JPH09262924A - Composite molded panel and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance the flexibility of a composite molded panel by forming a diffusion layer of reinforcing fibers such as glass or carbon fibers becoming low in diffusion density toward the inside on at least one surface of a panel main body molded from a hard foamed urethane resin. SOLUTION: A composite molded panel is obtained by forming diffusion layers 1a, 1b of glass or carbon fibers 20 on both surfaces of a panel main body 1 composed of a hard foamed urethane resin 10. The glass or carbon fibers 20 are pref. composed of filaments. Since the glass or carbon fibers 20 are diffused toward the central part of each of the diffusion layers from both upper and lower surfaces thereof in a mat form, the diffusion density thereof naturally becomes low toward the inside of the panel body 1. That is, the composite molded panel is formed by forming diffusion layers 1a, 1b of glass or carbon fibers 20 on both surfaces of a panel main body 1 composed of a hard foamed urethane resin 10 and the diffusion density of the glass or carbon fibers 20 in the diffusion layers 1a, 1b becomes low toward the inside of the panel main body 1.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a technical field relating to composite molding of a plate material composed of a urethane resin and a reinforcing fiber such as glass fiber or carbon fiber.

[0002]

2. Description of the Related Art Conventionally, as a composite molded plate using urethane resin, for example, one shown in FIG. 6 is known.

This conventional composite molded plate has FRP (Fiber) on both sides of a plate body 1 made of hard urethane foam resin.
It has a three-layer laminated structure in which a surface layer 2 made of Reinforced Plastics (fiber reinforced thermosetting resin) is provided. The surface layer 2 is laminated on both surfaces of the plate body 1 by being bonded or welded with an adhesive.

The FRP constituting the surface layer 2 is a resin material made of polyester resin, epoxy resin, melamine resin, diallyl phthalate resin, phenol resin or the like, and a fiber reinforcing material such as glass fiber, nylon fiber, asbestos or steel wire. It is made by mixing. The characteristics of this FRP are high bending strength, tensile strength, impact strength, heat resistance,
It has excellent wear resistance and chemical resistance.

Therefore, this conventional composite molded plate is widely used as a building material such as a wall material by utilizing the soundproofing property of the hard urethane foam resin constituting the plate body 1.

[0006]

In the above-mentioned conventional composite molded plate, since the surface layer 2 is FRP, so-called flexibility (flexibility, toughness) is low, and secondary processing is required depending on the application. There is a problem that becomes. Note that, as the secondary processing, for example, when used as a building material, there are splitting, nailing for preventing damage, and drilling of mounting holes for screwing.

The present invention has been made in consideration of such problems, and has a composite molding plate having high flexibility,
An object of the present invention is to provide a method for manufacturing a composite molded plate suitable for manufacturing this composite molded plate.

[0008]

Means for Solving the Problems In order to solve the above problems, the composite molded plate according to the present invention employs the following means.

That is, according to the first aspect of the present invention, a diffusion layer of reinforcing fibers such as glass fiber or carbon fiber having a lower diffusion density toward the inside is formed on at least one surface of a plate body formed of hard urethane resin. It becomes.

By this means, reinforcing fibers such as glass fibers or carbon fibers as a fiber reinforcing material are mixed to obtain the same characteristics as the conventional FRP. Moreover, since the glass fibers are integrally diffused and mixed inside the hard urethane resin that constitutes the plate body, and the diffusion density decreases toward the inside, the hardness distribution in the plate thickness direction becomes uneven. Flexibility is increased.

According to a second aspect of the present invention, in the composite molded plate according to the first aspect, the coating layer is laminated on the surface of the diffusion layer of the reinforcing fiber such as glass fiber or carbon fiber.

[0012] In this means, the coating layer hides defects such as surface roughening due to the mixing of reinforcing fibers such as glass fibers or carbon fibers.

Further, in order to solve the above-mentioned problems, the method for manufacturing a composite molded plate according to the present invention employs the following means.

That is, according to the third aspect of the present invention, reinforced fibers such as matt glass fibers or carbon fibers are laid on the molding die, and a liquid hard urethane resin is injected into the molding die, and the glass fiber is filled with the hard urethane resin. After impregnation, the hard urethane resin is foamed by heating and the reinforcing fibers are diffused inside the hard urethane foam resin.

In this means, a so-called cast molding method of a thermosetting resin is used for manufacturing, and the matting glass fiber or carbon fiber or other reinforcing fiber is diffused by utilizing the foaming of a hard urethane resin. . The diffusion density of the reinforcing fibers naturally decreases from the laying position on the mold toward the opposite side.

According to a fourth aspect of the present invention, in the method for producing a composite molded sheet according to the third aspect, a spacer made of a hard urethane foam resin block is provided on a reinforcing fiber such as matte glass fiber or carbon fiber laid in a molding die. It is characterized in that a matt glass fiber is further laminated via this, and a liquid hard urethane resin is injected between the reinforcing fibers.

By this means, reinforcing fibers such as glass fibers or carbon fibers are diffused on both sides of the composite molded plate. The spacer is integrated with the foamed hard urethane resin.

[0018]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of a composite molded plate and a method for manufacturing the same according to the present invention will be described below with reference to FIGS.

1 to 4 show an embodiment (1) of a composite molded plate and a method for manufacturing the same according to the present invention.

In this embodiment, as shown in FIG.
The composite molded plate has a diffusion layer 1a of glass fiber or carbon fiber 20 on both sides of the plate body 1 of urethane foam resin 10 having a hard structure.
1b is formed.

As shown in FIGS. 2 to 4, this composite molded plate is manufactured by using a so-called cast molding method.

That is, a mold release agent is applied to the cavities of the upper die 30a and the lower die 30b of the forming die 30 which has been preheated to about 30.degree. Then, as shown in FIG. 2, a mat-shaped glass fiber or carbon fiber 20 is formed on the lower mold 30b of the mold 30.
And a matting glass fiber or carbon fiber 20 is further interposed between the upper mold 30a and the glass fiber 20 or the carbon fiber 20 through a spacer 40 made of a hard urethane foam scrap.
Stack at position 0c. The glass fibers or carbon fibers 20 are preferably long fibers.

Next, the upper die 30a and the lower die 30 of the molding die 30.
The mold b is clamped, and as shown in FIG. 3, the liquid hard urethane resin 50 is injected from the injection port 30d of the molding die 30 into the cavities of the upper mold 30a and the lower mold 30b. A hardening agent or the like is injected together with the liquid hard urethane resin 50 as needed.

A part of the liquid hard urethane resin 50 injected into the molding die 30 is made of glass fiber or carbon fiber 2.
0 will be impregnated.

Thereafter, as shown in FIG. 4, in order to smoothly vent from the parting line 30c of the molding die 30, the parting line 30c is moved to the liquid surface 60 by 15 times.
Maintaining the posture at an angle θ of -80 degrees, set the mold 30 with warm water,
A warm oil 70 etc. is warm-bathed. The heating temperature of this hot bath is
Set to about 80 ° C. At this time, the molding die 30 is pressed at about ² Kgf / cm ² .

The liquid hard urethane resin 50 heated and pressurized inside the molding die 30 foams and hardens to become the hard urethane foam resin 10. At this time, the liquid hard urethane resin 50 impregnated in the glass fiber or carbon fiber 20 is also foamed, and the glass fiber or carbon fiber 20 is spread and diffused inside the hard urethane foam resin 10 which is cured by peeling. I will let you. Since the glass fibers or the carbon fibers 20 are mat-shaped and diffuse from both upper and lower sides of the drawing toward the central portion, the diffusion density naturally decreases toward the inside of the plate body 1. Further, the spacer 40 is integrated with the hard urethane foam resin 10.

Therefore, in the composite molded plate which is a molded product released from the mold 30, the diffusion layers 1a and 1b of the glass fiber or the carbon fiber 20 are formed on both surfaces of the plate body 1 of the hard urethane foam resin 10. The diffusion density of the glass fiber or the carbon fiber 20 in the diffusion layers 1a and 1b decreases toward the inside of the plate body 1.

In the embodiment configured as described above, no special treatment or processing is required except for the laying and lamination of the mat-shaped glass fiber or carbon fiber 20, and the so-called casting method is used as it is. Since a composite molded plate can be manufactured by using the above method, inexpensive and easy manufacturing is possible.

Further, the plate body 1 of the composite molded plate is the diffusion layer 1
Since it is reinforced by the glass fiber or carbon fiber 20 of a and 1b, it has high bending strength, tensile strength, impact strength, etc., and has excellent heat resistance, abrasion resistance, chemical resistance, etc. like FRP. Is obtained.

Further, as the glass fiber or the carbon fiber 20 is integrally diffused and mixed into the hard urethane foam resin 10 and the diffusion density is lowered toward the inside of the plate body 1, the plate body 1 The hardness distribution in the plate thickness direction becomes non-uniform and flexibility increases. For this reason,
No cracking or damage will occur even if nailing or screwing is performed directly, and there is no need to carry out secondary processing depending on the application.

FIG. 5 shows an embodiment (2) of the composite molded plate and the manufacturing method thereof according to the present invention.

In this embodiment, the diffusion layer 1 of the plate body 1 is
A coating layer 3 is laminated on the surfaces of a and 1b.

The coating layer 3 can be selected by laminating means such as application of a resin agent, attachment of a resin film, and adhesion of a resin plate. In addition, in the manufacturing means of the above-described embodiment (1), a resin plate or the like may be laminated on the outside of the mat-shaped glass fiber or carbon fiber 20 and then adhered or welded to the plate body 1.

In the embodiment configured as described above, it is possible to conceal problems such as surface roughening, clouding, and loss of gloss on the surfaces of the diffusion layers 1a and 1b due to the glass fibers or the carbon fibers 20.

The composite molded plate according to the present invention can be used not only as a building material but also as a formwork panel for construction because of the above-mentioned actions and effects.

As described above, in addition to the illustrated embodiment, the diffusion layers 1a and 1b may be provided only on one surface of the plate body 1.

[0037]

Example In the above-described illustrated embodiment, when the composite molded plate is used as a wall panel, if the plate body 1 has a plate thickness of about several cm, the matte glass fiber or carbon fiber 20 has a thickness of About 1 mm is sufficient.

[0038]

As described above, according to the configuration of the present invention,
The following effects can be obtained. (A) In the composite molded plate according to the present invention, in common with claims 1 and 2, reinforcing fibers such as glass fiber or carbon fiber as a fiber reinforcing material are integrated inside a hard urethane foam resin constituting the plate body. Since the diffusion density is lowered toward the inside by being diffusively mixed in, the hardness distribution and the like in the plate thickness direction becomes uneven, and the flexibility is increased.
Further, due to this effect, there is an effect that the secondary processing corresponding to the application is unnecessary. (B) Only claim 2 has an effect of concealing a defect on the surface due to the mixing of the reinforcing fiber such as glass fiber or carbon fiber. (C) Furthermore, the method for producing a composite molded plate according to the present invention comprises:
In common with claims 3 and 4, in addition to not impairing the effects of the composite molded plate according to the present invention described above, cast molding can be used as it is with almost no special treatment. There is an effect that the composite molded plate can be easily manufactured at low cost. (D) Further, according to claim 4, since the spacer is integrated with the plate body, there is an effect that it is suitable for forming diffusion layers on both surfaces of the plate body of the composite molded plate.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a composite molded plate showing an embodiment (1) of a composite molded plate and a manufacturing method thereof according to the present invention.

FIG. 2 is a cross-sectional view showing a step in the manufacturing of FIG.

FIG. 3 is a cross-sectional view showing a step that follows FIG.

FIG. 4 is a cross-sectional view showing a step that follows FIG.

FIG. 5 is a sectional view of a composite molded plate showing an embodiment (2) of the composite molded plate and the method for producing the same according to the present invention.

FIG. 6 is a cross-sectional view of a laminated board showing a conventional example.

[Explanation of symbols]

 1 Plate Main Body 1a Diffusion Layer 1b Diffusion Layer 3 Covering Layer 10 Hard Foam Urethane Resin 20 Reinforcing Fibers such as Glass Fiber or Carbon Fiber 30 Mold 40 Spacer 50 Hard Urethane Resin

Claims (4)

[Claims] 1. A composite molded plate formed by forming a diffusion layer of reinforcing fibers such as glass fibers or carbon fibers, the diffusion density of which decreases inward, on at least one surface of a plate body molded of a hard urethane foam resin. . 2. The composite molded plate according to claim 1, wherein a coating layer is laminated on a surface of the diffusion layer of the reinforcing fibers. 3. A mat-shaped reinforcing fiber is laid on a molding die, a liquid hard urethane resin is injected into the molding die, the reinforcing fiber is impregnated with the hard urethane resin, and the rigid urethane resin is heated. A method for producing a composite molded plate in which a reinforcing fiber is diffused into a hard urethane foam resin by foaming. 4. The method for manufacturing a composite molded plate according to claim 3, wherein mat-shaped glass fibers are further laminated on the mat-shaped reinforcing fibers laid in the molding die via a spacer made of a block of hard urethane foam resin, A method for producing a composite molded plate, which comprises injecting a liquid hard urethane resin between reinforcing fibers.