JPH07314523A - Composite resin sheet, production and machine therefor - Google Patents

Abstract

PURPOSE:To produce a composite resin sheet excellent in chip dispersion preventive function, transparency, weatherability, strength, etc., continuously through a quite simple method by embedding a resin stripe, where a plurality of resin components are laminated or dispersed fibrously, in a resin sheet. CONSTITUTION:Two kinds of resin component composing a resin stripe are distributed through a resin distribution nozzle 10 to a plurality of resin channels 17a, 18a. They are joined at the confluence 11a of resin channels 17b, 18b for each set formed in a multilayer die 11 and then pass through respective porous nozzles 12 before being delivered into a sheet molding die 13 while forming a plurality of resin stripes having specified shape, dimension, arrangement, etc. On the other hand, resin components of a resin sheet pass through respective resin channels 16a-16c and reach the sheet molding die 13 where a resin sheet is molded while embedding the previously molded resin stripe thus realizing continuous molding of a composite resin sheet.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite resin sheet in which a resin strip is embedded inside a resin sheet, and scattering and dropping of fragments are prevented, and a method and apparatus for producing the same.

[0002]

2. Description of the Related Art As an example of the application of a composite resin sheet, there is a composite resin sheet for the purpose of sound insulation on a highway, a high-speed railway, etc. These sound-insulating composite resin sheets, for example, a transparent laminated body in which a thermoplastic resin material is sandwiched in a transparent body composed of a plurality of glass plates or the like, or synthetic fibers are stretched in a mold chamber composed of two sheets of inorganic glass, A polymer sheet and the like obtained by injecting a syrup based on an acrylic monomer into a mold chamber and polymerizing and curing in a bath have been proposed.

Further, as an example of the structure of a composite resin sheet used for other purposes, a plurality of rod-shaped synthetic resin materials molded with reinforcing fibers aligned in one direction are scattered in the thermoplastic resin sheet. There is a fiber reinforced thermoplastic resin sheet.

[0004]

Therefore, it is attempted to impart not only sound insulation but also a scattering prevention effect to a transparent laminated body in which a thermoplastic resin material is sandwiched between the above-mentioned transparent bodies composed of a plurality of glass plates or the like. In order to achieve this, it is necessary to interpose a transparent film having excellent mechanical strength. However, with a transparent laminate having such a structure,
It is difficult to produce a composite resin sheet that has a distortion-free appearance and is excellent in anti-scattering performance.

A polymer obtained by stretching synthetic fibers or the like in a mold chamber made of two sheets of inorganic glass, injecting a syrup based on an acrylic monomer into the mold chamber, and polymerizing and curing in a bath. The sheet is obtained by a batch method, and there is a problem that the production is low and the production efficiency is low because the synthetic fiber is stretched in the mold chamber, the syrup is injected, and the polymerization and curing are performed in a bath.

Further, in the above-mentioned fiber-reinforced thermoplastic resin sheet, manufacturing steps such as a step of molding a rod-shaped synthetic resin material with the reinforcing fibers aligned in one direction, a step of embedding the rod-shaped body in the resin sheet, etc. There was a problem that it became complicated in various ways.

The present invention has been made in view of such circumstances, and an object thereof is to adopt extrusion molding of a thermoplastic resin,
Provided are a composite resin sheet which enables continuous production of a composite resin sheet excellent in shatterproof performance, transparency, weather resistance, strength, etc. by an extremely simple method, a manufacturing method and a manufacturing apparatus therefor. Especially.

[0008]

In order to achieve these, the main constitution of the first aspect of the present invention is that a resin sheet B is embedded in a resin sheet A as a base, and the resin sheet B is composed of a plurality of resin components. Are laminated in layers or dispersed in fine fibrous form with each other.

The resin sheet having such a structure is a method for producing a composite resin sheet in which a resin strip B is embedded in a resin sheet A as a base, which is the main constitution of the second invention of the present invention. Of the resin component B is extruded in a molten state through the main flow channel, and at the same time, a plurality of resin components incompatible with each other for the resin strip B are extruded in a molten state through the respective sub-flow channels. When a plurality of resin components of the resin strip B are merged into a layered structure to form a plurality of resin strips B, the resin strip B is continuously molded through the main flow path during molding of the resin strip B. A
It is manufactured by embedding and integrating in the inside.

Similarly, the above resin sheet is
A method for producing a composite resin sheet, in which a resin strip B is embedded in a resin sheet A serving as a base, which is a main constitution of the invention, wherein a resin component of the resin sheet A is extruded in a molten state through a main flow path. At the same time, a plurality of resin components of the resin strip B which are incompatible with each other are mixed in advance and kneaded through a sub-flow path to form a resin strip B in which the plurality of resin components of the resin strip B are dispersed in fine fibrous form. After being formed, it is extruded in a molten state, and the resin strip B is embedded and integrated in the resin sheet A during molding of the resin sheet A which is continuously molded through the main flow path.

Further, the resin sheet is a main flow path for shaping the resin sheet A, a sub-flow path for shaping the resin strip B, and the resin sheet, which is the main constitution of the fourth invention of the present case. The resin component A is extruded in a molten state through the main flow channel.
Extruder, each extruder for extruding each resin component of the resin strip B in a molten state through the sub-flow channel, and a plurality of resin components mounted in the sub-flow channel are joined together to form a layered structure. And a molding die for coextrusion molding while burying the resin strip B in the melted resin sheet A, which is efficiently manufactured by an apparatus for manufacturing a composite resin sheet.

Similarly, the resin sheet has a main flow path for shaping the resin sheet A, a sub-flow path for shaping the resin strip B, which is the main constitution of the fifth aspect of the present invention, and the resin. A first extruder for extruding the resin component of the sheet A in a molten state through a main flow path, and a plurality of previously incompatible resin components of the resin strip B, which are incompatible with each other, are kneaded through the sub flow path, A second extruder that extrudes the resin strip B in a molten state after the resin components are finely fibrous and are dispersed in each other to form the resin strip B, and the resin strip B is embedded in the molten resin sheet A. It is efficiently manufactured by a manufacturing apparatus of a composite resin sheet characterized by comprising a molding die for coextrusion molding.

[0013]

The composite resin sheet according to the first aspect of the present invention can be classified into two types according to its form. That is, the first form is a case where a resin strip B is embedded in a resin sheet A which is a base, and the resin strip B is formed by laminating a plurality of resin components in layers, and the second form is a substrate. A resin strip B is embedded in a resin sheet A, which has a plurality of resin components dispersed in fine fibrous form.

In the composite resin sheet according to the first embodiment, the resin component constituting the resin sheet A as the base is melt-extruded into the shaping head by the first extruder and passed through the resin flow path to obtain the first fixed amount. To the pump. On the other hand, the resin components constituting the resin strip B are melt-extruded into the shaping head by the second and third extruders, respectively, and reach the second and third metering pumps through the dedicated resin flow paths. The resin components constituting the resin sheet A and the two different resin components constituting the resin strip B flow through the main and sub resin flow passages with their flow rates adjusted by respective metering pumps, and each is distributed in a predetermined number. To be done.

That is, the two kinds of resin components constituting the resin strip B are respectively distributed to a plurality of resin flow paths, join each group at the joining portion of the resin flow paths, and pass through each multi-layered nozzle to obtain a desired one. Is layered to the number of layers of the specified cross-sectional shape, dimensions,
The plurality of resin strips B having an array or the like are formed and discharged into the sheet forming means. On the other hand, the resin component forming the resin sheet A reaches the sheet forming means through the resin flow path, and the resin strip B previously formed therein is embedded therein to continuously form a composite resin sheet.

That is, the composite resin sheet according to the first aspect of the present invention is first co-extruded using a plurality of resin components to form a resin strip B layered in multiple layers, and further the resin strip B is formed. The strip B is embedded inside the resin sheet A simultaneously with the molding of the resin sheet A. The resin strip B thus obtained has a structure in which thin layers of a plurality of resin components are laminated, and when flexed, it is dispersed in layers and exhibits excellent mechanical properties such as high bending rupture resistance and strength. When the sheet A is crushed, it is possible to effectively impart the scattering prevention performance of the fragments.

The composite resin sheet having the second aspect of the present invention is manufactured as follows. The flow rate of the resin component shaped as the resin sheet A and the plurality of incompatible resin components shaped as the resin strip B are adjusted by respective metering pumps and flow through the main and sub flow passages, respectively, and the resin distribution nozzles. Inside, each is distributed to each branch channel.
Among the resin components thus distributed, the resin component molded as the resin strip B passes through each branch flow path to form a plurality of resin strips B having a predetermined cross-sectional shape, size, arrangement and the like. On the other hand, the resin component molded as the resin sheet A is continuously molded by the sheet molding means while the resin strip B is embedded therein, and the composite resin sheet of the present invention is manufactured.

In the process of molding the resin strip B in the first half, a plurality of incompatible resin components that have been mixed in advance are finely dispersed in the second extruder, and at the same time, the dispersed phase is deformed to form a multifibrous flow. And a step of burying and molding this multi-fibrous flow as a resin strip B in a resin sheet A.
It consists of two.

A plurality of incompatible resin components are premixed in the form of particles or powder and supplied to the second extruder, in which the resin components having the lower melting points are sequentially melted. The melt-mixed state of the resin component at this time is combined with the mixing operation performed before being supplied to the second extruder, in the already-melted low-melting-point resin component, the high-melting-point resin component which is not melted at that time. However, it is in a well dispersed state while maintaining a granular or powdery form. In the latter stage of the second extruder where kneading further progresses, all of the plurality of resin components have completed melting, and due to the fluid shear in the screw groove direction and cross section of the extruder, the melt dispersion state of each resin component is Each element of the resin component that has been further refined and simultaneously refined is finely stretched to be a fibrous state, and forms a multi-fibrous flow in which the multi-components are uniformly dispersed.

The multi-fibrous flow molten resin formed as the resin strip B in the subsequent process is extruded into the coextrusion die device provided immediately after the kneading zone of the second extruder, and fine particles of different types are extruded. It is molded as a resin strip B in which a multi-fibrous resin component is dispersed, and the resin strip B is embedded in the resin sheet A through the above process to continuously produce the composite resin sheet of the present invention. . The composite resin sheet thus obtained is
The resin strip B is embedded and integrated in the resin sheet A, and the resin strip B is a composite resin sheet having a structure in which a plurality of resin components are dispersed in fine fibrous form.

By the way, the staying time from the completion of melt-kneading of a plurality of resin components to the discharge and shaping of the composite resin sheet has a great influence on the formation of the fine fiber structure. If the time is too long, the fibrous dispersed phase is cut due to interfacial tension, etc., and granulated,
With the progress of enlargement and the like, the fine fiber structure of the resin strip B is less likely to be formed. When the stay time cannot be shortened due to the structure of the apparatus, it is preferable to carry out the kneading operation by mounting, for example, a static stirring and mixing member in the sub-flow path. This allows
It is possible to form a fine fiber structure while suppressing the progress of granulation and enlargement of the dispersed phase.

[0022]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Representative embodiments of the present invention will be described below with reference to the drawings. 1 to 4 show one embodiment of a method and an apparatus for producing a composite resin sheet in which a layered resin strip is embedded in a resin sheet of the present invention, and FIG. 1 is a plan view of the apparatus, 2 is the same side view, FIG. 3 is a plan view showing the internal structure of the coextrusion unit in the same apparatus, and FIG. 4 is the same side view. FIG. 5 is a partial cross-sectional view schematically showing an example of the composite resin sheet of the present invention.

1 to 4 show an example of the method and apparatus of the present invention, this embodiment forms a main flow path for forming the resin sheet A and a plurality of resin strips B. The structure is not limited to the illustrated structure, and various structures can be adopted as long as the structure has a sub-flow path for forming the main flow path and the sub-flow path in the sheet molding section.

In FIGS. 1 and 2, reference numerals 1 to 3 denote the first.
-The 3rd extruder is shown, and each extruder 1-3 shares one shaping head 7 provided with exclusive metering pumps 4-6. The first extruder 1 is an extruder for molding the resin sheet A, and the second and third extruders 2 and 3 are extruders for the resin material B which is layered and has no compatibility. Further, the shaping head 7 is provided in each extruder 1 as shown in an enlarged view in FIG.
3 to 3 through the metering pumps 4 to 6 in a fixed amount are sent to the die unit 9 for molding the composite resin sheet according to the present invention through the respective resin flow paths 16 to 18.

As shown in FIGS. 3 and 4, the molding die unit 9 is a unit in which a resin distribution nozzle 10, a multi-layer die 11, a multi-hole nozzle 12 and a sheet molding die 13 are incorporated to form a unit. It is connected to 7. The resin distribution nozzle 10 is connected to the resin flow paths 16 to 18 of the shaping head 7, and resin flow paths 16a to 18b.
Of the resin flow paths 16a to 18a, the molding resin flow path 16a of the resin sheet A is branched to the left and right in the molding width direction, and the molding resin flow paths 17a and 18 of the resin strip B are formed.
Each of a is also branched into a predetermined number of moldings.

The multi-layer die 11 is made up of the resin sheet A.
Has a resin flow channel 16b connected to the left and right branch resin flow channels 16a, and is disposed between the resin flow channels 16b and connected to the branch resin flow channels 17a and 18a of the resin strip B. In addition, a plurality of multi-layered nozzles 14 that layer each pair of branched resin flow paths 17b and 18b via the confluence portion 11a are arranged in parallel in the sheet forming width direction. As shown in FIG. 9, the multi-layered nozzle 14 has a plurality of hollow cylindrical cell bodies 14a tightly fitted and fixed therein, and the resin inlet 14 'and the outlet 14''are divided into two while dividing the inside. Twist partition 14b forming a twist flow path between
And have. The multilayer nozzles 14 are connected in series. At this time, as clearly shown in FIG. 8, the resin inlet 14 'and the resin outlet 1 for connecting the cell bodies 14a are connected.
In 4 ″, the partition portions 14b are arranged so as to be orthogonal to each other.

Further, FIG. 9 shows the behavior of the multi-layer molten resin flowing inside the multi-layered nozzle 14, and as described above, two types of incompatible resins form two layers on the left and right sides to distribute the resin. The resin is discharged from the nozzle 10 to the multi-layer die 11 and merges with each other to form a multi-layer structure.
The molten resin layered on the left and right at 4'is the partition portion 14b.
Is divided into upper and lower parts and flows in the first cell body 14a. At the time of this flow, since the partition portion 14b is twisted in the flow direction, the multi-layer molten resin flow in which the resins of different materials are layered on the left and right sides in the upper and lower flow paths is gradually inverted while the flow is flowing. A layered state parallel to the portion 14b is formed, and four layers are formed at the resin outlet 14 ″. The four layers of molten resin are subsequently pushed into the resin inlet 14 'of the second cell body 14a.

At this time, the upper and lower four layers of molten resin extruded by sandwiching the partition 14b are divided into left and right by the partition 14b extending in the vertical direction at the resin inlet 14 'of the second cell body 14a. The same cell body 14a
Flows into the interior of. The multi-layer molten resin that flows by being divided into the left and right inside the second cell body 14a is also twisted partition part 1.
While flowing along the twisting flow path formed by 4b, the resin outlet 14 ″ is extruded from the cell main body 14a as eight layered molten resin laminated on the left and right at the resin outlet 14 ″ according to the above-described behavior. . Such an operation is repeated by the subsequent cell body 14a, and the number of layers increases exponentially each time. The number of resin layers when the resin distribution nozzle 10 supplies the multi-layer die 11 is m, and the cell body 1 is
When the number of layers 4a is n and the layers are ideally layered, a multilayer resin flow of m × 2 ⁿ is obtained after passing through the multilayer die 11.

In this embodiment, the multi-layer molten resin is a molten resin in which two or more molten resins are superposed on each other to form a multi-layer, each layer is clearly separated, and the resins are mixed between the layers. A material that is rarely used is selected. When the resin is mixed between the layers, the composite resin sheet aimed at by the present invention cannot be obtained.

The multi-hole nozzle 12 connected to the multi-layer die 11 has left and right resin flow channels 16c connected to the branch flow channels 16b formed on the left and right sides of the multi-layer die 11 for resin sheet molding. Between the resin flow passages 16c are formed resin flow passages 15 for molding the resin strip B, which communicate with the plurality of multilayer nozzles 14, respectively. Further, as shown in FIG. 4, a discharge port of the molding resin flow path 15 of the resin strip B is opened at the molding resin inlet of the resin sheet A of the sheet molding die 13 connected to the porous nozzle 12. There is. The arrangement of the openings is not limited to one horizontal row, and, for example, FIGS. 6A and 6B show the arrangement form of the resin strips B embedded in the resin sheet A, and the arrangement form is a single row. Besides, a staggered arrangement or a plurality of rows can be arranged, and this can be freely selected by changing the arrangement of the multi-layer nozzle 14 and the multi-hole nozzle 12. Further, the sectional shape of a single strip is not limited to a circular shape, and various modified sectional shapes can be adopted in addition to the oblong shape and the rectangular shape shown in FIGS.
It is also possible to arrange them in combination. The dimension of the cross section of a single resin strip B and the interval between adjacent resin strips B can be freely set according to the thickness and width of the resin sheet A to be molded, and according to the purpose and application of a plurality of resin sheets. is there.

1 to 4 show a single layer resin sheet and a die device for forming a resin strip by using the same resin component, but by adding a main flow path and a sub flow path, As shown in FIG. 7, it is possible to shape a plurality of resin sheets. Further, the resin strip B composed of a plurality of resin components can be embedded at the same time.

The resin component constituting the resin sheet A is melt-extruded into the shaping head 7 by the extruder 1 and reaches the metering pump 4 through the resin flow path 1a. The resin components constituting the resin strip B are also melt-extruded into the shaping head 7 by the extruders 2 and 3, respectively, and reach the metering pumps 5 and 6 through the resin flow paths 2a and 3a. The resin component forming the resin sheet A and the two different resin components forming the resin strip B are
The flow rate is adjusted by each of the metering pumps 4, 5, 6 to flow through the resin flow paths 16, 17, 18, respectively, and reach the resin distribution nozzle 10 provided in the die unit, where they are respectively distributed.

That is, the two kinds of resin components constituting the resin strip B are distributed by the resin distribution nozzle 10 to the plurality of resin flow paths 17a and 18a, respectively, and the resin for each group formed in the multilayer die 11 is formed. A plurality of flow channels 17b, 18b are joined at the joining portion 11a, layered into a desired number of layers through each multi-layer nozzle 14, pass through each of the multi-hole nozzles 12, and have a predetermined shape, size, arrangement, and the like. The resin strip B is discharged while being discharged into the sheet forming die 13. On the other hand, the resin component that constitutes the resin sheet A is the resin flow path 16
A through 16c to the sheet forming die 13, where the resin sheet B previously formed is embedded therein while the resin sheet A is formed at the same time to form a continuous composite resin sheet of the present invention. . Here, the flow paths 16, 16a to 16c, which are the flow paths of the resin component of the resin sheet A, constitute the main flow paths of the present invention, and the flow paths 15, 17 are the flow paths of the resin for molding the resin strip B. , 17a to 17b, 18, 18a
.About.18b form the sub-flow path of the present invention.

In the present invention, a resin strip B layered in multiple layers is first formed by coextrusion molding using a plurality of resin components, and the resin strip B is formed at the same time as the resin sheet A is formed. It is characterized in that it is embedded inside the sheet A. The resin strip B thus obtained has a structure in which thin layers of a plurality of resin components are laminated, and when flexed, it is dispersed in layers and exhibits excellent mechanical properties such as high bending rupture resistance and strength. When the sheet A is crushed, it is possible to effectively impart the scattering prevention performance of the fragments.

FIG. 8 is a schematic view showing an example of a cross-sectional structure of a resin strip B composed of two kinds of resin components having low compatibility. As a combination of the resin components that can be used in the resin strip B of the present invention, a combination of both that can be melted and generally have poor compatibility, or a combination that does not have good compatibility at least at room temperature is suitable.

A wide variety of thermoplastic resins are possible as the resin component used in the present invention. Suitable resins for use in the resin sheet A include, for example, polycarbonate, polystyrene, polyvinyl chloride, polyethylene terephthalate,
A wide range of resins such as acrylic resin such as polymethylmethacrylate, polypropylene, polyethylene, fluorine resin, single resin such as gen resin, copolymer resin, blended resin, etc. can be mentioned, but such as sound insulation sheet In the case where transparency and weather resistance are required, acrylic resin is a particularly preferable material.

As the resin component suitable for use in the resin strip B, a resin selected from the above-mentioned resins, resins having good impact resistance, or copolymers or blended resins thereof is selected. Can be used. Further, in order to improve the appearance of the composite resin sheet, it is possible to add an organic or inorganic dye or pigment to the resin component forming the resin strip B for use.

The method for producing the composite resin sheet in which the layered resin strip B according to the present invention is embedded and the sheet will be described in more detail below in Examples (1) to (3). The physical properties in the examples were evaluated as follows.

1) Anti-scattering performance test The obtained composite resin sheet was cut into a sample of 15 cm × 15 cm to make a sample, the sample was left standing horizontally, and a 1 Kg steel ball was dropped from the height of 1 m to the center of the sample. Then, it was observed whether or not the sample was scattered along with the occurrence of cracks. 2) Weather resistance test Using a sunshine weather meter, exposure was carried out for 500 hours under conditions of rain at 83 ° C.

(Specific Example 1) Polymethacrylic resin (Acrypet made by Mitsubishi Rayon) was used as the resin component of the resin sheet A, and polycarbonate resin (Iupilon made by Mitsubishi Gas Chemical Co., Ltd.) and polyolefin resin (as a resin component of the resin strip B were used. Mitsui Petrochemical, Tuffmer)
In the sheet forming die unit of the apparatus shown in FIG. 4, the perforated nozzles having a nozzle inner diameter of 2 mm and a distance between the nozzles of 20 mm and arranged in a single row are mounted, and coextrusion molding is performed at a shaping temperature of 240 ° C. A composite resin sheet having a thickness of 4 mm, a width of 50 cm and a length of 50 cm was formed. The number of cell bodies of the multi-layered nozzle was nine.

The obtained sheet is transparent and has a cross section of 4 mm.
There is a resin strip with an outer diameter of 2 mm in the center of the thick resin sheet.
It was observed that the resin strips were arranged in a line at an interval of mm, and the resin strip had a structure in which the resin was laminated in a layered form of about 1000 layers. As a result of evaluating the physical properties, it was colorless and transparent, and cracks were generated, but no scattering of fragments was observed.

(Specific Example 2) Polymethacryl resin (Acrypet) manufactured by Mitsubishi Rayon Co., Ltd. as a resin component of the resin sheet A, and polyester resin (Dianite manufactured by Mitsubishi Rayon Co., Ltd.) as a resin component of the resin strip B. And polymethylpentene resin (TPX manufactured by Mitsui Petrochemical Co., Ltd.) were used, and a multi-hole nozzle arranged in a single row with an inner diameter of 1 mm and a gap of 30 mm was installed, and the shaping temperature was 290 ° C. Extruded by the same apparatus and method as in Example 1, 4 m
A composite sheet of m thickness × 50 cm width × 1 m length was obtained. In addition,
The number of cell bodies of the multi-layered nozzle was 9 as in Example 1.

The obtained sheet was transparent, and the cross-section was observed. As a result, resin strips having an outer shape of about 1 mm were arranged in a single row at a pitch of about 30 mm in the central portion of the resin layer. As a result of evaluation of physical properties, it was colorless and transparent, and although cracks were generated, scattering of crushed pieces and the like was not observed. The resin strip had a slightly smaller number of layers than the calculated value, but had a laminated structure of thin films.

(Specific Example 3) As a resin component of the resin sheet A, a styrene / methyl methacrylate copolymer resin, a resin strip B
Polypropylene (made by Mitsubishi Yuka Co., Ltd.,
Sumiplast Blue G as a coloring dye for Mitsubishi Polypro)
A mixture of P (manufactured by Sumitomo Chemical Co., Ltd.) and polyamide (manufactured by Ube Industries, Ltd., UBE nylon) were used, and the nozzle inner diameter was 2 mm, the nozzle spacing was 100 mm, and the nozzle row spacing was 4 mm. Extrusion molding was carried out by the same apparatus and method as in Example 1 except that the porous nozzle was attached and the shaping temperature was set to 230 ° C. to obtain a composite sheet of 10 mm thickness × 50 cm width × 1 m length.

The obtained sheet was a transparent sheet having a blue stripe pattern, and as a result of cross-sectional observation, a resin strip was formed almost in the nozzle arrangement of the multi-hole nozzle. The resin strip had a layered structure, and the test results showed good weather resistance and anti-scattering properties.

FIGS. 10 to 13 show one embodiment of a method and apparatus for producing a composite resin sheet in which a resin strip formed by dispersing a plurality of resin components in a fine fibrous state is embedded in the resin sheet of the present invention. FIG. 10 is a plan view of the apparatus, FIG. 11 is a side view of the apparatus, FIG. 12 is a plan view showing an internal structure of a coextrusion unit in the apparatus, and FIG. 13 is a side view of the same. Also, FIG.
4 is a partial cross-sectional view schematically showing an example of the composite resin sheet of the present invention.

In this embodiment also, the resin sheet A is used.
And a sub-flow path for shaping the plurality of resin strips B, and a structure in which the main flow path and the sub-flow path merge in the sheet molding portion The structure is not limited to the illustrated structure, and various structures can be adopted.

10 and 11, reference numerals 21 and 21
2 shows the 1st and 2nd extruder, and each extruder 21,22
Shares one shaping head 25 equipped with dedicated metering pumps 23 and 24. The first extruder 21 is a resin sheet A
The second extruder 22 is an extruder for the resin component of the resin strip B. In addition, the shaping head 25
Is a composite resin according to the present invention through two resin flow passages 26 and 27, in which two kinds of molten resins are sent out in a fixed amount from the extruders 21 and 22 through the metering pumps 23 and 24 as shown in an enlarged scale in FIG. Sheet forming die unit 2
Send to 8.

As shown in FIGS. 12 and 13, the molding die unit 28 includes a resin distribution nozzle 29 and a multi-hole nozzle 30.
The sheet forming die 31 is assembled into a unit, and is connected to the shaping head 25. The resin distribution nozzle 29 is connected to the resin flow paths 26 and 27 of the shaping head 25, and the resin flow paths 26 and 2 are also connected to the resin flow paths 26 and 27.
It has resin flow paths 26a and 27a branched from 7.
Of these resin flow paths 26a and 27a, the molding resin flow path 26a of the resin sheet A is branched to the left and right of the molding resin flow path 27a, and the molding resin flow path 27a of the resin strip B has a predetermined number of moldings. Has been branched into.

The multi-hole nozzle 30 connected to the resin distribution nozzle 29 has left and right resin flow passages 26b connected to the branch flow passages 26a formed on the left and right of the resin distribution nozzle 29 for resin sheet molding. , The resin flow path 26
A plurality of branch resin flow paths 2 for molding the above resin strip are provided between b.
7a has a plurality of resin flow paths 27b that communicate with each other. Further, as shown in FIG. 13, at the molding resin inlet of the resin sheet A of the sheet molding die 31 connected to the perforated nozzle 30, the molding resin flow path 2 of the resin strip B as shown in FIG.
The discharge port 7b is open. The arrangement of the openings is not limited to a single row, and, for example, FIGS. 18A and 18B show an arrangement form of the resin strips B embedded in the resin sheet A, and the arrangement form is a single row. Besides, a staggered arrangement or an arrangement of a plurality of rows is also possible, and this can be freely selected by changing the nozzle arrangement of the resin distribution nozzle 29 and the multi-hole nozzle 30. Further, the sectional shape of the single strip is not limited to a circular shape, and various modified sectional shapes can be adopted in addition to the oval shape and the rectangular shape shown in FIGS. 7C and 7D, and it is also possible to arrange them in combination. it can. The dimension of the cross section of a single resin strip B and the interval between adjacent resin strips B can be freely set according to the thickness and width of the resin sheet A to be molded, and according to the purpose and application of a plurality of resin sheets. is there.

FIGS. 10 to 13 show a single layer resin sheet and a die device for forming a resin strip using the same resin component. As shown in 18, it is possible to shape a plurality of resin sheets. Further, the resin strip B composed of a plurality of resin components can be embedded at the same time.

FIG. 15 shows another embodiment of the apparatus of the present invention. For example, a static stirring / mixing member 32 is mounted near the upstream side of the resin distribution nozzle 29 in the sub-flow passage to perform a kneading operation. . By mounting the stirring / mixing member 32 in this way, it is possible to form a fine fiber structure while suppressing the progress of granulation, enlargement, etc. of the dispersed phase.

According to the above-described apparatus having the above-mentioned structure, the resin component shaped as the resin sheet A is
The extruder 21 melts and extrudes into the shaping head 25 and reaches the metering pump 23. A plurality of incompatible resin components shaped as the resin strip B are premixed and then melt-extruded into the shaping head 25 by the second extruder 22 and reach the metering pump 24.

The flow rates of the resin component shaped as the resin sheet A and the plurality of resin components shaped as the resin strip B are adjusted by the metering pumps 23, 24, and flow through the flow paths 26, 27 respectively to form the sheet. It reaches the resin distribution nozzle 29 provided in the die unit 28, and in the same nozzle 29, each is distributed to each branch flow path 26a, 27a.

Of the resin components thus distributed, the resin component molded as the resin strip B passes through each branch flow passage 27b arranged in the multi-hole nozzle 30 and has a predetermined shape, size, arrangement and the like. A plurality of resin strips B having the strips are formed. On the other hand, the resin component molded as the resin sheet A is continuously molded by the sheet molding die 31 while the resin strip B is embedded therein, and eventually the composite resin sheet of the present invention is manufactured.

Next, the process of molding the resin strip B will be described in detail. In the process of molding the resin strip B of the present invention, a plurality of incompatible resin components that have been mixed in advance are secondarily mixed.
The process of finely dispersing in the extruder 22 and simultaneously deforming the dispersed phase to form a multi-fibrous flow, and the process of embedding the multi-fibrous flow as a resin strip B in the resin sheet A It consists of two.

A plurality of incompatible resin components are premixed in a granular or powder form and supplied to the second extruder 22,
In the extruder 22, the resin components having a low melting point are sequentially melted. The melt-mixed state of the resin components at this time is
Coupled with the mixing operation performed before feeding to the second extruder 22, the resin component having a high melting point which is not melted at that time is in a granular or powdery form in the resin component having a low melting point which has already been melted. It is well dispersed while being held.
In the latter stage of the second extruder 22 where kneading further progresses, all of the plurality of resin components have completed melting, and due to fluid shear in the screw groove direction and cross section of the same extruder 22, the respective resin components are melted and dispersed. The state is further miniaturized, and at the same time, each element of the miniaturized resin component is thinly stretched to form a fibrous state, and a multifibrous flow in which the multicomponents are uniformly dispersed is formed.

The multi-fibrous flow molten resin formed as the resin strip B in the subsequent process is extruded into the co-extrusion die device provided immediately after the kneading zone of the extruder 2 and finely divided into different types. Resin strip B in which fibrous resin components are dispersed
And the resin strip B is embedded in the resin sheet A through the above process to continuously produce the composite resin sheet of the present invention. The composite resin sheet thus obtained is shown in FIG.
4, the resin strip B is embedded and integrated in the resin sheet A, and the resin strip B is a composite resin sheet having a structure in which a plurality of resin components are dispersed in fine fibrous form.

By the way, the staying time from the completion of melt-kneading of a plurality of resin components to the discharge and shaping of the composite resin sheet has a great influence on the formation of the fine fiber structure. If the time is too long, the fibrous dispersed phase is cut due to interfacial tension, etc., and granulated,
With the progress of enlargement and the like, the fine fiber structure of the resin strip B is less likely to be formed. If the staying time cannot be shortened due to the structure of the apparatus, a kneading operation can be performed by mounting, for example, a static stirring and mixing member 32 near the upstream side of the multi-hole nozzle 30 in the sub-flow passage as shown in FIG. preferable. This allows
It is possible to form a fine fiber structure while suppressing the progress of granulation and enlargement of the dispersed phase.

The cooling rate after being discharged and shaped as a composite resin sheet also affects the formation of the fiber structure of the resin strip B. When the cooling rate is too slow, that is, when the thickness of the resin sheet A is large, the dispersed phase is granulated and enlarged, and the fiber structure is hard to be formed. , A cooling device 3 as shown in FIGS.
3 is attached to control the cooling rate,
It is possible to form a fine fiber structure. In the illustrated example, a cooling roll is used as the cooling device 33, but a cold air blowing device or the like can also be used.

The resin strip B thus obtained is shown in FIG.
As shown in the longitudinal section of the two-component system in FIG. 6 (a), the first resin strip B-1 and the second resin component B-2 each have a structure in which they are dispersed in the form of fine fibers. According to the observation, depending on the combination of resin components, the outer diameter is about 5 mm
In the case of the resin strip, the number of fine fibers is estimated to be 100,000, and the diameter of the single fiber has a fine fiber structure of about 1 to 20 μm. The resin strip B having such a structure is dispersed in fine fibrous form when bent, and exhibits excellent mechanical properties such as flexural fracture resistance and tensile strength. Therefore, when embedded in the resin sheet A, the resin sheet B It becomes possible to effectively impart the scattering prevention performance of the fragments when the crushed. The resin strip B of the present invention has the structure shown in FIG.
As shown in (b), the resin component B-2 forming the matrix phase has a structure in which the other resin component B-1 is dispersed in the form of fine fibers. In this case, the matrix phase Since it itself constitutes a fine fibrous material, it is included in the present invention.

The formation of the resin strip B of the present invention is intended to perform fine structure control of the resin strip B without requiring a complicated nozzle structure or structure, and uses a plurality of incompatible resin components. It is characterized by being achieved by simultaneous kneading and extrusion. After being embedded in the resin sheet A, it becomes fibrous due to the dispersion effect obtained by sequentially melting by utilizing the difference in melting point of the respective resin components and the miniaturization and multifibrous flow due to the kneading action in the extruder. The resin strip B dispersed by phase separation is formed.

FIGS. 17 (a) and 17 (b) show the arrangement form of the resin strips B embedded in the resin sheet A. The arrangement form is a single row, a zigzag, or a plurality of rows. An arrangement or the like is also possible, which can be freely selected by changing the arrangement of the nozzles in the multi-hole nozzle 8. In addition, the cross-sectional shape of the single strip is not limited to a circular shape, and various modified cross-sectional shapes can be adopted in addition to the oval shape and the rectangular shape shown in (c) and (d) of the same figure, and further, they are arranged in combination. You can also do it. Further, the dimension of the cross section of the single resin strip B and the interval between the adjacent resin strips B are freely set according to the thickness and width of the resin sheet A to be molded, and according to the purpose and application of the multi-material sheet. It is possible.

10 to 13 show a mouthpiece device for forming a composite resin sheet in which a plurality of resin strips are embedded by using a single-layer resin sheet and three types of resin components. By adding additional sub-flow passages, it is possible to shape a plurality of layers of resin sheets as shown in FIG. 18, and it is also possible to embed a resin strip B composed of a plurality of resin components in each resin sheet. Further, in the present invention, it is also possible to dispose reinforcing fibers in the resin sheet A separately from the resin strip B in a random state in the longitudinal direction.

As the resin component used in the above examples, a wide range of thermoplastic resins can be adopted as in the above specific example 1. That is, as a suitable resin used for the resin sheet A, for example, polycarbonate, polystyrene,
A wide range of resins including acrylic resins such as polyvinyl chloride, polyethylene terephthalate, polymethylmethacrylate, etc., single resins such as polypropylene, polyethylene, fluorine resins, gen resins, etc. Among them, acrylic resin is a particularly preferable material for a material such as a sound insulation sheet which is required to have transparency and weather resistance.

Further, as the resin components suitable for use in the resin strip B, those which are both meltable and have poor compatibility, or those which have poor compatibility at least at room temperature are suitable, and the resins listed above can be used. Resin with good impact resistance,
A combination of required materials can be selected and used from these copolymers, blend resins and the like. In particular, when flexural fracture resistance, tensile strength and the like are required, a combination of resin components based on an olefin resin is suitable.
Further, in order to improve the aesthetic appearance of the composite resin sheet, it is also possible to add an organic or inorganic dye or pigment to the resin component forming the resin strip B for use.

The composite resin sheet and its method of the present invention are
It can be used for manufacturing various composite resin sheet materials in which a resin strip is embedded inside a resin sheet as a base. Hereinafter, the present invention will be described in more detail with specific examples (4) to (8). Incidentally, the evaluation of the physical properties in the examples,
It carried out like the above-mentioned specific example (1).

(Example 4) Polymethyl methacrylate (manufactured by Mitsubishi Rayon Co., Ltd.) was used as the resin component of the resin sheet A, and polymethyl methacrylate (same as above) and a polycarbonate resin (Mitsubishi Gas Chemical Co., Ltd.) were used as the resin components of the resin strip B. Prepared). Using the apparatus shown in FIGS. 10 to 14, the porous nozzles 30 arranged in a single row with the inner diameter of the nozzles being 1 mm and the distance between the nozzles being 20 mm were mounted in the sheet forming die unit 28, and the polymethylmethacrylate 1 Melted in the extruder 21, passed through the main flow path, and supplied to the sheet forming die 31. On the other hand, polymethylmethacrylate and polycarbonate are mixed and melt-kneaded in the second extruder 22, and the distribution nozzle 29 and the porous nozzle 3
It was supplied to the sheet forming die 31 after passing through the sub flow passage of No. 0.

In the sheet forming die 31, the shaping temperature is set to 2
Simultaneous extrusion molding is carried out at 40 ° C. so that the resin strip B made of polymethylmethacrylate and polycarbonate is embedded in the sheet A made of polymethylmethacrylate to obtain a composite resin sheet of 3 mm thickness × 50 cm width × 50 cm length. It was The resulting composite resin sheet is transparent and has a cross section of 3 mm
A resin strip B having an outer diameter of 1 mm is arranged in a row at an interval of 20 mm in a substantially central portion of the thick resin sheet A.
Was observed to have a structure dispersed in fine fibrous form. As a result of evaluating the physical properties, it was colorless and transparent, and cracks were generated, but scattering of fragments was not recognized.

(Example 5) Polymethylmethacrylate (manufactured by Mitsubishi Rayon Co., Ltd.) as a resin component of the resin sheet A, polyolefin (manufactured by Mitsui Petrochemical Co., Ltd.) and polycarbonate (Mitsubishi Gas Chemical Co., Ltd.) as resin components of the resin strip B. Manufactured), and the multi-hole nozzles 30 arranged in a single row with a nozzle inner diameter of 2 mm and an interval of 30 mm were mounted in the sheet forming die unit 28. The shaping temperature of the sheet forming die 31 is set to 240 ° C., and the other steps are extruded by the same method and apparatus as in Example 4, and 4 mm thickness × 50 cm width ×
A 1 m long composite sheet was obtained. The obtained composite resin sheet was transparent, and its cross section was observed. As a result, resin strips with an outer diameter of 2 mm were arranged in a single row at a pitch of approximately 30 mm in the central portion of the resin layer. As a result of evaluation of physical properties, it was colorless and transparent, and although cracks were generated, scattering of crushed pieces and the like was not observed.

(Specific Example 6) As a resin component of the resin sheet A, a styrene / methyl methacrylate copolymer resin, a resin strip B
Polypropylene (manufactured by Mitsubishi Petrochemical Co., Ltd.) as a resin component of Kneaded Sumiplast Blue GP (manufactured by Sumitomo Chemical Co., Ltd.) as a coloring dye and polyamide (manufactured by Ube Industries, Ltd.) are prepared, and a sheet molding die unit 28 is prepared. Inside, the multi-hole nozzles 30 having an inner diameter of 3 mm, a nozzle spacing of 100 mm, and a nozzle row spacing of 5 mm were arranged in two rows. Extrusion was performed by the same method and apparatus as in Example 4 except that the shaping temperature of the sheet forming die 30 was 230 ° C.
By cooling with a cooling device, a composite sheet having a thickness of 15 mm, a width of 50 cm and a length of 1 m was obtained. The obtained composite resin sheet was a transparent sheet having a blue stripe pattern, and as a result of cross-sectional observation, the resin strip B was formed almost in the nozzle arrangement of the multi-hole nozzle. The resin strip B had a finely dispersed structure, and the test results were good in both weather resistance and anti-scattering properties.

(Specific Example 7) As the resin component of the resin strip B,
A composite sheet was prepared by the same apparatus and method as in Example 4 except that polyolefin (manufactured by Mitsui Oil Co., Ltd.) was added to the resin component used in Example 4. The obtained sheet is transparent and has an outer diameter of 1 mm at approximately the center of a resin sheet having a cross section of 4 mm.
It was observed that the resin strips of mm were arranged in a line at intervals of 20 mm, and the resin strips had a structure in which they were dispersed in fine fibrous form. As a result of evaluating the physical properties, it is colorless and transparent,
Cracks were generated, but no scattering of fragments was observed.

(Specific Example 8) A composite resin sheet was prepared by using the resin component of Specific Example 4, the porous nozzle 30, the shaping temperature, etc., except that the apparatus shown in FIG. 15 was used. The obtained composite resin sheet is transparent, and the resin strips B having an outer diameter of 1 mm are arranged in a line at approximately the center of the resin sheet A having a cross section of 3 mm, and the resin strips B are fine. It was observed that the fibrous dispersed structure was maintained and formed. As a result of evaluating the physical properties, it was colorless and transparent, and cracks were generated, but scattering of fragments was not recognized.

[0074]

According to the present invention as described above in detail,
A composite resin sheet having transparency, weather resistance, strength, and excellent anti-scattering property can be continuously and efficiently obtained by using an extremely simple apparatus by coextrusion molding, and its industrial value is great.

[Brief description of drawings]

FIG. 1 is a plan view schematically showing an example of a method and an apparatus for manufacturing a composite resin sheet according to the first embodiment of the present invention.

FIG. 2 is a side view of the method and apparatus.

FIG. 3 is a plan view showing the internal structure of the device.

4 is a cross-sectional view taken along line XX in FIG.

FIG. 5 is a cross-sectional view showing one structural example of the composite resin sheet of the present invention.

FIG. 6 is a cross-sectional view schematically showing an arrangement form and a cross-section form of resin strips arranged in the composite resin sheet of the present invention.

FIG. 7 is a cross-sectional view showing an example of a composite resin sheet of the present invention having a plurality of layers.

FIG. 8 is a schematic cross-sectional view showing an example of the resin strip of the present invention.

FIG. 9 is a schematic view showing a function and a structural example of a multilayer nozzle.

FIG. 10 is a plan view schematically showing an example of a method and an apparatus for manufacturing a composite resin sheet according to the second embodiment of the present invention.

FIG. 11 is a side view of the method and apparatus.

FIG. 12 is a plan view showing the internal structure of the device.

13 is a cross-sectional view taken along the line YY in FIG.

FIG. 14 is a cross-sectional view showing one structural example of the composite resin sheet of the present invention.

FIG. 15 is an internal plan view showing another example of the same embodiment.

FIG. 16 is a cross-sectional view showing a configuration example of a resin strip embedded in the composite resin sheet of the present invention.

FIG. 17 is a cross-sectional view showing an arrangement form and a cross-section form of resin strips in the composite resin sheet of the present invention.

FIG. 18 is a cross-sectional view showing a cross-sectional form of a composite resin sheet including a resin sheet having a plurality of layers according to the present invention.

[Explanation of symbols]

 1 to 3,21,22 Extruder 4 to 6,23,24 Metering Pump 7,25 Molding Head 9,28 Molding Die Unit 10,29 Resin Distributing Nozzle 11 Multilayer Die 11a Merging Section 12,30 Perforated Nozzle 13 Sheet forming die 14 Multi-layer nozzle 14a Cell body 14b Twisting partition 14 'Resin inlet 14' 'Resin outlet 15-18,26,27 Resin flow passage 26,27 Resin flow passage

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Reference number within the agency FI Technology display location // B29L 7:00 (72) Inventor Yasuo Hiromoto 20-1 Miyuki-cho, Otake-shi, Hiroshima Mitsubishi Inside Rayon Co., Ltd. Central Research Laboratory (72) Inventor Akio Sasaki 20-1 Miyukicho, Otake City, Hiroshima Prefecture Mitsubishi Rayon Co., Ltd. Central Research Laboratory

Claims (5)

[Claims] 1. A resin strip B is embedded in a resin sheet A as a base, and the resin strip B is formed by laminating a plurality of resin components in layers or dispersed in fine fibrous form. A composite resin sheet characterized by the above. 2. A method for producing a composite resin sheet comprising a resin sheet A as a base material and a resin strip B embedded in the resin sheet A, wherein the resin component of the resin sheet A is extruded in a molten state through a main flow path, A plurality of resin components having a low compatibility with each other for the resin strip B are extruded in a molten state through each sub-channel,
After a plurality of resin components of the resin strip B are merged in the middle of the sub-flow path to form a layer and a plurality of resin strips B are formed,
A method for producing a composite resin sheet, wherein the resin strip B is embedded and integrated in the resin sheet A when the resin sheet A is continuously molded through a main flow path. 3. A method for producing a composite resin sheet comprising a resin sheet A as a base material and a resin strip B embedded in the resin sheet A, wherein the resin component of the resin sheet A is extruded in a molten state through a main flow path and at the same time, A plurality of incompatible resin components of the resin strip B are mixed in advance and kneaded through the same sub-channel,
Upon forming the resin sheet A in which a plurality of resin components for the resin strip B are finely fibrous dispersed in each other and are extruded in a molten state and continuously molded through a main flow path. A method for manufacturing a composite resin sheet, characterized in that the resin strip B is embedded and integrated in the resin sheet A. 4. A composite resin sheet manufacturing apparatus in which a resin strip B is embedded in a resin sheet A as a base, wherein a main flow path for shaping the resin sheet A and the resin strip B are shaped. And a first extruder for extruding the resin component of the resin sheet A in a molten state through the main flow channel, and each of the resin components of the resin strip B for extruding in a molten state through the sub-channel. Extruder, multi-layering means for merging a plurality of resin components mounted in the sub-flow passage to form a layer, and sheet molding for simultaneous extrusion molding while burying the resin strip B in the molten resin sheet A. An apparatus for producing a composite resin sheet, comprising: 5. A composite resin sheet manufacturing apparatus in which a resin strip B is embedded in a resin sheet A as a base, wherein a main flow path for shaping the resin sheet A and the resin strip B are shaped. And a first extruder for extruding the resin component of the resin sheet A in a molten state through the main channel, and a plurality of incompatible resin components of the resin strip B which are not compatible with each other. A second extruder for kneading through the flow path to form the resin strip B in a state where the plurality of resin components are dispersed in a fine fibrous state and then extruded in a molten state, and in the molten resin sheet A An apparatus for manufacturing a composite resin sheet, comprising: a sheet forming means for performing simultaneous extrusion molding while burying the resin strip B.