JPH0691833A - Production of composite panel - Google Patents
Production of composite panelInfo
- Publication number
- JPH0691833A JPH0691833A JP3268599A JP26859991A JPH0691833A JP H0691833 A JPH0691833 A JP H0691833A JP 3268599 A JP3268599 A JP 3268599A JP 26859991 A JP26859991 A JP 26859991A JP H0691833 A JPH0691833 A JP H0691833A
- Authority
- JP
- Japan
- Prior art keywords
- glass
- thermosetting resin
- spreaded
- inorganic
- laminated
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Landscapes
- Floor Finish (AREA)
- Laminated Bodies (AREA)
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は壁材、屋根材、床材等に
使用される複合パネルの製造法に関するものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a composite panel used for wall materials, roof materials, floor materials and the like.
【０００２】[0002]
【従来の技術】一般に、建築物の壁および床材等に利用
されるパネルは耐火性、寸法安定性、軽量性、加工性に
優れ、物理的性質としては耐疲労性、耐衝撃性が要求さ
れるが、特に床材として用いる場合には破壊靱性に対す
る要求が大きい。このための材料として、軽石を主体と
するコア層と、無機質繊維で強化された表層からなる軽
量成形体が公知である（特公昭５９ー１３４７３号公
報）。しかしこのような成形体は、例えば床材として用
いられる場合は、ＯＡフロアとしての基本的な要求物性
は満たすものの、さらに要求性能の厳しいＦＡフロアと
してはさらに大きな強度が要求されるため、それに対応
する必要がある。2. Description of the Related Art Generally, panels used for walls and floors of buildings are excellent in fire resistance, dimensional stability, lightness and workability, and physical properties require fatigue resistance and impact resistance. However, there is a great demand for fracture toughness, especially when used as a floor material. As a material for this purpose, a lightweight molded body including a core layer composed mainly of pumice and a surface layer reinforced with inorganic fibers is known (Japanese Patent Publication No. 59-13473). However, when such a molded product is used as a floor material, for example, it satisfies the basic physical properties required for an OA floor, but an FA floor with even more demanding performance requires greater strength. There is a need to.
【０００３】[0003]
【発明が解決しようとする課題】本発明は上記のような
欠点を改善し、軽量で耐久性、加工性に優れ、特に床材
として要求される破壊靱性を向上させた複合パネルを提
供することを目的とするものである。DISCLOSURE OF THE INVENTION The present invention provides a composite panel which is improved in the above-mentioned drawbacks, is light in weight and is excellent in durability and workability, and is particularly improved in fracture toughness required as a flooring material. The purpose is.
【０００４】[0004]
【課題を解決するための手段】本発明は上記の課題を解
決するためになされたものであって、その要旨とする所
は、熱硬化性樹脂を含浸したガラスまたはカーボン繊維
からなるクロスの上にガラスまたはカーボン短繊維チョ
ップドストランドを散布積層し、さらにその上に無機質
粉粒体と熱硬化性樹脂を主体とする乾式粉体組成物の散
布層を設け、これを少なくとも一方の表面層とする多層
構造の積層マットを熱圧成形することを特徴とする複合
パネルの製造方法にある。The present invention has been made to solve the above-mentioned problems, and the gist of the present invention is to provide a cloth made of glass or carbon fiber impregnated with a thermosetting resin. Glass or carbon short fiber chopped strands are sprinkled and laminated on the above, and further a spray layer of a dry powder composition mainly composed of an inorganic powder and a thermosetting resin is provided thereon, and at least one surface layer of this is provided. A method for producing a composite panel is characterized in that a laminated mat having a multi-layer structure is thermocompression-molded.
【０００５】以下、本発明を図面によって詳細に説明す
る。図面において、ａは本発明の一例である軽量骨材含
有層をコア層とする３層構造の複合パネルの原料の構成
を示す模式図、ｂは得られる複合パネル、ｃは部分拡大
図であるである。１は熱硬化性樹脂を含浸したガラスま
たはカーボン繊維からなるクロス、２はガラスまたはカ
ーボン短繊維ストランド、３は無機質粉粒体と熱硬化性
樹脂を主体とする乾式粉体組成物、４は無機質軽量骨材
が充填された無機質粉粒体と熱硬化性樹脂を主体とする
乾式粉体組成物、５はガラスまたはカーボン短繊維を含
有する無機質粉粒体と熱硬化性樹脂を主体とする乾式粉
体組成物である。The present invention will be described in detail below with reference to the drawings. In the drawings, a is a schematic diagram showing a raw material composition of a composite panel having a three-layer structure having a lightweight aggregate-containing layer as a core layer, which is an example of the present invention, b is a composite panel to be obtained, and c is a partially enlarged view. Is. 1 is a cloth made of glass or carbon fiber impregnated with a thermosetting resin, 2 is a glass or carbon short fiber strand, 3 is a dry powder composition mainly composed of an inorganic powder and thermosetting resin, and 4 is an inorganic material Dry powder composition mainly composed of an inorganic powder granule filled with a lightweight aggregate and a thermosetting resin, 5 is a dry powder composition mainly composed of an inorganic powder granule containing glass or short carbon fibers and a thermosetting resin It is a powder composition.
【０００６】無機質粉体は炭酸カルシウム、ケイ砂、ア
ルミナ、マイカ、ガラスパウダー、ガラスバルーン、フ
ライアッシュ、海砂等の一般に熱硬化性樹脂充填材とし
て用いられる無機質粉粒体で粒度が１ｍｍ程度以下で短
繊維ストランド間隙に入るサイズのものがそれぞれ単独
であるいは組み合わせて使用可能であるが、得られるパ
ネルの加工性からは粗粒フライアッシュが特に望まし
い。熱硬化性樹脂としては、フェノール樹脂、ユリア樹
脂、メラミン樹脂、エポキシ樹脂、不飽和ポリエステル
樹脂等の汎用のものであれば良い。熱硬化性樹脂の添加
量は使用する無機質粉体の種類や樹脂の種類によって多
少異なり、個々の場合に応じて設定すべきであるが、要
求性能、経済性の観点から、無機質粉体１００重量部に
対して熱硬化性樹脂が５〜３０重量部の範囲が好まし
い。また、必要に応じて撥水剤、滑剤等の添加剤を配合
することも出来る。The inorganic powder is an inorganic powder, which is generally used as a thermosetting resin filler such as calcium carbonate, silica sand, alumina, mica, glass powder, glass balloon, fly ash, sea sand, etc., and has a particle size of about 1 mm or less. Although those having a size that fits in the short fiber strand gap can be used alone or in combination, coarse-grain fly ash is particularly desirable from the viewpoint of the processability of the obtained panel. The thermosetting resin may be a general-purpose resin such as phenol resin, urea resin, melamine resin, epoxy resin, unsaturated polyester resin. The amount of the thermosetting resin added varies slightly depending on the type of inorganic powder and the type of resin used and should be set according to the individual case. The range of 5 to 30 parts by weight of the thermosetting resin is preferable with respect to parts. Further, additives such as a water repellent and a lubricant can be blended as necessary.
【０００７】短繊維ストランドはガラス繊維、カーボン
繊維が用いられるが、その他に公知の無機質繊維、或い
は有機質繊維を少量併用することも可能である。無機質
軽量骨材は軽石、火山れき、パーライト、膨張頁岩、水
砕スラグ等が用いられる。繊維クロスはガラス、カーボ
ン等の無機繊維が用いられるが、その他、公知の有機繊
維からなる繊維シート、ネットまたはクロスを若干併用
することは妨げない。Although glass fibers and carbon fibers are used as the short fiber strands, it is also possible to use a small amount of known inorganic fibers or organic fibers in combination therewith. As the inorganic lightweight aggregate, pumice, volcanic rubble, perlite, expanded shale, granulated slag, etc. are used. Inorganic fibers such as glass and carbon are used as the fiber cloth, but it is possible to use some known fiber sheets, nets or cloth made of organic fibers together.
【０００８】次に本発明の製造方法について述べると、
まず、適当な離型用シート上にあらかじめ熱硬化性樹脂
を含浸したガラスまたはカーボン繊維からなるクロスを
載置し、その上にガラスまたはカーボン短繊維チョップ
ドストランドを２次元ランダムに散布積層しマットを形
成する。さらにその上に無機質粉粒体と熱硬化性樹脂を
主体とする乾式粉体組成物を散布する。本発明では、ス
トランド状の集束された繊維を用いて、繊維間隙径を相
対的に大きくしたことによって、熱硬化性樹脂を含む乾
式粉体組成物を該粉体の自重のみでストランドマット中
に滑落させ、その間隙を充填する。このようにすると、
粉体と繊維間の摩擦抵抗によりマット上部は粉体組成物
濃度が大きく、下部にいくほど粉体濃度はひくく、繊維
リッチな構造を形成することができる。Next, the manufacturing method of the present invention will be described.
First, a cloth made of glass or carbon fiber impregnated with a thermosetting resin is placed on a suitable release sheet, and glass or carbon short fiber chopped strands are two-dimensionally scattered and laminated to form a mat. Form. Further, a dry powder composition mainly composed of an inorganic powder and a thermosetting resin is sprinkled thereon. In the present invention, a dry powder composition containing a thermosetting resin is formed in a strand mat by only the self-weight of the powder by making the fiber gap diameter relatively large by using the strand-shaped bundled fibers. Slide it down and fill the gap. This way,
Due to the frictional resistance between the powder and the fiber, the concentration of the powder composition is high in the upper part of the mat, and the powder concentration becomes lower toward the lower part, so that a fiber-rich structure can be formed.
【０００９】次いで、無機質軽量骨材を配合して軽量化
を図った無機質粉粒体と熱硬化性樹脂を主体とするコア
層用の乾式粉体組成物を散布し、さらにその上にもう一
方の表層としてガラスまたはカーボン繊維を含む無機質
粉粒体と熱硬化性樹脂を主体とする乾式粉体組成物を散
布し、多層構造の積層マットを形成する。該積層マット
を熱プレスに挿入して所定時間加熱圧締することによ
り、熱硬化性樹脂は反応硬化し、無機質粉体は圧密され
空隙を減じ、強化用短繊維、無機質軽量骨材が強固に固
着された多層構造の複合体が形成される。Then, a dry powder composition for a core layer, which is mainly composed of a thermosetting resin and an inorganic powder or granules which are made lightweight by blending an inorganic lightweight aggregate, is sprinkled, and then the other one is sprinkled thereon. An inorganic powder or granular material containing glass or carbon fibers and a dry powder composition mainly composed of a thermosetting resin are dispersed as a surface layer of the above to form a laminated mat having a multilayer structure. By inserting the laminated mat into a hot press and heat-pressing for a predetermined time, the thermosetting resin is cured by reaction, the inorganic powder is compacted to reduce voids, and the reinforcing short fibers and the inorganic lightweight aggregate are strengthened. An affixed multi-layered composite is formed.
【００１０】この方法で得られるパネルは、一方の表層
の最外層に熱硬化性樹脂で固化されたクロス状長繊維が
オーバーレイされており、そのクロスに接して熱硬化性
樹脂で結合された粉体組成物とチョップドストランドが
配置されている。チョップドストランドはクロス近傍で
高濃度、クロスから離れるにつれて粉体組成物が高濃度
となる構造となっている。引張強度、および弾性率は繊
維配合量に比例して増大するので、この構造は外層ほど
高強度、高弾性となる。したがって、この構造を３層構
造の表層とすることによって曲げモーメント負荷の大き
い外層部分を有効に補強することになり、繊維の均一分
散層が配置されている場合に比べてより薄い表面層で剛
性の大きい複合パネルが得られる。In the panel obtained by this method, cloth-like long fibers solidified with a thermosetting resin are overlaid on the outermost layer of one surface layer, and the powder bonded with the thermosetting resin is in contact with the cloth. The body composition and chopped strands are arranged. The chopped strand has a high concentration in the vicinity of the cloth, and the powder composition has a high concentration as the distance from the cloth increases. Since the tensile strength and elastic modulus increase in proportion to the fiber content, this structure has higher strength and higher elasticity in the outer layer. Therefore, by using this structure as the surface layer of the three-layer structure, the outer layer portion having a large bending moment load is effectively reinforced, and the rigidity is reduced with a thinner surface layer as compared with the case where the uniform dispersion layer of fibers is arranged. A large composite panel can be obtained.
【００１１】[0011]
【作用】無機質粉粒体を比較的少量の熱硬化性樹脂で固
めた材料は一般にブリットルな性質となる。そのため、
それらにあらかじめ熱硬化性樹脂を含浸したガラスある
いはカーボン等の長繊維素材からなるクロスを単に張り
合わせただけでは、双方の弾性挙動が大きく異なるので
十分な補強効果が得られない。無機質粉粒体に短繊維を
分散しておくと、無機質粉粒体単独の場合と比べて弾性
挙動は大きく改善され、クロスによる補強効果が効果的
に発現する。短繊維の配合割合が多くなるほどこの効果
は大きい。Function: A material obtained by hardening an inorganic powder or granular material with a relatively small amount of a thermosetting resin generally has a blitter property. for that reason,
Simply laminating a cloth made of a long fiber material such as glass or carbon impregnated with a thermosetting resin in advance does not provide a sufficient reinforcing effect because the elastic behaviors of both are greatly different. When the short fibers are dispersed in the inorganic powder or granule, the elastic behavior is greatly improved as compared with the case where the inorganic powder or granule is used alone, and the reinforcing effect of the cloth is effectively exhibited. This effect is greater as the proportion of short fibers is increased.
【００１２】本発明ではクロス上にガラスまたはカーボ
ンの短繊維を散布し、さらにその上から無機質粉粒体と
熱硬化性樹脂を主体とする乾式組成物を散布積層するこ
とによって、短繊維間隙が乾式組成物で充填された積層
構造を形成した。この積層構造はクロス近傍で短繊維リ
ッチ、クロスから離れるに従って乾式組成物リッチとな
る傾斜構造となる。この様に、クロス近傍で短繊維割合
が大きくなることにより、強度発現性、特に靱性の大き
な複合材が得られたと考えられる。あらかじめ短繊維原
料を樹脂組成物に分散させておく方法では、当然のこと
ながら、この効果は得られない。また、樹脂組成物が湿
式である場合も、この様な傾斜構造は形成されない。In the present invention, short fibers of glass or carbon are scattered on a cloth, and further, a dry composition mainly composed of an inorganic powder and a thermosetting resin is sprinkled and laminated, whereby a short fiber gap is formed. A laminated structure filled with the dry composition was formed. This laminated structure has an inclined structure that becomes rich in short fibers near the cloth and becomes rich in the dry composition as the distance from the cloth increases. As described above, it is considered that the composite material having a high strength development property, particularly a high toughness was obtained by increasing the short fiber ratio in the vicinity of the cloth. Naturally, this effect cannot be obtained by the method of previously dispersing the short fiber raw material in the resin composition. Further, even when the resin composition is wet, such an inclined structure is not formed.
【００１３】[0013]
【実施例】適当な離型シート上にレゾールタイプフェノ
ール樹脂３５％が含浸されている目付け量２００ｇ／ｃ
ｍ2 の平織りガラスクロスプリプレグを置き、その上に
２４００テックス、繊維長さ４０ｍｍのガラス繊維チョ
ップドストランドを０．５７ｋｇ／ｍ2 散布し、さらに
その上に１８％のノボラックタイプフェノール樹脂パウ
ダーを含むブレーン値１，５００ｃｍ2 ／ｇのフライア
ッシュを２．４８ｋｇ／ｍ2 散布する。次に粒径４ｍｍ
〜１ｍｍの範囲に調製した粒子密度０．５ｇ／ｃｍ3 の
火山礫４２重量部、フライアッシュ５０重量部、ノボラ
ックタイプフェノール樹脂８重量部からなる乾式組成物
を１５．４８ｋｇ／ｍ2 散布し、さらにこの上に再度表
面層を散布して３層構成のマットとする。該マットを熱
プレスに挿入して温度１６０℃、最大圧力２０ｋｇ／ｃ
ｍ2 で２５分間圧締して複合パネルを得る。このように
して造られた複合パネルは次のような性質となる。 厚み ２５ｍｍ 比重 ０．８６ 曲げ強さ ２５０ｋｇ／ｃｍ2 曲げ弾性率 ６５０ｋｇ／ｍｍ2 これに対し、繊維を均質に分散した場合は実施例と同じ
強度とするためには、表層の粉体組成物散布量を約２倍
とすることが必要であり、製品密度は０．９２となる。Example: A suitable release sheet is impregnated with 35% of a resole-type phenol resin, and a basis weight is 200 g / c.
A plain weave glass cloth prepreg of m 2 is placed, glass fiber chopped strands having a fiber length of 2400 tex and a length of 40 mm are sprinkled on the prepreg at 0.57 kg / m 2 and further, a brane containing 18% of novolac type phenol resin powder. 2.48 kg / m 2 of fly ash having a value of 1,500 cm 2 / g is sprayed. Next, particle size 4 mm
15.48 kg / m 2 of a dry composition composed of 42 parts by weight of volcanic gravel having a particle density of 0.5 g / cm 3 , 50 parts by weight of fly ash, and 8 parts by weight of novolac type phenolic resin prepared in a range of ˜1 mm, Further, the surface layer is again sprayed on this to form a mat having a three-layer structure. The mat is inserted into a hot press and the temperature is 160 ° C and the maximum pressure is 20 kg / c.
Clamp at m 2 for 25 minutes to obtain a composite panel. The composite panel thus manufactured has the following properties. Thickness 25 mm Specific gravity 0.86 Bending strength 250 kg / cm 2 Bending elastic modulus 650 kg / mm 2 On the other hand, when the fibers are homogeneously dispersed, in order to obtain the same strength as that of the example, the powder composition is sprayed on the surface layer. It is necessary to double the quantity, resulting in a product density of 0.92.
【００１４】[0014]
【発明の効果】本発明は要求性能の厳しいＦＡフロアな
どに要求される破壊靱性などの性質に優れ、しかも耐久
性、加工性にも優れた床材用の複合パネルの製造方法を
提供することが可能となるものであり、産業上の効果は
極めて顕著なものがある。EFFECTS OF THE INVENTION The present invention provides a method for producing a composite panel for a floor material, which is excellent in properties such as fracture toughness required for FA floors with severe performance requirements, and is also excellent in durability and workability. It is possible, and the industrial effect is extremely remarkable.
図１ ａ：本発明により得られる複合パネルの原料の構
成を示す模式図 図１ ｂ：本発明により得られる複合パネル 図１ ｃ：本発明により得られる複合パネルの部分拡大
図 １ ガラス又はカーボンクロス ２ ガラス又はカーボン短繊維ストランド ３ 乾式粉体組成物 ４ 軽量骨材を含む粉体組成物 ５ 短繊維を含む粉体組成物Fig. 1 a: Schematic diagram showing the constitution of the raw material of the composite panel obtained by the present invention Fig. 1 b: Composite panel obtained by the present invention Fig. 1 c: Partially enlarged view of the composite panel obtained by the present invention 1 Glass or carbon cloth 2 Glass or Carbon Short Fiber Strands 3 Dry Powder Composition 4 Powder Composition Containing Lightweight Aggregate 5 Powder Composition Containing Short Fibers
Claims (1)
ボン繊維からなるクロスの上にガラスまたはカーボン短
繊維チョップドストランドを散布積層し、さらにその上
に無機質粉粒体と熱硬化性樹脂を主体とする乾式粉体組
成物の散布層をもうけ、これらを少なくとも一方の表面
層とする多層構造の積層マットを熱圧成形することを特
徴とする複合パネルの製造方法。1. A glass or carbon short fiber chopped strand is sprinkled and laminated on a cloth made of glass or carbon fiber impregnated with a thermosetting resin, and an inorganic powder or granular material and a thermosetting resin are mainly formed thereon. A method for producing a composite panel, comprising: providing a dispersion layer of the dry powder composition described above, and thermocompressing a laminated mat having a multilayer structure having at least one surface layer thereof.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3268599A JPH0691833A (en) | 1991-09-20 | 1991-09-20 | Production of composite panel |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3268599A JPH0691833A (en) | 1991-09-20 | 1991-09-20 | Production of composite panel |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH0691833A true JPH0691833A (en) | 1994-04-05 |
Family
ID=17460776
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP3268599A Withdrawn JPH0691833A (en) | 1991-09-20 | 1991-09-20 | Production of composite panel |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH0691833A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4698869B2 (en) * | 2001-03-30 | 2011-06-08 | Ｄｉｃ株式会社 | Composite structure and method for producing the same |
| CN114074435A (en) * | 2021-03-26 | 2022-02-22 | 亨弗劳恩(江苏)复合材料研发有限公司 | Preparation method of thermoplastic composite material sheet |
-
1991
- 1991-09-20 JP JP3268599A patent/JPH0691833A/en not_active Withdrawn
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4698869B2 (en) * | 2001-03-30 | 2011-06-08 | Ｄｉｃ株式会社 | Composite structure and method for producing the same |
| CN114074435A (en) * | 2021-03-26 | 2022-02-22 | 亨弗劳恩(江苏)复合材料研发有限公司 | Preparation method of thermoplastic composite material sheet |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| A300 | Withdrawal of application because of no request for examination |
Free format text: JAPANESE INTERMEDIATE CODE: A300 Effective date: 19981203 |