp fiber panel having an open cell lattice is placed on the panel surface above the uncured fiber reinforced plastic layer , and both materials are integrated. The unreinforced fiber reinforced plastic layer is a fiber reinforced plastic layer obtained by impregnating a nonwoven fabric that is a reinforcing material with a resin that is a matrix, and the pulp fiber panel is formed by a plurality of ribs. A pulp fiber panel having a structure in which a structured open cell lattice, a continuous flat plate covering one opening of the lattice, and a flange covering a part of the other opening are integrally formed of dense compressed pulp fibers , and the open cells lattice side panel surface having a flange of the pulp fibers panel is placed in a state facing the fiber reinforced plastic layer side, 0 in the vertical direction And as the manufacturing method of the composite material with the pulp fibers panels and fiber-reinforced plastic to cure the fiber-reinforced plastic layer in a state where pressure is crimped both materials added to the 2~0.5kg / cm ^2.
[0010]
According to the manufacturing method according to the present invention described above, the fiber reinforced plastic layer can be formed in a state in which the fiber reinforced plastic layer is firmly and firmly fixed to the panel surface of the pulp fiber panel without using an adhesive. Since the layer was formed on the side of the open cell lattice side panel of the pulp fiber panel, bubbles present in the uncured fiber reinforced plastic were not in contact with the pulp fiber panel, that is, in the open cell lattice of the pulp fiber panel. Thus, no bubble hole is formed at the contact portion between the two, and a composite material of a pulp fiber panel and a fiber reinforced plastic that does not have poor bonding due to the bubble hole can be easily provided.
[0011]
The composite material of the pulp fiber panel and fiber reinforced plastic produced in this way has the advantage of light weight of the pulp fiber panel, while improving the strength, water resistance and design by combining with the fiber reinforced plastic. Products such as precision machine transport cases, ceiling members for hanging ceilings, concert tours, and other lightweight speaker components, internal partitions for automobiles, trains, aircraft, etc., and displays for studios (stages), stores, etc. In particular, it is a very useful material for a transport case as a transportation / distribution material that requires light weight.
[0012]
Here, the pulp fiber panel having an open cell lattice on the panel surface referred to in the present invention is an open cell lattice made of a plurality of ribs using a pulp raw material such as wood fiber and recycled paper, and one of the lattices. This is a panel having a structure in which a continuous flat plate covering the other opening and a flange covering a part of the other opening are integrally formed of dense compressed pulp fibers .
[0013]
In the present invention, the fiber reinforced plastic to be combined with the pulp fiber panel includes a general glass fiber reinforced plastic using a borosilicate glass fiber as a reinforcing material and an unsaturated polyester or an epoxy resin as a matrix. Further, high-performance reinforcing fibers such as boron fiber, carbon fiber, aramid fiber, or silicon fiber may be used as the reinforcing material, and so-called engineering plastics such as nylon, polycarbonate, and polyphenylene oxide may be used as the matrix.
[0014]
Further , the pressure bonding of the pulp fiber panel and the uncured fiber reinforced plastic layer in the present invention is performed by applying a pressure of 0.2 to 0.5 kg / cm ² from the vertical direction using a press machine or the like. Can be crimped.
[0015]
Moreover, the composite material of the pulp fiber panel and the fiber reinforced plastic produced according to the present invention is a composite in which the thickness of the fiber reinforced plastic layer is 20% or less of the total thickness in order not to impair the lightweight property of the pulp fiber panel. It is preferable to use a material.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of a method for producing a composite material according to the present invention will be described in detail with reference to the drawings.
[0017]
First, a fiber reinforced plastic layer is formed on a formwork.
In the present embodiment, the fiber reinforced plastic layer is formed by using a borosilicate glass fiber nonwoven fabric as a reinforcing material and using an unsaturated polyester as a matrix. However, the reinforcing material and the matrix are used. The present invention is not limited to the fiber reinforced plastic.
[0018]
First, 0.5 to 2.0% by weight of an unsaturated polyester (product number: PS2100, manufactured by Hitachi Chemical Co., Ltd.), methylethylene kent peroxide (product number: Permec N, manufactured by Nippon Oil & Fats Co., Ltd.), a pigment, A polyester resin toner (Tokyo Ink Co., Ltd., product number: PCN6302) is added and mixed in an amount of 0.7 to 1.0% by weight, and this mixture is used as matrix A and a release agent is applied as shown in FIG. Immediately apply | coated on the plate-shaped formwork 1 formed, and the non-woven fabric of the borosilicate glass fiber which is the reinforcing material B as shown in FIG.1 (b) (Nittobo Co., Ltd. product number: MC-450) ), And the matrix A was sufficiently impregnated in the reinforcing material B by repeating the application of the matrix A again by the roller 2 as shown in FIG. 1 (c). A fiber reinforced plastic layer P having an uncured reinforcing material content of 25 to 35% by weight shown in 1 (d) was formed on the mold 1.
[0019]
Thereafter, the pulp fiber panel X was immediately placed above the fiber reinforced plastic layer P.
For this pulp fiber panel X, a pulp fiber panel 60 having an open cell lattice on the existing panel surface as shown in FIG. 7 was used. That is, a turtle shell-shaped opening cell lattice 61 composed of a plurality of ribs as shown in FIG. 7, a continuous flat plate 62 covering one opening of the lattice 61, and a part of the other opening. The covering flange 63 is a panel having a structure integrally formed with dense compressed pulp fibers. The panel X has a bulk specific gravity of about 0.25 and a bending strength of about 40 kgf / cm ² .
[0020]
The pulp fiber panel X is placed with the open side panel surface of the open cell lattice 61 facing the fiber reinforced plastic layer P side in an uncured state as shown in FIG. Is transferred to the press 3 and a pressure of 0.2 to 0.5 kg / cm ² is applied from above and below to make the pulp fiber panel X into an uncured fiber reinforced plastic as shown in FIG. The layer P was pressed and allowed to stand at room temperature for 3 to 6 hours until the fiber-reinforced plastic layer P was cured in this state.
[0021]
By leaving the pulp fiber panel X and the uncured fiber reinforced plastic layer P to be cured under pressure bonding, a part of the matrix A in the fiber reinforced plastic layer P is gradually brought into contact with the surface of the pulp fiber panel X in contact therewith. Since the interface becomes continuous and the fiber reinforced plastic layer P is cured, the two are firmly and firmly fixed. Further, as shown in FIG. 3, the air bubbles present in the uncured fiber reinforced plastic layer P escape into the non-contact portion with the pulp fiber panel X, that is, into the open cell lattice 61 of the pulp fiber panel X. No bubble hole is formed on the surface of the flange 63 that covers a part of the open cell lattice 61 that becomes the contact portion of the above, so that no poor bonding occurs.
[0022]
In addition, since it is the fiber reinforced plastic layer P in which the fiber which is a reinforcing material exists in the present invention, the pulp fiber panel X is pressure-bonded. It is not extruded to a non-contact portion with the panel X, and is cured in a state where there is a fiber reinforced plastic layer P that is a continuous flat plate that closes the opening side panel surface of the opening cell lattice 61 of the pulp fiber panel X. proceed.
[0023]
When the curing under pressure bonding between the pulp fiber panel X and the uncured fiber reinforced plastic layer P is completed, the pulp fiber panel X is removed from the press machine 3 and demolded from the mold 1, as shown in FIG. A composite material Z of pulp fiber panel and fiber reinforced plastic could be produced.
As shown in FIG. 2 (c) or FIG. 4, the composite material Z is a panel in which a fiber reinforced plastic layer P is closely fixed to the open side panel surface of the open cell lattice 61 of the pulp fiber panel X. The bulk specific gravity of Z was about 0.35, and the bending strength was about 200 kgf / cm ² , resulting in a high strength product. Moreover, since the formed fiber reinforced plastic layer P was translucent, the turtle shell shape of the open cell lattice 61 of the pulp fiber panel X appeared on the panel surface on the fiber reinforced plastic layer P side, and the panel was excellent in design. It became.
[0024]
Using the obtained composite material Z of pulp fiber panel and fiber reinforced plastic, a case 10 for conveying equipment used in a concert or the like as shown in FIG. 5 was manufactured, and a conventional decorative plywood was used. It is extremely lightweight compared to the case, and the turtle shell-shaped open cell lattice of the pulp fiber panel is visible from the outside through the translucent fiber reinforced plastic layer, and the case has excellent design.
[0025]
As mentioned above, although one Embodiment of the manufacturing method of the composite material of the pulp fiber panel and fiber reinforced plastic concerning this invention was described, this invention is not limited to above-mentioned Embodiment, Various modifications and changes are possible within the scope of the technical idea.
[0026]
For example, the pulp fiber panel and fiber reinforced plastic used in the above embodiment are merely examples. For example, the pulp fiber panel may be a panel in which an open cell lattice for reducing the weight exists on the panel surface. For example, it can be used in the present invention regardless of its production method and shape, and the fiber reinforced plastic is not limited to a fiber reinforced plastic using a thermosetting resin called unsaturated polyester as a matrix, but other thermosetting resins. For example, it may be a phenol resin, an epoxy resin, or the like, or may be a fiber reinforced plastic using a thermoplastic resin such as nylon or polycarbonate as a matrix. However, when a fiber reinforced plastic using a thermoplastic resin as a matrix is used, a heating step is essential to form an uncured fiber reinforced plastic layer.
[0027]
【The invention's effect】
As described above, in the method for producing a composite material of a pulp fiber panel and fiber reinforced plastic according to the present invention, a pulp fiber panel having an open cell lattice on the panel surface is placed above an uncured fiber reinforced plastic layer. A method of manufacturing a composite material of a pulp fiber panel and a fiber reinforced plastic that integrates both materials, wherein the uncured fiber reinforced plastic layer impregnates a resin that is a matrix into a nonwoven fabric that is a reinforcing material. A fiber reinforced plastic layer, wherein the pulp fiber panel covers an open cell lattice constituted by a plurality of ribs, a continuous flat plate covering one opening of the lattice, and a part of the other opening. a pulp fiber panel and the flange are integrally formed by dense compressed pulp fiber structure, opening the cell grid having a flange of the pulp fibers panel Panel surface is placed in a state facing the fiber reinforced plastic layer side, curing the fiber-reinforced plastic layer in the vertical direction by applying a pressure of 0.2~0.5kg / cm ² while bonding the two materials This makes it possible to combine a new pulp fiber panel and fiber reinforced plastic composite material that combines the advantages of pulp fiber panels and fiber reinforced plastics without the use of adhesives. Easy to manufacture .
[Brief description of the drawings]
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a diagram showing an embodiment of a process for forming an uncured fiber reinforced plastic layer during a manufacturing process of a composite material of a pulp fiber panel and fiber reinforced plastic according to the present invention; ) Is a state where the matrix is applied on the mold, (b) is a state where the reinforcing material is placed above the applied matrix, (c) is a state where the matrix is further applied above the reinforcing material, and the matrix is strengthened by a roller. (D) is a conceptual diagram showing an uncured fiber-reinforced plastic layer formed on a mold, respectively.
FIG. 2 is a diagram showing an embodiment of a composite process of a pulp fiber panel and a fiber reinforced plastic during a manufacturing process of a composite material of a pulp fiber panel and a fiber reinforced plastic according to the present invention; ) Is a state in which a pulp fiber panel is placed above an uncured fiber reinforced plastic layer formed on a mold, (b) is a state in which both materials on the mold are pressure-bonded by a press, (c) FIG. 3 is a conceptual diagram showing a composite material of a manufactured pulp fiber panel and fiber reinforced plastic.
FIG. 3 is an enlarged conceptual view showing a state of a pulp fiber panel and an uncured fiber reinforced plastic layer in a press-bonding process by the press shown in FIG. 2 (b).
FIG. 4 is a perspective view showing an example of a composite material obtained by the method for manufacturing a composite material of a pulp fiber panel and fiber reinforced plastic according to the present invention.
FIG. 5 is a perspective view showing a transport case made using a composite material obtained by the manufacturing method according to the present invention.
FIG. 6 is a perspective view showing an example of a mold used for manufacturing a pulp fiber panel.
FIG. 7 is a perspective view showing an example of a pulp fiber panel used in the method for producing a composite material of a pulp fiber panel and fiber reinforced plastic according to the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Formwork 2 Roller 3 Press machine 10 Carrying case A Matrix B Reinforcement material P Unreinforced fiber reinforced plastic layer X Pulp fiber panel Z Composite material of pulp fiber panel and fiber reinforced plastic

Claims (2)

A method for producing a composite material of a pulp fiber panel and a fiber reinforced plastic, in which a pulp fiber panel having an open cell lattice on the panel surface is placed above an uncured fiber reinforced plastic layer and both materials are integrated. The uncured fiber reinforced plastic layer is a fiber reinforced plastic layer obtained by impregnating a nonwoven fabric, which is a reinforcing material, with a resin, which is a matrix, and the pulp fiber panel is an open cell lattice constituted by a plurality of ribs. And a pulp fiber panel having a structure in which a continuous flat plate covering one opening of the lattice and a flange covering a part of the other opening are integrally formed of dense compressed pulp fibers, open cell grid side panel surface having a flange of a panel is placed in a state facing the fiber reinforced plastic layer side, 0.2～0.5Kg the vertical direction characterized by applying a pressure of cm ² while bonding both materials curing the fiber-reinforced plastic layer, the manufacturing method of the composite material with the pulp fibers panels and fiber-reinforced plastic. 2. The method for producing a composite material of a pulp fiber panel and a fiber reinforced plastic according to claim 1, wherein the uncured fiber reinforced plastic layer has a reinforcing material content of 25 to 35% by weight.

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