JPH02276625A - Composite formed body in continuous form and manufacture thereof - Google Patents

Abstract

PURPOSE:To obtain composite formed body, which has no defect such as deformation due to thermal expansion and contraction, insufficient rigidity and ply separation, and is excellent in durability, by a method wherein base material, which is produced by fixing a large number of continuous log fiber with thermoplastic resin, is integrally bonded onto both sides of base materials, which has the same constitution as said base material and the content of the long fiber in which is higher than that in said base material. CONSTITUTION:Core material 10 is constituted by integrally bonding base material 10', which is produced by fixing a large number of continuous long fiber 11 with thermoplastic resin 12, on both sides of another base material 10'', which is produced similarly in the base material 10' by fixing a large number of continuous long fiber 11 with thermoplastic resin 13 and the content of the long fiber 11 in which is higher than that in the base material 10'. As the long fiber 11, roving of glass fiber or the like is favorably used. The content of the long fiber 11 in the base material 10'' is preferably set within the range of 30 - 60% by volume on the basis of the base material 10'' from the view point for improving thermal expansion and contraction and rigidity. Further, the content of the long fiber 11 in the base material 10' is preferably set with in the range of 5 - 10% by volume on the basis of the base material 10' from the view point for preventing adhesion, weatherability and surface flatness from lowering.

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.

As a molded product that has improved these drawbacks, we have developed a long eave gutter composite that is made by coating a base material with thermoplastic resin on both sides of a base material in which a large number of continuous long fibers, such as glass roving, are fixed with thermoplastic resin. A molded body has been proposed (for example, see Japanese Utility Model Publication No. 43309/1983).

In such a long eave gutter composite molded product, if the content of long fibers in the base material is too low, thermal expansion and contraction and rigidity will not be sufficiently improved; If the content is too high, the adhesion with the thermoplastic resin will decrease, resulting in peeling between the eyebrows and cracking. Therefore, the content of long fibers in the base material should be -
Generally, it is set as high as about 30 to 60% by volume.

(Problem to be solved by the invention) However, when the content of long fibers in the base material increases as described above, although considerable improvement is recognized, it is difficult to use the material for a long period of time in an environment with severe temperature changes. However, the base material and the thermoplastic resin coated thereon may partially peel off between the eyebrows, and there is a problem in terms of durability that should be further improved.

The present invention is intended to solve the above-mentioned problems, and its purpose is to provide a long composite molded article with excellent durability without problems of deformation, rigidity, or glabellar peeling due to thermal expansion and contraction, and a method for manufacturing the same. It is about providing.

(Means for Solving the Problems) The long composite molded article of the first invention has long fibers formed on both sides of a base material in which a large number of continuous long fibers are fixed with a thermoplastic resin. Another base material having a content lower than that of the above-mentioned base material is bonded and integrated. Further, the elongated composite molded article of the second invention uses the above-mentioned elongated composite molded article as a core material, and this core material is integrally coated with a thermoplastic resin.

Further, in the method for producing a long composite molded article according to the third invention, on both sides of a resin-impregnated fiber material made by introducing a large number of continuous long fibers into a fluidized bed and impregnating them with a powdered thermoplastic resin, The present invention is characterized in that another resin-impregnated fiber material made in the same manner as this resin-impregnated fiber material and having a lower long fiber content than the resin-impregnated fiber material is thermocompression bonded, and the resin is melted and integrated. Further, in the method for producing a long composite molded body according to the fourth aspect of the invention, the long composite molded body obtained by the above method is used as a core material, the core material is introduced into a crosshead mold of an extruder, and It is characterized by melt-extrusion coating and integration of thermoplastic resin.

The present invention will be described below 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 corresponding to the second invention molded in the shape of an eaves gutter, 10 is a core material, and 20 is a thermoplastic resin integrally coated with the core material 10. . The above-mentioned core material IO corresponds to the elongated composite molded body of the first invention.

As shown in FIG.
A large number of continuous long fibers 11 are fixed with a thermoplastic resin 12 on both sides of the substrate 10'', and the content of long fibers 11 is lower than that of the substrate 10''. ,1
0゛ is integrated with adhesive.

As the long fibers 11, rovings such as glass fibers, carbon fibers, alumina fibers, and aramid fibers are suitably used. Thermal expansion and contraction are the main problem, and when a large number of the above-mentioned rovings are arranged continuously in the longitudinal direction, the coefficient of linear expansion of the resulting composite molded article is good (in agreement) with the theoretical value.

The content rate of the long fibers 11 in the base material 10" is 30 to 30% with respect to the base material 10" from the viewpoint of improving thermal expansion/contraction and rigidity.
It is preferably in the range of 60% by volume.

In addition, the content of long fibers 11 in the base material 10° is as follows:
From the viewpoint of preventing deterioration of adhesion, weather resistance, and surface smoothness, the amount is preferably in the range of 5 to 10% by volume based on the base material 10'.

The thermoplastic resins 12 and 13 fixing the large number of long fibers 11 include vinyl chloride such as polyvinyl chloride, vinyl chloride-ethylene copolymer, vinyl chloride-acrylic copolymer, vinyl chloride-urethane copolymer, etc. based resins, chlorinated vinyl chloride resins, acrylic resins, acrylic-butadiene-styrene copolymers, olefin resins such as polyethylene and polypropylene, ethylene-vinyl acetate copolymers, polyamide resins, polycarbonate resins 1, polyphenylene sulfide, etc. Engineering resins such as polyether sulfone are used.

The combination of the thermoplastic resin 12 and the thermoplastic resin 13 is usually a combination in which the two have high compatibility (thermal fusion).

Further, as the thermoplastic resin 20 coated on the 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 usually used. For example, When the elongated composite molded body A is an eaves gutter, a vinyl chloride resin with good weather resistance is suitably used as the thermoplastic resin 12, 13, 20.

Note that if the thermoplastic resin 20 contains a filler with a small coefficient of linear expansion such as an inorganic salt such as calcium carbonate, a metal powder such as aluminum, short glass fibers, or wood flour, the linear expansion with the core material 10 will increase. This is preferable because the difference in coefficients becomes smaller.

The elongated composite molded article of the present invention is suitably used for eaves gutters, corrugated plates, and decking materials.

FIGS. 3 and 4 are schematic diagrams showing an example of the method for manufacturing the elongated composite molded body 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 30 having a porous bottom plate 31. The long fibers 11 are usually defibrated by a defibrator 32 before being introduced into the fluidized bed 30 or within the fluidized bed 30 .

In the middle fluidized bed 30, a powdered thermoplastic resin 13 is blown up by air pressure above a porous bottom plate 31 and kept in a floating state. The particle size of the powdered thermoplastic resin 13 is generally about 10 to 200 microns. and,
A large number of long fibers 11 introduced into the middle fluidized bed 30 are impregnated with powdered thermoplastic resin 13 in a floating state to produce a single sheet of resin-impregnated fiber material (10"). This resin-impregnated fiber material (10”) is the base material 10 of the composite molded body.
”.

Furthermore, long fibers 11 similar to those described above are introduced into the upper and lower fluidized beds 30 similar to those described above, and are impregnated with powdered thermoplastic resin I2. ), (10") are made. The particle size of the powdered thermoplastic resin 12 is also generally about 10 to 100μ. The other resin-impregnated fiber materials (10'), (10") are made.
) finally constitutes the base material 10', 10° of the composite molded body.

The other resin-impregnated fiber materials (10") and (10") are layered on both sides of the resin-impregnated fiber material (10"), passed through a heating furnace 40 via guide rolls, and heated there to an appropriate temperature. , passed through a pair of heated pinch rolls 41 heated to an appropriate temperature, where the resin-impregnated fiber material (10") in the center and the resin-impregnated fiber materials (10") stacked on both sides of the resin-impregnated fiber material (10"), (10°
) are bonded by thermocompression, and the thermoplastic resins 12 and 13 are melted and bonded to be integrated.

In this case, since the thermoplastic resin 13 of the resin-impregnated fiber material (10'') in the center is difficult to heat, it is preferable to heat them in advance before stacking them together.

In this way, a core material 10 is formed in which the other base materials 10'' are adhered to both sides of the base material 10''. This core material 10 is taken up by the take-up pinch rolls 50, and once rolled up as shown in the figure. Alternatively, it may be continued to the next step without being wound up.

Next, as shown in FIG. 4, the core material 10 is heated and softened by a heating forming device 60, and shaped into a desired shape such as eaves gutters, other corrugated plates, decking materials, etc., and then is heated and softened by a cooling forming device 61. cooled down. In this way, when the shaped core material 10 is manufactured and the subsequent steps are not performed, this method corresponds to the third invention. This core material 10 becomes a long composite molded body corresponding to the first invention.

The core material 0 shaped as described above is then passed through an extruder 7.
The thermoplastic resin 20 is introduced into the crosshead mold 70 of No. 1 and is melt-extruded from the crosshead mold 70 here.
The entire surface of the core material 10 is coated.

At this time, the thermoplastic resins 12 and 13 in the core material 10 are softened or melted in the crosshead mold 70.

The thermoplastic resin 20 is fused and integrated over the entire surface of the core material 10.

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 8° consisting of a cooling mold, cooled, and taken out by a tensioning device 90 such as a caterpillar tensioning machine, which corresponds to the second invention as shown in FIGS. 1 and 2. A long composite molded body A is manufactured.

(Function) In the long composite molded article of the present invention, a large number of continuous long fibers are fixed with a thermoplastic resin to form a central base material and core materials on both sides. Long fibers have a small linear expansion coefficient and high rigidity.

Moreover, since the long fiber content of the base materials on both sides is lower than that of the center base material, a long composite molded article consisting of the center base material and both side base materials has a large resin content on the surface portion. However, weather resistance and surface smoothness can be improved without additionally coating with thermoplastic resin. Further, even when the thermoplastic resin is coated, since a large amount of resin exists on the surface portions of the base material on both sides, the adhesion thereof is good.

In addition, in the method for manufacturing a long composite molded body 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 carried out evenly and easily.

Moreover, when the long composite molded body formed in this way consisting of the central base material and the base materials on both sides is used as a core material and introduced into the crosshead mold of the extruder, the crosshead mold Due to the heat and extrusion pressure of the thermoplastic resin being melted and extruded, the thermoplastic resin is strongly pressed against the core material and is firmly bonded and integrated.

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

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

First, glass roving (#4400: manufactured by Nittobo) 11
The polyvinyl chloride resin compound (with average particle size 100μ, melting point 180℃) (TK-
A sheet-like resin-impregnated fiber material (10") having a thickness of about 0.5 m, a width of 300 m, and a glass roving content of 35% by volume was prepared by impregnating it with Shin-Etsu Chemical Type 13.

In addition, in the same manner, the same glass roving 11 as above was impregnated with the same powdered vinyl chloride resin compound 12 as above to form a fabric with a thickness of about 0.5 wa, a width of 300 am, and a glass sloping content of 7% by volume. Two other sheets of resin-impregnated fiber material (10") were prepared.

The above-mentioned other sheet-like resin-impregnated fiber material (10°) is overlapped on both sides of the above-mentioned sheet-like resin-impregnated fiber material (10″), and this is passed through a heating furnace 40 and heated to 200°C.
Resins 12 and 13 are passed through heated pinch rolls 41 at 0°C.
was completely melted, thermocompression bonded, and taken off with take-up pinch rolls 50 to produce a sheet-like composite molded body 10.

This composite molded body 10 was heated and softened using a forming device 60 maintained at a temperature of 170° C., shaped into a square eaves gutter shape, and then cooled to produce a composite molded body 10 shaped into an eave gutter shape. . Subsequently, using the shaped composite molded body 10 as a core material, this core material 10 is passed through a crosshead mold 7 of an extruder.
0, and a vinyl chloride resin formulation 20 is applied to this surface.
The coating was melt extruded to a thickness of about 0.5 nv+ at 185°C.

Next, a sizing device 80 performs surface finishing,
It was cooled and taken out by a tensile machine 90 to produce a long eave gutter composite molded body A having a thickness of 1.5 mm.

The line speed at this time was 3IIIZ. Note that the crosshead mold 70 described above has a land length of 200 mm.
m, with square eaves gutter-like gaps was used. The heat stretchability, rigidity, and
Durability was evaluated. The results are shown in Table 1.

(1) A heat-stretchable eaves gutter molded body was cut into a length of 4 m to make a test piece, and this was placed in a constant temperature constant temperature room and the length L2° was measured at 20°C.
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=(shi,.−Lz@)/(40(“C)XLt.).

(2) 150 tm in the longitudinal direction and 20 tm in the width direction from the rigid eaves gutter molded body
Create a test piece by cutting it into mm and comply with JIS K 6911.
The bending strength in the longitudinal direction of the test piece was measured according to .

(3) Durability The eaves gutter molded body was cut into 1m length test pieces, which were subjected to 1000 cycles of heating and cooling tests from 110"C x 2 hours to 70℃ x 2 hours in a constant temperature room. A test piece was cut, and its cross-sectional state was observed using an electron microscope.

Cliff ■l In Example I, the composite molded body 10 was not coated with the vinyl chloride resin compound 20, and the sheet-like resin-impregnated fiber material (
A long eave with a thickness of about 1.5 m was prepared in the same manner as in Example 1, except that the thickness of both the sheet-like resin-impregnated fiber material (10') and the sheet-like resin-impregnated fiber material (10''') was about 0.5 mm+. A gutter composite molded body was manufactured.The obtained eave gutter composite molded body was evaluated for thermal stretchability, rigidity, and durability.The results are shown in Table 1.

Soil comparison ■ In Example 1 above, sheet-shaped resin-impregnated fiber material (10”)
The same procedure as in Example 1 was conducted except that the glass roving content of the resin-impregnated fiber material sheet (10'') was uniformly set to 30% by volume.

The obtained eaves gutter composite molded body was evaluated for thermal stretchability, rigidity, and durability. 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, has improved deformation and rigidity, has solved the problem of glabellar peeling, and can be used for long periods in environments with severe temperature changes. Even if you use it for a long time,
It has excellent durability and does not cause deformation, cracking, or peeling between the eyebrows.

Further, the method for producing a long composite molded body of the present invention has good impregnation of a large number of long fibers with a thermoplastic resin, and a high quality long composite molded body can be obtained. Furthermore, during melt extrusion coating, the core material and the thermoplastic resin coated thereon are firmly fused and integrated, making it possible to obtain a long composite molded article with excellent durability.

[Brief explanation of drawings]

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 portion (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... Core material (composite molded body), 10-... Base material, 10''... Other base material, (10''
)... Resin-impregnated fiber material, (10°)... Other resin-impregnated fiber material, 11... Long fiber, 12.13... Thermoplastic resin fixing the long fiber, 20...・Thermoplastic resin coated on core material, 30...Fluidized bed, 40...Heating furnace heating pinch roll, 41...Heating pinch roll, 5
0...Take-off pinch roll, 60...Heating forming device, 70...Extruder crosshead mold, 80...
...Sizing device, 90...Tension device.

Claims (1)

[Scope of Claims] 1. On both sides of a base material in which a large number of continuous long fibers are fixed with a thermoplastic resin, other materials having the same structure as this base material and having a lower content of long fibers than the above base material are provided. A long composite molded product made by bonding base materials together. 2. A long composite molded article, which uses the long composite molded article according to claim 1 as a core material, and the core material is integrally coated with a thermoplastic resin. 3. A resin-impregnated fiber material made by introducing a large number of continuous long fibers into a fluidized bed and impregnating them with a powdered thermoplastic resin is coated with a resin-impregnated fiber material made in the same manner as this resin-impregnated fiber material. A method for producing a long composite molded article, which comprises thermo-compression bonding another resin-impregnated fiber material having a content lower than that of the resin-impregnated fiber material, and melting the resin to integrate the resin-impregnated fiber material. 4. The long composite molded body obtained by the method according to claim 3 is used as a core material, this core material is introduced into a crosshead mold of an extruder, and a thermoplastic resin is melt-extruded and coated thereon and integrated. A method for producing a long composite molded body, characterized by: