JPH10113937A - Manufacture of fiber reinforced thermosetting foamed resin molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily realize the controlling of the starting time of the foaming and hardening of a thermosetting foaming resin by a method wherein the reaction catalyst of a thermosetting foaming resin liquid is housed in capsules made of filmy material which breaks by means of a desired heat or load. SOLUTION: In either one of an A agent and a B agent, which turn into thermosetting foaming resin liquids through reaction, capsules made of film, in which the mixture of a catalyst and a solvent is housed, are blended. A group of glass fiber rovings 23 are continuously passed through a fiber arrangement plate 21 and proceeded toward a molding passage 3 under the condition that a liquid thermosetting foaming resin composition prepared by mixing the A agent and the B agent with each other is sprinkled over the group by reciprocating a sprinkler 5a during the procession of the group. Next, a roving group 24 is converged with an impregnating stand 6 so as to impregnate a resin composition among glass fibers. After that, by being heated with a microwave heating device 4, the solvent is expanded and the capsules are broken down, resulting in dispersing the reaction catalyst in the composition so as to act on the resin liquid and start to foam and harden the resin liquid. In succession, the resultant glass fiber roving group is pulled in the passage 3 so as to further be heated, foamed and hardened in order to continuously obtain a molded article 7.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for producing a fiber-reinforced thermosetting foamed resin molded article.

[0002]

2. Description of the Related Art A fiber-reinforced thermosetting foamed resin molded article which is similar in appearance to natural wood and has physical properties equal to or higher than that of natural wood is used as a structure for building materials and sleepers. Have been. A conventional thermosetting foamed resin molded product of this type is disclosed in JP-A-55-134228 and JP-A-59-134228.
Japanese Patent Application Laid-Open No. Sho 48-364 and No. Sho 59-36415, and
No. 0137, JP-A-50-18905, JP-B-52-2421, JP-B-63-34807, and the like, thereby enabling continuous production. I have.

[0003] That is, a thermosetting foamed resin molded product is obtained by continuously forming a thermosetting foamed resin composition containing a thermosetting foamed resin liquid and a reaction catalyst thereof between glass fibers of glass fiber roving. After being impregnated, the resin is drawn into a cylindrical molding passage, and the thermosetting foamed resin liquid in the thermosetting foamed resin composition is heated and foamed before the molding passage or in the molding passage. Is obtained by

[0004] However, the above-mentioned conventional manufacturing method is intended to adjust the reaction rate of the thermosetting foamed resin liquid to foam and harden the thermosetting foamed resin liquid at a predetermined position in a molding passage. The reaction catalyst is added to the product, but when trying to obtain a large cross-sectional product by this method,
The amount of the reinforcing fiber and the thermosetting foamed resin composition impregnated therein is also increased. Therefore, in the current production method, the time required for the impregnation is inevitably long, and if the impregnation time is long, the thermosetting foamed resin liquid starts a foaming curing reaction before being drawn into the molding passage, resulting in molding failure. There is a problem to say.

[0005] Further, when trying to obtain a molded product having an irregular shape, the same problem as in the case of a product having a large cross-sectional area may be caused because the amount of the resin to be partially impregnated is different.

[0006]

SUMMARY OF THE INVENTION In view of such circumstances, the present invention can control the foaming and curing reaction start time of a thermosetting foamed resin, and can be applied to a large cross-sectional product or a complicated deformed product. It is an object of the present invention to provide a method for producing a fiber-reinforced thermosetting foamed resin molded article that can be produced using a conventional production apparatus.

[0007]

According to the present invention, there is provided a method for producing a fiber-reinforced thermosetting foamed resin molded article, in which a thermosetting foamed resin liquid is added to a long reinforcing fiber material. And then continuously impregnated with a thermosetting foamed resin composition containing the same, and then drawn into a cylindrical molding passage, where the thermosetting foam in the thermosetting foamed resin composition is molded. In the method for producing a fiber-reinforced thermosetting foamed resin molded article for foaming and curing a thermosetting foamed resin liquid, the thermosetting foamed resin is placed in a capsule formed by a film material that is broken by applying a desired heat or a desired load. The configuration was such that the reaction catalyst of the composition was accommodated.

In the above construction, an organic solvent may be put in the capsule together with the reaction catalyst as in claim 2, and the capsule may be contained in the thermosetting foamed resin composition as in claim 3. An unencapsulated reaction catalyst may be added in addition to the converted reaction catalyst.

The thermosetting foam resin is not particularly limited, and examples thereof include foams such as polyurethane resin, phenol resin and polyester resin. As the reinforcing fibers, organic fibers such as polyester fibers, carbon fibers, filaments such as glass fibers, strands,
Yarns, rovings, woven fabrics, non-woven fabrics and the like can be mentioned, and glass fibers are preferred.

Examples of the reaction catalyst include known ones used as reaction catalysts such as polyurethane resins, phenol resins and polyester resins.

The organic solvent is not particularly limited as long as it is inert to the reaction catalyst for a long period of time and has sufficient expandability to break the film by expansion due to heat. General organic solvents such as methylene chloride and acetone are exemplified. The coating material (wall material) forming the capsule is not particularly limited as long as it is not attacked by the reaction catalyst or the solvent and is inactive to the reaction catalyst or the solvent. For example, gelatin, ethyl cellulose, amino Resin, vinylidene chloride resin, polyethylene,
Organic polymer substances such as polystyrene and inorganic substances such as silica and calcium silicate can be appropriately selected according to the type of reaction catalyst and solvent.

The particle size of the capsule is preferably such that it can be dispersed in the thermosetting foamed resin composition to such an extent that the reaction does not become nonuniform, and from the viewpoint of cost balance, it is preferably about 10 to 200 μm. The method of heating the thermosetting foamed resin composition is not particularly limited, and includes, for example, commonly used hot air heating, electric heater, microwave heating capable of uniform heating in a short time, far-infrared heating, and the like. You may use them together.

[0013]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below.
This will be described in detail with reference to the drawings. 1 and 2 show an example of an apparatus used in the method for producing a fiber-reinforced thermosetting foamed resin molded product according to the present invention. As shown in FIG. 1, in this production method, an A agent and a B agent, which become a thermosetting foamed resin liquid by a reaction, are separately prepared in respective containers 52, 52, and either one of the A agent and the B agent is prepared. On the other hand, as shown in FIG. 3, a capsule 1 in which a mixture 11 of a catalyst and a solvent is accommodated in a film 12 which is broken by thermal expansion of the solvent is mixed.

First, a group of glass fiber rovings 23 arranged at a desired pitch through small holes 22 provided in a fiber arrangement plate 21 is continuously connected to four endless belts (in FIG. 1 and FIG. 2, two upper and lower endless belts). A molding passage 3 having a quadrangular cross section formed by 31, 31
Proceed in the direction. Next, during the progress of the roving group 23, a liquid thermosetting foamed resin composition (hereinafter referred to as “resin composition”) obtained by mixing the agent A and the agent B while reciprocating the sprayer 5a left and right. ) Is sprayed from above the roving group 23 to adhere the resin composition 51 to the roving group 23.

The roving group 24 to which the resin composition has adhered is converged at the impregnating table 6 as shown in FIGS. 1 and 2, and the impregnating plate 6 provided above the impregnating table 6
1 and 61 and the impregnating table 6, and the impregnating plate 61 is slid left and right as shown by arrows in FIG.
4 is rubbed, and the resin composition is impregnated between the glass fibers constituting the roving group 23.

Next, the roving group 24 sufficiently impregnated with the resin composition is passed through the microwave heating device 4 and microwave-heated to expand the solvent in the capsule 1 and break the capsule 1 by the expanding force. The reaction catalyst is dispersed in the resin composition and acts on the thermosetting foamed resin liquid to start foaming and curing.

Then, the roving group 25 in which the thermosetting foamed resin liquid in the impregnated resin composition has begun to foam and harden is drawn into the molding passage 3 as shown in FIG. The molded product 7 is continuously obtained by heat foaming and curing. In FIG. 1, 8 is an impregnation chamber of a thermosetting foamed resin liquid,
81 is an air conditioner for the impregnation chamber 8, 26a is a fixed amount supply pump for the A agent, 26b is a fixed amount supply pump for the B agent, 27a is a heat exchanger for adjusting the temperature of the A agent, 27b is a heat exchanger for adjusting the temperature of the B agent,
Reference numeral 38 denotes a hot air generator for heating the thermosetting foamed resin liquid in the molding passage 3. In FIG.
Reference numeral 3 denotes a low-temperature section, and 34 denotes a cooling section.

In this manufacturing method, as described above, the reaction catalyst is housed in the capsule 1 together with the solvent, and the capsule 1 is destroyed by the expansion of the solvent due to the heating by the microwave heating device 4, and the thermosetting is performed only when the capsule 1 is broken. The reaction catalyst acts on the water-soluble foamed resin liquid. That is, since the reaction catalyst does not act on the thermosetting foamed resin liquid at all until the resin composition is heated, foaming hardening does not occur during impregnation even if the time until completion of impregnation is lengthened.

Therefore, even a product having a large cross-sectional area or a complicated deformed product can be easily manufactured using a conventional manufacturing apparatus. Further, if this manufacturing method is used for manufacturing a product of the current size such as a thin type, it is possible to increase the molding speed as compared with the present. Of course, the final product strength, physical properties and appearance quality are not impaired. In addition, since the capsule 1 is broken by applying a load from the inside by the expansion force of the solvent, the capsule 1 is heated by lower temperature.
Can be broken, and the heating energy can be saved as compared with the method of melting and breaking the coating material 12 of the capsule 1 by heating.

The method for producing a fiber-reinforced thermosetting foamed resin molded article according to the present invention is not limited to the above embodiment.

[0021]

Embodiments of the present invention will be described below in more detail. (Example 1) Using the manufacturing apparatus of FIG. 1, glass fiber roving (2.0 × 10 ⁶ single fibers having a thickness of 17 μm were collected to form 12 strands, and 12 strands were collected).
Is supplied so as to be 5280 g per meter, and a resin composition having the following composition is sprayed from a sprayer onto a glass fiber roving so as to be 6720 g per meter,
After the resin composition is sufficiently impregnated between the glass fibers with a kneading pressure of about 1 kg / cm ² between the impregnating table and the impregnating plate, 800 w / h microwaves are applied in a microwave heating device. Irradiation was performed for about 1 minute, and the mixture was heated to expand the solvent and the reaction catalyst, thereby breaking the capsule coating material, diffusing into the resin composition, and foaming and curing without being drawn into the molding passage to obtain a molded product.

[Thermosetting Foam Resin Composition] 100 parts of agent A (polyether polyol) 150 parts of agent B (4,4'-diphenylmethane diisocyanate) 0.6 part of capsule Coating material: Mainly gelatin polymer Particle size: about 200 μm Contents: reaction catalyst (metal organic compound) about 3.3 × 10 ⁻⁷ g / 1 capsule Solvent (methylene chloride) about 6.6 × 10 ⁻⁷ g / 1 capsule

(Example 2) A molded article was obtained in the same manner as in Example 1 except that the thermosetting foamed resin composition having the following composition was used.

[Thermosetting foamed resin composition] ・ A part (polyether polyol) 100 parts ・ B part (4,4′-diphenylmethane diisocyanate) 150 parts ・ Capsule 0.2 part Film material: Mainly gelatin polymer Film material to be used Particle size: about 200 μm Contents: reaction catalyst (metal organic compound) about 1.0 × 10 ⁻⁶ g / 1 capsule

(Comparative Example 1) Except for using a conventional method of directly mixing a reaction catalyst into a thermosetting foamed resin composition in advance, and without using microwave heating, the reaction was allowed to proceed by the self-reaction heat of the resin. A molded product was obtained in the same manner as in Example 2. In Examples 1 and 2 and Comparative Example 1, the foaming time (X), the foaming stop time (Y), and the foaming time (YX)
Was measured, and the foamed state of the molded articles obtained in Examples 1 and 2 was compared with the molded article of Comparative Example 1 as a blank. The results are shown in Table 1. Also, the specific gravities, bending strengths, and the like of the molded articles obtained in Examples 1 and 2 and Comparative Example 1
The bending Young's modulus, partial compressive strength, and water absorption were also investigated and are shown in Table 1.

The foaming time (X) and the foaming stop time (Y) were expressed as the total time from the start of spraying, respectively, with the time of starting spraying from the sprayer being 0 seconds when the agent A and the agent B were stirred. . Further, three test pieces were cut out from the molded products of Examples 1 and 2 and Comparative Example 1, and the specific gravity,
The bending strength, bending Young's modulus, partial compressive strength, and water absorption
The partial compressive strength is determined by a test method based on ISZ 2101 and is a proportionally limited value.

[0027]

[Table 1]

As shown in Table 1, according to the method of the present invention, it can be clearly understood that a molded product can be obtained without any change even when the time required for foaming hardening is long. That is, it is well understood that a product having a large cross-sectional area can be obtained with good moldability, similarly to a thin product.

(Example 3) The kneading pressure was set to 3 kg / cm ^2, and the resin composition was impregnated between the glass fibers by this kneading, and the coating material of the capsule was broken.
A molded product was obtained in the same manner as in Example 2 except that microwave heating was not applied. (Comparative Example 2) A molded product was obtained in the same manner as in Comparative Example 1, except that the kneading pressure was 1 kg / cm ² .

In Example 3 and Comparative Example 2, the foaming time (X), foaming stop time (Y), and foaming time (Y)
-X), the molded product obtained in Example 3 was compared with the molded product of Comparative Example 2 as a blank to check the foaming state, and the results are shown in Table 2. The specific gravity, bending strength, bending Young's modulus, partial compressive strength, and water absorption of the molded articles obtained in Example 3 and Comparative Example 2 in the same manner as in Example 1 were also examined and shown in Table 2.

[0031]

[Table 2]

Example 4 As the thermosetting foamed resin composition, the thermosetting foamed resin composition of Example 2 was prepared such that the ratio of the reaction catalyst in the capsule was 7 and that of the liquid reaction catalyst was 3. Further, a molded product was obtained in the same manner as in Example 1 except that the reaction was started by the self-heating of the resin without using microwave heating and using a liquid reaction catalyst.

In the above Example 4, the foaming time (X),
The foaming stop time (Y) and the required foaming time (YX) were measured, and the molded product obtained in Example 4 was compared with the molded product of Comparative Example 1 as a blank, and the foaming state was examined. 3 is shown. In addition, the specific gravity, bending strength, bending Young's modulus, partial compressive strength, water absorption, and the maximum internal temperature during molding (central portion) of the molded product obtained in Example 4 were also examined and compared in the same manner as in Example 1. The results are shown in Table 3 in comparison with Example 1.

[0034]

[Table 3]

[0035]

The method for producing a fiber-reinforced thermosetting foamed resin molded article according to the present invention is configured as described above, so that the foaming and curing reaction start time of the thermosetting foamed resin can be controlled. Even large cross-section products and complicated deformed products can be manufactured using conventional manufacturing equipment.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an apparatus used for a method for producing a fiber-reinforced thermosetting foamed resin molded product according to the present invention.

FIG. 2 is a sectional view of the apparatus of FIG.

FIG. 3 is a sectional view of a capsule.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Capsule 11 Mixed liquid 12 Membrane material 23 Glass fiber roving group (reinforcing fiber material) 3 Molding passage

──────────────────────────────────────────────────の Continued on front page (51) Int.Cl. ⁶ Identification code FI B29L 31:10

Claims (3)

[Claims] 1. A long-form reinforcing fiber material which is continuously impregnated with a liquid thermosetting foamed resin composition containing a thermosetting foamed resin liquid and a reaction catalyst thereof, and is then impregnated into a cylindrical molding passage. In the method for producing a fiber-reinforced thermosetting foamed resin molded article in which the thermosetting foamed resin liquid in the thermosetting foamed resin composition is foamed and cured in the molding passage, a desired heat or a desired load is applied. A process for producing a fiber-reinforced thermosetting foamed resin molded product, wherein a reaction catalyst of the thermosetting foamed resin composition is accommodated in a capsule formed of a film material which is broken by being applied. 2. The method for producing a fiber-reinforced thermosetting foamed resin molded article according to claim 1, wherein the capsule contains an organic solvent together with a reaction catalyst. 3. The fiber-reinforced thermosetting foam according to claim 1, wherein the thermosetting foamed resin composition contains an unencapsulated reaction catalyst in addition to the encapsulated reaction catalyst. Manufacturing method of resin molded product.