JPH091682A - Manufacture of composite molding - Google Patents

Abstract

PURPOSE: To provide a method for manufacturing a composite molding which can be produced speedily and continuously by using a grainy or powdery thermoplastic resin and a grainy material. CONSTITUTION: A manufacturing method has a process for mixing a grainy or powdery thermoplastic resin and a grainy material so as to continuously form molding materials in such a manner that the mixture is wrapped in sequence by both side edges of a flexible continuous film 11, a process for leading the molding materials into a molding hole of a molding die 16 and pulling them out continuously for shaping, a process for heating and melting the grainy or powdery thermoplastic resin in the molding materials, and a process for solidifying the thermoplastic resin thereafter so as to integrate the grainy material.

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 composite molded article in which granules, particularly wood granules, are integrated with a thermoplastic resin.

[0002]

2. Description of the Related Art Conventionally, in a method of manufacturing a molded article using a granular material as a filler or an aggregate, it is mixed with a binder (eg, thermosetting resin) which is fluid at room temperature to form a slurry. After that, it is cured by heating, or a material that shows fluidity when heated (for example, thermoplastic resin)
Using, and after mixing with the particulate material heated to a slurry,
There is known a method of obtaining a molded product by cooling and solidifying thereafter.

When a molded product having an arbitrary cross-sectional shape is to be obtained by these methods, for example, when a thermosetting binder is used, batch processing such as pressing is performed, so that productivity is not so good. There is a problem. Further, when a thermoplastic resin is used, injection molding or extrusion molding is generally used, but expensive equipment such as an injection molding machine and an extrusion molding machine is required, and it is necessary to secure the fluidity of the material. Therefore, there is a problem in that the ratio of the particulate material to the binder has to be considerably low, and the injection molding is batch molding, so that the productivity is not good. On the other hand, even in the method of manufacturing a wood-based material such as particle board, most of them are mainly batch-produced by press molding, and there is a problem that productivity is not good.

On the other hand, as a continuous production method for improving productivity, a thermosetting resin having fluidity at room temperature is used, continuous glass fibers are impregnated with the resin, and the resin is placed in a drawing mold. A pultrusion molding method is known in which shaping and curing are performed while continuously drawing (for example, Japanese Patent Laid-Open No. 4-339).
635).

[0005]

In the case of this pultrusion molding method, it is necessary to use a material having continuity such as glass fiber or glass non-woven fabric as an essential component constituting the pultrusion molded article. There is a problem that a pultrusion molded article composed of a discontinuous and non-fluidic granular material cannot be obtained without a material having .

The present invention solves the above-mentioned conventional problems and provides a method for producing a composite molded article which can be continuously produced at high speed by using a granular or powdery thermoplastic resin and a granular material. It was done for the purpose.

[0007]

The invention according to claim 1 of the present application (hereinafter referred to as invention 1) is to mix a granular or powdery thermoplastic resin and a granular material and to make the mixture flexible. A step of continuously forming a molding material by sequentially wrapping it in both side edges with a continuous film having, and a step of guiding the molding material into a molding hole of a molding die and continuously withdrawing and shaping it A method for producing a composite molded article, which includes a step of heating and melting a granular or powdery thermoplastic resin in a molding material and a step of subsequently solidifying the thermoplastic resin to integrate the granular material.

In a second aspect of the present invention (hereinafter referred to as the second aspect of the present invention), a molding material is formed by wrapping the mixture in a continuous film through a thermoplastic resin film at both side edges thereof. The present invention 1 in which a surface layer is formed by heating, melting and solidifying the thermoplastic resin film.
The method for producing a composite molded article according to 1.

In the invention according to claim 3 of the present application (hereinafter referred to as the present invention 3), the granular or powdery thermoplastic resin in the molding material is heated and melted, and the thermoplastic resin film is heated and melted and then solidified. It is a method for producing a composite molded article according to the second aspect of the present invention.

The invention according to claim 4 of the present application (hereinafter referred to as the present invention 4) is the present invention 2 or the present invention 3 in which the thermoplastic resin film is subjected to arbitrary decoration and surface decoration. It is a method for producing the composite molded article described.

The invention according to claim 5 of the present application (hereinafter referred to as the present invention 5) is that the molding material is introduced into the molding hole of the molding die and shaped, and then the granular or powdery heat in the molding material is applied. The method for producing a composite molded article according to any one of the present invention 1 to invention 4, wherein the plastic resin is melted by heating and then solidified.

In the invention according to claim 6 of the present application (hereinafter referred to as the present invention 6), both ends of the continuous film are connected endlessly, and after the molding material has passed through the molding hole of the molding die, the continuous molding is continued. The method for producing a composite molded article according to the present invention 1, wherein the continuous film is circulated and used so that the wrapping by the both side edges of the film is released.

The present invention 1 relates to the shaping step of the molding material and the heating step of the granular or powdery thermoplastic resin, and includes the case where both are performed at the same time.

In the present invention, as the granular or powdery thermoplastic resin, known ones can be used, and the material thereof is, for example, polyvinyl chloride, polyvinyl chloride such as vinyl chloride-vinyl acetate copolymer, Low density polyethylene, high density polyethylene, linear low density polyethylene,
Polyolefins such as polypropylene and polybutene, polystyrenes, acrylic resins such as polyacrylic acid, polymethacrylic acid, polymethyl acrylate and polymethyl methacrylate, polyesters such as polyethylene terephthalate and polybutylene terephthalate, polyamides, polyether ether ketone , Engineering plastics such as polyphenylene sulfide, and thermoplastic elastomers.

In the present invention, as the granular material, a conventionally known inorganic granular material, wood-based granular material, metallic granular material or the like is used.

Examples of the inorganic particles include glass beads, glass powder, glass flakes, mica, talc, potassium titanate whiskers, zinc oxide whiskers, wollastonite, silica, calcium carbonate, calcium sulfate,
Examples thereof include magnesium carbonate, magnesium hydroxide, magnesium oxide, kaolin clay, wax stone clay, carbon black, graphite, titanium oxide and asbestos. Any shape, such as size and length, of the inorganic granular material may be used depending on the application of the obtained composite molded article and the required strength.

As the material of the wood-based granular material, for example,
Woods such as cedar, cypress, pine, toga, straw, fir, ifara, beech, oak, lauan, hiba, chestnut, zelkova, shii, willow, bamboo, etc.,
Examples include granular materials obtained by crushing construction scraps, waste wood, and thinned wood. As a method for obtaining a wood-based granular material from such wood, for example, known methods such as pressing, crushing, and cutting can be applied. The shape, such as size and length, of the wood-based granules may be arbitrary depending on the intended use of the resulting composite molded article and the required strength, but it is usually 0. 1
Those having a thickness of 10 mm, preferably 0.8 mm to 5 mm are used.

Examples of the metal particles include iron, aluminum, copper, brass, stainless steel, lead, zinc, tin, titanium, brass and bronze particles. Any shape, such as size and length, of the metal granules may be used depending on the application of the obtained composite molded article and the required strength.

As a method for mixing the granular or powdery thermoplastic resin and the granular material, a known method can be used,
For example, a method of charging the granular or powdery thermoplastic resin and the granular material into a mixer and mixing, a method of using a kneader, a method of sprinkling the granular or powdery thermoplastic resin on the granular material on the conveyor belt, and the like. To be The blending amount is usually 1 to 50 parts by weight, preferably 5 to 20 parts by weight, of the granular or powdery thermoplastic resin as a binder with respect to 100 parts by weight of the granular material.

The flexible continuous film used in the present invention may be a known one having a melting (decomposing) temperature higher than the heating melting temperature of the granular or powdery thermoplastic resin used, Usually, a thermoplastic resin film is used. In some cases, it is possible to use leather, woven fabric made of natural fibers (hemp, silk, etc.), a resin-impregnated composite thereof, or the like. The material is appropriately selected according to the melting temperature of the granular or powdery thermoplastic resin used. Generally, a film becomes more flexible as it becomes thinner, but its strength decreases. Therefore, the width, thickness, etc., of the cross-sectional shape of the target composite molded article,
Set appropriately according to the circumference.

Specific examples of the continuous film include, for example,
Examples include thermoplastic polyester resins such as polyethylene terephthalate, cellulose resins, polyamide resins, fluorine resins such as polyvinylidene difluoride, engineering plastics such as polyether ether ketone and polyphenylene sulfide.

As the thermoplastic resin film, for example,
Of the above continuous films, those made of olefin resins such as polyethylene, polypropylene and polybutene, vinyl chloride resins, styrene resins and the like are preferably used.

As a method of decorating the thermoplastic resin film, a known method can be adopted, for example, a method of printing a desired pattern on the surface of the thermoplastic resin film, or a method of pre-calendering with a pattern. Examples thereof include a method of producing a thermoplastic resin film.

The present invention will be described below with reference to the drawings.
FIG. 1 is a perspective view illustrating a process of an example of the present invention.
A mixture 13 in which a granular or powdery thermoplastic resin and a granular material are mixed in advance is supplied from a hopper 12 onto a flexible continuous film 11 which continuously advances. The continuous film 11 is a U-shaped shaping guide 14 and an O-shaped shaping guide 1
5 through the mixture 13 at both edges
A molding material is continuously formed so as to wrap around. A roller or the like may be appropriately installed around the guides 14 and 15 to facilitate the molding of the molding material.

The molding material is introduced into the molding hole of the molding die 16 and continuously drawn by the take-up machine 18 to be shaped, and the thermoplastic resin in the molding material is heated by the molding die 16. After melting and heating, the thermoplastic resin is solidified to integrate the granular material, the molded body 17 is continuously drawn by the take-up machine 18, and cut to an appropriate length by the cutting machine 19, Obtain a molded product. The film remaining on the surface may be left as it is or may be peeled off if there is no problem in use. Mold 1
The heating temperature by 6 is appropriately set according to the length of the molding die 16, the line length, the type of thermoplastic resin, and the type of continuous film.

FIG. 2 is a perspective view illustrating a process of another example of the present invention. In this example, a molding material is formed according to the above method except that the mixture is wrapped with the continuous film 11 via the thermoplastic resin film 20.

The molding material is introduced into the molding hole of the molding die 16 and continuously drawn out by the take-up machine 18 to be shaped, and is heated by the molding die 16 so that the thermoplasticity in the molding material is increased. The resin and the thermoplastic resin film are heated and melted, and then integrally solidified to form a surface layer around the base material layer formed by integrating the granular material with the thermoplastic resin, and the molded body 17 is formed. A take-up machine 18 continuously picks it up, and a cutting machine 19 cuts it to an appropriate length to obtain a composite molded article.

FIG. 3 is a perspective view illustrating a process of another example of the present invention. In this example, the molding material is the molding die 16
Of the thermoplastic resin on the surface of the molding material by heating and melting, and then solidifying, and the molded body 10 is further molded into a molding die 16 By passing through the heating device 21 disposed on the downstream side of the above, the heating causes the thermoplastic resin in the central portion of the molding material to be completely heated and melted and then solidified.

As a heating method of the heating device 21, for example, known methods such as hot air, steam, electromagnetic wave induction heating, and induction heating can be adopted. The heating temperatures of the molding die 16 and the heating device 21 are the length of the molding die 16 and the heating device 21.
Length, line length, type of thermoplastic resin, type of continuous film. Incidentally, when the molding material is introduced into the molding hole of the molding die 16 and continuously drawn out, only shaping may be performed without heating.

FIG. 4 is a perspective view illustrating a process of another example of the present invention. In this example, the mixture is wrapped with the continuous film 11 through the thermoplastic resin film 20 to form a molding material. The molding material is guided into the molding hole of the molding die 16 and continuously drawn out to form a shape, and the thermoplastic resin and the thermoplastic resin film on the surface of the molding material are heated and melted, and then solidified. Then, the molded body 10
Is further passed through a heating device 21 disposed on the downstream side of the molding die 16 so that the thermoplastic resin at the center of the molding material is completely heated and melted by the heating, and then integrally solidified. Thus, a composite molded article is obtained in which the surface layer is formed around the base material layer formed by integrating the granular material with the thermoplastic resin.

FIG. 5 is a perspective view illustrating a process of another example of the present invention. In this example, the thermoplastic resin film 11
As the above, the surface of the composite molded article is decorated by using the thermoplastic resin film whose surface is arbitrarily decorated.

FIG. 6 is a perspective view for explaining a process of another example of the present invention. In this example, both ends of the film 31 are connected endlessly, and after passing through the molding die 16 of the molding material, the wrapping by the both side edges 311 of the film 31 is released, and the film 31 is circulated and utilized.

[0033]

In the method for producing a composite molded article according to the first aspect of the present invention, the granular or powdery thermoplastic resin and the granular material are mixed, and the mixture is sequentially wrapped with a flexible continuous film on both side edges thereof. To continuously form a molding material, a step of guiding the molding material into a molding hole of a molding die and continuously withdrawing the molding material, and a granular or powdery thermoplastic resin in the molding material. Since the film bears the force for drawing out by including the step of heating and melting, and then the step of solidifying the thermoplastic resin and integrating the granular material, continuous molding of glass roving fiber, nonwoven fabric, etc. Efficiently and continuously producing a composite molded product at a high speed while maintaining the outer shape of a molded product, using a mixture of granular or powdery thermoplastic resin and granular material as a raw material, without requiring a material It can be.

A method for producing a composite molded article according to the present invention 2 is the same as in the present invention 1, further comprising forming a molding material by wrapping the mixture with a continuous film through a thermoplastic resin film at both side edges thereof. By forming the surface layer by forming a surface layer by heating and melting and solidifying the thermoplastic resin film, it is possible to obtain a composite molded article having a smooth surface and excellent external dimension accuracy.

The method for producing a composite molded article according to the third aspect of the present invention is the same as the second aspect, except that the granular or powdery thermoplastic resin in the molding material is heat-melted and the thermoplastic resin film is heat-melted and then solidified. This makes it possible to obtain a composite molded article having a surface layer having excellent interfacial adhesion.

The method for producing a composite molded article according to the present invention 4 is the same as in the present invention 2 or 3, wherein the thermoplastic resin film is further subjected to arbitrary decoration, and surface decoration is carried out. It is possible to efficiently obtain a composite molded article having a surface-decorating layer having excellent decoratability at the time of molding, and since the surface-decorating layer is integrally molded with the base material, it has excellent durability.

The method for producing a composite molded article of the present invention 5 is the same as in the present invention 1 to 4, further comprising introducing the molding material into the molding holes of the molding die for shaping, and then forming the granular material in the molding material. Alternatively, by heating and melting the powdery thermoplastic resin and then solidifying it, the thermoplastic resin in the molding material is provided on the downstream side of the molding die regardless of the type of the thermoplastic resin or the continuous film in the molding material. The heating and melting can be appropriately performed according to the type.

The method for producing a composite molded article according to the present invention 6 is the same as in the present invention 1, except that the both ends of the continuous film are connected endlessly, and the molding material passes through the molding holes of the molding die, and then is continuously processed. It is economical because the continuous film can be reused by releasing the wrapping by the both side edges of the film.

[0039]

The present invention will be described below with reference to examples. Example 1 Building ends of rice paddy (thickness x width x length ≈ 50 mm x 100 m
m × 500 mm) was crushed with a hammer mill to obtain a granular material having an average diameter of about 1 mm. This granular material 100
Parts by weight and granular low density polyethylene (melting temperature of about 120
C.) 10 parts by weight were mixed in a mixer at room temperature to obtain a mixture.

According to the process described with reference to FIG. 1, the mixture 13 was applied to the center of a continuous film 11 made of a polyester (PET) film having a thickness of 50 μm and a width of 500 mm (melting temperature of about 200 ° C. or higher). Length 10
An amount of 150 g per 0 mm was supplied from the hopper 12. The continuous film 11 was sequentially passed through the U-shaped shaping guide 14 and the O-shaped shaping guide 15 to wrap the mixture on both side edges thereof to continuously form a molding material.

The molding material was changed to a length 10 of a molding die 16.
A linear speed of 1 m is continuously applied in the 00 mm forming hole by the take-up machine 18.
The thermoplastic resin in the molding material is heated and melted by heating at 150 ° C. by the molding die 16 and then solidified to integrate the rice cake granules to have a thickness of 3
After forming a rod-shaped body having a width of 0 mm and a width of 100 mm, a cutting machine 19 cuts the product into a length of 3000 mm to obtain 40 composite molded articles /
Got in time. Incidentally, the PET film on the surface was peeled off after cutting.

Example 2 According to the process described with reference to FIG. 2, a thermoplastic resin film (melting temperature: about 120 ° C.) 20 having a thickness of 1
Using a low-density polyethylene film of 00 μm and a width of 500 mm, the thermoplastic resin and the thermoplastic resin film in the molding material are heated and melted by heating with the molding die 16, and then integrally solidified, In the same manner as in Example 1 except that the surface layer was formed around the integrated base material layer, composite molded articles of substantially the same size as in Example 1 were obtained at 40 pieces / hour. The outside dimension accuracy of the obtained composite molded product was within ± 0.1 mm.

Example 3 A low density polyethylene film similar to that of Example 2 was used as the thermoplastic resin film 20 according to the process described with reference to FIG. 4, and a molding hole having a length of 500 mm was formed. The molding material is continuously drawn out from the molding hole of the molding die 16 whose temperature is set to 135 ° C. to shape the molding material, and the molding material is heated to form the thermoplastic resin and the thermoplastic resin film on the surface of the molding material. After being heated and melted, it is solidified, and the molded body 10 is further heated by being irradiated with electromagnetic waves of 915 MHz and 2 kW for 1 minute by the heating device 21 to completely heat and melt the thermoplastic resin in the center portion of the molding material. A composite molded article of substantially the same size as in Example 1 was prepared in the same manner as in Example 1 except that a surface layer was formed around the base material so as to be solidified later and the linear velocity was set to 2 m / min. 40 pieces / hour Obtained. The cross-sectional dimension accuracy of the obtained composite molded product is within ±
It was 0.05 mm or less.

Example 4 According to the process described with reference to FIG. 4, the same low-density polyethylene film as in Example 2 was used as the thermoplastic resin film 20, and the molding die 16 had a length of 300 mm. The heating device 2 has a molding hole, and the temperature of the molding material is set to room temperature.
A composite molded article of substantially the same size as in Example 2 was prepared in the same manner as in Example 2 except that the molding material was irradiated with electromagnetic waves of 915 MHz and 2 kW for 1 minute in Example 1 and the linear velocity was set to 2 m / min. It was obtained at 40 lines / hour. The cross-sectional dimension accuracy of the obtained composite molded product was within ± 0.1 mm.

Example 5 Other than using the thermoplastic resin film 20 made of the same low-density polyethylene film as that of Example 2 with wood grain decoration by the process described with reference to FIG. In the same manner as in Example 2, 40 composite molded articles having substantially the same size as in Example 2 were obtained. The cross-sectional dimension accuracy of the obtained composite molded product was within ± 0.05 mm. Further, the resulting composite molded article was subjected to an outdoor exposure test for 1000 hours, but no peeling of the decorative film on the surface occurred.

Example 6 A continuous film 11 having a thickness of 100 μm and a width of 500 m
m, a 20 m long tetrafluoroethylene resin film was used in the same manner as in Example 1 except that both ends of the film were joined together to form an endless composite composite product. Obtained at 20 bottles / hour. The continuous pultrusion process was stable.

Comparative Example 1 The same mixture as in Example 1 was heated and pressed at 120 ° C. and 5 kgf / cm ² for 10 minutes in a ^double press die to obtain the same composite molded article as in Example 1. A molded product with dimensions was obtained. Since it is a wood-based material, if the mold temperature is higher than this, it will not be possible to raise it because charring etc. will occur, and because of the type of binder, it is very difficult to remove it from the mold,
Only molded bodies could be obtained at 6 pieces / hour. The cross-sectional dimension accuracy of the obtained composite molded product was within ± 1 mm.

Comparative Example 2 A commercially available laminated plate was attached to the surface of the molded body obtained in Comparative Example 1, and the same exposure test as in Example 4 was conducted.
Peeling occurred on the attached plate after the lapse of 00 hours.

[0049]

EFFECTS OF THE INVENTION Since the method for producing a composite molded article according to the present invention 1 is configured as described above, the outer shape of a molded article is obtained by using a mixture of granular or powdery thermoplastic resin and granular material as a raw material. It is possible to continuously produce composite molded products at a high speed while maintaining the same.

Since the method for producing a composite molded article of the second aspect of the present invention is configured as described above, it is possible to obtain a composite molded article having a smooth surface and excellent external dimension accuracy.

Since the method for producing a composite molded article according to the third aspect of the present invention is configured as described above, a composite molded article having a surface layer excellent in interfacial adhesion can be obtained.

Since the method for producing a composite molded article according to the fourth aspect of the present invention is configured as described above, it is possible to efficiently obtain a composite molded article having a surface-decorated layer having an excellent decorative property at the time of pultrusion molding. The surface decoration layer has excellent durability.

Since the method for producing a composite molded article according to the fifth aspect of the present invention is configured as described above, the thermoplastic resin heating and melting in the molding material is adjusted according to the type on the downstream side of the molding die. It can be performed appropriately.

Since the method for producing a composite molded article of the sixth aspect of the present invention is configured as described above, it is possible to circulate and utilize a continuous film.

[Brief description of the drawings]

FIG. 1 is a perspective view illustrating a step of an example of a method for manufacturing a composite molded article according to the present invention.

FIG. 2 is a perspective view illustrating steps of another example of the method for manufacturing a composite molded article of the present invention.

FIG. 3 is a perspective view illustrating steps of another example of the method for manufacturing a composite molded article of the present invention.

FIG. 4 is a perspective view illustrating steps of another example of the method for manufacturing a composite molded article of the present invention.

FIG. 5 is a perspective view illustrating steps of another example of the method for manufacturing a composite molded article of the present invention.

FIG. 6 is a perspective view illustrating steps of another example of the method for manufacturing a composite molded article of the present invention.

[Explanation of symbols]

11 Continuous film 13 Mixture of granular or powdery thermoplastic resin and granular material 16 Mold for molding 20 Thermoplastic resin film

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Claims (6)

[Claims] 1. A molding material is continuously formed by mixing a granular or powdery thermoplastic resin and a granular material and sequentially wrapping the mixture in a flexible continuous film at both side edges thereof. Step, the step of guiding the molding material into the molding hole of the molding die and continuously drawing it out and shaping, the step of heating and melting the granular or powdery thermoplastic resin in the molding material, and then the thermoplastic A method for producing a composite molded article, which comprises a step of solidifying a resin to integrate a granular material. 2. A surface layer is formed by forming a molding material by wrapping the mixture in a continuous film through a thermoplastic resin film on both side edges thereof, and melting and solidifying the thermoplastic resin film by heating. The method for producing a composite molded article according to claim 1, wherein: 3. A thermoplastic resin film in a molding material is melted by heating, and a thermoplastic resin film is melted by heating and then solidified.
The method for producing a composite molded article according to. 4. The thermoplastic resin film is subjected to arbitrary decoration and surface decoration is performed.
Alternatively, the method for manufacturing the composite molded article according to claim 3. 5. The granular or powdery thermoplastic resin in the molding material is heated and melted and then solidified after the molding material is guided into the molding hole of the molding die and shaped. ~ The method for producing a composite molded article according to claim 4. 6. The continuous film is circulated by connecting both ends of the continuous film in an endless manner, and after the molding material has passed through the molding hole of the molding die, the wrapping by the both side edges of the continuous film is released. It utilizes, The manufacturing method of the composite molded product of Claim 1 characterized by the above-mentioned.