JP5128543B2 - Manufacturing method and manufacturing apparatus for glass chopped strand mat, glass chopped strand mat, and automobile molded ceiling material - Google Patents

Description

  The present invention relates to a glass chopped strand mat used as a reinforcing material such as an automobile molded ceiling material, a manufacturing method thereof, and a manufacturing apparatus.

  The glass chopped strand mat is a sheet material obtained by bonding a plurality of glass chopped strands cut to a predetermined length to each other with a binder, and is widely used as a reinforcing material for various products. And this kind of glass chopped strand mat is manufactured by the following processes. First, in a state where a glass fiber obtained by drawing a molten glass having a composition such as E glass melted in a homogeneous state from a heat-resistant nozzle is coated with a pre-adjusted sizing agent and bundled into a bundle. A glass strand is used. Next, the glass strand is cut into a predetermined length by a cutting machine to produce a glass chopped strand, and the produced many glass chopped strands are deposited in a sheet form evenly and randomly. Thereafter, an appropriate amount of binder (for example, powdered polyester resin) is sprayed from above the sheet-like deposit. Finally, after heating the sheet deposit on which the binder is spread, the glass chopped strands in the sheet deposit are bonded together by rolling and solidifying while rolling between paired cooling rolls. By doing so, a glass chopped strand mat is produced.

Specifically, as the glass strand, a glass fiber having an E glass composition having a single fiber diameter of 11 μm and a strand count of 25 tex (tex is the weight in grams per 1000 m of length) is used. This is cut into a glass chopped strand by cutting with a cutter so that the length dimension is about 50 mm. Next, it is deposited evenly and randomly so that the basis weight is 50 to 900 g / m ² to form a sheet-like deposit, and further sprayed so that the amount of powder polyester resin adhering is 1 to 20% by mass. The glass chopped strands in the sheet deposit are solidified and bonded together.

  The glass chopped strand mat manufactured by such a process is used for an automotive molded ceiling material whose rigidity and dimensional stability are improved by bonding to both surfaces of a foamed resin polyurethane sheet. The performance required for automobile molded ceiling materials is the basis weight of materials used to reduce the weight of the entire automobile in addition to characteristics such as rigidity, dimensional stability, thermal insulation or sound insulation, that is, units It is necessary to reduce the mass per area. However, the smaller the basis weight of the glass chopped strand mat, the more uneven the strand distribution of the glass chopped strand mat, and the lower the mechanical strength of the mat. As a result, after the mat is wound around the winding core, the occurrence rate of the phenomenon that the mat is torn during the so-called unwinding operation, where the mat is pulled and unwound from the outer layer, is increased. Therefore, it is necessary to perform the unwinding work slowly while taking care not to break the mat, and there is a problem that workability is greatly reduced.

  Thus, attempts to improve the mechanical strength of the chopped strand mat have been made so far. For example, in patent document 1, the fall of the chopped strand from a conveyance conveyor is prevented by prescribing | regulating the form of a chopped strand. Patent Document 2 discloses an invention in which the tensile strength (also referred to as tensile strength), which is an index of mechanical strength, can be increased to 150 kgf or more by increasing the ignition loss value. Moreover, in patent document 3, it has sufficient intensity | strength by using what contained polyethylene resin 5 mass% or more as a binder which couple | bonds a glass chopped strand, and improves the moldability of an automotive molded ceiling material. The invention is also disclosed.

Japanese Patent Laid-Open No. 6-93546 JP 2003-175777 A JP 2008-038297 A

  However, the above technique is not sufficient to provide a glass chopped strand mat having more stable quality and performance.

For example, an automobile molded ceiling material has a single fiber diameter of 10 μm to 14 μm, a glass strand having an average strand count of 18 tex to 30 tex is cut into a length of about 50 mm, and the basis weight is 50 g / m ² to 200 g / m. ^The powdered polyester resin is deposited evenly and randomly so as to be in the range of ² , and the powdered polyester resin is sprayed so that the adhesion amount is in the range of 8% by mass to 16% by mass, then heated to melt the powdered polyester resin, and then cooled. A glass chopped strand mat obtained by cooling and solidifying with a roller and bonding the glass chopped strands to each other has been used. Further, foamed resin automotive ceiling material having a glass chopped strand mat is adhered structure on both surfaces of the sheet, at least the glass chopped strand mat ranges basis weight on one surface is from 50 g / m ² of 250 g / m ² Has come to be used.

  In such a glass chopped strand mat, there may be a situation in which the tensile strength is partially reduced due to factors such as the dispersion and deposition state of the glass chopped strands or the non-uniformity in the bonding state of the binder described above. is there. Therefore, the chopped strand mat coated with the adhesive in such a state is laminated in the order of the skin (the interior side of the automobile), the glass chopped strand mat, the foamed resin polyurethane sheet, the glass chopped strand mat, and the protective sheet (the ceiling side of the automobile). For this reason, when the mat is continuously pulled out from the mat wound body wound up in a roll shape, there is a concern that the mat may be broken in the middle.

  So far, we have dealt with such problems by limiting the binder of glass chopped strands and so on, but it will produce some results, but it is sufficient to aim for higher quality. Absent.

In the above-described mat, a glass chopped strand mat is impregnated with an adhesive such as phenol, melamine, or isocyanate, and the skin (inside the vehicle interior), glass chopped strand mat, foamed resin sheet, glass chopped strand mat, and protection When pressed into the shape of a molded ceiling with the sheets (car ceiling side) stacked in order, the skin called “sink” is formed in the opening of the molded ceiling shade and other corners that are deep-drawn. Wrinkles (hereinafter simply referred to as sinks) may occur. The incidence of such a sink defect is a thin non-woven fabric with a basis weight of 50 g / m ² or less, especially for the purpose of reducing the material cost, or a flat knit skin is used with emphasis on design. In recent years, it has become prominent.

  In view of the above circumstances, the present invention is used by pulling out from a mat wound body while securing the flexibility and rigidity necessary for the molded product when used as a reinforcing material for molded products such as automobile molded ceiling materials. It is a technical problem to provide a glass chopped strand mat that can surely suppress the occurrence of partial tearing or sink marks in a molded product.

  The method of manufacturing a glass chopped strand mat according to the present invention, which was created to solve the above-described problems, deposits glass chopped strands in a sheet shape, sprays a binder on the sheet deposit, and heats the sheet deposit. Then, the sheet-like deposits are cooled while being rolled with a cooling roll having a rubber layer on at least one outer periphery, and the glass chopped strands in the sheet-like deposits are bonded to each other. A glass chopped strand mat is manufactured.

  While the present inventors are conducting various studies on glass chopped strand mats, a metal cooling roll that constitutes a cooling and rolling mill used in the glass chopped strand mat manufacturing process rolls sheet deposits. At the same time, it has been found that there is a problem though it has a function of easily cooling and solidifying the heated and melted binder. That is, in a pair of upper and lower metal cooling rolls rotating in opposite directions, due to the presence of uneven thickness of the sheet-like deposit caused by the unevenness of the weight of the glass chopped strands, unevenness of the roll outer peripheral surface, bending, undulation, etc. At the time of rolling, the thick part of the sheet-like deposit is strongly rolled and hardened by the outer periphery of the cooling roll, and the flexibility becomes poor. For this reason, when this chopped strand mat is formed, for example, as an automobile-molded ceiling material and applied to an opening such as a shade or a corner that has been deep-drawn, sinking may occur in the opening or the like, resulting in a defect. . Further, the portion having a small thickness of the sheet-like deposit is weakly rolled due to unevenness, bending, undulation or the like on the outer peripheral surface of the roll, and the bond becomes weak. The glass chopped strand mat is formed into a mat roll form by applying an adhesive such as phenol, melamine, or isocyanate, so when the glass chopped strand mat is pulled out from the mat roll, the glass chopped strand mat is torn from the weakly bonded portion. There is a case.

  For the above problem, the present inventors uniformly cooled and solidified the sheet-like deposit of glass chopped strands by providing a rubber layer on the outer periphery of at least one of the cooling rolls paired up and down, It has been found that a homogeneous glass chopped strand mat can be produced and the details are presented here.

  The said structure WHEREIN: It is preferable to position the cooling roll provided with the said rubber layer in the downward side.

  In this way, the elasticity of the rubber layer of the cooling roll located on the lower side allows efficient cooling by pressing the upper surface of the sheet-like deposit on which a large amount of binder is adhered to the surface of the upper cooling roll. Can do. Therefore, there is an advantage that troubles due to the sheet-like deposit winding around the outer periphery of the cooling roll are less likely to occur during cooling and solidification.

  In the above configuration, the thickness of the rubber layer is 2 mm or more and 4 mm or less, and the hardness of the rubber layer is compliant with Japanese Industrial Standard JIS K6253 (2006) “Vulcanized Rubber and Thermoplastic Rubber—How to Obtain Hardness”. It is preferably a value of 40 degrees or more and 100 degrees or less as measured by a compliant type A durometer (rubber hardness meter).

  In this way, the elasticity of the rubber layer becomes optimal, and the effects of uneven thickness of the sheet-like deposit, unevenness of the outer peripheral surface of the cooling roll, bending, and undulation can be reliably absorbed. That is, the sheet-like deposit can be uniformly rolled.

  As a method for measuring the thickness of the rubber layer, it is only necessary to use various calibrated measuring devices such as a laser measuring instrument and a micrometer and measure the accuracy with a precision of one decimal place in mm units.

  When the thickness of the rubber layer is less than 2 mm, the rubber layer cannot sufficiently exhibit the ability to absorb irregularities, bends and undulations on the outer peripheral surface of the cooling roll. On the other hand, if the thickness of the rubber layer exceeds 4 mm, the thickness of the rubber layer becomes excessive, and the cooling function by the cooling roll is not sufficiently exhibited, which is not preferable.

  If the hardness of the rubber layer is less than 40 degrees in the above measurement, the rubber layer becomes too soft and the rolling pressure by the cooling roller is not sufficiently transmitted to the sheet-like deposit, and the tensile strength of the glass chopped strand mat is reduced. This is not preferable because it becomes weak. On the other hand, when the hardness of the rubber layer exceeds 100 degrees, the rubber layer becomes too hard, and it is not preferable because the performance of absorbing irregularities on the outer surface of the cooling roll, the bending of the cooling roll, and the swell cannot be sufficiently exhibited. From such a viewpoint, the hardness of the rubber layer is more preferably 90 degrees or less, and still more preferably 80 degrees or less.

  In addition to the above hardness characteristics, the rubber layer preferably has a desired heat-resistant performance over time. Specifically, for example, a rubber material reinforced with aramid fiber, glass fiber, heat-resistant metal powder, or the like, or fluoro rubber (heat-resistant temperature 230 ° C.) having a heat-resistant temperature exceeding 100 ° C., acrylic rubber (heat-resistant temperature 160 ° C.), Use polyethylene rubber (heat resistant temperature 150 ° C), silicon rubber (heat resistant temperature 230 ° C), ethylene propylene rubber (heat resistant temperature 140 ° C), hydrogenated nitrile rubber (heat resistant temperature 140 ° C), butyl rubber (heat resistant temperature 140 ° C), etc. It is preferable. Moreover, it is good also as a structure which laminated | stacked these several rubber materials in the layer form. Further, the rubber layer may be fixed by extrapolating a tube-shaped rubber material in advance to the outer periphery of the cooling roll. Alternatively, an unvulcanized ribbon-shaped rubber material may be wound around the outer periphery of the cooling roll and then vulcanized and bonded in water vapor at 150 ° C. using a rubber adhesive. Moreover, what was shape | molded by the other method as needed can also be employ | adopted.

  Further, the cooling method of the cooling roll is not particularly limited as long as the cooling effect can be sufficiently obtained, and it is possible to use a gas such as air or a liquid such as water as the refrigerant. Considering the characteristics, cooling with water is preferable.

  Moreover, the cooling roll which provides a rubber layer should just have a structure which circulates refrigerant | coolants, such as cooling water, and has sufficient intensity | strength. Moreover, in order to improve the adhesiveness of the interface with a rubber layer, you may provide a desired fine unevenness | corrugation or a groove | channel on the outer peripheral surface of a cooling roll as needed. The outer peripheral surface of the cooling roll may be roughened by sandblasting or the like. As the cooling water, underground water, industrial water, city water, antioxidant-added water, rust inhibitor-added water, or the like may be appropriately employed.

The glass chopped strand mat according to the present invention, which was created to solve the above problems, is manufactured by the above-described manufacturing method, and has a basis weight of 50 g / m ² or more and 200 g / m ² or less. Here, the basis weight is measured according to JIS R3420 (2006).

If the glass chopped strand mat has a basis weight of less than 50 g / m ² , the basis weight is too small to have sufficient tensile strength, and thus problems such as tearing occur during the unwinding operation of the glass chopped strand mat. It becomes easy and is not preferable. On the other hand, if the basis weight exceeds 200 g / m ² , the basis weight of the glass chopped strand mat is too large, and the weight of the composite material using the mat becomes too heavy. It will be unsuitable for use. Therefore, the glass chopped strand mat weight per unit area is preferably in the above numerical range, and within this numerical range, the mat can have a sufficient tensile strength, and the weight can be appropriately reduced. Can be planned.

  And such a glass chopped strand mat can be suitably used as an automotive molded ceiling material by adhering to either one of the front and back surfaces of the foamed resin sheet.

  In addition, as an adhesive agent that adheres the glass chopped strand mat to the foamed resin sheet, for example, phenol, melamine, isocyanate, or the like can be used. Further, the glass chopped strand mat may be adhered only to the front surface or the back surface of the foamed resin sheet, or may be adhered to the front and back surfaces. In the case where the glass chopped strand mat is bonded only to one surface of the foamed resin sheet, whether or not the other reinforcing material is used on the other surface is not particularly limited.

  An apparatus for producing a glass chopped strand mat according to the present invention, created to solve the above problems, includes a cutting machine for cutting glass strands into glass chopped strands, and sheet-like deposition of glass chopped strands deposited in a sheet form. A spreader that spreads the binder on the object, a heater that heats the sheet deposit, and a cooling roll that forms a glass chopped strand mat that is paired up and down and cooled while rolling the sheet deposit The glass chopped strand mat manufacturing apparatus is characterized in that a rubber layer is provided on the outer periphery of at least one of the pair of cooling rolls.

  In addition to the above configuration, the conveyance means for conveying the sheet-like deposit and the glass chopped strand mat rolled by the cooling roll are continuously wound, and it is detected that the winding length is a predetermined length. When a mat cutting machine that cuts the glass chopped strand mat and a drive system that winds the glass chopped strand mat so as to form a mat roll (rolled body) having a predetermined length, the continuous mat can be manufactured. Since it can be performed smoothly, high production efficiency can be realized.

  (1) Locally weak parts are hardly formed in the tensile strength of the formed glass chopped strand mat, and a homogeneous sheet-like structure can be realized. Therefore, when the glass chopped strand mat is pulled out from the mat roll, the occurrence of tearing of the glass chopped strand mat can be suppressed. In addition, the molded glass chopped strand mat is less likely to have a portion with poor flexibility. For example, this chopped strand mat is molded as an automotive molded ceiling material and applied to openings such as shades and deep-drawn corners. Even in the case of doing so, it is possible to suppress the occurrence of sink marks.

  (2) By positioning the cooling roll provided with the rubber layer on the lower side, it is possible to efficiently cool the upper surface of the sheet-like deposit on which a large amount of the binder is adhered, Troubles caused by winding around the outer periphery of the cooling roll are less likely to occur.

  (3) When the thickness of the rubber layer is 2 mm or more and 4 mm or less and the hardness of the rubber layer is a value of 40 degrees or more and 100 degrees or less as measured by a type A hardness meter according to Japanese Industrial Standard JIS K6253 Due to the appropriate elasticity of the layer, it is possible to absorb the influence of uneven thickness of the sheet-like deposit, unevenness of the outer peripheral surface of the cooling roll, bending, undulation, etc., and uniform rolling can be achieved.

(4) The glass chopped strand mat produced by the method for producing a glass chopped strand mat of the present invention and having a basis weight of 50 g / m ² or more and 200 g / m ² or less has sufficient flexibility and a complicated shape. A site | part can be reinforced and generation | occurrence | production of the wrinkle-shaped shaping | molding defect of skins, such as a sink, can be suppressed when it uses for the shaping | molding ceiling material for motor vehicles.

  (5) An automotive molded ceiling material obtained by bonding the glass chopped strand mat of the present invention to at least one surface of a foamed resin sheet is lightweight and has sufficient strength, and can be applied to various automobiles. Demonstrate performance.

The conceptual diagram near a water cooling roll. The conceptual diagram of the manufacturing apparatus of a glass chopped strand mat.

  Embodiments of the present invention will be described below.

  First, the manufacturing process of a glass chopped strand is demonstrated. A glass fiber made of E glass is formed as a glass filament having a diameter of 11.6 μm from a platinum bushing having 1200 nozzles. On the surface of the drawn glass fiber, a polyvinyl acetate emulsion having a solid content of 50% by mass is 6% by mass, γ-methacryloxypropyltrimethoxysilane is 0.3% by mass, and a quaternary ammonium salt is 0.5% by mass. %, And the sizing agent adjusted so that the ion exchange water is 93.2% by mass is applied so that the adhesion amount is 0.4% by mass. The glass filament to which the sizing agent is applied is wound into 18 pieces by a carbon shoe to form a glass cake 5. For example, a glass strand composed of 1200 glass filaments becomes 18 glass strands composed of approximately 68 glass filaments. Thereafter, the glass cake 5 is dried for a predetermined time, and the sizing agent is fixed on the surface of the glass filament.

  The glass strand 10 is continuously unwound from the inner layer of the glass cake 5 that has finished the drying process, sent to a cutting machine 12 provided with a plurality of cutting blades, and cut into chopped strands 10a having a length of 50 mm. Each cutting machine 12 includes a pair of cutter rolls 12a and rubber rolls 12b that rotate in opposite directions. The glass strands 10 are sequentially fed between the cutter roll 12a and the rubber roll 12b of the cutting machine 12 and are continuously cut. The cutting machine 12 is disposed on the ceiling portion of the chamber 11, and the chopped strand 10 a cut to a size of 50 mm falls on the first transport conveyor 13 disposed on the bottom of the chamber 11 in a disorderly manner. It will be.

  The glass chopped strands 10a cut to a length of 50 mm are piled in a state of being uniformly distributed on the first conveyor 13, and are successively deposited in the form of sheets in the first conveyance. It is conveyed out of the chamber 11 by the conveyor 13. Next, the sheet-like deposit 10b of the dispersed glass chopped strands 10a is transferred to the second transport conveyor 14 on the downstream side, and on the sheet-like deposit 10b moving on the second transport conveyor 14, the spreader 15 The binder of the chopped strand 10a is sprayed so as to have a predetermined adhesion amount (12% by mass). This binder is, for example, a powdery resin P made of a bisphenol unsaturated polyester resin.

And the glass chopped strand 10a of the sheet-like deposit 10b and the powdery resin P spread | dispersed on it are transferred from the 2nd conveyance conveyor 14 to the 3rd conveyance conveyor 16 in the mutually disperse | distributed state. A heating furnace 17 is disposed in the middle of the third conveyor 16, and the sheet-like deposit 10 b on which the powdery resin P is dispersed moves into the heating furnace 17 and is heated at a predetermined temperature. As a result, the dispersed powdered resin P is heated and softened, and is melted on the surface of the glass chopped strand 10a. Next, the sheet-like deposit 10b is moved to the outside of the heating furnace 17 and rolled and cooled by the water-cooled roll 2a and the water-cooled roll 2b of the cooling rolling mill 1. As shown in FIG. 1, the water-cooled roll 2a and the water-cooled roll 2b are paired up and down, and the outer periphery of the lower water-cooled roll 2b has a thickness of 3 mm and a hardness of 70 degrees (in accordance with Japanese Industrial Standard JIS K6253 (2006)). A silicon rubber layer 3 having heat resistance is fixed by a type A durometer (measured with a rubber hardness meter). With respect to the feed direction V of the sheet-like deposit 10b, the water-cooled roll 2b rotates in the Ka direction in the figure, and the water-cooled roll 2a rotates in the Kb direction in the figure. When the sheet-like deposit 10b enters the gap between the water-cooled roll 2a and the water-cooled roll 2b and is rolled, the melted powdery resin P is cooled and solidified, and the glass chopped strand mat 19 is formed. The glass chopped strand mat 19 exiting the cooling and rolling mill 1 is wound up by a winder 21, and finally a mat roll (rolled body) 20 of the glass chopped strand mat 19 (weight per unit area: 100 g / m ² ) is obtained. . In addition, the winding length of the glass chopped strand mat 19 is measured by a detector such as a measuring machine, and when it is detected that this has reached a predetermined value, the glass chopped strand mat is cut by a cutting machine (not shown). Is done. Further, the glass chopped strand mat 19 is taken up by a rotation drive system (not shown).

  An automotive molded ceiling material was produced using the glass chopped strand mat 19 produced by obtaining the above production process, and the performance was investigated. The contents will be described below.

  First, as shown in Table 1, sample No. 1 to sample no. 5 and comparative sample No. A total of seven types of samples (car-molded ceiling materials) were prepared. That is, after impregnating a glass chopped strand mat 19 having a predetermined dimension of an E glass material, which is a strand count of Table 1, and adjusted to have a predetermined mat basis weight, with an isocyanate-based adhesive, The glass chopped strand mat 19, the foamed polyurethane sheet, another glass chopped strand mat 19 and a protective sheet (on the ceiling side of the automobile) were superposed in this order. Next, this laminate was placed in a press die having a shape of a molded ceiling, and press molding was performed in this state to obtain a predetermined shape having a ceiling portion, and then the periphery thereof was trimmed and arranged.

  In addition, the measurement of the strand count tex (tex) in the glass chopped strand mat 19 was performed by incinerating the glass chopped strand mat 19 at 620 ° C. for 30 minutes, and then extracting 50 glass chopped strands constituting the glass chopped strand mat 19. After measuring the average length L (mm), 50 total masses W (g) were measured using a scale having a sensitivity of 0.1 mg or less, and calculated by the equation shown in Equation 1. Since this equation represents the weight of a strand length of 1000 m, the unit is converted from mm (millimeter) to m (meter).

  Each sample prepared by the above procedure was investigated by the following evaluation method.

  The adhesion amount of the binder of the glass chopped strand mat is obtained by subtracting the ignition loss of the cake used for the production of the glass chopped strand from the ignition loss of the glass chopped strand mat measured by the method described in JIS R3420 (2006). Asked.

  Moreover, about the automotive molded ceiling material, the expert inspected the quantity which the sink defect which is a wrinkle-like defect generate | occur | produced on the skin side about 1000 automotive molded ceiling materials. The above results are shown in Table 1.

As is clear from Table 1, sample No. No. 1 is a sample having a strand count of 20 tex, a mat basis weight of 107 g / cm ² , and a binder adhesion amount of 12%. Cooling with a rubber layer having a thickness of 2 mm and a hardness of 50 degrees fixed to the outer periphery of the lower water-cooling roll 2b. Although it manufactured with the manufacturing apparatus which has the rolling mill 1, when pulling out a mat | matte from a mat roll, a glass chopped strand mat was not torn off and the defect rate by poor sink was also 0%.

Sample No. No. 2 is a sample having a strand count of 18 tex, a mat basis weight of 107 g / cm ² , and an adhesion amount of binder of 11%. Cooling with a rubber layer having a thickness of 3 mm and a hardness of 60 degrees fixed to the outer periphery of the lower water-cooled roll 2b. Although it was manufactured with the manufacturing apparatus which has the rolling mill 1, when pulling out a mat from a mat roll, a glass chopped strand mat is not torn off, and the defect rate by a sink defect is also sample No. Similar to 1, it was 0%.

Furthermore, sample no. No. 3 is a cold rolling mill 1 having a strand count of 20 tex, a mat basis weight of 107 g / cm ² , a binder adhesion amount of 10%, and a rubber layer having a thickness of 3 mm and a hardness of 65 degrees fixed to the outer periphery of the lower water-cooled roll 2b. Manufactured by a manufacturing apparatus having a sample No. No. 4 is a cold rolling mill 1 having a strand count of 22 tex, a mat basis weight of 107 g / cm ² , a binder adhesion amount of 9%, and a rubber layer having a thickness of 3 mm and a hardness of 70 degrees fixed to the outer periphery of the lower water-cooled roll 2b. Manufactured by a manufacturing apparatus having a sample No. No. 5 is cold-rolled with a strand count of 19 tex, a mat basis weight of 107 g / cm ² , a binder adhesion amount of 9%, and a rubber layer having a thickness of 3.5 mm and a hardness of 80 degrees fixed to the outer periphery of the lower water-cooled roll 2b The glass chopped strand mat is not torn when pulling out the mat from the mat roll, and the defect rate due to poor sink is also the same as that of Sample No. Similar to 1, it was 0%.

On the other hand, sample No. which is a comparative example. No. 6 was manufactured by a manufacturing apparatus having a cold rolling mill 1 having a strand count of 18 tex, a mat basis weight of 107 g / cm ² , a binder adhesion amount of 10%, and upper and lower water-cooled rolls having no rubber layer. However, the glass chopped strand mat partially had a portion with low tensile strength, and tearing occurred when it was pulled out from the mat roll.

In addition, sample No. 7 is a sample in which the strand count is 20 tex, the mat basis weight is 107 g / cm ² , and the adhesion amount of the binder is 15%, but using the cooling and rolling mill 1 in which upper and lower water-cooling rolls having no rubber layer are arranged. Since it was rolled, the glass chopped strand mat had a part that was partially hard, so that the flexibility was lost and the incidence of sink defects was as high as 16%.

  As mentioned above, the manufacturing method of the glass chopped strand mat of this invention can manufacture the glass chopped strand mat of the stable quality efficiently. In addition, it is clear that automotive molded ceiling materials can be reduced in weight without causing problems due to insufficient strength, and can be manufactured with an excellent quality that does not cause sink defects in appearance quality. became.

  The glass chopped strand mat of the present invention is suitable for use in automobile molded ceiling materials, but also various precision housing components such as electronics industry, building materials, various components for industrial use, etc. Can be used for applications.

1 Cold rolling mill 2a Water cooling roll (upper side)
2b Water-cooled roll (lower side)
3 Rubber layer 5 Glass cake 10 Glass strand 10a Glass chopped strand 10b Sheet deposit 11 Chamber 12 Cutting machine 12a Cutter roll 12b Rubber roll 13 First transport conveyor 14 Second transport conveyor 15 Spreader 16 Third transport conveyor 17 Heating furnace 19 Glass chopped strand mat 20 Mat roll (Glass chopped strand mat wound body)
21 Winder 50 Glass fiber mat manufacturing equipment P Powder polyester resin (binder)
Ka Rotating direction of lower water-cooled roll Kb Rotating direction of upper water-cooled roll L Average length of glass chopped strand V Moving direction of glass chopped strand mat W Total mass of 50 glass chopped strands

Claims (6)

  A binder is sprayed on a sheet-like deposit in which glass chopped strands are deposited in a sheet form, the sheet-like deposit is heated, and the sheet-like deposit is paired vertically and a rubber layer on at least one outer periphery A method for producing a glass chopped strand mat in which the glass chopped strands in the sheet-like deposit are bonded to each other by rolling while being rolled with a cooling roll provided with.   The method for producing a glass chopped strand mat according to claim 1, wherein the cooling roll provided with the rubber layer is positioned on the lower side.   The thickness of the rubber layer is 2 mm or more and 4 mm or less, and the hardness of the rubber layer is a value of 40 degrees or more and 100 degrees or less as measured by a type A durometer according to Japanese Industrial Standard JIS K6253 (2006). The manufacturing method of the glass chopped strand mat of Claim 1 or 2. A glass chopped strand mat produced by the method for producing a glass chopped strand mat according to any one of claims 1 to 3, wherein the basis weight is 50 g / m ² or more and 200 g / m ² or less.   An automotive molded ceiling material, wherein the glass chopped strand mat according to claim 4 is bonded to at least one surface of a foamed resin sheet.   A cutting machine that cuts glass strands into glass chopped strands, a spreader that spreads the binder on the sheet-like deposits of glass chopped strands deposited in a sheet, and a heater that heats the sheet-like deposits, A glass chopped strand mat manufacturing apparatus comprising a cooling roll that forms a glass chopped strand mat by rolling while rolling a sheet-like deposit to form a glass chopped strand mat, and at least one of the paired cooling rolls An apparatus for producing a glass chopped strand mat, wherein a rubber layer is provided on the outer periphery of the glass chopped strand mat.