JPH10330503A - Fiber-reinforced thermoplastic resin material and molding resin composition containing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fiber-reinforced thermoplastic resin material containing well-dispersed reinforcing fibers in a high concentration and used alone or in the form of a blend with another thermoplastic resin and a molding resin composition containing the same. SOLUTION: A continuous fiber bundle A is passed through an immersion tank 2 to make an amorphous thermoplastic resin emulsion adhere to the individual monofilaments uniformly without fail. This is led to a heating drier 4 to effect the drying and melting of the resin emulsion. Next, the resin-coated continuous fiber bundle B is twisted in the axial direction by means of a twister 5, and the continuous fiber bundle C passed through a cooling section 12 is cut to a specified size with a pelletizer 14 to form pellets. These pellets are mixed with an amorphous thermoplastic resin, and the resultant mixture is extruded to obtain resin pellets Q.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a fiber-reinforced resin pellet obtained by cutting a continuous fiber bundle coated with an amorphous thermoplastic resin emulsion, and a pellet obtained by dry-blending an amorphous thermoplastic resin. The present invention relates to a fiber-reinforced thermoplastic resin material extruded into a shape and a resin composition for molding obtained thereby.

[0002]

2. Description of the Related Art For example, a conventional method for producing pellets for molding a glass fiber reinforced thermoplastic resin is as follows: (1) Dry blending of a glass fiber chopped strand and a thermoplastic resin, extruding with an extruder, and extruding the glass fiber. (2) A continuous fiber bundle of glass fibers, that is, a glass fiber roving is passed through a molten thermoplastic resin, and the glass fiber is coated with the resin by a so-called pultrusion method. And
Thereafter, a method of cutting and pelletizing (3) There is a method of dipping glass fiber roving into a thermoplastic resin emulsion, drying and homogenizing, and then cutting and pelletizing.

[0003]

In the method of producing pellets for molding a glass fiber reinforced thermoplastic resin, those having a fiber content of about 20% by weight are usually (1)
However, in this method, it is difficult to stably produce pellets having a high fiber content of about 50% by weight. Although the method (2) may be carried out for a crystalline thermoplastic resin, there is no satisfactory technique for an amorphous thermoplastic resin having a high melt viscosity. Further, the method (3) has a problem such as generation of free fibers.

[0004] In view of such a situation, the inventor of the present invention has made amorphous thermoplastic resin pellets which provide molded articles containing reinforcing fibers in a high concentration and in a well-dispersed state which have been conventionally difficult to produce. And succeeded in developing a molding resin composition that surpasses the conventional method described above.

[0005]

That is, according to the first aspect of the present invention, a continuous fiber bundle is immersed in an amorphous thermoplastic resin emulsion, and the attached amorphous thermoplastic resin is dried or dried. A fiber-reinforced heat obtained by extruding a blend of an amorphous thermoplastic resin and a pellet obtained by melting the continuous fiber bundle coated with the resin and cutting the bundle into a predetermined length. It is a plastic resin material.

The invention according to claim 6 of the present invention is a molding resin composition characterized in that a thermoplastic resin is blended into a pellet-shaped molded product of the fiber-reinforced thermoplastic resin material. .

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION The fiber-reinforced thermoplastic resin material of the present invention comprises a continuous fiber bundle coated with an amorphous thermoplastic resin obtained by adhering an amorphous thermoplastic resin emulsion to the continuous fiber bundle. Into a pellet (hereinafter referred to as a resin pellet P), and an amorphous thermoplastic resin is mixed with the resin pellet P to obtain a fiber-reinforced thermoplastic resin material by extrusion molding.

[0008] The molding resin composition of the present invention is formed into a substantially pellet-like shape comprising the fiber-reinforced thermoplastic resin material obtained by blending an amorphous thermoplastic resin with the resin pellet P and extruding the mixture. It is obtained by blending a thermoplastic resin with a product (hereinafter referred to as resin pellet Q).

In the present invention, there is no particular limitation on the type of fiber of the continuous fiber bundle to be used, and for example, high melting point fiber such as glass fiber, carbon fiber, metal fiber, and aromatic polyamide fiber can be used. . Of these fibers,
The use of glass fibers is particularly preferred in consideration of the strength and price of the obtained resin pellets and the molding composition using the same.

[0010] The resin pellets P in the present invention can be specifically obtained by sequentially performing the following steps. That is, (1) after opening the individual monofilaments constituting the continuous fiber bundle in parallel at intervals, and then immersing the opened monofilaments in an amorphous thermoplastic resin emulsion, (2) heating the continuous fiber bundle to which the thermoplastic resin has been adhered to evaporate the water, and drying or drying and melting the solid content of the adhered resin to obtain the surface of the monofilament; In this case, a step of twisting and twisting the continuous fiber bundle coated with the thermoplastic resin can be added. This is obtained by (3) a step of cooling the continuous fiber bundle and (4) a step of cutting the cooled continuous fiber bundle into a predetermined length to obtain a resin pellet P. These steps are more specifically described. Can be continuously achieved by the manufacturing apparatus 1 illustrated in FIG.

The manufacturing apparatus 1 includes a dipping tank 2 for uniformly adhering an amorphous thermoplastic resin to each of the monofilaments constituting the continuous fiber bundle A, and an amorphous thermosetting resin obtained in the dipping tank 2. A heating dryer 4 for evaporating the moisture of the continuous fiber bundle A in which the thermoplastic resin is uniformly adhered to the surface and drying and melting the resin solids, and is coated with an amorphous thermoplastic resin obtained by the heating, drying and melting treatment. A twisting machine 5 for twisting the continuous fiber bundle B, a cooling unit 12 for cooling the continuous fiber bundle C twisted by the twisting machine 5, and a continuous fiber bundle C after cooling. A pelletizer 14 for cutting into resin pellets P of a predetermined length, a pellet stocker 17 for stocking the obtained resin pellets P, and an extrusion molding of the resin pellets P together with the thermoplastic resin R into resin pellets Q. A molding machine 18, It is constructed from pellet stocker 19 for stocking a fat pellet Q. The twisting machine 5 can be omitted.

The continuous fiber bundle A introduced into the immersion tank 2 is
Prior to immersion, the individual monofilaments are set in an open state. For this purpose, the continuous fiber bundle A is passed through the surface of the roller 3 while being tensioned, or the monofilaments of the continuous fiber bundle A are scattered by static electricity. For example, a means such as making

The emulsion of the amorphous thermoplastic resin contained in the immersion tank 2 is compatible with the other amorphous thermoplastic resin (matrix resin) constituting the fiber-reinforced thermoplastic resin material of the present invention. In consideration of the above, it is desirable to use an amorphous thermoplastic resin of the same kind or close to the resin.

When the acrylonitrile / styrene copolymer (AS resin) is used as the matrix resin, acrylonitrile / styrene copolymer emulsion (AS emulsion), styrene / acrylic acid copolymer, styrene / methacrylate copolymer and styrene -An emulsion such as a methyl methacrylate copolymer can be used.

When the matrix resin is polystyrene, a styrene / butadiene copolymer emulsion (SB latex) can be used.

A preferable amount of the amorphous thermoplastic resin emulsion adhered in the immersion tank 2 is 5 to 100 parts by weight based on 100 parts by weight of the continuous fiber bundle A in terms of the amount of the adhered resin after drying the emulsion. And more preferably 10 to 70 parts by weight. When the amount is less than 5 parts by weight, the individual monofilaments constituting the continuous fiber bundle A are not completely dispersed in the matrix resin, and even when the amount exceeds 100 parts by weight, a coating having a thickness corresponding to this is obtained. Not economically disadvantageous.

The preferred resin solids content of the emulsion is 3
It is in the range of 0 to 70% by weight. The method of immersing the continuous fiber bundle A in the amorphous thermoplastic resin emulsion is as follows:
The resin emulsion may be placed in the immersion tank 2 and a vibrator such as an ultrasonic oscillator may be installed. Is vibrated to improve the coating effect on the monofilament by immersion.

The preferred passing speed of the continuous fiber bundle A in the immersion tank 2 is 5 to 30 m / min. By passing the continuous fiber bundle A at such a speed, each monofilament of the opened continuous fiber bundle A is heated. The plastic resin emulsion can adhere to form a uniform coating.

The continuous fiber bundle A to which the amorphous thermoplastic resin emulsion is adhered by the immersion treatment in the immersion tank 2 evaporates the moisture of the resin emulsion adhered to the surface of the monofilament by the heating dryer 4 having a heater or the like. And drying and melting of the resin to form the coating more reliably.

The heating / drying unit 4 can be constituted by a heater utilizing radiant heat such as a heating wire or a heater utilizing hot air.

The internal temperature of the heating / drying device 4 when passing the continuous fiber bundle A to which the amorphous thermoplastic resin emulsion is adhered is about 150 to 400 ° C., and the optimum temperature differs depending on the type of the resin emulsion used. is there. For example, in the case of the AS resin emulsion, the temperature is 150 to 40.
The temperature may be in the range of 0 ° C., but in the case of SB latex, heat resistance is not good and heat shrinkage occurs at high temperature.
Desirably, it is dried and melted at 150 ° C.

In the drying and melting step, evaporation of water in the adhered resin emulsion, drying and melting and homogenization of the resin are performed to ensure the surface coating of the monofilament of the continuous fiber bundle A. At the time of heating, consideration should be given to the melt viscosity and heat resistance of the amorphous thermoplastic resin to be used, and particularly, rapid exposure to a high-temperature atmosphere should be avoided.

When the continuous fiber bundle B is twisted, it is immediately introduced into the twisting machine 5 without cooling, and the continuous fiber bundle B is twisted in the axial direction and twisted.

As shown in the figure, the twisting machine 5 includes a pair of pinch rollers 6 and 6 for holding a continuous fiber bundle B coated with an amorphous thermoplastic resin by drying and melting.
And a pulley 8 and a motor 9 provided in the casing.
A pulley 10 directly connected to the motor 9
The motor 9 is driven to rotate the casing 7 to rotate the continuous fiber bundle pinched by the pair of pinch rollers 6 and 6 to rotate B to apply the rotation. It is twisted.

In the twisting process in this step, the number of twists of the continuous fiber bundle B per meter is preferably 5 to 50 times / m, more preferably 10 to 30 times / m by rotating the casing 7. Is what you do.

The continuous fiber bundle C obtained by the twisting process is separated from the non-crystalline thermoplastic resin covering the individual monofilaments with certainty by being sandwiched between the twisted monofilaments. Can be held without.

The continuous fiber bundle C dried and melted as described above is then air-cooled or water-cooled in the cooling unit 12.
A pair of take-off rolls 13, 13 arranged after the cooling unit 12
While being pulled by the guide, it is guided into a pelletizer 14 having a cutter 15 composed of a rotary blade and a support roll 16, and
It is cut into a length of about 20 mm and is stocked as a resin pellet P in the pellet stocker 17.

The resin pellets P thus obtained are mixed with an amorphous thermoplastic resin so as to have a desired fiber concentration, and are extruded into pellets by an extruder 18 according to a conventional method to form a pellet. This is referred to as a resin pellet Q of the invention.

At this time, the amorphous thermoplastic resin (matrix resin) that can be used is preferably compatible with the thermoplastic thermoplastic resin emulsion.
Examples include polystyrene resin, acrylonitrile-styrene-butadiene copolymer resin, polycarbonate, polyphenylene ether, and the like.

Such a matrix resin and resin pellet P
Because there is a difference in the specific gravity and the shape of the pellets between the two, it is desirable to use a quantitative supply device and a mixing device so that both have a desired glass concentration as a supply device to the extruder. .

The resin pellet Q of the present invention thus obtained
Is used as a matrix resin.
A thermoplastic resin of the same kind or close to that of the amorphous thermoplastic resin used in the production of the resin, for example, an AS resin, a polystyrene resin, an ABS resin, a polycarbonate resin, and a PPE resin are blended to form a molding resin composition. An excellent molded product can be obtained.

[0032]

The fiber-reinforced thermoplastic resin material of the present invention is obtained by mixing a continuous fiber bundle coated with an amorphous thermoplastic resin emulsion into pellets, and mixing the amorphous thermoplastic resin with the pellets. When melt-kneaded with the blended resin, the fiber pellets with the plastic resin coating are easily dispersed in the resin,
The fibers can be uniformly dispersed in the resin at a higher concentration than in the case where the conventional chopped strand is melt-kneaded.

When the chopped strand is pressed into the resin at a high concentration and kneaded by an extruder, the screw is severely worn, but the continuous fiber bundle immersed in the amorphous thermoplastic resin emulsion according to the present invention is pelletized. When dry-blending a material and an amorphous thermoplastic resin and melt-kneading, the entire surface of the glass fiber is uniformly coated with the resin, and since it is long-fiber glass, the end of the glass fiber is also small, The wear of the cylinder and screw of the extruder is also small.

The molding resin composition obtained by blending a thermoplastic resin with the fiber-reinforced thermoplastic resin material, when molded into a molded article using the composition, has the above-described excellent fiber-reinforced thermoplastic resin properties. Depending on the material, a molded article with high strength can be obtained.

[0035]

The present invention will be described in more detail with reference to the following examples. <Examples 1 to 3 and Comparative Example 1> A continuous fiber bundle A composed of glass fiber rovings using 2,000 monofilaments having a thickness of 13 μφ as one bundle and using five bundles was individually manufactured by the manufacturing apparatus 1 shown in FIG. Of the continuous fiber bundle A by continuously introducing into the immersion tank 2 at a speed of 10 m / min while opening the monofilament, and passing through the amorphous AS resin emulsion having a solid content of 40% by weight charged in the immersion tank 2. The AS resin emulsion was uniformly attached to the surface of each monofilament.

Next, this is introduced into the heating / drying device 4,
It consists of a glass fiber roving which is dried at a temperature of 380 ° C. and has a uniform coating of the AS resin formed on the surface thereof in order to evaporate the moisture in the AS resin emulsion adhered to the surface of the continuous fiber bundle A and to melt the resin uniformly. Continuous fiber bundle B was obtained continuously.

The continuous fiber bundle B coated with the AS resin that has exited the heating / drying unit 4 is run in the air of the cooling unit 12 and cut to a length of 9 mm in a pelletizer 14 at a temperature higher than room temperature to form resin pellets P. I got The glass fiber content of this resin pellet P was 80% by weight.

This resin pellet P and an equal amount of an AS resin as a matrix resin are mixed and extruded into a pellet by an extruder 18 in a conventional manner to obtain a resin pellet Q. And

The resin pellets Q were further blended with the same AS resin at the ratios shown in Table 1 and extruded into pellets to obtain samples of Examples 2 and 3, respectively. These samples were formed into molded articles of a predetermined shape by a usual injection molding method, and various physical properties of the molded articles were measured. Table 1 shows the results.

As Comparative Example 1, the physical properties were also measured for resin pellets obtained by dispersing 20 parts by weight of glass fiber chopped strand having a thickness of 13 μφ in 80 parts by weight of a thermoplastic resin (AS resin). These results are also shown in Table 1. The production of the resin pellets was carried out by feeding a chopped strand quantified from the hand vent portion of the algae position into a twin-screw extruder.

According to the results shown in Table 1, it can be seen that the physical properties of the molded articles using the molded resin compositions of Examples 1 to 3 are not inferior or inferior to those of Comparative Example 1. In particular, it often shows a high value such as an impact value, which is caused by the fact that the fiber length remaining in the molded product is longer than that of Comparative Example 1 using a normal chopped strand as a raw material. Is what it is.

In Table 1, the units of the test items are as follows. Glass concentration ・ ・ ・ wt% Tensile strength ・ ・ ・ kgf / cm ² Elongation ・ ・ ・% Flexural strength ・ ・ ・ kgf / cm ² Elasticity ・ ・ ・ kgf / cm ² Izod impact value ・ ・ ・ kgf- cm / cm ² [Margin below]

[0043]

[Table 1]

[0044]

The fiber-reinforced thermoplastic resin material of the present invention is obtained by blending an amorphous thermoplastic resin with a resin pellet P obtained by cutting a continuous fiber bundle coated with an amorphous thermoplastic resin emulsion to form a fiber. The resin pellets Q are uniformly dispersed at a high concentration in the resin pellets. In the production of the resin pellets Q, there is a problem in operation due to the dispersed glass filaments in the production room as seen when a normal chopped strand is used. It has no environmental problems, no free fibers when handling, and can be used without damaging the environment.

Also, when manufacturing the resin pellets Q using the resin pellets P, there is no need for special contrivance for putting the glass into the resin as compared with the case of using chopped strands. There is no need for a screw extruder, etc.
Not only can the cost of equipment and repair be reduced, but also because the glass is well dispersed in the resin, the extrusion capacity is large, and a resin molded product can be economically manufactured with stable and high productivity.

The resin composition for molding of the present invention is obtained by further mixing a thermoplastic resin with the resin pellet Q. When a molded article is formed using such a resin composition for molding, A high-strength molded article can be obtained by the fiber-reinforced thermoplastic resin material having excellent performance.

[Brief description of the drawings]

FIG. 1 is a process chart for producing a fiber-reinforced thermoplastic resin material of the present invention.

[Description of Signs] 1 Resin pellet manufacturing device 2 Dipping tank 4 Heat dryer 5 Twisting machine 6 Pinch roller 7 Casing 12 Cooling unit 13 Take-off roller 14 Pelletizer 18 Extruder

Claims (6)

[Claims] 1. A continuous fiber bundle immersed in an amorphous thermoplastic resin emulsion, and the attached amorphous thermoplastic resin is dried or dried and melted, and the continuous fiber bundle is coated with the amorphous thermoplastic resin. Pellets obtained by cutting into a predetermined length,
A fiber-reinforced thermoplastic resin material obtained by extruding a mixture of an amorphous thermoplastic resin. 2. The fiber-reinforced thermoplastic resin material according to claim 1, wherein the amorphous thermoplastic resin emulsion is an acrylonitrile-styrene copolymer emulsion. 3. The fiber-reinforced thermoplastic resin material according to claim 1, wherein the amorphous thermoplastic resin blended with the pellets is an acrylonitrile-styrene copolymer. 4. The fiber-reinforced thermoplastic resin material according to claim 1, wherein the continuous fiber bundle coated with the amorphous thermoplastic resin is twisted. 5. The fiber-reinforced thermoplastic resin material according to claim 1, wherein the fiber-reinforced thermoplastic resin material is a pellet-shaped molded product. 6. A continuous fiber bundle immersed in an amorphous thermoplastic resin emulsion, and the attached amorphous thermoplastic resin is dried or dried and melted, and is coated with the amorphous thermoplastic resin. Pellets obtained by cutting into a predetermined length,
A molding resin composition comprising a thermoplastic resin blended into a pellet-like molded product obtained by extrusion molding a blend of an amorphous thermoplastic resin.