JPH0367646A - Manufacture of fiber reinforced resin long composite molded body - Google Patents

Abstract

PURPOSE:To improve the impact resistance of a fiber reinforced resin long composite molded body reinforced by a large number of continuous long fibers by repeatedly applying tension and relaxation to at least one resin impregnated fiber material and integrally laminating all of resin impregnated fiber materials. CONSTITUTION:A large number of the long fibers 1 introduced into fluidized beds 30 are impregnated with a powdery thermoplastic resin 12 held to a suspended state to prepare three upper, intermediate and lower strip-like resin impregnated fiber materials 10'. When a tension control roll 21 moves upwardly, tension is applied to the intermediate resin impregnated fiber material 10' and, when the tension control roll 21 moves downwardly, relaxation is applied to the intermediate resin impregnated fiber material 10'. The intermediate resin impregnated fiber material 10' is passed through a shaking apparatus 20 and transferred while repeatedly shaken in the lateral direction to be passed between heating pinch rolls 40 and all of the resin impregnated fiber materials 10' are thermally welded herein to be integrally laminated.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for manufacturing a fiber-reinforced resin elongate composite molded article reinforced with a large number of continuous long fibers.

(Prior technology) A technology for manufacturing fiber-reinforced resin long composite molded bodies using prepreg sheets formed by impregnating woven fabrics, non-woven fabrics, or rovings such as glass fibers with synthetic resin liquids such as unsaturated polyester resins. is widely known.

In the manufacturing technology of such fiber-reinforced resin long composite molded bodies, when woven fabrics or non-woven fabrics are used, the strength balance is good, but the material cost is high and it is difficult to impregnate the synthetic resin liquid uniformly and sufficiently. There's a problem. On the other hand, when long fibers such as rovings are used, there is an advantage that the above-mentioned problems are less likely to occur.

(Problems to be Solved by the Invention) However, in a fiber-reinforced resin long composite molded article using long fibers such as roving, the long fibers are arranged only in the longitudinal direction, and the strength in the width direction is low. Therefore, there is a problem that the impact resistance is not sufficiently improved compared to those using woven fabrics or nonwoven fabrics.

In addition, when such a fiber-reinforced resin long composite molded product is introduced into a crosshead mold of an extruder as a core material and is melt-extruded coated with a thermoplastic resin and integrated, the strength is directional. Heat resistance is also insufficient, and as a result, the core material may be deformed or warped due to resin pressure within the crosshead mold, making it difficult to obtain a uniform product.

The present invention solves the above-mentioned problems, and its purpose is to provide a method for producing a long fiber-reinforced resin composite molded article that has sufficiently improved impact resistance and improved product uniformity. Our goal is to provide the following.

(Means for Solving the Problems) The method for producing a fiber-reinforced resin elongated composite molded article of the present invention consists of the following two inventions.

The first invention involves introducing a large number of continuous long fibers into a fluidized bed, impregnating them with a powdered thermoplastic resin to create at least two belt-shaped resin-impregnated fiber materials, and laminating them into one piece. At this time, tension and relaxation are repeatedly applied to at least one resin-impregnated fiber material, and then this resin-impregnated fiber material is repeatedly swung in the width direction as well as the longitudinal direction, and then all the resin-impregnated fiber materials are It is characterized by being laminated and integrated.

The second invention is characterized in that the fiber-reinforced resin long composite molded article produced by the above method is introduced into a crosshead mold of an extruder, and the thermoplastic resin is melt-extruded coated and integrated. do.

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

The method of the present invention will be explained below with reference to the drawings.

FIG. 1 is a schematic diagram for explaining the first invention. In FIG. 1, a large number of continuous long fibers 11 are unwound from a bobbin, arranged in a strip in the longitudinal direction, and introduced into a fluidized bed 30 equipped with a porous bottom plate 31. The long fibers are usually fed before being introduced into the fluidized bed 30 or before being introduced into the fluidized bed 30.
It is defibrated in 0. In the figure, the fibers are defibrated by a defibrator 32 in a fluidized bed 30. As the long fibers 11, rovings such as glass fibers, carbon fibers, and ceramic fibers are preferably used.

In the upper, intermediate, and lower fluidized beds 30, powdered thermoplastic resin 12 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 12 is generally about 10 to 200 microns. Then, a large number of long fibers 11 introduced into the upper, middle, and lower fluidized beds 30 are each impregnated with powdered thermoplastic resin 12 in a suspended state, and three belt-shaped resin-impregnated fibers are formed in the upper, middle, and lower parts. 10” of wood is made.

As the thermoplastic resin 12, engineering resins such as polyvinyl chloride, polyethylene, polypropylene, polyphenylene sulfide, and polyether sulfone are used. The long fibers 11 may be impregnated with the thermoplastic resin 12 up to 90% by volume, but preferably within a range of 60% by volume or less.

The intermediate resin-impregnated fibrous material lO'' is then applied to a tension control bar or roll 21 which moves upwardly and downwardly, relatively quickly, with constant amplitude and periodicity, as shown in dotted lines. Therefore, the tension control roll 2 is configured to reciprocate in the vertical direction.
1 moves upward, the intermediate resin-impregnated fiber material 10
Tension is applied to the intermediate resin-impregnated fibrous material 10'', and as the tension control roll 21 moves downward, relaxation is applied to the intermediate resin-impregnated fibrous material 10''. is applied repeatedly, and the middle resin-impregnated fiber material 10'' is drawn out from the fluidized bed 30 more than the upper and lower resin-impregnated fiber materials 10''.

Next, the intermediate resin-impregnated fiber material 10 is moved to a rocking device 20.
passed through. This swing device 20 is installed on a rail,
It is configured to reciprocate with a constant amplitude and period in the width direction of the resin-impregnated fiber material 10' in the longitudinal direction (transfer direction), that is, in the direction perpendicular to the plane of the paper. Therefore, the intermediate resin-impregnated fibrous material 10" passed through this rocking device
is transported while repeatedly swinging in the width direction.

Immediately thereafter, the upper and lower resin-impregnated fiber materials 10' are superimposed on this intermediate resin-impregnated fiber material 10', and passed through a pair of heating pinch rolls 40 for lamination, where all of the resin-impregnated fiber materials 10' are stacked. The layers are thermally welded and laminated into one piece.

At this point, the resin 12 of the resin-impregnated fiber material 10' may not be completely melted, so it is subsequently passed through a heating furnace 41 equipped with an infrared heater, etc., where the resin 12 is completely melted, and the thickness of the pair of fibers is After the thickness is adjusted by the adjustment pinch rolls 42, it is taken up by a pair of take-up pinch rolls 50. In this way, the fiber-reinforced resin elongated composite molded body 10 is manufactured. This long composite molded body 10 may be wound up once as shown in the figure, but it may also be continued to the next step without being wound up.

FIG. 2 is a schematic diagram for explaining the second invention. The long composite molded body 10 manufactured by the method shown in FIG. 1 is heated and softened by a heating forming device 60, as shown in FIG. It is then cooled by a cooling forming device 61. Long composite molded body 1 shaped into a desired shape
0 is preferably cooled by the cooling forming device 61 as described above because it can be smoothly introduced into the next crosshead mold, but the shaped composite core material 10 does not necessarily need to be cooled.

The elongated composite molded body 10 shaped in this way is subsequently introduced into the crosshead mold 70 of the extruder 71, where the thermoplastic resin 13 melted and extruded from the crosshead mold 70 is The entire surface of the composite molded body 10 is fused and coated integrally. As the thermoplastic resin 13, the long fibers 11
The same resin as the thermoplastic resin 12 impregnated in is used. In addition, the length of the land portion of the crosshead mold 70 is
The window is adjusted appropriately depending on the extrusion temperature, extrusion speed, resin used, etc.
The gap is designed into a desired shape and shaped into a desired shape such as an eaves gutter, corrugated plate, or decking material.

Thereafter, the surface is finished by a sizing device 80 consisting of a cooling mold, etc., and after cooling, it is taken out by a tensioning device 90 such as a caterpillar tensioning machine, and the fiber-reinforced resin long composite molded body 14 is coated with a thermoplastic resin 13. is manufactured.

(Function) According to the method of the first 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. Further, at least one resin-impregnated fiber material is repeatedly swung in the width direction with respect to the longitudinal direction,
Since it is laminated and integrated with all the resin-impregnated fiber materials, the long fibers that make up the oscillated resin-impregnated fiber materials are oriented obliquely so as to cross the longitudinal direction, improving the strength balance in different directions. .

Moreover, since tension and relaxation are repeatedly applied to the resin-impregnated fiber material before rocking, this resin-impregnated fiber material is pulled out of the fluidized bed more than other resin-impregnated fiber materials, and this excess The resin-impregnated fiber material that is drawn out allows subsequent repeated swinging operations in the width direction to be performed smoothly without resistance. Therefore, during lamination and integration, the degree of oscillation of the oscillated resin-impregnated fiber material is reliably prevented from returning and decreasing.

Further, according to the method of the second invention, since the elongated composite molded body produced by the method of the first invention is used as a core material, this core material has a good balance of strength in different directions, and is extruded. Even when introduced into a crosshead mold, the core material of the long composite molded product is prevented from deforming or tearing due to the heat and extrusion pressure of the thermoplastic resin melted and extruded from the crosshead mold. Ru.

Then, due to the heat and extrusion pressure of the thermoplastic resin melted and extruded from the crosshead mold, the thermoplastic resin is strongly pressed against the core material of the elongated composite molded body, and is firmly adhered and integrated.

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

1. In this example, a fiber-reinforced resin long composite molded body to be used as an eaves gutter was manufactured by the method shown in FIGS. 1 and 2.

First, glass roving (114400: manufactured by Nittobo) 1
1 is introduced into the fluidized bed 30 in a plurality of strips arranged in the longitudinal direction,
There, the powdered vinyl chloride resin compound (average particle size 100μ, melting point 180℃) is blown up by air at a pressure of 2.5 kg/c+fi while being defibrated (average particle size 100μ, melting point 180℃)
TK-400 (manufactured by Shin-Etsu Chemical Co., Ltd.) 12 was impregnated to create three belt-shaped resin-impregnated fiber materials 10' at the top, middle, and bottom. The speed at this time was 0.2 m/min. The thickness of these three resin-impregnated fiber materials of 10 mm was approximately 0.5 m, and the glass roving content was 30% by volume. Then, the intermediate resin-impregnated fiber material 10'' was passed through a tension control roll 21 that moves vertically at an amplitude of 2CI+1 and a cycle of 3 reciprocations/second.

Next, this intermediate resin-impregnated fiber material 10'' is
It was passed through a swinging device 20 that swings in the width direction at 0CII and a cycle of 1.5 reciprocations/minute. After that, 10" of upper and lower resin-impregnated fiber materials are placed on top of this intermediate resin-impregnated fiber material 10", passed through a heating vinyl roll 40 for welding at 200°C, and all layers are thermo-pressed and laminated together. Subsequently, the resin 12 was heated to 200° C. in a heating furnace 41 to completely melt it, and then passed through a pinch roll 42 for thickness adjustment.
The fiber-reinforced resin elongated composite molded article 10 was produced by taking it off with a take-up vinyl roll 50. In this case, the long fibers 11 constituting the intermediate resin-impregnated fiber material 10 degrees were oriented obliquely at about 13 degrees with respect to the longitudinal direction. The above method corresponds to the first invention.

This long 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. Subsequently, the shaped long composite molded body IO is introduced into the crosshead mold 70 of the extruder,
PVC resin compound 13 was applied to this surface at 185°C with a temperature of 0.
The coating was melt extruded to a thickness of 5 mm.

Next, the product was surface-finished using a sizing device 80, cooled, and taken up by a tensile machine 90 to produce a fiber-reinforced resin elongated composite molded product 14 that would become an eaves gutter with a thickness of 1.5 cm. The line speed at this time was 3a+/min. The crosshead mold 70 used had a land length of 200 m and a rectangular gutter-like gap. The above method corresponds to the second invention.

Thermal stretchability, impact resistance, and extrusion moldability of this eave gutter composite molded body 14 were evaluated using the following methods.

As a result, the coefficient of linear expansion was 2X10-'/''C1, the impact strength was 30 kg-cm, and in the extrusion moldability evaluation, no deformation or tearing of the composite molded body 10 was observed, and the obtained eave gutter composite molded body 14 The thickness was uniform.

(1) The heat-stretchable eaves gutter composite molded body 14 is cut into a length of 4 m to obtain a test piece, which is placed in a thermostatic chamber and the length Lm (l) at 20°C is measured, and then The length at 60°C was measured by increasing the temperature to 60°C, and the coefficient of linear expansion α was calculated using the following formula: α
・(Li2-Lto)/(40("C) XLz.).

(2) A test piece was prepared by cutting the impact-resistant eaves gutter composite molded body 14 into 50 nuw x 50 m+ pieces, and a 1.5 kg weight was dropped onto this test piece using a DuPont impact tester, and the test piece was damaged. The impact strength was measured from the falling distance.

(3) Extrudability When the composite molded body 10 serving as the core material is introduced into the crosshead mold 70 of the extruder, and the vinyl chloride resin compound 13 is coated on the surface by continuous melt extrusion for 5 hours, The state of deformation and tearing of the composite molded body 10 was observed.

In the comparative example, the intermediate resin-impregnated fiber material lO' was not passed through the tension control roll 21 and the rocking device 20, but otherwise the same procedure as in the example was carried out. As a result, the coefficient of linear expansion is 2X1
0-'/"C1 impact strength is 7.5 kg cm, and extrusion moldability evaluation shows that the composite molded product 10
A tear occurred, and the thickness of the obtained eave gutter composite molded body 14 was non-uniform at the torn portion of the composite molded body 10.

(Effects of the Invention) As described above, in the method of the first invention, the thermoplastic resin impregnates a large number of long fibers with good impregnation, and the long fibers constituting the composite molded article intersect with the long plane direction. As such, it is reliably and well oriented diagonally, and the strength balance in different directions is improved. Therefore, the impact resistance of the composite molded body is improved.

Further, in the method of the second invention, the composite molded body serving as the core material is prevented from being deformed or broken during melt extrusion coating, and the composite molded body serving as the core material and the composite molded body are The coated thermoplastic resin is firmly fused and integrated. Therefore, the uniformity of the product is improved, and a resin-coated composite molded article with excellent durability can be obtained.

[Brief explanation of drawings]

FIG. 1 is a schematic diagram showing an example of the first invention method, and FIG. 2 is a schematic diagram showing an example of the second invention method. DESCRIPTION OF SYMBOLS 10... Long composite molded object, 10゛... Resin-impregnated fiber material, 11... Long fiber, 12... Powdered thermoplastic resin, 13... Coated thermoplastic resin, 14 ... Resin-coated elongated composite molded body, 20... Rocking device, 21.
...Tension control bar or roll, 30...Fluidized bed, 40
...Heating pinch roll for lamination, 41...Heating furnace,
42...Pinch roll for thickness adjustment, 50...Take-up pinch roll, 60...Heating forming device, 70
...Crosshead mold of extruder, 80...Sizing device, 90...Tension device.

Claims (1)

[Claims] 1. A large number of continuous long fibers are introduced into a fluidized bed and impregnated with a powdered thermoplastic resin to form at least two belt-shaped resin-impregnated fiber materials, which are laminated together. During the process, tension and relaxation are repeatedly applied to at least one resin-impregnated fiber material, and then this resin-impregnated fiber material is repeatedly rocked in the width direction as well as the longitudinal direction, and then all the resin-impregnated fibers are A method for manufacturing a fiber-reinforced resin elongated composite molded article, characterized by laminating and integrating materials. 2. The fiber-reinforced resin elongated composite molded body produced by the method according to claim 1 is introduced into a crosshead mold of an extruder, and a thermoplastic resin is melt-extruded coated thereon and integrated. A method for producing a fiber-reinforced resin long composite molded article.