JPH02220842A - Composite formed body in continuous form and manufacture thereof - Google Patents

Abstract

PURPOSE:To improve the deformation due to thermal elongation and contraction, rigidity, impact resistance, heat resistance and ply separation and enhance the durability of a formed body by a method wherein composite core material produced by boding fiber sheeting between core materials, each of which is produced by fixing a large number of long fibers by thermoplastic resin, is integrally covered by thermoplastic resin. CONSTITUTION:Composite formed body in continuous form A consists of composite core material 10 and thermoplastic resin 20, which covers the composite core material 10 integrally. The core material 10 is produced by bonding fiber sheeting 13 between two sheets of core material 10' and 10', each of which is produced by fixing a large number of long fibers 11 by thermoplastic resin. As the long fiber 11, roving made of glass fiber, carbon fiber, alumina fiber or the like is used. As the thermoplastic resin 12, polyvinyl chloride, vinylidene chloride resin or the like is used. As the fiber sheeting, paper such as paper board or the like, woven fabric, non-woven fabric made of synthetic fiber or these impregnated with liquid synthetic resin is used. Further, as the thermoplastic resin 20, which covers the composite core material 20, any resin, which thermally fuses with the thermoplastic resin 12 in combination, is used.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a long composite molded article with excellent durability and a method for producing the same.

(Prior Art) Building materials such as rain gutters are molded into long lengths from thermoplastic resin such as vinyl chloride resin and are widely used. However, such thermoplastic resin molded articles have large thermal expansion and contraction and low rigidity, and therefore have the disadvantage that they are easily deformed due to the seasons and changes in temperature between day and night, and are prone to cracking.

In order to improve such drawbacks, for example, Japanese Patent Application Laid-Open No. 1986-
No. 209560 discloses that a fiber base material such as a glass fiber mat is impregnated with a thermosetting resin liquid such as an unsaturated polyester resin to form a semi-cured prepreg core material, and this is applied to the crosshead of an extruder. A method is disclosed for manufacturing elongated composite molded bodies, such as rain gutters, by introducing and melt extrusion coating a thermoplastic phase such as vinyl chloride.

However, in such long composite molded bodies, residual monomers and solvents from the thermosetting resin liquid remaining in the semi-cured prepreg core material are removed by the melting of the thermoplastic resin by the crosshead mold of the extruder. During extrusion coating, the resin evaporates and foams, creating voids inside.

As a result, the adhesion between the fiber base material and the thermosetting resin decreases, and cracks are likely to occur from voids, and if the resulting composite molded product is used for a long time, the core material may crack or crack due to impact. There is a problem in that glabellar peeling occurs. Further, even if the prepreg core material is completely cured and then coated with a thermoplastic resin by melt extrusion, similar voids will occur in the prepreg core material before melt extrusion coating, resulting in the same problem as above.

(Problems to be Solved by the Invention) Therefore, the present inventor developed a powdered thermoplastic resin that does not contain volatile components such as sulfur and solvent, and a series of continuous polyester resins that are easily impregnated with the powdered thermoplastic resin. A large number of continuous long fibers are introduced into a fluidized bed and impregnated with powdered thermoplastic resin to form a core material, and this core material is introduced into the crosshead of an extruder. An attempt was made to melt-extrude the thermoplastic resin and integrate it.

As a result, it was found that the adhesion between the core material and the thermoplastic resin coated thereon was improved, and peeling between the eyebrows was prevented.

However, when a large number of continuous long fibers are used, the impregnating properties of the powdered thermoplastic resin are good, but since the long fibers are oriented in one direction, the strength is directional and the impact resistance is insufficient. It was found that there was a problem in that the symptoms did not appear. Also,
Because thermoplastic resin is used, the core material does not have sufficient heat resistance.
In particular, when the content of long fibers is relatively small, there is a problem that the core material may be deformed due to the resin pressure in the crosshead mold, or that the resulting molded product is significantly deformed when used at high temperatures.

The present invention solves the above problems, and aims to improve deformation due to thermal expansion and contraction, rigidity, impact resistance,
It is an object of the present invention to provide a long composite molded article with improved heat resistance and delamination and excellent durability, and a method for producing the same.

(Means for Solving the Problems) The long composite molded article of the present invention is made by bonding a fiber sheet material between at least two core materials in which a large number of continuous long fibers are fixed with a thermoplastic resin. It is characterized in that a core material is formed, and this composite core material is integrally coated with a thermoplastic resin.

Furthermore, the method for producing a long composite molded article of the present invention includes introducing a large number of continuous long fibers into a fluidized bed and impregnating them with a powdered thermoplastic resin to produce at least two sheets of resin-impregnated fiber material.
A fiber sheet material is thermocompressed between the at least two resin-impregnated fiber materials to form a composite core material, and the composite core material is introduced into a crosshead mold of an extruder to melt the resin, It is characterized by melt-extrusion coating and integration of thermoplastic resin.

With the above configuration, the object of the present invention is achieved.

Hereinafter, the present invention will be explained with reference to the drawings.

FIGS. 1 and 2 show an example of the elongated composite molded article of the present invention. In FIG. 1, A is a long composite molded body shaped like an eave gutter, 10 is a composite core material, and 20 is a composite core material 10.
It is a thermoplastic resin that is integrated with the coating. As shown in FIG. 2, the above composite core material 10 consists of two core materials 10' and 10' in which a large number of long fibers 11 are fixed with a thermoplastic resin 12.
A fiber sheet material 13 is bonded between them.

As the long fibers 11, rovings such as glass fiber, carbon fiber, alumina fiber, aramid fiber, etc. are preferably used. If a large number of such rovings are arranged in the longitudinal direction, the coefficient of linear expansion of the resulting composite molded article will closely match the theoretical value. preferable.

Examples of the thermoplastic resin 12 fixing the large number of long fibers 11 include vinyl chloride resin, vinylidene chloride resin, olefin resin such as polyethylene and polypropylene, acrylic resin, ethylene-vinyl acetate copolymer resin, and vinyl chloride resin.
Ethylene copolymer resin, vinyl chloride-vinyl acetate copolymer resin, vinyl chloride-acrylic copolymer resin, vinyl chloride-urethane copolymer resin, graft resin in which vinyl chloride is grafted onto ethylene-vinyl acetate copolymer resin, polyamide resin, polyphenylene Engineering resins such as sulfide resin and polyether sulfone resin are used.

Theoretically, the long fibers 11 have a ratio of 90 to the thermoplastic resin 12.
Although it may be contained up to 60% by volume, it is usually preferably used in a range of 60% by volume or less. If the content of the long fibers 11 exceeds 60% by volume relative to the thermoplastic resin 12, cracks and glabellar peeling are likely to occur due to impact.

The fiber sheet material 13 may be paper such as kraft paper or paperboard, woven fabric or non-woven fabric made of synthetic fibers, or these papers, woven fabrics or non-woven fabrics impregnated with liquid synthetic resin such as acrylic resin emulsion or vinyl acetate resin emulsion. The one that was made is used.

Further, as the thermoplastic resin 20 coated on the composite core material 10, a resin similar to the above-mentioned thermoplastic resin 12, and a combination that can be thermally fused with the thermoplastic resin 12, is used. For example, if the long composite molded body A is an eaves gutter,
As both thermoplastic resins 12 and 20, a vinyl chloride resin with good weather resistance is preferably used. Note that if the thermoplastic resin 20 to be coated contains fillers with a small coefficient of linear expansion, such as inorganic salts such as calcium carbonate, metal powders such as aluminum, short glass fibers, and wood powder, it will be difficult to combine with the composite core material 10. This is preferable because the difference in linear expansion coefficient becomes small.

In this way, the elongated composite molded article A of the present invention is constructed.

FIGS. 3 and 4 show an example of a method for manufacturing the elongated composite molded body A of the present invention. In FIG. 3, a large number of continuous long fibers 11 such as glass rovings are unwound from a bobbin, arranged in the longitudinal direction, and introduced into a fluidized bed 3o equipped with a porous bottom plate 31. The long fibers 11 are usually defibrated by a defibrator 32 before being introduced into the fluidized bed 3o or within the fluidized bed 30.

In the fluidized bed 30, a powdered thermoplastic resin 12 is blown up by air pressure above a porous bottom plate 31 and maintained in a floating state. The particle size of the powdered thermoplastic resin 12 is generally about 10 to 200 microns. Then, a large number of long fibers 11 introduced into the fluidized bed 30 are impregnated with powdered thermoplastic resin 12 in a suspended state, and the resin-impregnated fiber material (
10') is created. This resin-impregnated fiber material (10°) ultimately constitutes the core material 10' of the composite molded body A.

At least two resin-impregnated fiber materials (10') are made as shown. These at least two resin-impregnated fiber materials (
The fiber sheet material 13 is stacked between the fiber sheets (10") and passed through a pair of heated pinch rolls 40, where at least two resin-impregnated fiber materials (10°) and the fiber sheet material 13 are bonded by thermocompression. In this case, the pair of pinch rolls 40 may be arranged in one set (or in plural sets. In the figure, two sets are arranged. The plastic resin 12 does not need to be completely melted, and only a surface portion thereof may be melted.

If the thermoplastic resin 12 is not completely melted, the thermoplastic resin 12 is heated in a heating furnace 50 equipped with an infrared heater or the like to completely melt the thermoplastic resin 12. In this way, the composite core material 10 is formed. The composite core material 10 may be wound up once as shown in the figure, but it may be continued to the next step without being wound up. Further, the arrangement of the pair of pinch rolls 40 and the heating furnace 50 was reversed, and the metal sheet material 13 was stacked between at least two resin-impregnated fiber materials (10'), and this was heated in the heating furnace 50. Afterwards, thermocompression bonding may be performed using a pair of pinch rolls 40.

Next, as shown in FIG. 4, the composite core material 10 is heated and softened by a heating forming device 60 to form eaves gutters, corrugated plates,
It is formed into a desired shape such as a decking material, and then cooled by a cooling forming device 61. It is preferable that the composite core material 10 formed into a desired shape is cooled by the cooling forming device 61 as described above because it can be smoothly introduced into the next crosshead mold. The core material 10 does not necessarily need to be cooled.

The composite core material 10 shaped in this way is then introduced into the crosshead mold 70 of the extruder 71, where the thermoplastic resin 20 is melted and extruded from the crosshead mold 70.
is coated on the outer surface of the composite core material 10. At this time, the thermoplastic resin 12 in the composite core material 10 is melted in the crosshead mold 70, and the thermoplastic resin 20 to be melt-extruded and coated is fused and integrated.

The length of the land portion of the crosshead mold 70 is determined by the extrusion temperature,
The gap is appropriately determined depending on the extrusion speed, the resin used, etc., and the gap is designed to have a desired shape, and is formed into a desired shape such as eaves troughs, corrugated plates, decking materials, etc.

Thereafter, the surface is finished by a sizing device 80 consisting of a cooling mold or the like, cooled, and taken out by a tensioning device 90 such as a caterpillar tensioning machine to produce a long composite molded product A.

(Function) In the elongated composite molded article of the present invention, since the core material is formed by fixing a large number of continuous long fibers with a thermoplastic resin, the coefficient of linear expansion is small and the rigidity is high. Moreover,
Since the fiber sheet is bonded between at least two core materials to form a composite core material, impact resistance and heat resistance are further improved.

In addition, in the method of the present invention, since a large number of continuous long fibers are introduced into a fluidized bed and impregnated with a powdered thermoplastic resin, impregnation is easily performed, and the above-mentioned composite core formed in this way is Since the material is introduced into the crosshead mold of the extruder, the above-mentioned thermoplastic resin is well melted by the heat of both the crosshead mold and the heat of the thermoplastic resin melt-extruded from this mold. Adheres well to many long fibers.

Furthermore, due to the extrusion pressure of the thermoplastic resin extruded from the crosshead mold, the composite core material and the thermoplastic resin melt-extruded thereto are strongly fused and integrated.

(Example) Examples and comparative examples of the present invention are shown below.

Step 1 In this example, the elongated eave gutter composite molded body shown in FIGS. 1 and 2 was manufactured by the method shown in FIGS. 3 and 4.

First, glass roving (14400: manufactured by Nittobo) 1
A powdered vinyl chloride resin compound (TK-400 : Shin-Etsu Chemical Type) 12 was impregnated to prepare two sheet-like core materials 10' having a thickness of 0.3 mm, a width of 300 trm, and a glass roving content of 30% by volume.

A thickness of 0゜1 m between the two sheet-like core materials 10゜
A layer of resin-impregnated paper (impregnated with an acrylic resin emulsion with a solid content of 53111% and a glass transition temperature of 0°C) 13 was layered and passed through a pair of pinch rolls 40.40 at a surface temperature of 200"C to bond by thermocompression. Subsequently, the resin 12 was passed through a heating furnace 50 to be heated to 180''C to completely melt it, and taken off with a take-off pinch roll 51 to form a composite core material 10.

This composite core material lO was heated to 80℃ using a forming device 6o.
The material was softened by heating, shaped into a square eaves gutter shape, and then cooled. Subsequently, the shaped composite core material 1° was introduced into the crosshead mold 7o of the extruder, and a vinyl chloride resin 20 mixed with stabilizers etc. was added to the surface of the core material to a thickness of 0.5 mm at 180°C. Coated by melt extrusion.

Next, a sizing device 80 performs surface finishing,
Cool it and take it out with a tensile machine 90 to a thickness of 1゜511I1m.
A long eave gutter composite molded body A was manufactured. The line speed at this time was 3 m/min. The crosshead mold 70 used had a land length of 200 mm and a rectangular gutter-like gap.

Thermal stretchability, impact resistance, rigidity, and heat resistance of this eave gutter composite molded article were evaluated using the following methods.

The results are shown in Table 1.

(1) Cut the heat-stretchable eaves gutter molded product into a length of 4 m to obtain a test piece, place it in a constant temperature constant temperature room, and lengthen it at 20°C. measure,
Next, increase the temperature to 60°C and lengthen at 60°C,
. was measured, and the linear expansion coefficient α was calculated using the following formula. α=(
Lio-Lzo)/(40(“C)XLzo).

(2) Create a test piece by cutting the impact-resistant eaves gutter molding into 20 mm x 20 mm, and test this test piece with a DuPont impact tester of 1.5
A weight of 1 kg was dropped, and the impact strength was measured from the falling distance at which the test piece was damaged.

(3) Create a test piece by cutting the rigid eaves gutter molded body to 15011II11 in the longitudinal direction and 25a++++ in the width direction.
The bending elastic modulus of the test piece in the longitudinal direction was measured according to K 6911.

(4) The heat-resistant eaves gutter molded body was cut to a length of 4 m to obtain a test piece, which was left in an oven at 80''C for 5 hours, and its deformation state was observed.

1 star ±1 The same procedure as in Example 1 was carried out except that the resin-impregnated paper having a thickness of 0.1ffll11 was replaced with the same resin-impregnated glass surfaging mat having a thickness of 0.2ffflflI. The results are shown in Table 1.

The same procedure as in Example 1 was carried out except that resin-impregnated paper was not used in Example 1 for the sake of proofreadability. The results are shown in Table 1.

Table 1 (Effects of the Invention) As mentioned above, the long composite molded article of the present invention has low thermal expansion and contraction, and has improved deformation and rigidity, as well as improved impact resistance, heat resistance, and glabella peeling, and is resistant to temperature changes. Even when used for long periods in harsh environments, it does not deform, crack, or peel off between the eyebrows, and has excellent durability.

In addition, the method for producing a long composite molded body of the present invention prevents the generation of internal voids in the composite molded body, compared to the conventional method in which long fibers are impregnated with a thermosetting resin liquid to form a core material. Further, the composite core material and the thermoplastic resin coated thereon are firmly fused and integrated, and it is possible to obtain a long composite molded article having excellent durability as described above.

[Brief explanation of the drawing]

FIG. 1 is a partially cutaway perspective view showing an example of the elongated composite molded article of the present invention, and FIG. 2 is an enlarged view of the part (A) in FIG. 1. FIGS. 3 and 4 are schematic diagrams showing an example of the method for manufacturing the elongated composite molded body of the present invention. A... Long composite molded body, 10... Composite core material, 10°
... Resin cored fiber material (core material), 11... Long fiber, 1
2... Thermoplastic resin, 13... Fiber sheet material, 20
... coated thermoplastic resin, 30 ... fluidized bed, 4
0... Heating pinch roll, 50... Heating furnace, 60...
...Heating forming device, 70... Crosshead mold of extruder, 80... Sizing device, 90... Tensioning device.

Claims (1)

[Claims] 1. A composite core material is formed by bonding a fiber sheet material between at least two core materials in which a large number of continuous long fibers are fixed with a thermoplastic resin, and this composite core material A long composite molded article characterized by being integrally coated with a thermoplastic resin. 2. A large number of continuous long fibers are introduced into a fluidized bed and impregnated with powdered thermoplastic resin to form at least two sheets of resin-impregnated fiber material, and a fiber sheet is placed between the at least two sheets of resin-impregnated fiber material. A composite core material is formed by thermocompression bonding of materials, and this composite core material is introduced into a crosshead mold of an extruder to melt the resin, and a thermoplastic resin is melt-extruded and coated and integrated. A method for producing a long composite molded body.