JPH0759365B2 - Manufacturing method of resin reinforcement material and manufacturing method of molding material - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a resin-reinforced material which is suitably used for producing a fiber-reinforced resin molded article such as a FRTP molded article, and a molding which is preferably used for producing a FRTP molded article. It relates to a method of manufacturing a material.

[0002]

2. Description of the Related Art A glass fiber bundle or a cut product of a glass fiber bundle obtained by adding and focusing a sizing agent to a large number of glass fibers pulled out from a bushing is widely used as a resin reinforcing material. Number of bundled resin reinforcement materials or 1,000m
If the glass molding is made of a glass fiber bundle having a large weight per unit (gr) (TEX), the fiber bundle is raised on the surface of the obtained resin molding, and a smooth surface cannot be obtained. On the other hand, when the resin-reinforcing material is composed of a fiber bundle or monofilament having an extremely small TEX, the surface smoothness is improved, but the glass fiber fluidity during molding is lowered. For this reason, there has been proposed a resin-reinforcing material composed of a sandwich-shaped mat-like material whose surface is composed of fiber bundles or monofilaments having extremely small TEX and whose central portion is composed of fiber bundles having large TEX.
(See Japanese Patent Publication No. 57-54304)

[0003]

[Problems to be Solved by the Invention] Japanese Patent Publication No. 57-5430
The method of No. 4 (prior art) has the following drawbacks.
A fiber bundle having an extremely small TEX can be manufactured by making the number of bundles small, but if the number of bundles is made small, the productivity is significantly reduced.
A fiber bundle with a large EX is cut, and the cut product (CS) is supplied to a carding machine and opened to form TE.
A mixture of very small X fiber bundles and monofilaments is produced. For this reason, the fibers are scattered during the fiber-opening process to pollute the environment, or the fibers are damaged or cut during fiber-opening.Therefore, the resin molded product using the reinforcing material obtained by this method is of high quality. Is likely to occur, and the glass fiber fluidity at the time of molding is deteriorated because the monofilaments are entangled. The present invention solves the above-mentioned problems of the prior art, does not cause environmental pollution and deterioration of glass fiber fluidity at the time of molding, has little variation in quality, and has a simple manufacturing process, which is extremely suitable for industrial production. It is intended to provide a simple manufacturing method.

[0004]

In order to achieve the above object, in the present invention, a cut glass fiber bundle having a spread coefficient of 2 to 4.5 and a cut glass fiber bundle having a spread coefficient of 1.2 to 1.8 are used. And a cut glass fiber bundle having a spread coefficient of 2 to 4.5 are deposited in this order to form a mat-like material, and the glass fibers constituting the mat-like material are combined to impart shape retention. Manufacture resin reinforcement material. Further, a glass fiber bundle having a spread coefficient of 2 to 4.5, a glass fiber bundle having a spread coefficient of 1.2 to 1.8, and a glass fiber bundle having a spread coefficient of 2 to 4.5 are cut on a thermoplastic resin sheet. Press to cut into cut pieces, which are dropped and deposited in this order to form a mat-like material, and a thermoplastic resin sheet is laid on top of it and heated by pinching to melt and soften the thermoplastic resin sheet. Then, the thermoplastic resin sheet is allowed to soak into the mat-like material to produce a molding material.

The present inventor has attempted to defibrate a glass fiber bundle by utilizing a cutting step of pressing a cutting blade to cut it.
The present invention has been reached. In the process of repeating various experiments, the present inventor uses a cutting blade to cut a glass fiber bundle having a spreading coefficient within a specific range A (2 to 4.5, preferably 2.2 to 3.5) described in detail below. If the glass fiber bundle is cut by pressing, the glass fiber bundle is flattened by the pressing force associated with this cutting and opened into a fiber bundle with a small TEX or a monofilament during falling, and the above-mentioned sandwich-like mat-like material A glass fiber bundle having a very suitable state for forming a surface portion and having a spread coefficient in a specific range B (1.2 to 1.8, preferably 1.4 to 1.7) is similarly cut. If so, it has been found that a cut piece of glass fiber bundle that is extremely suitable for forming the central portion of the mat-like article can be obtained.

Definition of Spreading Coefficient As shown in FIG. 1, a winding body 2 in which a glass fiber bundle 1 is wound in a cylindrical shape is rotatably supported on a rotary shaft 3, and the glass fiber bundle 1 is wound from the winding body 2. The guide bar 4 with a diameter of 2 cm
Are arranged in parallel at a distance of 3 cm such that the respective central axes are on the same plane and are parallel to each other and are orthogonal to the drawing direction of the glass fiber bundle, and a tension of 3 Kgf is applied between them. The width (spread) of the fiber bundle is measured at the point of X, the point of entry to the guide bar, and the point of Y, the exit from the guide bar, and the spread at the exit / spread at the entrance is defined as the spread coefficient. The influence of the thickness and spacing of the guide bar on the spread coefficient is slight, and the size of this spread coefficient is determined by the line H connecting the centers of the guide bars, the contact point between the glass fiber bundle and the guide, and the center of the guard bar. It is almost determined by the angle Θ formed by the connecting straight line and the tension applied to the glass fiber bundle. In addition, 5 is a heavy stake provided for the other end of the band brake 6 which fixed one end for giving a predetermined tension to a glass fiber bundle. In addition, the glass fiber bundle is once bundled in T
When a plurality of fiber bundles with a small EX are drawn and aligned, the spread coefficient is measured with respect to the fiber bundle with a small TEX.

According to the results of experiments conducted by the inventor of the present invention, a glass fiber bundle having a spread coefficient of 2 to 4.5, preferably a spread coefficient of 2.2 to 3.5, is used to press a rubber roll or the like with a cutting blade to cut it. If it is allowed to fall, the fiber bundle is flattened by this pressing force, and it is extremely suitable for defibrating during the fall to form the surface portion of the above-mentioned sandwich-shaped mat-like product, and a cut product with small variation. It turned out to be obtained. If the spread coefficient is too large, the glass fiber is likely to be fluffed, and the appearance tends to be poor. If the spread coefficient is too small, the spread will be insufficient and the appearance will be likely to be poor.
The spreading factor is the number of kinds of sizing agents applied to the glass fiber,
Although it depends on the degree of polymerization, the applied amount, the drying conditions, etc., a film forming agent in the sizing agent that has a weak film forming action is used, and the amount of the film forming agent in the sizing agent is small, and the coupling agent is used. When the amount of lubricant is large, the above conditions are easily satisfied.

Spread coefficient 1.2 to 1.8 Desirably, a glass fiber bundle having a spread coefficient of 1.4 to 1.7 is cut and dropped in the same manner to obtain a very suitable cut as a central portion of a sandwich-shaped mat-like material. I was able to get things. If the spread coefficient is too large, the fiber bundle is likely to open and the fluidity of the glass fiber at the time of molding tends to be impaired. If the spread coefficient is too small, impregnation of the resin will be insufficient and the strength tends to be insufficient. In this case, it is preferable to use glass fiber bundles which are bundled by using a relatively large amount of a film forming agent having a strong film forming action.

Next, referring to FIG. 2, a method for manufacturing the resin-reinforced material according to claim 1 will be described. Spreading coefficient 2 to 4.5 Desirably, a glass fiber bundle 7 is drawn from a winding body 8 made of a glass fiber bundle having a spreading coefficient of 2.2 to 3.5, and the cutting blades 9 that rotate in opposite directions are radially formed. The fiber bundle 7 is sent between the fixed cylindrical support 10 and the rubber roll 11, the glass fiber bundle 7 is cut, and the cut product is dropped onto the continuously drawn non-woven cloth 12. Then, the spread coefficient 1.2 to
1.8 Desirably, the glass fiber bundle 13 having a spread coefficient of 1.4 to 1.7 is similarly pulled out from the winding body 14, cut in the same manner, and dropped onto the cut product of the glass fiber bundle 7. Further, the spread coefficient 2 to 4.5, preferably the spread coefficient 2.2 to
Similarly, the glass fiber bundle 7 of 3.5 is cut and dropped.
The cutting length of these glass fiber bundles 7 and 13 is 3 to 3, respectively.
1,000 mm, 3 to 1,000 mm, preferably 6 to
300 mm, 6 to 300 mm, and the amount of fiber bundle to be dropped and deposited is 100 to 3,000 gr per 1 m ² , respectively.
20 to 1,000 gr, 100 to 3,000 gr, preferably 200 to 1,500 gr, 50 to 500 gr, 20
It is suitable to be 0 to 1,500 gr.

The glass fibers constituting the mat-like material having a sandwich structure thus obtained are combined with each other to impart shape retention. For example, while the mat-like material 15 is wound by the winding device 16 and continuously pulled, the needling device 17 performs needling to bond the glass fibers. Alternatively, it is also possible to bond the glass fibers together by supplying a mat binder between cutting devices and heating the mat-like material while pinching it.
As matte binder, thermoplastic polyester, PP,
PE, nylon, PBT, PET, PVA, PVC, PO
M, vinyl acetate and the like can be preferably used. The amount of the mat binder added is 1 to 15 wt%, preferably 2 to 10 wt% of the weight of the glass fiber as a solid content. The resin-reinforcing material thus obtained is particularly suitable for FRTP, but can also be used for FRP.
The mat binder may be added as powder and then melted by heating, or the melt may be sprayed.

Next, the invention according to claim 4 will be described with reference to FIG. In FIG. 3, a synthetic resin sheet 18 is used instead of the non-woven cloth 12 of FIG. As a synthetic resin sheet, thermoplastic polyester, PP, PE, nylon, PBT, P having a thickness of 0.2 to 3 mm, preferably 0.4 to 2 mm
Sheets of ET, PVA, PVC, POM, vinyl acetate, etc. can be preferably used. After forming the sandwich-shaped mat-like material 15 on the synthetic resin sheet 18 as in FIG. 2, the synthetic resin sheet 18 is further stacked and, for example, a continuous pressing device 20 having a metal plate 19 that moves in the direction of a pair of arrows. The synthetic resin sheet 18 is melted or softened by being sandwiched and heated during this period to allow the synthetic resin sheet 18 to permeate into the mat-like material to produce the molding material 21. The sheet can also be manufactured by extrusion online.

A preferable result can be obtained by using the molding material 21 as it is as a stampable sheet for stamp molding.

[0013]

Function: A glass fiber bundle having a spread coefficient of 2 to 4.5, a glass fiber bundle having a spread coefficient of 1.2 to 1.8, and a spread coefficient of 2
Each of the glass fiber bundles of 4.5 is cut by pressing with a cutting blade into a cut product, and the cut products are dropped and deposited in this order to form a mat-like product, thereby flattening the glass fiber bundle forming the surface. Then, the fibers are opened to form a sandwich-like mat-like material suitable as a resin reinforcing material.

[0014]

Example 1 3 wt% of polyolefin emulsion and 0.5 w of aminosilane were added to glass fiber having an average diameter of 13 μm.
0.4% by weight of a sizing agent containing t% and 0.5% by weight of a nonionic surfactant as a solid content, and 3,200 fibers are bundled and dried, and TEX 1,150 and a spreading factor of 2.8 are glass fibers. A bundle (roving 1) was obtained. 5 wt% of epoxy emulsion, 0.5 wt% of aminosilane, 0.5 wt% of nonionic surfactant on glass fiber having a flat diameter of 13 μm
A sizing agent containing 0.6 wt% was added as a solid content, and 200 sizing agents were bundled and dried to obtain a glass fiber bundle having TEX70 and a spreading coefficient of 1.6. This glass fiber bundle 32
Alignment roving (ROVING 2) of TEX2,310 was manufactured by this alignment. A polypropylene sheet having a thickness of 1 mm is continuously drawn out, and the roving 1 is supplied to a cutting device composed of a rubber roll and a support having a rotating cutting blade fixed radially, and the support is rotated to press the roving 1 against the rubber roll. Then, it was cut into a length of 25 mm and dropped and deposited on the sheet at a rate of 500 gr / m ² . The roving 2 was similarly cut to a length of 25 mm, and a cut product was dropped and accumulated at a rate of 200 gr / m ² , and a roving 1 cut to a length of 25 mm was further cut to 500 gr / m ^2. Was dropped and deposited at a rate of 5 to obtain a sandwich-like mat-like material. A polypropylene sheet with a thickness of 1 mm is placed on top of this, and 10 kg / c at 210 ° C.
It was pinched with a pressure of m ² to allow polypropylene to soak into the mat-like material to obtain a sheet-like molding material. Table 1 shows the strength and appearance of the molded product obtained by using this molding material.

[Table 1]

[0015]

Example 2 Table 1 shows the results of a similar experiment performed by using rovings 1 and 3 of Example 1 with spreading factors 2, 1 and 1, 3.

[0016]

[Example 3] Table 1 shows the results of a similar experiment conducted by using rovings 1 and 2 of Example 1 with spreading factors of 3, 9 and 1, 8.

[Comparative Examples 1, 2, 3] Instead of the rovings 1, 2 of Example 1, the spreading factors 2.7 and 1.1, respectively.
Table 1 shows the results of similar experiments performed using 1.6 and 1.6, 1.5 and 1.1.

[0018]

EFFECT OF THE INVENTION An FRT having a smooth surface and high strength.
A P molded product is obtained.

[0019]

[Brief description of drawings]

FIG. 1 is a front view for explaining a method for measuring a spread coefficient.

FIG. 2 is a front view for explaining a method for manufacturing a resin reinforcing material.

FIG. 3 is a front view for explaining a method for manufacturing a molding material.

[Explanation of symbols]

 1 glass fiber bundle 2 winding body 3 rotating shaft 4 guide bar 5 weight 6 band brake 7 glass fiber bundle 8 winding body 9 cutting blade 10 support 11 rubber roll 12 non-woven cloth 13 glass fiber bundle 14 winding body 15 matte shape Item 16 Winding device 17 Needling device 18 Synthetic resin sheet 19 Metal plate 20 Continuous press device 21 Molding material

Claims (4)

[Claims] 1. A glass fiber bundle cut product having a spread coefficient of 2 to 4.5, a glass fiber bundle cut product having a spread coefficient of 1.2 to 1.8, and a glass fiber bundle cut product having a spread coefficient of 2 to 4.5. A method for producing a resin-reinforcing material, which comprises dropping and depositing in order to form a mat-like material, and binding the glass fibers constituting the mat-like material to impart shape retention. 2. The method according to claim 1, wherein the glass fibers are bonded by needling. 3. The method according to claim 1, wherein the binding of the glass fibers is performed by adding a mat binder. 4. A glass fiber bundle having a spread coefficient of 2 to 4.5 and a spread coefficient of 1.2 to 1.8 on a thermoplastic resin sheet.
The glass fiber bundle of No. 1 and the glass fiber bundle having the spread coefficient of 2 to 4.5 are pressed and cut by a cutting blade to obtain a cut product, and the cut product is dropped and deposited in this order to form a mat-like product, and the mat-like product is formed thereon. A method for producing a molding material, which comprises stacking thermoplastic resin sheets, heating them by pinching, melting and softening the thermoplastic resin sheets to allow them to permeate into a mat-like material.