JPH10244599A - Manufacture of fiber-reinforced thermosetting resin formed article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a fiber-reinforced thermosetting resin formed article having no material loss at the time of manufacturing low density articles and sheet articles, and being compact and having an excellent strength. SOLUTION: Thermosetting resin liquid 6 is sprinkled from upside on the way of a roving group 4 in alignment of alternately disposing a yarn doubling type roving 1a combining a plurality of kinds of strands having different physical properties and a single yarn type roving 1b combining one kind of strands, and thereafter the roving group 4 is crumpled between an impregnation table 7 and impregnation plates 71 in order that thermosetting resin liquid 6 is impregnated between the glass fibers forming each roving 1a, 1b and, following this, they are conducted in a heat-forming passage for heat-curing the thermosetting resin to be formed in conformity with a cross-section configuration of the heat- forming passage.

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 fiber-reinforced thermosetting resin molded product used as artificial wood or the like.

[0002]

2. Description of the Related Art Fiber-reinforced thermosetting resin moldings such as artificial timbers used as sleepers and building materials (for example, Eslon Neo Lumber FFU manufactured by Sekisui Chemical Co., Ltd.) are made of glass fiber as a reinforcing material. As a raw material, a plurality of long glass fiber direct rovings wound in a roll shape are used, each roving is pulled out from the roll, and is advanced in one direction as a roving group while being aligned at a predetermined interval. Sprinkle the thermosetting resin liquid from above the roving group, rub the roving group with the impregnated plate, separate each roving, and apply the thermosetting resin liquid between the glass fibers constituting the roving and the glass fibers. After being impregnated, it is introduced into a cylindrical thermoforming mold and molded into the cross-sectional shape of the mold in the thermoforming mold that cures the thermosetting resin. Thus it is produced (JP-B-52
2421, JP-A-3-81116).

[0003] The roving alignment interval is standardized according to the number of rovings used, taking into account the amount of resin falling down the rovings.

[0004] However, the aligned direct rovings have a columnar shape having the longitudinal direction of the direct rovings elongated by the twist (twist) when they are pulled out, in addition to the tensile tension, and the aligned rovings are aligned. When viewed from above, the gap between the rovings is large, and if the resin liquid is sprinkled from above the roving group, the resin will inevitably fall out from the gaps and the raw material loss will increase, and only the surface of each roving will be applied. However, a portion that does not sprinkle on the glass fiber inside the roving is generated, and the resulting molded article becomes dense and has a problem in strength. This tendency is particularly remarkable when a low-density product or a thin product using a small amount of glass fiber per unit area of a product cross section is manufactured.

Therefore, the inventor of the present invention has previously proposed a manufacturing method in which bulky roving is used at least partially instead of direct roving (Japanese Patent Laid-Open No. 8-207).
No. 146). That is, according to this manufacturing method, since bulky roving having a larger volume than direct roving is used, the gap between roving and roving when a thermosetting resin liquid is sprinkled is smaller than in the case where only conventional direct roving is used. At the same time, the glass fibers of adjacent rovings are easily entangled by the kneading step.

Therefore, it is possible to obtain a molded article which is dense and excellent in strength as compared with the conventional production method. But,
When bulky roving is used, it is possible to produce a molded product having higher density and superior strength than when direct roving is used, but the bulky roving is also reduced in diameter by twisting (twisting) when aligned. Therefore, when the roving group is viewed from above, the gap between the rovings is still large, and sufficient elimination of the raw material loss cannot be expected.

[0007]

SUMMARY OF THE INVENTION In view of such circumstances, the present invention provides a fiber reinforced material which is low in raw material loss, dense and excellent in strength when producing low specific gravity products and thin plate products. It is an object of the present invention to provide a method for producing a thermosetting resin molded product.

[0008]

According to the present invention, there is provided a method for producing a fiber-reinforced thermosetting resin molded article, which comprises the steps of: The rovings are advanced in one direction while being aligned at predetermined intervals, and a thermosetting resin liquid is sprinkled from above the aligned rovings in the middle of the roving, and the thermosetting resin is formed between the fibers constituting each roving. After impregnating the resin liquid, introduced into the heat molding passage, the thermosetting resin is thermoset and the fiber-reinforced thermosetting resin molding method of molding into a cross-sectional shape of the heating molding passage, the method for producing At least one part of the rovings constituting the roving group is a plying type roving in which a plurality of types of strands having different physical properties are combined.

In the above structure, the reinforcing fiber is not particularly limited, and may be, for example, glass fiber, carbon fiber,
Vinylon fiber, cellulose fiber and the like can be mentioned. The physical properties mean the diameter of a single fiber constituting the strand, the number of the strand, the number of single fibers, loss on ignition, and the like.

[0010] In addition, plying type roving (hereinafter, referred to as roving)
Although it is also possible to use only “combined roving”, it is possible to impair workability during molding and uniformity of product physical properties by using combined roving alone. , "Single yarn roving"). When using both the ply roving and the single yarn roving, it is preferable to form a roving group in which both are dispersed as uniformly as possible.

[0011] The thermosetting foamed resin is not particularly limited, and examples thereof include a polyurethane resin, a phenol resin, and a polyester resin. In the thermosetting foamed resin liquid, a foaming agent, a foaming aid, a filler, a reinforcing fiber, a coloring agent, an ultraviolet absorber, an antioxidant, a flame retardant, etc., as required, in addition to the above-mentioned resins, may be used. They may be mixed.

The filler is not particularly restricted but includes, for example, powders of calcium carbonate, talc, wood powder, aluminum hydroxide, water-absorbing polymer, carbon black and the like. By the way, if cheap fillers such as calcium carbonate and talc are used as fillers, it is possible to obtain inexpensive molded products with high compressive strength, and if aluminum hydroxide is used, it is possible to obtain molded products rich in flame retardancy. When carbon black is used, a molded article having conductivity can be obtained, and a lightweight molded article using wood powder can be obtained.

[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. As shown in FIG.
This manufacturing method firstly comprises the roll 1 of the twine roving 1a.
1 and a predetermined number of rolls 12 of the single yarn roving 1b are set in the supply 2.

Next, the ends of the rovings 1a and 1b are pulled out from the rolls 11 and 12, respectively, and are aligned at a desired pitch through small holes (not shown) provided in the array plate 3, so that the rovings 1a and 1b are aligned. 1b is moved in one direction as a roving group 4 arranged at a predetermined interval, and a thermosetting foamed resin liquid 6 is sprayed from above the roving group 4 while reciprocating the spreader 5 right and left during the movement, and each roving 1a , 1
b. The thermosetting foamed resin liquid 6 is attached.

Next, each roving 1a, 1
The roving group 4 having the thermosetting foamed resin liquid 6 adhered to the impregnating table 7 is converged at the impregnating table 7, and is sandwiched between the impregnating tables 6, 71 provided above the impregnating table 7. 7
The roving group 4 is rubbed by sliding the rovings 1 and 71 left and right as shown by the arrows, and the thermosetting foamed resin liquid 6 is impregnated between the fibers constituting the rovings 1a and 1b.

Then, as shown in FIG. 2, the roving group 4 in which the thermosetting foamed resin liquid 6 is sufficiently impregnated between the fibers is combined with four endless belts 81 (only three are shown in the figure). From the inlet of the formed molding passage 8 into the molding passage 8 continuously.
The thermosetting foamed resin liquid 6 is heated and foamed and hardened in the inside to continuously obtain a molded product 9 having the same cross-sectional shape as the molding passage 8.

That is, according to this manufacturing method, the plying roving 1a is used as a part of the roving group 4, and when the plying roving 1a is aligned and advanced,
As shown in FIG. 3, the rovings 1a and 1b of the roving group 4 have almost no gap between the rovings 1a and 1b, since they are not rounded into a cylindrical shape as in the single yarn roving 1b, and are in a state where they are appropriately loosened and slackened. Become.

[0018] Therefore, the roving group 4
When the thermosetting foamed resin liquid 6 is sprinkled thereon, the amount of the thermosetting foamed resin liquid 6 flowing down the roving group 4 is reduced. The roving group 4 advances to the impregnating table 6 while the sufficient thermosetting foamed resin liquid 6 is held on the roving group 4, and is uniformly impregnated by rubbing between the fibers. Thus, it is possible to obtain a molded article 9 which is excellent in terms of quality.

[0019]

Embodiments of the present invention will be described below in more detail.

(Example 1) Glass fiber roving A as single yarn roving (count 1150 tex, single fiber diameter 1
7 μm, 12 strands having a loss on ignition of 0.35% combined), glass fiber roving B (count 4400 tex, single fiber diameter 17 μm) as a plying roving
2 strands with 0.4% ignition loss and 2300t count
ex, one strand having a single fiber diameter of 17 μm and a loss on ignition of 1.0% combined with two strands having a count of 1150 tex, a single fiber diameter of 17 μm and a loss on ignition of 0.6%), and a urethane resin In the calculation, the final product has a reinforcing fiber content of 170 kg / glass fiber roving A.
m ³ , the reinforcing fiber content of glass fiber roving B is 50
kg / m ^3, the proportion of the urethane resin is such that the feed composition of 280 kg / m ^3, and a molded article in the same manner as conventional in the molding apparatus shown in FIGS.

(Example 2) In the calculation, a glass fiber was used as the final product.
120kg / m reinforcement fiber by fiber roving A ^Three, Mo
100 kg / m reinforcement fiber content by lath fiber roving B
^ThreeExcept that the molding was performed in the same manner as in Example 1.
The product was molded.

Example 3 Instead of glass fiber roving B, glass fiber roving C as a plying roving C
(One strand having a count of 4800 tex, single fiber diameter of 23 μm, ignition loss of 0.4%, a strand of 2500 tex, single fiber diameter of 17 μm, one strand of ignition loss of 0.8%, a count of 1150 tex, single fiber diameter of 13 μm Example 2 except that two strands each having a loss on ignition of 0.6% and four strands each having a count of 750 tex, a single fiber diameter of 13 μm, and a loss on ignition of 1.0% were used. To form a molded article.

Comparative Example 1 The same as Example 1 except that only glass fiber roving A was used as the reinforcing fiber, and the reinforcing fiber content of glass fiber roving A was 220 kg / m ^{3 in the} final product. To form a molded article.

From the molded products obtained in Examples 1 to 3 and Comparative Example 1, a thickness of 20 mm, a width of 100 mm and a length of 400 mm
Was cut out, and its actual specific gravity, bending strength in the lateral and longitudinal directions, compressive strength, and water absorption were measured, and the appearance of the surface and the appearance of the cross section were visually examined.
It was shown to. Each measured value is an average value of the number of tests n = 5 and is rounded off to the decimal point.

[0025]

[Table 1]

From Table 1, it can be seen that according to the production method of the present invention, the actual specific gravity obtained is increased, that is, the raw material loss is reduced, the thermosetting resin liquid is uniformly applied, and no fine holes are formed. It is clear that a molded product can be obtained.

[0027]

The method for producing a fiber-reinforced thermosetting resin molded product according to the present invention is configured as described above, so that when the thermosetting resin liquid is sprinkled on the roving group, the roving The thermosetting resin liquid hardly flows down from the gap between the roving and the thermosetting resin liquid can be evenly impregnated between each fiber when producing low specific gravity products and thin plate products, etc. It is possible to obtain a molded article excellent in terms of quality. Also, raw material loss can be reduced, and product cost can be reduced.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing an example of a manufacturing apparatus for performing a method for manufacturing a fiber-reinforced thermosetting resin molded product according to the present invention.

FIG. 2 is an explanatory view showing a latter half of the manufacturing apparatus of FIG. 1;

FIG. 3 is a top view of a sprinkling portion of a thermosetting resin liquid of the manufacturing apparatus of FIG. 1;

[Explanation of symbols]

1a Double yarn roving (single yarn type roving) 1b Single yarn roving (single yarn type direct roving) 6 Thermosetting resin liquid 8 Heat molding passage 9 Molded product

──────────────────────────────────────────────────続 き Continued on front page (51) Int.Cl. ⁶ Identification code FIB29L 7:00 31:10

Claims (1)

[Claims] 1. A roving of a large number of long reinforcing fibers as a reinforcing material is advanced in one direction while being aligned at a predetermined interval,
The thermosetting resin liquid is sprinkled from above the roving group arranged in the course of the progress, and the thermosetting resin liquid is impregnated between the fibers constituting the respective rovings, and then introduced into the heating molding passage. Then, in the method for producing a fiber-reinforced thermosetting resin molded article, which is formed by thermosetting the thermosetting resin and forming the cross-sectional shape of the thermoforming passage, at least a part of the roving constituting the roving group has physical properties. A method for producing a fiber-reinforced thermosetting resin molded product, comprising using a plying type roving in which a plurality of different types of strands are combined.