JPH08103934A - Light-weight resin molding plate using inorganic hollow sphere and manufacture thereof, light-weight woody synthetic powder using the same sphere and manufacture thereof and light-weight woody synthetic plate using the same powder and manufacture thereof - Google Patents

Abstract

PURPOSE: To obtain a light-weight woody synthetic plate having a thickness of a wide range from a thin plate having high density, small specific weight and light weight to a thick plate by applying inorganic hollow sphere having small true specific weight to thermoplastic resin molding material, and suppressing the failure rate of the sphere to the minimum limit. CONSTITUTION: 15-50wt.% inorganic hollow sphere is mixed with 50-85wt.% thermoplastic resin molding plate having 30 mesh or less, heated, incorporated, extruded to a molding die 10 by a uniaxial screw 71, and molded in a predetermined thickness. It is annealed by a molding part 21, a restricting force against the extruding force is applied to extruded textile 70 to enhance the density of the textile, thereby obtaining a light-weight resin molding material. A light-weight woody synthetic powder using an inorganic hollow sphere is set to 15wt.% or less of a contained water content, 35-80wt.% thermoplastic resin molding material is mixed with 10-55wt.% cellulose crushed material having a mean particle size of 20 mesh or less, gelatinized and kneaded.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a lightweight resin molded plate and a method for producing the same, which are made of an inorganic hollow spherical body having a small true specific gravity and a thermoplastic resin molded material as main molding materials.
A lightweight wooden synthetic powder and a method for producing the same, the inorganic hollow spheres and a cellulosic crushed material as a main molding material, a lightweight wooden synthetic plate using the lightweight wooden synthetic powder, and a method for producing the same, more specifically, extrusion. A lightweight resin molded plate using an inorganic hollow sphere by molding and a method for producing the same, the cellulose-based crushed material, the inorganic hollow sphere and a thermoplastic resin molding material are kneaded with an extruder to a predetermined wall thickness from a molding die. The present invention relates to a light weight synthetic wood powder suitable for molding and extrusion and a method for producing the same.

In particular, inorganic hollow spheres have recently been used for cement building products, inorganic building materials such as rock wool ceiling materials, and FRP.
It is in the spotlight as a filling material that aims to reduce the weight of resin members, paints, etc., heat insulation and insulation, and to prevent shrinkage, or to improve abrasion resistance and weather resistance. Hollow glass spheres such as glass balloons and shirasu balloons are mainly used. A lot of bodies are used (the manufacturing method of this hollow glass spherical body is Japanese Patent Publication No. 36-125).
77, Japanese Patent Publication No. 48-17645, Japanese Patent Publication No. 4
-50264). However, the hollow glass spheres have a drawback that they are easily damaged in the process of mixing and dispersing with other materials, and there has been a demand for development of means for effectively mixing and dispersing in other materials without causing damage.

Further, one or both of the cellulosic crushed material and the thermoplastic resin molding material are used in a wide range of applications such as construction waste materials, automobiles, household electric appliances, and daily necessities with the diversification of life. A wide variety of products are used in large quantities, and a large amount of them are discarded. Waste materials of these various thermoplastic synthetic resin products are reused, and inorganic hollow spheres are added to them to reduce the weight. The present invention relates to a method for recycling as a synthetic wood molding material.

Conventionally, the development of molded resin products based on this type of wood powder has been carried out in various ways for the purpose of improving water resistance, heat insulation, etc., and in particular, in response to the recent demand for preservation of the global environment. From the standpoint of securing forest resources, rising cost of wood, and perceptually strong potential demand for wood products, cellulosic crushed materials and thermoplastic resin molding materials are kneaded with an extruder and molded with a molding die. Development of a wood synthetic board is required.

However, in the conventional extrusion molding of this type of wood-based synthetic board, cellulosic crushed materials such as wood powder, rice grain, bacas, crushed chips and pulp materials obtained by crushing wood are used. The fluidity of the cellulosic crushed material when mixing and crushing the crushed material, and the crushed material of the cellulose type, such as the dispersibility of the wood powder and the resin material, has a great influence on the properties of the wood powder during extrusion. Met.

[0006] That is, the fact that the frictional resistance of these wood powders and other cellulosic crushed materials during flow is large and that they are not well compatible with the resin material, the texture of the wood powders in the molded wood synthetic board is coarse and dense. If the wood powder and resin are filled and heated in the extruder, a large amount of steam or wood acid gas will be generated from the mixed wood powder, which may cause corrosion or molding of the inner wall of the extruder. This causes wear of a die, a molding die, and the like, and also causes roughening of the surface of the molded wooden synthetic board itself, bubbles, cavities, and the like, which causes various problems in extrusion molding.

Among the cellulose-based crushed materials, wood powder is impacted, sheared, and crushed by the above-mentioned construction waste materials, waste materials such as sawdust in the lumbering process and woodworking process, and other raw wood by a crusher such as an impeller mill or a ball mill. The wood powder obtained by crushing by an action such as rubbing is fluffy and contains many long and narrow fibrous wood powders, and the dispersibility in resin materials, solvents and solutions is extremely poor. Agglomeration is likely to occur even during the storage process, and particularly when mixed with a resin material to form a synthetic wood board, it has a drawback of agglomeration. Therefore, the angular portion, protruding portion, cilia-shaped beard portion, etc. of this wood powder are deformed into spherical or spherical-like particles by crushing due to friction between the crushing balls, so that they are relatively fluid. And wood powder with good dispersibility is molded.

Further, as described above, the wood powder itself is improved in terms of fluidity and dispersibility, and at the same time, the wood powder and the thermoplastic resin molding material are well acclimated to each other during molding of the synthetic wood board. To maintain a good kneading and kneading state is a major factor for forming a uniform and dense wood composite board by reducing the friction resistance of wood powder with a thermoplastic resin molding material that has a smaller friction resistance than wood powder. It was something that

[0009]

2. Description of the Related Art Molded articles in which hollow lightweight materials such as conventional shirasu balloons are mixed with resin are dispersed by using a mixer utilizing high-speed convection mixing.
Regarding the wooden synthetic board in which the wood powder and the resin are mixed, Japanese Patent Publication No. 3-59804 and Japanese Patent Publication No.
Various techniques such as No. 83 have been disclosed and have been put to practical use, but a practical means has not yet been developed for a wood-based synthetic board in which wood powder, a resin, and a hollow lightweight material are mixed. Not in.

[0010]

Even if a hollow weight-reducing material having a small true specific gravity is mixed with a resin for the purpose of reducing the weight of a molded product, it can be extruded at the time of mixing in an Eirich mixer or the like. There is a disadvantage that the above-mentioned inorganic hollow spheres are damaged in large quantity during molding, resulting in poor efficiency.

Further, the true specific gravity of wood powder, which is the main molding material of conventional wood-based synthetic boards, is 1.4, and the true specific gravity of thermoplastic resin molding materials is about 0.9 to 1.5 (depending on the material). Therefore, the conventional wood-based synthetic board formed by kneading the wood powder and the thermoplastic resin molding material is different depending on the mixing ratio of the wood powder and the thermoplastic resin molding material and the thermoplastic resin molding material,
The specific gravity is 0.97 to 1.48, and the general wood plate material (for example, plywood such as plywood has a specific gravity of 0.45 to 0.45).
0.75) has a problem that the true specific gravity of the wooden synthetic board is large, that is, the conventional wooden synthetic board is heavy.

Incidentally, PP is used as a thermoplastic resin molding material.
The true specific gravity of (polypropylene) is 0.90 to 0.91,
The true specific gravity of rigid PVC (hard vinyl chloride) is 1.35
1.45, and most of the thermoplastic resin molding materials are 0.9
Although it is in the range of about 1.5, vinylidene chloride (true specific gravity: 1.68 to 1.75), fluororesin (true specific gravity: 2.1
There is also a resin having a high true specific gravity such as ~ 2.2). As an example, the specific gravity of the wood synthetic board formed by kneading 25 wt% of the thermoplastic resin molding material and 75 wt% of wood powder is about 1.23.

The present invention was developed in order to solve the above problems, and an inorganic hollow sphere having a small true specific gravity is added to a thermoplastic resin molding material to minimize the damage rate of the inorganic hollow sphere. And a method for producing the same, and a thermoplastic resin molding material capable of steadily maintaining the thermally and chemically stable state of being immobilized on wood powder particles. Mixing powder and thermoplastic resin molding material and inorganic hollow spheres, in order to constantly maintain the dispersed state, a lightweight wooden synthetic powder that gives good fluidity, and a method for producing the lightweight wooden synthetic powder, Further, by using the lightweight woody synthetic powder, the inorganic hollow spheres are mixed, dispersed and supplied to the extruder, and at the time of extrusion molding, the familiarity between the wood powder, the resin and the inorganic hollow spheres is maintained well, and the wood flour surroundings In addition, it suppresses the generation of bubbles, nests, etc. To provide a lightweight wood synthetic board having a wide range of thickness from a light weight thin plate to a thick board, which has a uniform density with a hollow hollow spherical body and has a small specific gravity, and a method for producing the lightweight wood synthetic board. With the goal.

[0014]

In order to achieve the above object, the lightweight resin molding plate of the present invention comprises a thermoplastic resin molding material of 30 mesh or less in 50 to 85 wt% of an inorganic hollow spherical body 1.
5 to 50 wt% is mixed, heated and kneaded, extruded into a molding die with a single screw to form a predetermined thickness, and slowly cooled and extruded in the forming section, and extruded into this extruded dough. It is characterized in that it is formed by increasing the density of the extruded dough by adding a suppressing force against the force.

In the manufacturing method, the inorganic hollow spheres are mixed in an amount of 50 to 85 wt% of the thermoplastic resin molding material having a particle size of 30 mesh or less, preferably substantially the same as or smaller than that of the inorganic hollow spheres. Then, heat and knead, stick a sheet of fluororesin on the inner wall surface with a single screw, or extrude into a molding portion of a molding die coated with fluororesin to extrude to a predetermined wall thickness, and the molding portion It is characterized by increasing the density of the extruded dough by gradually cooling with and extruding, and by applying a suppressing force against the extruding force to the extruded dough.

The light weight synthetic wood powder using the inorganic hollow spheres of the present invention has a water content of 15 wt% or less and an average particle size of 20 mesh or less cellulosic crushed product 10-55.
Characteristic is that 10% to 45% by weight of inorganic hollow spheres are mixed and dispersed in a woody synthetic powder obtained by mixing 35% to 80% by weight of a thermoplastic resin molding material, gelling and kneading, cooling, crushing and sizing. And

In the above method for producing a woody synthetic powder, the content of water content is within 15 wt% and the thermoplastic resin molding material is agitated together with 10 to 55 wt% of the cellulosic crushed material having an average particle size of 20 mesh or less. Mix by impact wing,
At least including a step of kneading by gelling by frictional heat, cooling, pulverizing and sizing to obtain a woody synthetic powder, and a step of adding 10 to 45 wt% of inorganic hollow spheres to the woody synthetic powder, and mixing and dispersing. Characterize.

In the above method, the crushed cellulosic material is mixed with a thermoplastic resin molding material by a stirring impact blade, gelled and kneaded by frictional heat, cooled, and pulverized to form an inorganic hollow spherical body. It is possible to go through the step of adjusting the particle size to the same or smaller, and in this case, the dispersion becomes good.

Further, the above mixing ratio can be such that the total amount of the cellulosic crushed product and the inorganic hollow spheres is 20 to 65 wt% and the thermoplastic resin molding material is 35 to 80 wt%.

Further, the total amount of the cellulosic crushed product and the inorganic hollow spheres is 20 to 65 wt%, the thermoplastic resin molding material is 35 to 80 wt%, and the cellulosic crushed product and the inorganic hollow sphere are the same weight. It is preferable to set the ratio in terms of dispersion.

For the same reason, the thermoplastic resin molding material is preferably 60 mesh or less, preferably in the form of fine powder.

Further, the lightweight wooden synthetic board using the lightweight wooden synthetic powder of the present invention has a water content of 15 wt% or less and an average particle size of 20 mesh or less cellulosic crushed material 10-55.
Thermoplastic resin molding material 35 to 80 wt% is mixed with wt%, gelled, kneaded, cooled, pulverized and sized to obtain a wood synthetic powder mixed with inorganic hollow spheres 10 to 45 wt% and dispersed. It is characterized in that the lightweight synthetic wood powder is heated and kneaded and is extruded into a molding die with a single screw.

Further, in the manufacturing method thereof, the content of water content is within 15 wt% and the thermoplastic resin molding material is added together with 35 to 80 wt% of the cellulosic crushed material having an average particle size of 20 mesh or less to 10 to 55 wt%. 10-45 wt% inorganic hollow spheres in wood-based synthetic powder that is mixed by a stirring impact blade, gelled by friction heat, kneaded, cooled, and crushed to form sized particles
Is added, mixed and dispersed to heat and knead the light weight synthetic wood powder, and the mixture is extruded into a molding die with a single screw.

Further, in the above-mentioned method, the extruded dough extruded to the forming die is gradually cooled, and a suppressing force against the extruding force is applied to the extruded dough to increase the density of the extruded dough. It is desirable for promoting compaction at the damaged part of the hollow sphere.

Further, it is preferable to extrude the extruded material by extruding the extruded material into a molding portion of a molding die having a fluororesin sheet attached to the inner wall surface or coated with the fluororesin.

Further, the depth of the screw groove portion from the base to the tip of the screw is shallowly changed, for example, from 10 mm at the base to about 7 mm at the tip.
The breakage rate of the inorganic hollow spheres can be reduced.

Further, the extrusion into the molding die forms a rectangular injection port having a height equal to or lower than the height of the molding chamber of the molding portion of the molding die, and gradually narrows toward this injection port. It can be performed by an extrusion die formed so as to change the cross section.

The inorganic hollow spherical body is an inorganic hollow body having a shell structure and having a substantially spherical shape, and is made of natural materials such as shirasu, pearlite, obsidian, etc., shirasu balloon, pearlite, fly ash balloon and the like. Or glass balloons and alumina bubbles manufactured from artificial raw materials such as sodium borosilicate and alumina. In consideration of pressure resistance, a glassy shirasu balloon or a glass balloon in terms of reducing the weight of a lightweight wooden synthetic board, a glass balloon is preferable, and a particle size is (US) 100 mesh or less, preferably 140 mesh. It is the following.

The thermoplastic resin molding material is a semi-rigid or soft vinyl chloride or PVC (polyvinyl chloride), PET (polyester), recovered from various discarded resin moldings and used as a material for the thermoplastic resin molding material. One of resins such as PP (polypropylene), PC (polycarbonate), PE (polyethylene), and PTO, or a mixture of several kinds thereof can be used.

As the thermoplastic resin molding material, recycled thermoplastic resin molding material obtained from waste material of thermoplastic synthetic resin product is reused, or virgin thermoplastic resin is added, or virgin thermoplastic resin is used. It is also possible to use a mixture of the resin and the recovered thermoplastic resin molding material in appropriate amounts, for example, 50% each.

The thermoplastic resin molding material is preferably powder of 30 mesh or less, and 60 mesh or less from the viewpoint that the inorganic hollow spheres are well dispersed in the thermoplastic resin molding material.

[0032]

In the method for producing a lightweight resin molded plate using the inorganic hollow spheres of the present invention, a thermoplastic resin molding material having a particle size of 30 mesh or less, preferably about the same as or smaller than the inorganic hollow spheres, is used. % Inorganic hollow spheres 15 to 50 wt% are mixed and put into an extruder, the inorganic hollow spheres and the thermoplastic resin molding material are transported along the screw groove in the process of being extruded to the molding die with a single screw. While being heated, it is gradually melted and kneaded to form an extruded dough. Since it is extruded into the molding die with a single screw, the shearing force of the screw applied to the inorganic hollow spherical body is small unlike the multi-screw screw, and the single screw is moved from the base of the depth of the screw groove to the tip. Due to the reduced throttling, the pressure exerted on the inorganic hollow spheres in the extruded dough transported along this screw groove does not increase extremely. Therefore, the breakage rate of the inorganic hollow spheres is lower than that of a normal single screw.

Moreover, when the inorganic hollow spheres are mixed with the thermoplastic resin molding material having a particle size of 30 mesh or less, the inorganic hollow spheres are kneaded in a state in which they are well dispersed in the thermoplastic resin molding material. By mixing inorganic hollow spheres into a thermoplastic resin molding material having a particle size approximately equal to or smaller than that of the body, the thermoplastic resin molding material penetrates evenly between the inorganic hollow spheres, resulting in a better dispersed state. Since it is mixed with, it is extruded while maintaining a good kneading state in the extruder.

Next, the extruded material is extruded into a forming die through an extrusion die. Since the extrusion die has a rectangular injection port having a height equal to or less than the height of the molding chamber of the molding section of the molding die and is formed so as to gradually change its cross section toward this injection port, There is no clogging in the die, and rather a large amount of extruded dough is discharged from the injection port, so the pressure applied to the inorganic hollow spheres in the extruded dough does not become extremely high and the damage rate of the inorganic hollow spheres is high. Contribute to lowering.

The extruded material is extruded to the molding portion of a molding die having a fluororesin sheet having a small frictional resistance attached to the inner surface or coated with the fluororesin, and the inorganic hollow spherical body in the extruded material does not receive a large resistance. While smoothly flowing and maintaining a uniform and high-density kneaded state, the molded plate is gradually extruded by a molding die and extruded. Further, even if some of the inorganic hollow spherical body is damaged by the shearing force of the screw at the time of extrusion molding, since the suppressing force against the extrusion force is added to the molding plate, the extrusion dough in the molding die is Since the suppression force is applied, it is possible to prevent the generation of bubbles, cavities, etc. due to the gas leaking from the damaged inorganic hollow spherical body, and a lightweight resin molded plate using a uniform, high-density and lightweight inorganic hollow spherical body is formed. It

In the method for producing a light weight synthetic wood powder using the inorganic hollow spheres of the present invention, the grain size of the wood powder is made to be well compatible with the thermoplastic resin molding material, and the wood is used at the time of gel kneading and molding extrusion. In order to reduce the frictional resistance of the powder and prevent the wear and damage of the molding machine, make granules or powders with an average particle size of 20 mesh or less, volatilize the wood acid gas during gelation kneading and molding, and generate steam or bubbles. In order to reduce the surface roughness and prevent the surface from being roughened, the water content is within 15 wt%, preferably within 11 wt%, and ideally within 8 wt%.

The cellulosic crushed material is crushed by the stirring impact blade and dried by frictional heat of the stirring impact blade and the raw material itself, and the thermoplastic resin molding material is kneaded with the cellulose crushed material by the stirring impact blade. When the raw materials themselves are mixed and dispersed by frictional heat, they are kneaded and gelled without agglomeration, and then the stirring impact blades are rotated at a low speed to near the freezing point, that is, the melting point (melting point + 10 °) of the thermoplastic resin molding material in the raw material. It is granulated while being cooled to C) to obtain granulated wood flour.

Further, the granulated wood powder is approximately equal to or less than the inorganic hollow spheres by a sizing means comprising a crusher such as a cutter mill having a screen approximately equal to or less than the inorganic hollow spheres. The wood-based synthetic powder is obtained by adjusting the particle size to. Next, 10 to 45 wt% of inorganic hollow spheres are added to this synthetic wood powder, mixed and dispersed,
A lightweight woody synthetic powder using an inorganic hollow sphere is obtained.

As described above, the so-called thermoplastic resin molding material can be constantly maintained in a state of being fixed to thermally and chemically stable wood powder particles, so that the cellulosic crushed product and the thermoplastic resin can be maintained. A woody synthetic powder that gives good fluidity is formed in order to constantly maintain a mixed and dispersed state with a molding material, and combined with cooling condensation and contraction, woody synthesis that does not rely on chemical reactions or adhesion. Since powder is formed, the friction resistance of the cellulosic crushed material in the extruded material is reduced during extrusion. Moreover, since the average particle size of the synthetic wood powder is adjusted to be equal to or smaller than that of the inorganic hollow spheres, the synthetic wood powder and the inorganic hollow spheres are well mixed and dispersed.

When the light weight synthetic wood powder using the above-mentioned inorganic hollow spheres of the present invention is introduced into the same extruder as in the method for producing the light weight resin molded plate of the present invention described above, the cellulosic crushed product and the inorganic hollow spheres are introduced. And the thermoplastic resin molding material are kneaded in a well-dispersed state, and extruded while maintaining a good kneading state, and a uniform, high-density and lightweight lightweight wooden synthetic board is molded.

The total amount of the cellulosic crushed product and the inorganic hollow spheres is 20 to 65 wt%, and the thermoplastic resin molding material is 35
The weight ratio of the cellulose crushed material to the inorganic hollow spheres is 80% by weight, and the lightweight woody synthetic powder has the same weight ratio of the cellulose crushed material to the inorganic hollow spheres. Since it is good, the dispersed state of the cellulosic crushed material, the inorganic hollow sphere and the thermoplastic resin molding material is good.

For the same reason as described above, a lightweight woody synthetic powder obtained by using a thermoplastic resin molding material of 60 mesh or less, preferably in the form of fine powder, is a thermoplastic resin molding material or a wood powder grain of each inorganic hollow sphere. Intrudes evenly between the bodies, and the cellulosic crushed material and the inorganic hollow spheres are well mixed and dispersed in the thermoplastic resin molding material.

Further, even when some of the inorganic hollow spheres in the lightweight wooden synthetic powder are damaged by the shearing force of the uniaxial screw during the extrusion molding using the lightweight wooden synthetic powder of the present invention, the above-mentioned present invention is used. Like the lightweight resin molded plate of, since the suppression force against the extrusion force is added to the extruded fabric,
Gas bubbles leaking from the damaged inorganic hollow spheres,
It is possible to prevent the formation of cavities, etc. Also, because the extruded dough is extruded and molded into the molding part of the molding die with a fluororesin sheet attached to the inner surface or coated with fluororesin, the cellulosic crushed material in the extruded dough Also, the inorganic hollow spheres smoothly flow without receiving a large resistance and are extruded while maintaining a uniform and high-density kneading state, and a uniform, high-density and lightweight lightweight wooden synthetic board is formed.

[0044]

An embodiment will be described with reference to the drawings.

Manufacturing Example of Light-weight Resin Molded Plate A light-weight resin molded plate according to the manufacturing example shown in the table below was manufactured.

[0046]

[Table 1]

Explaining the apparatus constitution of the above-mentioned manufacturing example, first, the thermoplastic resin molding material and the inorganic hollow spherical body are mixed and dispersed at a super low speed rotation of 10 rpm or less by supplying both into a container having a constant volume. Alternatively, use a pan-type rotary mixer to maintain the dry state of the raw materials for dispersion mixing.

Here, the thermoplastic resin molding material and the glass balloon are satisfactorily dispersed and mixed, and the thermoplastic resin molding material and the glass balloon are aggregated, and there is no adhesiveness between the thermoplastic resin molding material and the glass balloon. Therefore, it becomes a good material which can be more efficiently kneaded in the later-described extruder 70. The glass balloon itself has a good fluidity.

In FIG. 3, 70 is a single-screw extruder, but in general, the extruder is usually a screw type, and there are a single-screw extruder and a multi-screw extruder, which have a modification or a structure in which these are combined. However, in the present invention, a single-screw extruder is used so as not to break the inorganic hollow spheres.

In FIG. 3, reference numeral 71 denotes a screw, and a general screw has a large change in the drawing of the screw groove so as to pressurize the raw material in the extruder 70 from the base portion to the tip. By reducing the change in screw groove drawing, the breaking force of the inorganic hollow spheres in the raw material is reduced. By the way, the depth of the general screw groove is 10 mm at the base and 1-2 mm at the tip, but the screw 71 of the present invention forms the depth of the screw groove at 10 mm at the base and 7-8 mm at the tip. ing.

The screw 71 is driven by a motor (not shown) via a gear reducer 72 and rotates in the barrel 74. When the glass balloons, which are inorganic hollow spheres dispersed and mixed as described above, and PP, which is a thermoplastic resin molding material, are charged from the hopper 73, the glass balloons and PP
Are extruded forward of the screw 71 while being kneaded by the rotating screw 71. A band heater 75 is provided on the outer surface of the barrel 74. The band heater 75 heats the glass balloon and PP in the barrel 74, and the glass balloon and PP are gradually melted while being transported forward along the groove of the screw 71, and the glass balloon and PP are gradually melted. Be trained. Then, through the screen 76 and the adapter 17, the material is extruded from the extrusion die 19 of the adapter 17 to the molding die 10 as the extrusion material 79.

[Extrusion Die] In FIG. 4, reference numeral 17 denotes an adapter, which has an inflow port 18 into which an extrusion material 79 kneaded by an extruder 70 flows and an extrusion material 79 which will be described later.
And an extrusion die 19 for discharging to. Further, a protrusion having a rectangular cross section is provided at the tip of the adapter 17.
The extrusion die 19 has an elongated rectangular shape with a width of 50 mm and a height of 12 mm so as to form a wall thickness of about 8 mm at the tip of the protrusion (FIGS. 8 and 9), and the inflow port 18 has an adapter 17 The rear end face has a circular shape with a diameter of 50 mm, and a communication hole is formed from this inflow port 18 toward the extrusion die 19 where the cross-section is gradually deformed. The inflow port 18 is formed in the same size as the discharge port having a circular cross section of the extruder 70, while the extrusion die 19 is formed.
The width of the rectangle is preferably formed to have the same size as the diameter of the inflow port 18, and the height is preferably formed to have the same size as the height of the molding chamber 22 of the molding die 10 described later.

The adapter 17 can be formed in various sizes according to the size of the extruder 70. For example, the inlet 18
When the diameter is 150 mm, the width of the rectangle of the extrusion die 19 can be 150 mm, and the height can be 12 mm, which is the same as the height of the molding chamber 22.

The rear end of the adapter 17 is the adapter 17
Via a fitting 28 fitted to the outer periphery of the extruder 70, and connected to the tip end surface of the screen portion 16 provided with the screen 76 of the extruder 70 with a fitting such as a bolt and the inlet port 18 of the adapter 17 and the screen portion of the extruder 70. Communicating with 16 outlets, while
A recess having a rectangular cross section is formed at a substantially central position on the rear end surface of the molding die 10, and a projection having a rectangular cross section at the tip of the adapter 17 is mounted in the recess to connect the extrusion die 19 and the introduction hole 12 of the molding die 10. Communicate.

A heater 14a as a heating means is embedded in the peripheral wall of the communication hole of the adapter 17.

The extruded dough 79 extruded from the exit of the screen portion 16 of the extruder 70 flows in from the inflow port 18 of the adapter 17 and is heated and kept warm by the heater 14a while passing through the communication hole and extruded from the extrusion die 19 to the molding die 10. Introduction hole 12
Flows inward. The cross-section change of the communication hole from the inflow port 18 to the extrusion die 19 narrows relatively rapidly, but since this cross-section change is only the change in the height direction, the extrusion material 79
The flow condition of is not complicated and is good. In addition, unlike the general die, the extrusion die 19 has a large injection port and is formed in a shape capable of discharging a large amount of the extrusion material 79 and promoting the compaction. The die does not become clogged. Therefore, it is possible to prevent an extremely large pressure from being applied to the glass balloon in the extruded material 79 passing through the die, and the breakage rate of the glass balloon is reduced.

In FIG. 4, reference numeral 10 denotes a forming die, which has a shape similar to that of a so-called T-die type forming die, and heats and heats the extruded dough 79 discharged from the extrusion die 19 having a rectangular cross section of the extruder 70. And a forming part 21 having an introducing part 11 for extruding the extruded dough 79 while maintaining the fluidity of the extruded dough 79, and a forming chamber 22 for forming the extruded dough 79 extruded from the introducing part 11 into a wide plate having a predetermined wall thickness. Consists of.

The introducing part 11 has an introducing hole 12 and an introducing chamber 13, and the introducing hole 12 extends from the extrusion die 19 to a width 910.
forming chamber 22 having a slender rectangular cross section with a height of 12 mm and a height of 12 mm
The cross section is rapidly deformed to the entrance of. The distance from the extrusion die 19 to the inlet of the molding chamber 22 (distance in the extrusion direction of the introduction part 11) is about 200 mm.

The introduction hole 12 is bulged to have an elliptical cross section in vertical section and is formed to be substantially the same size as or slightly larger than the extrusion die 19, and the shape of the cross section is the width of the molding die 10 as shown in FIG. Is curved in the direction of the molding chamber 2
It is formed into a so-called coat-hanger type over the both ends in the longitudinal direction of the rectangular cross section of the inlet of 2, and communicates with the extrusion die 19 of the extruder 70 at a substantially central position of the introduction hole 12 in the longitudinal direction. ing. Further, from the introduction hole 12 to the inlet of the molding chamber 22, there is communicated with the introduction chamber 13 whose longitudinal section is formed to have the same height as the inlet of the molding chamber 22.

Reference numeral 14 denotes a heater, which may be provided on the outer circumference of the peripheral wall of the introduction hole 12 and the introduction chamber 13 by a heating means such as an electric heater, but in the embodiment, the heating effect is excellent.
The extruded dough 79, which is provided in the peripheral wall and flows in the introduction hole 12 and the introduction chamber 13, is heated and kept warm to extrude the extruded dough 79.
Maintain the liquidity of.

The width of the molding die 10 in the longitudinal direction is 910.
mm, height 12 mm, forming an elongated rectangular section, forming chamber 2
The distance from the inlet 2 to the die outlet 23 (distance in the extrusion direction of the molding part 21) is 500 mm.

Sheets 24 made of fluororesin having a thickness of 0.25 mm are attached to the inner wall surfaces of the upper, lower, left and right sides of the molding chamber 22. In addition to this, the fluorine resin can be directly surface-coated on the four inner wall surfaces of the molding chamber 22 in the upper, lower, left, and right directions, but it is easy to replace the fluorine resin, and the fluorine resin coating process is easy and highly durable. It is particularly preferable to attach the resin sheet 24.

A cooling pipe 25 is an example of cooling means for cooling the molding portion 11 of the molding die 10, and is suitable for the extrusion direction of the molding portion 21 in the molding dies 10 above and below the molding chamber 22. The extruded dough 79 in the molding chamber 22 is cooled by supplying water to the cooling pipe 25 as a cooling medium such as water at room temperature or water up to about 70 to 80 ° C. or oil to the cooling pipe 25, which is inserted at intervals. .

Reference numeral 15 is a guide plate, as shown in FIG. 5, which is a symmetrical trapezoidal plate having a short side of about 200 mm, a long side of about 850 mm and a height of about 100 mm and a thickness of 7 mm. A sheet made of fluororesin such as Teflon having a thickness of 0.1 to 0.5 mm is attached to the entire outer surface of the plate 15. The outer surface of the guide plate 15 may be directly coated with fluororesin.

This guide plate 15 is 12 mm high and 910 mm wide.
In the introduction hole 12 forming the
Further, the rear end edge of the guide plate 15 is positioned so as to be substantially parallel to the rear end wall surface of the introduction hole 12, and the guide plate 15 is fixed to the lower surface of the introduction hole 12 on the molding die 10 with four bolts 27. . Therefore, a gap of 5 mm is formed between the upper surface of the guide plate 15 and the upper surface of the introduction hole 12.

The guide plate 15 has the same thickness as that of the introduction hole 1.
The size of the guide plate 15 is 70% or less of the height of the introduction hole 12 according to the height of the guide hole 15.
It is preferably formed to have a length of 95%.

Further, the guide plate 15 can be positioned substantially at the center in the height direction of the introduction hole 12 so that the upper and lower surfaces of the guide plate 15 are provided with a gap similar to the upper and lower surfaces of the introduction hole 12.
If the guide plate 15 of the present embodiment is positioned approximately at the center of the introduction hole 12 in the height direction, the introduction hole 12 is formed so as to have a gap of 2.5 mm vertically in the height direction. The guide plate 15 is screwed and fixed to the molding die 10 with four stepped pins.

When the extruded dough 79 is heated and kept warm in the introduction part 11 to maintain fluidity and maintains a good kneading state, when the guide plate 15 is provided, the extruded dough 79 is introduced by the guide plate 11.
In the inside, depending on the raw material, the extruded dough 79 prevents different linear orientations of the central portion and the end portion by differentiating the molecular orientation in the extruding direction, and aims to homogenize the linear expansion and control the molecular orientation. And is evenly diffused into the molding chamber 22 of the molding unit 21,
Extruded with a uniform density. Since the inner wall surface of the molding chamber 22 is provided with a fluororesin sheet 24 having a small friction coefficient or is coated with the fluororesin, the glass balloon in the extruded material 79 passing through the inner wall surface is smoothly subjected to no great resistance. And is extruded while maintaining a uniform and high-density kneading state. In the process of being extruded in the forming chamber 22, the extruded dough 79 is gradually cooled and cooled with a cooling medium such as water or oil at room temperature to 60 ° C. to 90 ° C. to form the forming plate 29. Since the fluororesin has a lower coefficient of thermal conductivity than metal, the extruded material 79 is gradually cooled, and the distortion caused by cooling is reduced, so that a lightweight wooden synthetic board, which is a molded board 29 as a uniform and high-density product with less distortion, is formed. To be done.

In FIGS. 6 and 7, bearings 34a that support both ends of the shafts of the three free pinch rollers 31b are fixed to the bearing fixing frame 36, and the fixed pinch rollers 31a and the gears 116 provided on the respective shafts. The gear 117 meshing with the gear 116 is interlocked to connect the input shaft of the powder brake 115 to the shaft of one fixed pinch roller 31a among the three fixed pinch rollers 31a. The powder brake 115 is a so-called electromagnetic brake, and can electrically finely adjust the friction torque.

Further, a frame 114 is erected on the bearing fixing frame 36, two block-shaped guide bodies 119 each having a guide groove are provided on the wall surface of the frame 114, and the axial direction of the 119 is oriented vertically. Bearings 34b, which are provided substantially parallel to each other and support both ends of the shafts of the three free pinch rollers 31b, are vertically movable along the guide grooves of the guide body 119, and the bearings 34b are respectively provided on the upper surface of the frame 114. Are connected to the tips of the rods of the three air cylinders 118 provided in the.

Therefore, by operating the cylinder 118, each of the three free pinch rollers 31b is pressed against the fixed pinch roller 31a via the forming plate 29, and one of the three fixed pinch rollers 31a is fixed pinch roller 31a. Three
The rotation of the shaft 1a is suppressed by the powder brake 115, and the gear 11 provided on the shaft of the fixed pinch roller 31a.
6 meshes with the gears 116, 116 provided on the shafts of the other two fixed pinch rollers 31a, 31a via the gears 117, 117, so that the friction of the powder brake 115 with the three fixed pinch rollers 31a. The same rotation suppression force by the torque acts.

By the way, the friction torque for suppressing the rotation of the fixed pinch roller 31a by the powder brake 115 is
It is adjusted according to the thickness of the forming plate 29 to be formed.

Therefore, the friction torque of the powder brake 115 becomes a restraining force against the pushing force of the molding plate 29,
The extruded dough 79 in the introduction portion 11 of the molding die 10 is made even more dense and uniform, and the extruded dough 79 having a uniform and high density is restrained by the braking means 30a by the extruding force of the extruded dough 79 by the extruder 70. It moves forward against the force and is cooled in the forming chamber 22 to form the forming plate 29.
The molding plate 29 resists the restraining force of the powder brake 115 and the fixed pinch roller 31a and the free pinch roller 3 are provided.
Move forward while rotating 1b.

The restraining force is applied to the forming part 2 via the forming plate 29.
1 does not exert a restraining force on the molding plate 29 as described above by giving a resistance to the extrusion dough 79 in the introduction part 11 and the extrusion force of the extrusion dough 79 in the molding chamber 22 applied by the extruder. Compared with the case, the entire extruded material 79 in the molding chamber 22 has a more uniform density and a higher density. By the way, as shown in Table 1, the breakage rate of the glass balloon was about 30%, but even if the glass balloon was broken, the density of the extruded dough 79 was increased by applying the restraining force to the molding plate 29. Therefore, it is possible to prevent bubbles, nests, and the like caused by the gas leaked from the damaged glass balloon. Therefore, a lightweight resin molded plate containing a large amount of inorganic hollow spheres and having a more uniform and high density and a light weight can be molded.

After that, the light-weight resin molded plate which is the molded plate 29 as the product is cut to a desired length by a cutting machine such as a cutter, a shearing machine or a saw. A cutting machine such as a cutter is used for the thin molded plate 29, and a shearing machine or a saw machine is used for the thick molded plate 29 of 12 mm or the like.

A lightweight resin molding plate W: 910 mm, H: 12 mm, which is the molding plate 29 as the above product, is 1
It was cut every 820 mm to obtain a beige light-weight resin molded plate having a weight of 12.5 kg and being almost entirely thin. In this lightweight resin molded plate, the glass balloon has a breakage rate of 30%, and the lightweight resin molded plate has a specific gravity of about 0.63.

By the way, if the PP of the thermoplastic resin molding material is 10
The specific gravity of the resin molded plate molded with 0% is about 0.9, and the weight of the resin molded plate W: 910 mm, H: 12 mm, L: 1820 mm is 17.9 kg, and the lightweight resin molded plate of the present invention is light. is there.

Incidentally, the calculation formula; specific gravity of light-weight resin molded plate (ρA) = M / V = M / [(βM / ρp) + (γM / ρg)] = (ρp × ρg) / (β × ρg + γ × ρp ) However, M = weight of the light weight resin molding plate V = volume of the light weight resin molding plate β = weight ratio of the thermoplastic resin molding wt% γ = weight ratio of the inorganic hollow spheres wt% ρp = of the thermoplastic resin molding material True Specific Gravity ρg = True Specific Gravity of Inorganic Hollow Spherical Body The above calculation formula is for the case where the inorganic hollow sphere is not damaged at all.

The specific gravity of the lightweight resin molded plate when 30% of the inorganic hollow spheres are broken is calculated by the following formula: ρA = M / V = M / [(βM / ρp) + (γM ×
0.7 / ρg)] = (ρp × ρg) / (β × ρg + γ × ρp × 0.7) The specific gravity (ρA) of the lightweight resin molded plate of the example is β of PP = 55 wt%; γ of the glass balloon = 45 wt% PP ρp = 0.9; glass balloon ρg = 0.32, so ρA = (ρp × ρg) / (β × ρg + γ × ρp × 0.7) = 0.9 × 0.32 /(0.55×0.32+0.45
X 0.9 x 0.7) ≈ 0.63 Therefore, W: 910 mm, H: 12 mm, L: 1820
The weight (M) of the lightweight resin molded plate of mm is: M = 91 × 1.2 × 182 × 0.63 = 12520
(G) ≈ 12.5 (kg) By changing the height of the molding die 10 to 20 to 30 mm, or to 2 to 3 mm, it is possible to form lightweight resin molded plates of various thicknesses, The thickness of the formed lightweight resin molded plate is not limited to the above-mentioned embodiment.

Means for producing lightweight woody synthetic powder [Fluid mixing and kneading means] In FIG. 1, 80 is a fluid mixing and kneading means for mixing and kneading raw materials, cooling and crushing to form "granulated wood powder", In this embodiment, it is referred to as a "mixer" for convenience.

Reference numeral 81 denotes a mixer main body, which is a cylindrical casing having an upper surface opening and a capacity of 300 liters. The opening is an input port 94 for inputting raw materials into the mixer main body 81, and this input port 94 is opened and closed. Cover with the free upper lid 82. A gas discharge pipe 95 for discharging a large amount of steam or wood acid gas generated from wood powder in the mixer body 81 is connected to the upper lid 82. Furthermore, the mixer body 8
A discharge port 88 is provided on the outer peripheral surface near the bottom surface of No. 1 and a lid 89 for covering the discharge port 88 is provided at the rod tip of the cylinder 91.
Is openable and closable. A discharge duct 93 communicates with the discharge port 88.

Further, at the center of the bottom surface of the mixer main body 81, a shaft 83 which rotates at a high speed of 820 rpm / max is rotatably supported by the rotation driving means of a motor 37KW (DC) (not shown) upward in the mixer main body 81. A scraper 84, stirring impact blades 85, 86, 87 in order from bottom to top on the shaft 83
Is mounted and tightened with a tightening nut 92 from the tip of the shaft 83. The shape of each of the stirring impact blades 85, 86, 87 is not particularly limited, but in the present embodiment, it is two blades symmetrical about the axis 83. When three stirring impellers are stacked as shown in Fig. 1, it consists of a total of six blades.
Each of the blades is a plane with an equal angle (60
Are overlapped with each other so as to form a degree). When a plurality of stirring impact blades are provided, it is preferable that the raw materials be efficiently kneaded in such a manner that they are overlapped with each other at an angle that is equal to 360 degrees, which is the total number of stirring impact blades.

The scraper 84 is rotated by slightly sliding the bottom surface of the mixer body 81 into contact with the mixer body 8.
The raw material kneaded in 1 is scraped out so as not to remain on the bottom surface of the mixer body 81, and the raw material is circulated.

Raw materials which are opened from the upper lid 82 and are introduced through the introduction port 94 include wood powder which is a cellulosic crushed product, inorganic hollow spheres, thermoplastic resin molding materials, urea, calcium carbonate, titanium oxide, pigments and the like. Consisting of additives.

Further, the calcium carbonate brings good dimensional stability to the woody synthetic board of the present invention and contributes to remarkably reducing expansion and contraction due to temperature change.
It prevents deformation of the molded product during extrusion and is inexpensive per se.

Further, the titanium oxide is excellent in fluidity and dispersibility in a solution, and contributes to remarkably reducing expansion and contraction due to temperature change in the woody synthetic board of the present invention.

The thermoplastic resin molding material is a semi-hard or soft vinyl chloride or PVC (polyvinyl chloride), PET (polyester), PP (polypropylene), PC (polycarbonate), PE (polyethylene), as in the above-mentioned examples. One kind of resin such as PTO or a mixture of several kinds of these can be used.

Similarly, a recycled thermoplastic resin molding material obtained from a waste material of a thermoplastic synthetic resin product is reused, or a virgin thermoplastic resin is added, or a virgin thermoplastic resin and the above recovery are collected. It is also possible to use a mixture of thermoplastic resin molding materials at an appropriate mixing ratio.

The thermoplastic resin molding material may be in the form of pellets, but from the viewpoint that the inorganic hollow spheres are well dispersed in the thermoplastic resin molding material, fine powder of 60 mesh or less is preferable.

[Grain sizing means] This sizing means is a means for sizing the "granulated wood powder" formed by the fluid mixing and kneading means to a particle size of 10 mm or less to form a "wood synthetic powder". is there.

In FIG. 2, reference numeral 120 denotes a sizing means for sizing the above-mentioned granulated wood powder, and a "cutter mill" is used in this embodiment.

Reference numeral 121 denotes a cutter mill main body, which is a cylindrical casing having an upper surface opening, and the opening is covered with a lid 122 which can be freely opened and closed. The lid 122 is provided with a charging port 123 for charging the granulated wood powder in the cutter mill body 121.

In the cutter mill body 121, there is provided a cutter support body 124 which is supported on the bottom surface of the cutter mill body 121 and rotates in the horizontal direction by a rotation driving means (not shown). 3 long blades 125 are installed on the
Are arranged so as to form an equal angle of 120 degrees in the rotation direction of the cutter support body 124, and the blade tips of the three rotary blades 125 are located on the same rotation locus. Further, the second fixed blade 126 is fixed to the cutter mill main body 121 at a position substantially symmetrical to the rotational locus of the blade tip of the rotary blade 125 with a slight gap with respect to the rotational trajectory of the blade tip of the three rotary blades 125. Fixed blade 1
26, the cutter support member 124, and the rotary blade 125 divide the inside of the cutter mill main body 121 into two parts, and a charging chamber 127 and a sizing chamber 128.
To form. The charging port 123 of the lid 122 communicates with the charging chamber 127. The second fixed blade 126 and the rotary blade 1
The gap with 25 can be freely adjusted so that the granulated wood powder can be sized to a desired size. Further, the sizing chamber 128 is partitioned by a screen 129 between the two fixed blades 126 so as to surround the circumference of the rotation locus of the rotary blade 125. In this embodiment, the screen 129 is formed of a mesh through which a sized product which is a “wood synthetic powder” having a size substantially equal to or smaller than that of the inorganic hollow sphere can pass. Also,
At the lower end of the cutter mill body 121 of the sieving chamber 128, a discharge port 131 for discharging the sized product by the cutter mill 120 is provided.

In the above cutter mill 120, the lid 12
When the above-described granulated wood powder is charged from the second charging port 123 and the cutter support 124 is rotated by a rotation driving means (not shown), the granulated wood powder is transferred between the rotary blade 125 and the fixed blade 126 of the cutter support 124. A state in which a so-called thermoplastic resin molding material is fixed to a thermally and chemically stable wood powder grain by crushing to a particle size of about the same as or smaller than that of an inorganic hollow sphere, and a "wood synthetic powder" is formed. To maintain the mixing and dispersion state of the wood powder and the thermoplastic resin molding material so that it can be maintained constantly, a synthetic wood powder that gives good fluidity is formed, and it is condensed and reduced by cooling. Coupled with the action,
A synthetic wood powder that is not formed by chemical reaction or adhesion is formed, passes through the mesh of the screen 129 of the sizing chamber 128, is discharged from the discharge port 131, is mixed and dispersed with the inorganic hollow spheres, and is the extruder of the next step. Sent to 70.

Production Example of Lightweight Woody Synthetic Powder In this example, the main molding materials of the raw materials are wood powder which is a cellulosic crushed material, hollow glass balloon which is an inorganic hollow spherical body, and thermoplastic resin molding material. It consists of PP.

27 wt% of the raw material has an average particle size of 20 mesh or less, a true specific gravity of 1.4, and a bulk specific gravity of 0.2 13 kg of wood flour.
(At this time, the wood powder contains about 4 wt% of water) and 0.3 kg of a 40% concentration aqueous solution of urea such as ammonia, phenol, melamine, etc., which is a neutralizing agent for wood acid gas (the ratio of urea to wood powder is 1 wt%) and 3 kg of calcium carbonate. 28 wt% of the raw material has an average particle size (U.S.) of 140 mesh (105 μ) or less, a true specific gravity of 0.32 and a bulk specific gravity of 0.16 to 0.24. Glass balloon (S32 manufactured by Sumitomo 3M) of 17 kg, and 45 wt% of the raw material is 27 kg of PP (polypropylene) which is a thermoplastic resin molding material.

The average particle size of the wood flour means a particle size of 50 weight percent of the cumulative weight percent distribution of the wood flour, and the average particle size of the glass balloon is 14
It means a particle size with a residual rate of 3 wt% or less on a 0 mesh (105μ) sieve.

The step of kneading with the mixer 80, which is the fluid mixing and kneading means described above, will be described in detail below.

(1) The stirring impact blades 85, 86, 87 and the scraper 84 are rotated at a high speed, the upper lid 82 is opened, and 13.5 kg of wood powder is charged through the charging port 94, and 0.3 kg of the urea is added.
Is added little by little.

(2) After about 1 minute, 3 kg of calcium carbonate of 5 to 10 wt% is added and kneaded for about 10 to 20 minutes. When calcium carbonate is added, the specific gravity of the raw material becomes heavier, so the shearing force of the stirring impeller rotating at a high speed is increased, so that the generation of frictional heat due to the shearing force is improved, and the temperature in the mixer 80 becomes 180 to 190 ° C. Moisture of raw material is 1wt
% Or less, preferably 0.3 wt% or less. By the way, in this embodiment, 17 minutes after the wood flour was added, 09
After a second, the temperature in the mixer body 81 was 190 ° C., and the raw material water content was 0.1 wt%. The wood powder is crushed by the high-speed rotation of the stirring impact blades 85, 86, 87, and a large amount of steam or wood acid gas generated from the wood powder at this time is discharged from a gas discharge pipe 95 provided on the upper lid 82.

(3) Next, PP of thermoplastic resin molding material
27 kg of (polypropylene) is put into the mixer main body 81 and kneaded for 5 to 8 minutes (kneading for about 8 minutes in this embodiment). The thermoplastic resin molding material used in the present embodiment is a granular pellet having a diameter of about 3 mm.

The melting point of PP of the thermoplastic resin molding material was 165 ° C., and the temperature in the mixer main body 80 in this step was 186 ° C.

In this step, PP does not become a large lump due to the wood powder in the raw material, and does not aggregate even when mixed and dispersed, and gels into a clay form. In this step, the clay-like gelled material became a lump-shaped kneading material having a diameter of about 10 to 100 mm.

(4) When the motor is operated at a low speed and the temperature is lowered to about 10 ° C. higher than the melting point of the thermoplastic resin molding material in the raw material, the gelled and kneaded material in the mixer 80 is cooled and the stirring impact blades are used. It is crushed and granulated into a lump having a diameter of about 25 mm or less.

The granulated lumps are formed in a state where the individual wood flour has the thermoplastic resin attached to the entire surface of the individual wood flour.

(5) The cylinder 91 is operated to retract the lid 89 and open the discharge port 88. The gelled and granulated raw material in the mixer body 81 is discharged from the discharge port 88 to the discharge duct 93.
And then discharged to the next step. The entire process from the input of raw materials to the discharge of raw materials was processed in 27 minutes 54 seconds.

Another manufacturing example will be shown below.

As the raw material, 32 wt% of the raw material was wood powder having an average particle size of 20 mesh or less and a bulk specific gravity of 0.2.
5 kg and 0.3 kg of a 40% urea aqueous solution,
20wt% titanium oxide consists of 3kg, 32wt% of raw material
Is 14.5 kg of hollow glass balloons having an average particle size of 140 mesh or less, a true specific gravity of 0.32, and a bulk specific gravity of 0.16 to 0.24, and the remaining 36 wt% is PC of a thermoplastic resin molding material. It consists of 16 kg (polycarbonate). When this raw material is kneaded in the mixer 80, the same steps as those in the above-described embodiment are performed, and 17 minutes and 30 seconds after the wood powder is charged into the mixer main body 81, the PC is charged at 159 ° C. for about 26 minutes. After 14 minutes, gelation was carried out at 223 ° C. Immediately after the gelation, the motor was operated at a low speed and 1 minute later, the cooled granulated wood flour was discharged.

(6) Grain sizing The granulated wood powder formed by the cooling granulation means is further sized by a cutter mill to a particle size substantially equal to or smaller than that of the inorganic hollow spheres, "Powder" is formed.

The granulated wood powder is the rotary blade 1 of the cutter support member 124.
25 to the fixed blade 126 is cut into wood synthetic powder of about 0.1 to 8 mm to form “wood synthetic powder”, which passes through the mesh of the screen 129 of the sizing chamber 128 and is discharged from the discharge port 131.

(7) The wood synthetic powder and the inorganic hollow spheres are dispersed and mixed in the same manner as in the above-mentioned embodiment by using a mixer such as a pan to maintain the dry state of the wood synthetic powder, and a lightweight wood synthetic powder is obtained. A powder is obtained.

Manufacturing Example of Lightweight Woody Synthetic Plate Using Lightweight Woody Synthetic Powder The extruder is similar to the above-mentioned embodiment in that the change in the screw groove is reduced to reduce the destructive force to the inorganic hollow spheres in the raw material. Single-screw extruder 7 with screw 71 lowered
0. Further, similarly, a method of applying a resistance to the extrusion force of the extrusion material 79 in the molding chamber 22 applied by the extruder is adopted.

[0113]

[Table 2]

[0114] A lightweight wooden synthetic board W: 910 mm, H: 12 mm, which is the molded board 29 as the above product, is 1
By cutting every 820 mm, a beige lightweight wooden synthetic board with a weight of 15.3 kg was obtained. In this lightweight wooden synthetic board, the glass balloon had a breakage rate of 30%, but the specific weight of the lightweight wooden synthetic board was about 0.77.

Calculation formula: Specific gravity of light wood composite board (ρB) = M / V = M / [(αM / ρt) + (βM / ρp) + (γ
M / ρg)] = (ρt × ρp × ρg) / (α × ρp × ρg + β × ρt × ρg
+ Γ × ρt × ρp) where M = weight of lightweight wooden synthetic board V = volume of lightweight wooden synthetic board α = weight ratio of cellulose crushed material wt% β = weight ratio of thermoplastic resin molding material wt% γ = inorganic material Weight ratio of hollow spheres wt% ρt = true specific gravity of crushed cellulosic material ρp = true specific gravity of thermoplastic resin molding ρg = true specific gravity of inorganic hollow spheres The above formula is used when the inorganic hollow spheres are not damaged at all is.

The specific gravity of the lightweight wooden synthetic board when 30% of the inorganic hollow spheres are damaged is calculated by the following formula: ρB = M / V = M / [(αM / ρt) + (βM / ρp) +
(ΓM × 0.7 / ρg)] = (ρt × ρp × ρg) / (α × ρp × ρg + β × ρt × ρg
+ Γ × ρt × ρp × 0.7) The specific gravity (ρB) of the lightweight wooden synthetic board of the example is α = 27 wt% of wood powder; β = 45 wt% of PP; γ = 28 wt% of glass balloon ρt of wood powder = 1.4; PP ρp = 0.9; Glass balloon ρg = 0.32, so ρB = (ρt × ρp × ρg) / (α × ρp × ρg + β × ρt × ρg
+ Γ × ρt × ρp × 0.7) = 1.4 × 0.9 × 0.32 // (0.27 × 0.9 × 0.32 + 0.45 × 1.4 × 0.3
2 + 0.28 × 1.4 × 0.9 × 0.7) ≈ 0.77 Therefore, W: 910mm, H: 12mm, L: 1820
The weight (M) of the lightweight wooden synthetic board of mm is: M = 91 × 1.2 × 182 × 0.77 = 15303
(G) ≈ 15.3 (kg) In addition, lightweight wooden synthetic boards with a wall thickness of 10 to 12 mm are used for various applications such as concrete panels, interior and exterior boards for vehicles, furniture materials such as desks, tables and cupboards. used.

The height of the molding die 10 is 20 to 30 mm.
As a result, a lightweight wooden synthetic board having a wall thickness of 20 to 30 mm is formed, and this lightweight wooden synthetic board is used as a floor board or a plate material for other purposes. Therefore, the thickness of the light-weight synthetic wood board to be formed is not limited to the above-mentioned embodiment.

[0118]

[Table 3]

The light-weight wooden synthetic board W: 910 mm, H: 3 mm, which is the molded board 29 as the above product, was cut into 1820 mm intervals by shearing to obtain a lightweight wooden synthetic board having a weight of 4.0 kg. In this lightweight wooden synthetic board, the damage rate of the glass balloon was 30%, but the specific gravity of the lightweight wooden synthetic board was about 0.81.

The specific gravity (ρB) of the lightweight wooden synthetic board in which 30% of the inorganic hollow spheres of the example was broken is α = 32 wt% of wood powder; β = 36 wt% of PC; γ = 32 wt% of glass balloon Powder ρt = 1.4; PC ρp = 1.2; Glass balloon ρg = 0.32, so ρB = (ρt × ρp × ρg) / (α × ρp × ρg + β × ρt × ρg
＋ γ × ρt × ρp × 0.7) = 1.4 × 1.2 × 0.32 / (0.32 × 1.2 × 0.32 + 0.36 × 1.4 × 0.
32 + 0.32 × 1.4 × 1.2 × 0.7) ≈0.81 Therefore, W: 910mm, H: 3mm, L: 1820mm
The weight (M) of the lightweight wooden composite board of M is: M = 91 × 0.3 × 182 × 0.81 = 4024 (g)
≈4.0 (kg) Such a thin plate is a material for a wide range of purposes such as various building materials, furniture materials, equipment parts, and the like. For example, the above-mentioned thin lightweight wooden synthetic board is used as a construction material such as a decorative board for interior decoration of a house, or about 30
It is processed into a 0 mm square size and used as flooring materials such as flooring blocks. Further, as another application, as an interior material of the interior of an automobile, for example, a decorative plate around the driver's seat meter panel, a decorative plate around the transmission,
It is used as a decorative plate on the wall surface inside other vehicles, and can give a high-class feeling. As equipment parts, it is used as a box panel for electric equipment and a decorative plate for other equipment.

[0121]

[Table 4]

[0122] A lightweight wooden synthetic board W: 910 mm, H: 12 mm, which is the molded board 29 as the above product, is 1
It was cut at intervals of 820 mm to obtain a beige light weight synthetic wood board having a weight of 16.7 kg. In this lightweight wooden synthetic board, the glass balloon had a breakage rate of 30%, but the specific weight of the lightweight wooden synthetic board was about 0.84, which is light.

The specific gravity (ρB) of the lightweight wooden synthetic board in which 30% of the inorganic hollow spheres of the example was broken was α = 30 wt% of wood powder; β = 40 wt% of soft vinyl chloride; γ = 30 wt% of glass balloon. Wood powder ρt = 1.4; soft vinyl chloride ρp = 1.25; glass balloon ρg = 0.32, so ρB = (ρt × ρp × ρg) / (α × ρp × ρg + β × ρt × ρg
+ Γ × ρt × ρp × 0.7) = 1.4 × 1.25 × 0.32 / (0.3 × 1.25 × 0.32 + 0.4 × 1.4 × 0.3
2 + 0.3 × 1.4 × 1.25 × 0.7) ≈0.84 Therefore, W: 910mm, H: 12mm, L: 1820
The weight (M) of the lightweight wooden synthetic board of mm is M = 91 × 1.2 × 182 × 0.84 = 16694
(G) ≈ 16.7 (kg) The thickness of the light-weight wooden synthetic board to be molded is not limited to that in the above-mentioned embodiment, and as described above, the light-weight wooden synthetic board having a thickness of about 10 to 12 mm is made of concrete. Used for various applications such as panels, interior and exterior boards for vehicles, furniture materials such as desks, tables, cupboards, etc. Lightweight synthetic wood boards with a wall thickness of 20 to 30 mm are used as floor boards and board materials for other purposes, and are thin plates. Is a material for a wide range of purposes such as various building materials, furniture materials, equipment parts, etc.

[0124]

Since the present invention is configured as described above, it has the following effects.

(1) 30 mesh or less, preferably 50 to 85 wt% of a thermoplastic resin molding material having a particle size substantially equal to or smaller than that of the inorganic hollow spheres and 15 to 5 of the inorganic hollow spheres.
Since 0 wt% was mixed, heated and kneaded, the inorganic hollow spheres and the thermoplastic resin molding material were kneaded in a well-dispersed state and extruded while maintaining a good kneading state. We were able to mold a lightweight resin molded plate.

(2) Since the inorganic hollow spheres are mixed in the thermoplastic resin molding material, it is possible to provide a lightweight resin molding plate, and further, some of the inorganic hollow spheres are damaged by the shearing force of the screw during extrusion molding. Even if it does, since the suppression force against the extrusion force is applied to the extruded material, it is possible to prevent the generation of bubbles, cavities, etc. due to the gas leaked from the damaged inorganic hollow spherical body, and to provide a uniform and high density. We were able to provide a lightweight resin molded plate.

(3) The extruded extruded cloth was extruded by extruding the extruded cloth into the molding portion of a molding die having a fluororesin sheet attached to the inner surface or coated with the fluororesin. Since it smoothly flows without receiving a large resistance and is extruded while maintaining a uniform and high-density kneaded state, it is possible to provide a uniform, high-density and lightweight lightweight resin molded plate.

(4) Since a single screw is extruded into a molding die, and the screw changes in the depth of the screw groove from the base to the tip are reduced, the shearing force due to the rotation of the screw causes an inorganic hollow spherical body. The influence exerted can be reduced, the breakage rate of the inorganic hollow spherical body can be reduced, and a lightweight lightweight resin molded plate or a lightweight wooden synthetic plate can be provided.

(5) The extrusion into the molding die forms a rectangular injection port having a height equal to or less than the height of the molding chamber of the molding section of the molding die, and gradually narrows toward this injection port. Since it is performed by the die formed so that the cross section changes,
Discharge a large amount of extruded dough, it is possible to prevent clogging of the die, thereby preventing a large pressure from being applied to the inorganic hollow spheres, which contributes to reducing the damage rate of the inorganic hollow spheres, It was possible to provide a lightweight lightweight resin molded plate or a lightweight wooden synthetic plate.

(6) The lightweight woody synthetic powder using the inorganic hollow spheres of the present invention is well compatible with the cellulosic crushed material and the thermoplastic resin molding material, and the thermoplastic resin molding material is the cellulose crushed material. A synthetic wood powder is formed that is adhered to the entire surface and can be constantly maintained in a thermally and scientifically stable state that is fixed to wood powder granules. This will reduce the frictional resistance of the cellulosic crushed material inside, and since the average particle size of this wood-based synthetic powder is adjusted to a particle size approximately equal to or less than that of the inorganic hollow spheres, this wood-based synthetic powder And the inorganic hollow spheres are well mixed and dispersed. Therefore, when the lightweight wood synthetic powder using the inorganic hollow spheres of the present invention is put into an extruder, the cellulosic crushed product, the inorganic hollow spheres, and the thermoplastic resin molding material are kneaded in a well-dispersed state, and good kneading is performed. Since it was extruded while maintaining the state, it was possible to form a lightweight wooden synthetic board that was uniform, high-density and lightweight.

(7) The total amount of the cellulosic crushed product and the inorganic hollow spheres is 20 to 65 wt%, the thermoplastic resin molding material is 35 to 80 wt%, and the crushed cellulosic product and the inorganic hollow spheres have the same weight. Since the ratio is good, the mixture ratio of the cellulosic crushed material and the inorganic hollow spheres to the thermoplastic resin molding material is good, so the mixed dispersion state of the cellulosic crushed material, the inorganic hollow spheres and the thermoplastic resin molding material I was able to do well.

(8) When a thermoplastic resin molding material of 60 mesh or less, preferably in the form of fine powder, is used, the crushed cellulose material and the inorganic hollow spheres are well dispersed in the thermoplastic resin molding material. It was possible to obtain a lightweight woody synthetic powder in which the mixed state of the product, the inorganic hollow sphere and the thermoplastic resin molding material was good.

(9) During extrusion molding using the lightweight wooden synthetic powder using the inorganic hollow spherical body of the present invention, a part of the inorganic hollow spherical body in the lightweight wooden synthetic powder is damaged by the shearing force of the uniaxial screw. Even if it does, since the suppression force against the extrusion force is applied to the extruded material, it is possible to prevent the generation of bubbles, cavities, etc. due to the gas leaked from the damaged inorganic hollow spherical body, and to provide a uniform and high density. In addition, it was possible to provide a lightweight wooden synthetic board.

(10) The extruded extruded dough was extruded by extruding the extruded dough into the forming part of a forming die having a fluororesin sheet attached to the inner surface or coated with the fluororesin. Since the inorganic hollow spheres flow smoothly without receiving a large resistance and are extruded while maintaining a uniform and high density kneading state,
We were able to provide a lightweight wooden composite board that is uniform, dense, and lightweight.

[Brief description of drawings]

FIG. 1 is an overall front view showing a cross section of a main part of a mixer (fluid mixing and kneading means) used in an example of the present invention.

FIG. 2 is an overall front view showing a cross section of a main part of a cutter mill (size regulating means) used in an example of the present invention.

FIG. 3 is a front view showing a vertical section of the extruder according to the embodiment of the present invention.

FIG. 4 is a front view showing a vertical section of a molding die according to an example of the present invention.

FIG. 5 is a plan view showing a cross section of a main part of a molding die according to an example of the present invention.

FIG. 6 is a plan view showing a cross section of a main part of the braking means of the embodiment of the present invention.

FIG. 7 is a vertical cross-sectional view taken along the line NN of FIG.

8 is a vertical cross-sectional view taken along the line JJ of FIG.

9 is a vertical cross-sectional view taken along the line KK of FIG.

[Explanation of symbols]

 10 Molding Die 11 Introductory Part 12 Introducing Hole 13 Introducing Chamber 14, 14a Heater 15 Guide Plate 16 Screen Part 17 Adapter 18 Inlet 19 Extrusion Die 21 Forming Part 22 Forming Chamber 23 Die Outlet 24 Sheet (of Fluorine Resin) 25 Cooling Pipe 27 Pin 28 Mounting tool 29 Forming plate 30a Braking means 31 Pinch roller 31a Fixed pinch roller 31b Flexible pinch roller 34a, 34b Bearing 36 Bearing fixed frame 70 Extruder 71 Screw 72 Gear reducer 73 Hopper 74 Barrel 75 Band heater 76 Screen 77 Adapter 78 Extrusion die 79 Extrusion dough 80 Mixer (fluid mixing and kneading means) 81 Mixer body 82 Upper lid 83 Shaft 84 Scraper 85,86,87 Stirring impact blade 88 Discharge port 89 Lid 91 Cylinder 92 Tightening nut 93 Exhaust duct 94 Input port 95 Gas exhaust pipe 120 Cutter mill (grinding means) 121 Cutter mill main body 122 Lid 123 Input port 124 Cutter support 125 Rotating blade 126 Fixed blade 127 Input chamber 128 Particle size chamber 129 Screen 131 Discharge port

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁶ Identification code Internal reference number FI technical display location B29C 47/60 9349-4F 47/86 9349-4F // B29K 101: 12 105: 16 509: 00 (54) [Title of Invention] Light-weight resin molded plate using inorganic hollow spherical body and its manufacturing method, lightweight wooden synthetic powder using inorganic hollow spherical body, its manufacturing method, and said light wooden synthetic powder Lightweight wood composite board and method of manufacturing the same

Claims (16)

[Claims] 1. 50 to 85 wt% of a thermoplastic resin molding material of 30 mesh or less is mixed with 15 to 50 wt% of inorganic hollow spheres, heated and kneaded, and extruded into a molding die with a single screw to obtain a predetermined meat. An inorganic hollow spherical body, characterized in that it is formed into a thick and extruded after being slowly cooled in the forming part, and that the extruded material is made to have a high density by applying a suppressing force against the extruding force. Lightweight resin molded board using. 2. A thermoplastic resin molding material having a particle size of 30 mesh or less, preferably substantially the same as or smaller than that of the inorganic hollow sphere, and 15 to 50 wt% of the inorganic hollow sphere to 50 to 85 wt% of the thermoplastic resin molding material.
%, Mixed with heating and kneading, and using a single screw to stick a fluororesin sheet on the inner wall surface or extrude to the molding part of a fluororesin-coated molding die to extrude to a predetermined wall thickness, and Slowly extruded in the molding part, and, and, to the extruded fabric, a lightweight resin molded plate using an inorganic hollow spherical body characterized by increasing the density of the extruded fabric by adding a suppressing force against the extruding force. Production method. 3. A lightweight resin molding using an inorganic hollow spherical body according to claim 2, wherein the change in the depth of the screw groove from the base to the tip is reduced to reduce the breakage rate of the inorganic hollow spherical body. Method of manufacturing a plate. 4. The extrusion into the molding die forms a rectangular injection port having a height equal to or less than the height of the molding chamber of the molding section of the molding die, and gradually narrows toward this injection port. The method for producing a lightweight resin molded plate using an inorganic hollow spherical body according to claim 2 or 3, which is carried out by an extrusion die formed so as to change in cross section. 5. A crushed cellulosic material having an average particle size of 20 mesh or less and having a water content of 15 wt% or less 10 to 55 wt%
Of the thermoplastic resin molding material, mixed, gelled, kneaded, cooled, pulverized, and sized to a particle size substantially equal to or smaller than that of the inorganic hollow spheres. Light-weight synthetic wood powder using inorganic hollow spheres, characterized by mixing and dispersing 10 to 45 wt% of the body. 6. A cellulosic crushed product having an average particle size of 20 mesh or less and having a water content of 15 wt% or less, 10 to 55 wt%
On the other hand, 35-80 wt% of the thermoplastic resin molding material is mixed together by a stirring impact blade, and gelled and kneaded by friction heat,
An inorganic hollow spherical body comprising at least a step of cooling, pulverizing and sizing to obtain a synthetic wood powder, and a step of adding 10 to 45 wt% of the inorganic hollow spherical body to the synthetic wood powder, and mixing and dispersing. A method for producing a lightweight synthetic wood powder used. 7. The crushed cellulosic material is mixed with a thermoplastic resin molding material by a stirring impact blade, gelled and kneaded by frictional heat, cooled and pulverized to be approximately equal to or less than the inorganic hollow spherical body. The method for producing a lightweight woody synthetic powder using an inorganic hollow sphere according to claim 6, which comprises at least a step of adjusting the particle size to the above. 8. A lightweight wood material using an inorganic hollow spherical body according to claim 6, wherein the total amount of the cellulosic crushed product and the inorganic hollow spherical body is 20 to 65 wt% and the thermoplastic resin molding material is 35 to 80 wt%. Manufacturing method of synthetic powder. 9. The total weight of the cellulosic crushed product and the inorganic hollow spheres is 20 to 65 wt%, the thermoplastic resin molding material is 35 to 80 wt%, and the cellulosic crushed product and the inorganic hollow sphere are the same weight. The method for producing a lightweight synthetic wood powder using the inorganic hollow spheres according to claim 6. 10. The method for producing a lightweight wooden synthetic powder using an inorganic hollow spherical body according to claim 6, wherein the thermoplastic resin molding material has a size of 60 mesh or less. 11. A cellulosic crushed product having an average particle size of 20 mesh or less and having a water content of 15 wt% or less 10 to 55 wt
% Thermoplastic resin molding material 35-80 wt% is mixed,
Gel-kneading, cooling, crushing, sizing, and sizing, and mixing and dispersing 10-45 wt% of inorganic hollow spheres into the synthetic wood powder. The lightweight synthetic wood powder obtained by heating and kneading is mixed with a single screw. A lightweight wooden synthetic board using a lightweight wooden synthetic powder, characterized by being extruded into a molding die. 12. A crushed cellulosic material having an average particle size of 20 mesh or less and having a water content of 15 wt% or less 10 to 55 wt
% Of the thermoplastic resin molding material together with a stirring impact blade, gelled and kneaded by frictional heat, cooled, pulverized, and sized by pulverization to form synthetic hollow wood powder and inorganic hollow spheres 10 The light-weight synthetic wood powder is characterized by including at least a step of heating and kneading the light-weight synthetic wood powder obtained by mixing, dispersing and adding ~ 45 wt% and extruding to a molding die with a single screw. A method for manufacturing a lightweight wooden synthetic board. 13. A wood synthetic powder, which is prepared by mixing a cellulose resin crushed product with a thermoplastic resin molding material by a stirring impact blade, gelling and kneading by frictional heat, cooling, and crushing to form an inorganic hollow sphere. A process of adding a body, mixing and dispersing, gradually cooling the extruded dough extruded to a forming die with a single screw, and adding a suppressing force against the extruding force to the extruded dough to increase the density of the extruded dough. Claim 1 including
2. A method for manufacturing a lightweight wooden synthetic board using the lightweight wooden synthetic powder according to 2. 14. The lightweight wood-synthesized wood according to claim 13, wherein the extruded material is extruded by extruding the extruded cloth onto a molding portion of a molding die having a fluororesin sheet attached to the inner wall surface or coated with the fluororesin. A method for manufacturing a lightweight wooden synthetic board using powder. 15. A lightweight wood-based synthetic method using a lightweight wood-based synthetic powder according to claim 12, 13 or 14, wherein a change in drawing from a base of the screw to a tip thereof is reduced to reduce a breakage rate of the inorganic hollow spherical body. Method of manufacturing a plate. 16. The extrusion into the molding die forms a rectangular injection port having a height equal to or less than the height of the molding chamber of the molding section of the molding die, and gradually narrows toward this injection port. The method for producing a lightweight wooden synthetic board using the lightweight wooden synthetic powder according to claim 12, 13, 14 or 15, which is carried out by an extrusion die formed so as to have a changed cross section.