JP5705650B2 - Inorganic fiber wound tape and method for producing the same - Google Patents

Description

  The present invention relates to an inorganic fiber wound tape in which an inorganic fiber tape excluding carbon is wound around a cylindrical core material, and a method for producing the same.

  Inorganic fibers made of glass, silica, alumina, basalt, and the like are inexpensive and have high mechanical strength, and are therefore widely used as reinforcing fibers for resin materials used in various applications.

  Patent Document 1 is an invention of a method for producing a long fiber reinforced composite material, and paragraph No. 0007 shows continuous fibers such as glass fibers, carbon fibers, metal fibers, and aromatic polyamide fibers as examples of fibers. Yes.

  Patent Document 2 is an invention of a tape-shaped molding material obtained by impregnating a reinforcing fiber satisfying a predetermined conditional expression with a thermoplastic resin. In paragraph 0007, glass fibers, carbon fibers, aramid fibers, ceramic fibers, metal fibers, etc. are exemplified as reinforcing fibers.

  Patent document 3 is invention of the manufacturing apparatus of a carbon fiber reinforced thermoplastic resin tape. The manufacturing apparatus is characterized by discharging fluff generated during the manufacture of a carbon fiber reinforced thermoplastic resin tape.

  Patent Document 4 is an invention of a method for producing a carbon fiber reinforced thermoplastic resin tape, but there is no description of inorganic fibers. Further, it is described that the obtained tape thickness is 130 μm or less, and those exceeding 130 μm have inferior bending strength (see Table 1). The invention of Patent Document 4 attempts to increase the bending strength by reducing the tape thickness based on the knowledge that the bending strength is poor when the tape thickness is large.

Japanese Patent No. 3119699 Japanese Patent No. 3386158 JP 2007-76224 A JP 2007-118216 A

  When storing and transporting tapes containing inorganic fibers, it is difficult to handle them as long as they are long. Get better. Furthermore, depending on the type of work, a small-diameter winding tape may be easy to use, or a large-diameter winding tape may be easy to use.

However, it is difficult to produce a small-diameter winding tape or a large-diameter winding tape with only one tape containing inorganic fibers.
For example, as described in Patent Document 4, in the case of a tape containing carbon fiber, when the thickness of the tape is increased (when the thickness exceeds 130 μm), the bending strength is inferior (that is, when the thickness is increased, winding is performed). It was known that it was difficult to preserve). From this fact, it is sufficient to make the carbon fiber tape thin. However, it is technically difficult to make the carbon fiber tape too thin.
As described above, inorganic fiber tapes that can be wound around core materials of different diameters, can be stored and transported in a wound state, and can be taken out from the wound state at a work site and used are known. It was not done.

  An object of the present invention is to provide an inorganic fiber wound tape in which an inorganic fiber tape is wound around a cylindrical core material, which can be easily stored and transported, and can significantly improve workability, and a method for producing the same. To do.

As a means for solving the problems, the present invention
An inorganic fiber tape composed of a composite containing inorganic fibers (not including carbon fibers) and an olefin resin is an inorganic fiber wound tape wound around a cylindrical core material,
The width (W) of the inorganic fiber tape obtained from the formula (I) is in the range of 5 to 100 mm,
Provided is an inorganic fiber wound tape in which the minimum diameter (D) of a cylindrical core member around which an inorganic fiber tape having a width (W) of 5 to 100 mm is wound is obtained from the formula (II).
2.5 × 10 ⁻⁵ × N × d ≦ W ≦ 5.0 × 10 ⁻⁴ × N × d (I)
(In formula (I), W is the width of the inorganic fiber tape, N is the number of inorganic fibers constituting the inorganic fiber tape, and the number that can make the width (W) in the range of 5 to 100 mm, d is (The fiber diameter of the inorganic fiber is in the range of 5 to 30 μm.)
3.0 × F × t ≦ D (II)
(In Formula (II), F is the amount of inorganic fibers and is in the range of 20 to 60% by mass, and t is the thickness of the inorganic fiber tape and is in the range of 0.1 to 1.0 mm.)

The present invention also provides a solution to other problems.
A method for producing the above inorganic fiber wound tape,
Introducing a bundling body including one or more inorganic fibers into a crosshead die;
Tape-shaped composite in which tape-shaped inorganic fiber and thermoplastic resin are integrated by bringing the bundle containing inorganic fiber into contact with the molten resin in the cross-head die in the heated and pressurized state. Obtaining a step,
A step of obtaining an inorganic fiber tape by extruding the tape-shaped composite from the slit outlet of the cross-head die, supporting it from both sides in the thickness direction, and cooling;
A step of winding around the obtained inorganic fiber tape cylindrical core material,
The manufacturing method of the inorganic fiber winding tape which has this.

  Since the inorganic fiber wound tape of the present invention is in a form in which the inorganic fiber tape is wound around the core material, it can be easily stored and transported, and can be taken out and used in a necessary amount.

Schematic which shows the manufacturing flow for demonstrating the manufacturing method of an inorganic fiber winding tape. Schematic which shows the other manufacturing flow for demonstrating the manufacturing method of an inorganic fiber winding tape.

<Inorganic fiber wound tape>
The inorganic fiber wound tape of the present invention is one in which an inorganic fiber tape is wound (wound) around a cylindrical core material many times (multiple layers).

  The inorganic fiber tape used in the inorganic fiber wound tape of the present invention can be wound around a cylindrical core material and has no change in appearance when at least the durability tests 1 and 2 described in the examples are carried out ( That does not cause cracks).

The inorganic fiber tape used in the inorganic fiber wound tape of the present invention has a width (W) determined from the following formula (I) in the range of 5 to 100 mm.
2.5 × 10 ⁻⁵ × N × d ≦ W ≦ 5.0 × 10 ⁻⁴ × N × d (I)
(In formula (I), W is the width of the inorganic fiber tape, N is the number of inorganic fibers constituting the inorganic fiber tape, and the number that can make the width (W) in the range of 5 to 100 mm, d is (The fiber diameter of the inorganic fiber is in the range of 5 to 30 μm.)

The width (W) of the inorganic fiber tape obtained from the formula (I) is, for example,
20,000 inorganic fibers having a fiber diameter of 10 μm are used, and the width (W) of the inorganic fiber tape is set in the range of 5 to 100 mm.
10,000 inorganic fibers having a fiber diameter of 20 μm are used, and the width (W) of the inorganic fiber tape is set in the range of 5 to 100 mm.
7,000 inorganic fibers having a fiber diameter of 30 μm are used, and the width (W) of the inorganic fiber tape can be in the range of about 5 to about 100 mm.
If the width (W) of the inorganic fiber tape obtained from the formula (I) is 5 mm or more, the resin (olefin resin) is sufficiently impregnated, so that the strength of the inorganic fiber tape itself is increased, and the fiber during production Cutting is difficult to occur.
When the width (W) of the inorganic fiber tape obtained from the formula (I) is 100 mm or less, the distribution of the inorganic fibers in the tape becomes uniform, so that the function due to the inclusion of the inorganic fibers is sufficiently expressed. Besides, it is easy to handle.
10-80 mm is preferable and, as for the width | variety (W) of the inorganic fiber tape calculated | required from Formula (I), 10-50 mm is more preferable.

The cylindrical core material used in the inorganic fiber-wound tape of the present invention has a circular cross section in the width (diameter) direction, but may be polygonal (more than a triangle, but preferably hexagonal, octagonal, etc.). It may be oval.
The cylindrical core material can be made of paper, wood, plastic, metal, ceramics, or the like.

  The minimum diameter (minimum outer diameter) (D) of the cylindrical core material is obtained from the formula (II). The minimum diameter (D) of the cylindrical core material can take up the inorganic fiber tape having the above-mentioned width (W), and the appearance changes when at least the durability tests 1 and 2 described in the examples are performed. It is the minimum value that does not cause (crack or the like not to occur).

3.0 × F × t ≦ D (II)
(In Formula (II), F is the amount of inorganic fibers and is in the range of 20 to 60% by mass, and t is the thickness of the inorganic fiber tape and is in the range of 0.1 to 1.0 mm.)
In addition, when the cross-sectional shape of the cylindrical core is a polygon, for example, a hexagon, the length connecting the opposite corners is D, and in the case of an ellipse, the length of the major axis is D. .

As the inorganic fiber tape has a smaller amount of inorganic fiber (that is, a larger amount of olefin-based resin), the flexibility is improved and the core fiber is easily wound. However, if a certain width is to be secured from the viewpoint of handling, etc., it becomes difficult to uniformly disperse the fibers, and the amount of inorganic fibers is small, so that the mechanical strength is also lowered.
In addition, the greater the amount of inorganic fiber (that is, the smaller the amount of olefinic resin), the lower the flexibility and the difficulty of winding on the core material.
Furthermore, although the inorganic fiber tape is easy to manufacture when the thickness is large, it is difficult to wind the core around the core material. When the thickness is small, the manufacture becomes difficult, but it is easy to wind around the core material.

Formula (II) calculates | requires the minimum diameter (D) of the cylindrical core material which can wind and hold | maintain an inorganic fiber tape from the relationship of the inorganic fiber density | concentration (F) and thickness (t) of an inorganic fiber tape.
Specifically, when an inorganic fiber tape having various concentrations (F) and thicknesses (t) is wound around a core material having various diameters, the minimum diameter of the core material when no change in appearance occurs in the inorganic fiber tape ( D) is measured experimentally, and equation (II) can be derived from the relationship with concentration (F) and thickness (t).

When the diameter is equal to or larger than the minimum diameter (D) of the cylindrical core material obtained from the formula (II), the inorganic fiber tape is not cracked when wound and held. In addition, the minimum diameter (D) of the cylindrical core material is 25 mm among those satisfying the minimum diameter (D) obtained from the formula (II) from the viewpoint of ease of handling during transportation, storage, work, etc. It is preferable that it is above, and it is more preferable that it is 30 mm or more.
In addition, the upper limit of the cylindrical core material is not limited for the reason that the inorganic fiber tape can be wound and does not cause cracks, etc., according to requests from the manufacturing process, storage and transportation, work site, etc. For example, it can be set to 1000 mm or less, but is preferably 800 mm or less, more preferably 600 mm or less and 500 mm or less from the viewpoint of handling.

Depending on the type of inorganic fiber used, the rigidity (flexural modulus, tensile strength, etc.) of the tape varies even with the same tape width, tape thickness, and tape length.
For this reason, depending on the type of inorganic fiber tape (the type of inorganic fiber contained in the inorganic fiber tape), it is desirable to adjust the minimum diameter (D) of the core material determined by the formula (II).
For example, the flexural modulus (or tensile strength) (S1) and minimum diameter (D1) of a glass fiber tape having a width of 50 mm, a thickness of 0.4 mm, and a length of 80 mm determined from the formula (I) and 60% by mass of an olefin resin. ) As a standard, the minimum diameter (D2) when the flexural modulus (or tensile strength) (S2) of other fibers is the same as
It can be obtained from the following formula: D2 = D1 × S2 / S1.

The inorganic fiber tape used as an inorganic fiber winding tape consists of a composite containing inorganic fiber and olefin resin. In addition, carbon fiber is not contained in the inorganic fiber used by this invention.
Inorganic fibers are known, and those selected from glass fibers, basalt fibers, silica fibers, silica / alumina fibers, zirconia fibers, boron nitride fibers, silicon nitride fibers and the like can be used.

Olefin resins include polypropylene, high density, low density and linear low density polyethylene, poly-1-butene, polyisobutylene, ethylene / propylene copolymer, ethylene-propylene-diene terpolymer (as raw materials) Diene component is 10% by mass or less), random with polymethylpentene, ethylene or propylene (50 mol% or more) and other copolymerization monomers (vinyl acetate, alkyl methacrylate, alkyl acrylate, aromatic vinyl, etc.) Blocks, graft copolymers and the like can be used. These olefinic resins may be used alone or in combination of two or more.
In addition, the olefin resin can contain acid-modified polyolefin in the olefin resin in order to enhance the adhesion with the inorganic fiber. The content of the acid-modified polyolefin is preferably 20% by mass or less in the total amount of the olefin resin and the acid-modified polyolefin. As the acid-modified polyolefin, for example, the same ones as described in [0010] to [0014] of JP-A-2005-125581 can be used.

  The inorganic fiber wound tape of the present invention is in the form of being wound around a cylindrical core material, and can be used as an inorganic fiber tape by drawing out an appropriate length and cutting it to a desired length during operation. .

  The inorganic fiber tape taken out from the inorganic fiber wound tape of the present invention can be used as a reinforcing material for various resin molded products.

The inorganic fiber tape taken out from the inorganic fiber wound tape of the present invention can be formed into a sheet-like woven fabric by applying a method such as plain weave, twill weave, satin weave, etc. Can also be processed.
Moreover, the inorganic fiber tape taken out from the inorganic fiber wound tape of the present invention can be knitted into a cylindrical shape.

  Since the inorganic fiber tape taken out from the inorganic fiber wound tape of the present invention, the sheet and the cylindrical body obtained therefrom, etc. contain an olefin resin, it can be transformed into a desired shape by heating.

<Inorganic fiber wound tape manufacturing method>
The manufacturing method of an inorganic fiber winding tape is demonstrated with FIG. 1, FIG.
In the first step, the bundling body 10 including one or more inorganic fibers is introduced into the crosshead die 20 while being supported by the feed rolls 15 and 16.
The bundle 10 is preferably an inorganic fiber bundle having a fiber diameter of 5 to 24 μm and a fiber count of 1000 to 200,000, more preferably 3000 to 150,000.
As this inorganic fiber bundle, a commercially available inorganic fiber bundle (for example, 20K = 20,000) may be used as it is, or a plurality of commercially available inorganic fiber bundles are used in combination (for example, 5K = 5,000 fiber bundles). 4 bundles may be used to make 20,000).
Moreover, this bundling body 10 may use the inorganic fiber bundle as it is, or the surface of the inorganic fiber bundle is surface-treated with a bundling agent so as to be temporarily fixed (the bundle does not come apart and the subsequent fiber opening operation) It is also possible to have an integrated state that does not damage the surface.

  Next, in the cross-head die 20, the bundling body 10 containing inorganic fibers is brought into contact with a molten resin (a molten olefin resin) in a heated and pressurized state while opening.

  The converging body 10 may be opened by any method that can apply pressure to the converging body 10 in the thickness direction. In the present invention, the cross head die 20 in which the upper die 21 and the lower die 22 are combined is used. .

  The cross-head die 20 includes an upper die 21 having a wave-shaped unevenness 21a formed continuously in the length direction, and a wave-shaped unevenness formed so as to be fitted to the wave-shaped unevenness 21a of the upper mold 21. A lower die 22 having 22a is combined.

  The upper mold 21 (or the lower mold 22) is provided with a molten resin introduction line (introduction hole) 25, and the molten resin is supplied to the passing gap of the focusing body 10 between the upper mold 21 and the lower mold 22. It can be done.

  A heating means is attached to each of the upper mold 21 and the lower mold 22 to heat the focusing body 10 passing through the passage gap. The heating temperature at this time is a temperature equal to or higher than the melting point of the resin (olefin resin) supplied from the introduction line (introduction hole) 25.

  When the converging body 10 passes through the passage gap between the upper die 21 and the lower die 22, it is opened in the process of zigzag passing through the gaps between the irregularities 21a and 22a, and impregnated with a molten olefin resin between the inorganic fibers. Is done.

  Then, the composite body in which the focusing body 10 and the olefin resin are integrated is extruded from the slit outlet 26 of the crosshead die 20 into a tape shape (inorganic fiber tape 11). At this time, the thickness and width of the inorganic fiber tape 11 are adjusted by adjusting the size of the slit outlet 26.

Then, it is taken up while being cooled by cooling rolls 31, 32, 33 appropriately disposed, and wound around a cylindrical core material to obtain an inorganic fiber wound tape.
In FIG. 1, the cooling rolls 31, 32, and 33 are arranged at positions where they do not come into contact with each other via the inorganic fiber tape 11, and one surface of the inorganic fiber tape 11 is cooled first, and then the other surface is To be cooled.
In FIG. 2, the cooling rolls 31 and 32 are arrange | positioned in the position which each contact | abuts via the inorganic fiber tape 11, and both surfaces of the inorganic fiber tape 11 are cooled simultaneously.

Production example (Manufacture of inorganic fiber tape)
The inorganic fiber tape having the fiber concentration and thickness shown in Table 1 was manufactured by the flow shown in FIG.

<Inorganic fiber bundle 10>
Glass fiber bundle: RS240QR-489 (manufactured by Nitto Boseki Co., Ltd.)
Basalt fiber bundle: BCF13-1200-KV12 (manufactured by KAMENNY VEK LTD)
<Olefin resin>
Mixture of 97% by mass of polypropylene (PMB60A (manufactured by Sun Allomer Co., Ltd.)) and 3% by mass of maleic acid-modified polypropylene (1.0% by mass of maleic acid-modified, OREVAC CA100: manufactured by Atofina) <Production conditions>
Feed speed of focusing body 10: 5 m / min Heating temperature of crosshead die 20: 290 ° C.
Slit exit: width (tape thickness) 0.1-1.0 mm x length (tape width) 10-50 mm
Surface temperature of cooling roll 31: 80 ° C.
Surface temperature of cooling roll 32: 80 ° C.
Surface temperature of cooling roll 33: 60 ° C

表１に示す円筒状芯材の最小直径（Ｄ）はガラス繊維テープのものであり、式（II）：３．０×Ｆ×ｔ≦Ｄ、から求めた。

The minimum diameter (D) of the cylindrical core material shown in Table 1 is that of the glass fiber tape, and was determined from the formula (II): 3.0 × F × t ≦ D.

The minimum diameter (D) of the cylindrical core material when using the basalt fiber tape was calculated as follows from the minimum diameter (D) of the glass fiber tape shown in Table 1.
The tensile strength of a glass fiber tape having a width of 50 mm, a thickness of 0.4 mm, and a length of 80 mm and 60% by mass of polypropylene was 1260 MPa, and the tensile strength of a basalt fiber tape having the same dimensions was 1330 MPa. Tensile strength (MPa): measured in accordance with ISO527-1.
The minimum diameter (D2) of the cylindrical core material when using basalt fiber tape is the minimum diameter (D1) when using the glass fiber tape shown in Table 1 × Tensile strength (S2) of basalt fiber tape / glass fiber It was calculated from the tensile strength (S1) of the tape.

From the results shown in Table 1, a glass fiber tape having a fiber concentration (F) of 20 mass% and a thickness (t) of 0.6 mm can be wound around a core material having a minimum diameter (D) of 36 mm.
Moreover, since the basalt fiber tape having a fiber concentration (F) of 20% by mass and a thickness (t) of 0.6 mm is 36 × 1.06 = 38.2 mm, it can be wound around a core material of 39 mm or more. Become.

Examples and Comparative Examples The following durability test 1 was performed on the inorganic fiber tapes shown in Tables 2 and 3. The results are shown in Tables 2 and 3.

(Durability test 1)
The inorganic fiber wound tape was manufactured by using the apparatus shown in FIG. 1 and mechanically winding the core material having the diameters shown in Tables 2 and 3 into 3 to 5 layers. The winding end was fixed with an adhesive tape. The obtained inorganic fiber-wound tape was wound up with each layer in a dense state by visual observation. The obtained inorganic fiber wound tape was subjected to the durability test 1 shown below.
The inorganic fiber wound tape was kept at room temperature (20 to 25 ° C.) in a humidity (50%) atmosphere for 24 hours (one day) or more.
Then, all the inorganic fiber tapes were unwound from the inorganic fiber wound tape, and the surface was observed with the naked eye to observe whether there were changes such as cracks. The results are shown in Tables 2 and 3.

Comparative Example A is an example in which the concentration of inorganic fibers is outside the scope of the present invention (10% by mass), and as a result of non-uniform fiber dispersion, the fiber spacing is too wide, causing poor appearance and Sufficient mechanical properties due to blending were not obtained, resulting in product defects.
In Comparative Example B, the width (W) was outside the range of the present invention (3 mm), and fiber breakage occurred at the time of production, making it impossible to produce a tape.
Examples 1 to 6 and Comparative Examples 1 to 6 are examples of pairs. In Examples 1 to 6, there was no occurrence of cracks due to the use of the core material satisfying the minimum diameter (D) shown in Table 1, but Comparative Examples 1 to 6 were from the minimum diameter (D). Since a core material with a small diameter was used, cracks were generated.

(Durability test 2)
Each of the tapes of Examples 1 to 6 shown in Tables 2 and 3 is the original shape as soon as one end of the tape is fixed and the other end is grasped and rotated by 180 ° and then deformed, and then the other end is released. Recovered. Even when this was repeated 10 times or more, no change was observed in the appearance of the tape.

DESCRIPTION OF SYMBOLS 10 Inorganic fiber tape-like bundling body 11 Inorganic fiber tape 20 Crosshead die 21 Upper mold | type 22 Lower mold | type 25 Molten resin supply line (supply hole)
26 Slit exit 31, 32, 33 Cooling roll

Claims (5)

An inorganic fiber tape composed of a composite containing inorganic fibers (not including carbon fibers) and an olefin resin is an inorganic fiber wound tape wound around a cylindrical core material,
The width (W) of the inorganic fiber tape obtained from the formula (I) is in the range of 5 to 100 mm,
The inorganic fiber winding tape whose minimum diameter (D) of the cylindrical core material around which the inorganic fiber tape having the width (W) in the range of 5 to 100 mm is wound is obtained from the formula (II).
2.5 × 10 ⁻⁵ × N × d ≦ W ≦ 5.0 × 10 ⁻⁴ × N × d (I)
(In formula (I), W is the width of the inorganic fiber tape, N is the number of inorganic fibers constituting the inorganic fiber tape, and the number that can make the width (W) in the range of 5 to 100 mm, d is (The fiber diameter of the inorganic fiber is in the range of 5 to 30 μm.)
3.0 × F × t ≦ D (II)
(In Formula (II), F is the amount of inorganic fibers and is in the range of 20 to 60% by mass, and t is the thickness of the inorganic fiber tape and is in the range of 0.1 to 1.0 mm.)   The inorganic fiber wound tape according to claim 1, wherein the width (W) of the inorganic fiber tape is 10 to 80 mm.   The inorganic fiber according to claim 1 or 2, wherein the inorganic fiber (not including carbon fiber) is selected from glass fiber, basalt fiber, silica fiber, silica / alumina fiber, zirconia fiber, boron nitride fiber, and silicon nitride fiber. Winding tape. It is a manufacturing method of the inorganic fiber winding tape according to any one of claims 1 to 3,
Introducing a bundling body including one or more inorganic fibers into a crosshead die;
Tape-shaped composite in which tape-shaped inorganic fiber and thermoplastic resin are integrated by bringing the bundle containing inorganic fiber into contact with the molten resin in the cross-head die in the heated and pressurized state. Obtaining a step,
A step of obtaining an inorganic fiber tape by extruding the tape-shaped composite from the slit outlet of the cross-head die, supporting it from both sides in the thickness direction, and cooling;
A step of winding around the obtained inorganic fiber tape cylindrical core material,
The manufacturing method of the inorganic fiber winding tape which has this. The crosshead die has an upper mold having wave-shaped irregularities formed continuously in the length direction, and a lower mold having wave-shaped irregularities formed so as to be fitted to the wave-shaped irregularities of the upper mold. The molds are combined, and one of the molds is provided with a molten resin introduction hole,
The method for producing an inorganic fiber wound tape according to claim 4, wherein the opening of the bundling body including the inorganic fibers is performed by zigzaging the bundling body between the upper mold and the lower mold.

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