JPH11216736A - Method and apparatus for manufacturing fiber reinforced foamed resin molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a fiber reinforced foamed resin molding which uses a very small amount of filaments such as glass roving and can produce a thick molding even with simple apparatus constitution and in a narrow space, and an apparatus for the method. SOLUTION: A bundle of a prescribed amount of glass roving 6 is dispersed uniformed and held by a drawing-in guide 4, is drawn in the longitudinal direction of the molding part 8 of a lower mold 1 by a pair of drawing-in rollers 4a, and is folded in two with a spacer 5 held between them. After that, an expandable, curable resin base liquid 11 is sprayed from a nozzle 3 to make the glass roving 6 impregnated with the liquid 11. The process is repeated, the laminated glass roving 6 and the liquid 11 is pressed by an upper mold 2 until the thickness reaches a desired molding thickness, and the liquid 11 is cured while being pressed. After that, the molding is demolded, and both ends are cut as required to finish the fiber reinforced foamed resin molding.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to a fiber-reinforced foamed resin molded article, for example, a railroad sleeper, a deodorant lid for a sewage treatment plant, a flight collector, a corner dropper, or a material for civil engineering and construction.
The present invention relates to a method and an apparatus for manufacturing a resin molded product such as synthetic wood used for an electric wire sleeper or the like.

[0002]

2. Description of the Related Art In the production of such a fiber-reinforced foamed resin molded article, a reinforcing material such as glass fiber is laid in a mold called a batch method, and foaming hardening is performed on the reinforcing material. After impregnating the fibers by dispersing the conductive resin stock solution, the resin stock solution is foamed and hardened by covering (see, for example, Japanese Patent Publication No. 63-34809), or the foamed hardening resin is impregnated in a continuous method. There is known a method of introducing a reinforcing material such as glass fiber into a molding passage and foaming and curing the resin solution in the molding passage (for example, see Japanese Patent Publication No. 48-30137).

In the above-mentioned batch method, since a foaming-curable resin stock solution is scattered over a reinforcing material such as glass fiber or the like, a relatively thick molded product called a thick product is required to produce a bulky fiber. The bundle must be impregnated with the foam-curable resin stock solution to such an extent that the voids are filled. However, there is a problem that such impregnation tends to be insufficient because the bundle of fibers is bulky.

In the batch method, the shape and state of the reinforcing material are changed by some means such as making the glass fiber into a mat shape (the glass fiber is not aligned in one direction and is so-called non-directional). By holding, it is easy to produce a molded body that is homogeneous in all directions, in other words, isotropic. On the other hand, when manufacturing a resin molded body that requires strength in a certain desired direction, it is advantageous to reinforce the resin molded body in one direction using long fibers such as glass roving. If other long fibers were used as reinforcement materials as they were,
The long fibers are unevenly distributed during the foaming of the foam-curable resin stock solution, so that the reinforcement of the molded product tends to be uneven, and the strength, particularly the bending strength and the bending Young's modulus, are weak. Therefore, in the batch method, it has not been possible to actually use long fibers as the reinforcing material.

On the other hand, in the case of the continuous system, since the glass roving or the like can be used as a reinforcing material, the molded article has an advantage that the bending strength and bending Young's modulus in a desired one direction are large. For this reason, conventionally, a fiber-reinforced foamed resin molded product made of long fibers has been manufactured not by a batch system but by a continuous system.

However, in this method, a large number of glass roving rolls are provided, and a large number of glass rovings are introduced and used from these rolls. Therefore, not only large-sized equipment is required, but also after the foaming and curing reaction. If the internal temperature of the resin does not drop, the required strength will not be attained and the mold cannot be released.Therefore, when molding thick products, it is necessary to secure sufficient time before the mold release in order to lower the temperature. There is a problem that becomes longer. That is, this method is originally unsuitable for forming a thick material, and to the knowledge of the present inventors, it has not been manufactured integrally with a material having a thickness of 70 mm or more. For example, a method in which three sheets having the following thickness are bonded to each other to produce a sheet having a thickness of 200 mm is adopted.

In view of the above-mentioned conventional problems, the present invention is applicable to the batch method, but not only can use long fibers such as glass roving as a reinforcing material, but also can obtain glass roving necessary to obtain a required number of long fibers. The number of rolls is much smaller than that of the continuous method, and the fiber reinforced foam resin molding that can produce thick molded products in a single molding even in a narrow space with a very simple equipment configuration compared to the continuous method An object of the present invention is to provide a body manufacturing method and a manufacturing apparatus.

[0008]

Means for Solving the Problems The method according to claim 1 of the method for producing a fiber-reinforced foamed resin molded article according to the present invention comprises, in order to achieve the above object, a mold having a predetermined cross-sectional shape. A step of arranging a bundle of long fibers such as a predetermined amount of glass rovings, which are substantially uniformly spread, to form a multilayer, a step of spraying a foam-curable resin stock solution on the bundle of long fibers, and Foaming and curing the foam-curable resin stock solution in the molding die to form a molded article having a desired thickness and the like.

[0009] In the method according to the second aspect, the dispersing step may include, after disposing all required layers in the multilayering step,
Alternatively, it is characterized in that the method is repeated a plurality of times after arranging one layer or an appropriate number of layers.

[0010] The method according to claim 3 is characterized in that the bundle of long fibers is previously cut to an appropriate length in accordance with the arrangement in the mold.

According to a fourth aspect of the present invention, in the method, the end of the cut bundle of long fibers is hooked or pinched by a hook, a spacer, or the like combined in the molding die, or is attached to the inner wall surface of the molding die. It is characterized by being attached and held by a tape or the like.

According to a fifth aspect of the present invention, in the method, the bundle of long fibers is continuous over the entire length of the length to be disposed in the mold, and the bundle of long fibers is turned at least once. It is characterized by multilayering.

[0013] The method according to claim 6, wherein the bundle of long fibers is drawn into the molding die from the outside of the molding die once, and the drawing is performed at least once to form a multilayer. Features.

[0014] The method according to claim 7 is that the bundle of long fibers is folded a predetermined number of times outside the molding die in advance, and then the folded bundle of long fibers is mounted in the molding die. Features.

The method according to claim 8 is characterized in that the bundle of long fibers is folded a desired number of times in the mold.

According to a ninth aspect of the present invention, there is provided an apparatus for manufacturing a fiber-reinforced foamed resin molded article, the mold having a predetermined cross-sectional shape and having at least one open end face. One or more of a predetermined amount of glass rovings or other long bundles of glass rovings, etc., which are scattered almost uniformly from the opened end face side in the direction of drawing into the mold and in a direction perpendicular to the drawing direction. Means for drawing in, a means for spraying the foamed curable resin stock solution to the bundle of drawn long fibers in the molding die, and a method for forming the bundle of long fibers and the sprayed foamed curable resin stock solution to a desired thickness. And a lid for holding, wherein the foam-curable resin stock solution is foam-cured in the molding die while the bundle of long fibers and the spread foam-curable resin stock solution are compressed to a desired thickness. I do.

According to a tenth aspect of the present invention, in the apparatus, the drawing means spreads the bundle of long fibers so as to spread the bundle of long fibers substantially uniformly in a direction perpendicular to the direction of drawing into the mold. A comb-like, lattice-like or ring-like guide member having a regular concave-convex portion on the edge side to be hooked is included.

[0018] In the apparatus according to the eleventh aspect, the drawing-in means extends along the drawing direction of the forming die so that the drawing-in means wraps the bundle of long fibers passed through the guide member and draws the bundle into the forming die. It is characterized by including a reciprocating roller-shaped member.

An apparatus according to a twelfth aspect of the present invention includes a molding die having a predetermined cross-sectional shape and having at least one surface opened, and a glass roving or the like previously cut to an appropriate length in accordance with the arrangement in the molding die. A means for holding both ends of a bundle of long fibers, a means for spraying a foaming curable resin stock solution on the bundle of long fibers in the molding die, a bundle of long fibers which can be installed with respect to the opening surface, and A lid body for holding the sprinkled foaming curable resin stock solution at a desired thickness, the bundle of long fibers and the sprinkled foaming curable resin stock solution being compressed to a desired thickness in the molding die. It is characterized in that a foam-curable resin stock solution is foam-cured.

In the apparatus according to the thirteenth aspect, the means for holding both ends of the bundle of long fibers can be inserted into the molding die from the opening surface in a plate-like body or a frame-like body. It is characterized in that it also serves as a spacer forming a space between the bundles.

In the apparatus according to the present invention, the means for holding both ends of the bundle of long fibers may include a hook or the like disposed in the mold so as to hook an end of the cut bundle of long fibers. It is a sticking means such as a stopping means or a tape for sticking the end of the cut long fiber bundle to the inner wall surface of the forming die.

[0022]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a cross-sectional view showing a first embodiment of the apparatus for producing a fiber-reinforced foamed resin molded article according to the present invention. In the figure, 1 is a lower mold as a molding die, 2 is an upper mold, 3 is a nozzle for spraying a foam-curable resin stock solution, 4 is a drawing guide, 4a is a drawing roller pair, 5 and 5 are spacers, and 6 is a drawing roller. A bundle of glass rovings 7 is a holder for the glass roving end. The foam-curable resin stock solution is a synthetic resin solution that foams and cures in a short time, such as polyurethane, unsaturated polyester, phenol resin, urea resin,
Melamine resin, refers to a resin stock solution such as an epoxy resin, of course, is not limited to those that can be employed in the present invention, it is initially liquid, it may be any as long as it produces a foamed resin by curing . Among these resin stock solutions, hard polyurethane is particularly preferred. The long fiber used in the present invention is not limited to glass roving, but may be carbon fiber, synthetic fiber, natural fiber, or the like.

The lower mold 1 has a molded part 8 having a rectangular cross-sectional shape with an opening on the upper surface and both end surfaces in the longitudinal direction. Of course, the cross-sectional shape of the molded portion 8 of the lower die 1 differs depending on the shape of the molded product to be molded. The upper die 2 serves as a lid for the molded portion 8 of the lower die 1, and has wall surfaces 9 at both ends in the longitudinal direction.
9, a pressing portion 10 that is thinner than the depth of the forming portion 8 is provided. Although the drawing-in guide 4 is not shown in detail, regular irregularities such as a comb shape are provided on an edge around which the glass roving 6 is hung so that the glass roving 6 can be uniformly spread and held in the concave portion. It is. Although not shown, the drawing roller pair 4a is supported so as to be able to reciprocate along the drawing direction of the glass roving 6.
The number of spacers 5 to be installed or used depends on the thickness and specific gravity of the molded product to be manufactured. The apparatus of the present embodiment includes a device for supplying a glass roving 6, a device for holding the spacer 5 and moving the lower die 1 in and near the lower die 1 along the longitudinal direction of the lower die 1, a device for moving the nozzle 3, A device for supplying a foam-curable resin stock solution such as a urethane foam stock solution spouted from the upper mold 3;
And a device for cutting both ends of the molded product. However, since various known means can be employed, illustration and description thereof are omitted. Furthermore, instead of the pull-in guide 4 or the pull-in roller pair 4a, if a long state such as glass roving can be hung such as a ring-shaped, comb-shaped, or lattice-shaped member to maintain a constant state,
Any means can be employed and is not limited to the means shown and described above.

Next, the operation of the apparatus of the above embodiment and an embodiment of the method for producing a fiber-reinforced foamed resin molded article according to the present invention will be described with reference to FIGS. First, a predetermined amount of glass rovings 6 are bundled around the pull-in guide 4 and evenly spread in a direction perpendicular to the paper surface of FIG.
a, and the lower end is held and fixed by the jig 7 (FIG. 1). Then, the spacer 5 is slid onto the bundle of the glass rovings 6 in a direction perpendicular to the plane of the drawing on the bundle of the glass rovings 6 between the jig 7 and the forming die 8 and placed on the bundle of the glass rovings 6 and held down. The drawing roller pair 4a is moved to the right in the drawing, and the bundle of the glass rovings 6 is evenly dispersed, spread and held inside the forming part 8 of the lower mold 1 along the longitudinal direction thereof while holding the opening. The glass rovings 6 are again passed therethrough.
, And the pull-in roller pair 4a is returned to the original position together with the bundle of the glass rovings 6, and the spacer 5 is again placed on the bundle of the glass rovings 6 (FIG. 2). In this state, in the forming section 8 of the lower mold 1, the bundle of the glass rovings 6 is almost uniformly spread in the short direction of the forming section 8 (perpendicular to the drawing sheet). Further, since the middle part of the bundle of the glass rovings 6 is hooked on the spacers 5, it is folded in two steps at appropriate intervals as shown in the figure. Immediately thereafter, the nozzle 3 is put into the forming part 8, and while moving in the longitudinal direction in the forming part 8, the foaming-curable resin stock solution 11 is sprinkled from the nozzle 3 onto the bundle of glass rovings 6, The inside is impregnated with a foam-curable resin stock solution 11 (FIG. 2). The amount of the foaming curable resin stock solution 11 supplied at this time needs to be sufficient to sufficiently impregnate the bundle of the glass rovings 6 (this amount can be easily determined by experiment). When the bundle of the glass rovings 6 is not sufficiently impregnated by merely spraying the foaming curable resin stock solution 11, the bundle of the glass rovings 6 is beaten with a comb-like member or the like, or What is necessary is just to add the process of giving a vibration.

Further, the nozzle 3 is taken out of the forming section 8 or slightly lifted up in the forming section 8, and the pair of drawing rollers 4a is moved rightward in the drawing, and the glass roving 6 is moved in the same manner as the previous operation. Fold the bundle and hold. In this state, in the forming section 8 of the lower mold 1, a new bundle of glass rovings 6 is formed at an appropriate interval above the bundle of glass rovings 6 previously impregnated with the foam-curable resin stock solution 11, and a new bundle of glass rovings 6 is formed. Are spread almost evenly in the short direction of. Immediately thereafter, while moving the nozzle 3 in the forming section 8 in the longitudinal direction thereof, the newly introduced glass roving 6
The raw foaming curable resin solution 11 is scattered on the bundle, and the raw foaming curable resin solution 11 is impregnated into the bundle of the glass rovings 6 (FIG. 3). That is, the bundle of the glass rovings 6 folded in two is repeatedly impregnated with a predetermined amount of the foaming curable resin stock solution 11 by a predetermined amount, and laminated.

The above steps are repeated as many times as the desired thickness of the molded body can be obtained. In the illustrated example, the number is only two, but the present invention is of course not limited to the number of times in this example. Then, as shown in FIG. 3, after repeating lamination, dispersing and impregnation a predetermined number of times, the upper mold 2 is lowered from above the lower mold 1, and the pressing portion 10 of the upper mold 2 enters the forming section 8 of the lower mold 1. The state is maintained if the thickness of the laminated bundle of glass rovings 6 and the foamed curable resin stock solution 11 match the desired molded product thickness, and if the thickness is larger than the desired product thickness, the desired thickness is maintained. , And the foam-curable resin stock solution 11 is foam-cured while maintaining the state. At this time, the wall portions 9, 9 of the upper mold 2 hold the glass roving 6 together with the spacer 5 at a position just outside the molding portion 8, and minimize the movement of the glass roving 6 at both ends and leakage of the foam-curable resin stock solution. suppress. After the foaming curable resin stock solution 11 is cured,
The molded product is released from the mold by raising the upper die 2, and both ends thereof are cut by a cutter (not shown) as necessary to obtain a finished product as a fiber-reinforced foamed resin molded product. Of course, depending on the product specifications, processing other than cutting at both ends may be required.

In the above-described first embodiment, the glass roving 6 is drawn into the molding die by the drawing roller pair 4a, but the present invention is not limited to this. For example, a lower mold having an opening only on the upper surface side may be used, and the glass roving 6 which has been folded once or a plurality of times in advance may be stretched in the lower mold. In this case, in order to stretch the glass roving 6, the spacer 5 may be sandwiched between the folded portions of the glass roving 6 in advance, and both ends of the spacer 5 may be supported in a lower mold by appropriate means. It is also possible to provide a hook in the lower mold so that the folded portion of the glass roving 6 can be hooked, or the folded portion can be adhered and held on the inner wall surface of the lower mold with an adhesive tape or the like. . Of course, in any case, the folding of the glass roving 6 is performed at both ends in the drawing direction in the above embodiment. Also, a foam-curable resin stock solution 11
The nozzle 3 is inserted between the folded glass rovings 6 so that the spraying is performed for each turn.

In the first embodiment described above, the pull-in roller pair 4a is moved inward from the outside of the molding die so as to return to the outside again on the other side of the molding die. Is not limited to this.
a may be moved only inside the mold. For example, a lower mold having only an upper surface side opened is used, and a movable draw roller pair 4a and a fixed spacer 5 are provided in the lower mold.
Are alternately arranged, the glass roving 6 is drawn into the lower mold from the opening on the upper surface, the drawn end is fixed to the bottom surface or the lowermost spacer 5 in the lower mold, and only the drawing roller pair 4a is It is also possible to adopt a configuration in which the glass rovings 6 are folded back in a substantially similar manner to the above embodiment by sequentially moving them. Also in this case, the spraying of the foaming curable resin stock solution is performed for each turn by inserting a nozzle between the turned glass rovings 6.

FIG. 5 is a sectional view showing a second embodiment of the apparatus for producing a fiber-reinforced foamed resin molded article according to the present invention. In the following description, portions that are the same or similar to those of the first embodiment described above are denoted by the same reference numerals and described. In the figure, 20 is a lower mold forming a molding die, 21 is an upper mold similarly,
Reference numeral 22 denotes a glass roving cut into a bundle at a predetermined length, and reference numerals 23... Denote spacers serving as holders for glass roving ends.

The lower mold 20 has a bottom surface 20a and both side surfaces 2a.
0b, 20b, and has a molded portion 24 having a rectangular cross-sectional shape with an open top surface and both longitudinal side surfaces. Of course, the cross-sectional shape of the molding portion 24 of the lower mold 20 differs depending on the shape of the molded product to be molded, as in the previous embodiment. The opening portion is also set as appropriate. The upper die 21 serves as a lid for the forming part 24 of the lower die 20, and has a pressing part 25 thinner than the depth of the forming part 24 between the lower surfaces.
The spacer 23 is composed of two plate members 2 made of a rigid foam or the like.
3a and 23b.
End of the bundle. Although the surfaces of the plate members 23a and 23b sandwiching the glass roving 22 may be flat surfaces, regular irregularities are provided similarly to the retracting member 5 of the previous embodiment, and the glass rovings 22 are easily dispersed uniformly in the concave portions. Good to do. Further, the spacer may be formed in a frame shape including a pair of frame bodies. Further, also in the present embodiment, the number of spacers 23 to be installed or used depends on the thickness of the molded product to be manufactured, and the nozzle 3 is moved in the horizontal direction, the depth direction,
The apparatus includes a device for moving in the vertical direction, a device for supplying a foam-curable resin stock solution such as a urethane foam stock solution ejected from the nozzle 3, a device for moving the upper mold 21, a device for cutting both ends of a molded product, and the like. Since various known means can be adopted, illustration and description are omitted.

Next, the operation of the second embodiment and the second embodiment of the method for producing a fiber-reinforced foamed resin molded article according to the present invention will be described with reference to FIGS. FIG. 6 is a side cross-sectional view (A) of a state in which the first-stage glass roving 22 is set and the foaming-curable resin stock solution 11 is poured in the manufacturing apparatus in FIG. 5, and three-stage glass roving 22 is set and foamed. FIG. 4B is a side cross-sectional view (B) of a state where the dispersion of the curable resin stock solution 11 has been completed, and the upper mold 21 has been put on and pressed.

First, a small amount of the glass roving 22 is cut into a predetermined length outside the forming die so as to fit in the forming part 24 of the lower die 20, and both ends are sandwiched between plate members 23 a and 23 b forming spacers 23. Hold. At this time, the bundle of the glass rovings 22 is held so as to be in a substantially uniformly spread state. This is manufactured in advance for the required number of stages. Then, using the upper part of the lower mold 20 and the openings on both sides, 1
The glass roving 22 forming the step is formed into the forming part 2 of the lower mold 20.
Put into 4. At this time, the spacers 23, 23
The glass roving 22 is positioned and fixed so as to be positioned as closely as possible between the side walls of the lower mold 20 that forms the glass roving 22.
It is advisable to apply an appropriate tension to the bundle. In this manner, the spacers 23 that are stacked as the bundle of the glass rovings 22 is set define the molded portion 24 together with the side walls of the lower mold.

Next, the nozzle 3 is put in the forming part 24,
While moving between the spacers 23 on the bundle of the glass rovings 22, the foaming curable resin stock solution 11 is scattered on the glass roving 22 bundle, and the bundle of the glass rovings 22 is impregnated with the foaming hardening resin stock solution 11 (FIG. 6 (A)). The amount of the foaming-curable resin stock solution 11 supplied at this time needs to be sufficient to sufficiently impregnate the bundle of one-stage glass rovings 22 (this amount can also be easily determined by experiment). Also in this embodiment, if the impregnation of the glass rovings 22 with the bundle of the glass rovings 22 is not sufficient simply by sprinkling the foam-curable resin stock solution 11, the bundle of the glass rovings 22 is beaten with a comb-like member or the like. A step of giving vibration to the bundle of rovings 22 may be added.

Further, the nozzle 3 is moved out of the molding section 24, and the glass roving 22 forming the next stage and the spacers 23 at both ends thereof are set in the molding section 24 in the same manner as the first stage. In this state, in the molding part 24 of the lower mold 20, a new glass roving 22 is formed on the bundle of the glass rovings 22 impregnated with the foaming curable resin stock solution 11 by the thickness of the spacer 23. The bundle is spread almost evenly. Immediately thereafter, the nozzle 3 is
4, the raw foaming curable resin solution 11 is spread on the bundle of glass rovings 22 newly introduced in the same manner as described above, and the bundle of glass rovings 22 is impregnated with the raw foaming curable resin solution 11. By repeating this, a bundle of multilayer glass rovings 22 is laminated and formed.

The above steps are repeated as many times as the desired thickness of the molded article can be obtained. Although only three stages are shown in the illustrated example, the present invention is of course not limited to the number of times in this example. Then, after repeating lamination and impregnation a predetermined number of times, the upper mold 21 is lowered from above the lower mold 20, and the pressing portion 25 of the upper mold 21 enters the forming portion 24 of the lower mold 20, and the laminated glass roving 22 If the thickness of the bundle and the foam-curable resin stock solution 11 match the desired molded product thickness, the state is maintained. If the thickness is larger than the desired product thickness, the state is pressed down to the desired thickness. The foam-curable resin stock solution 11 is foam-cured while maintaining this state (FIG. 6B). In FIG. 6B, reference numeral 26 denotes a spacer block, which is placed on a spacer 23 sandwiching the glass roving 22 to form an upper mold 21.
Is held at an appropriate position. After the foaming-curable resin stock solution 11 is cured, the upper mold 21 is lifted to remove the molded product, and both ends thereof are cut by a cutter (not shown) to obtain a finished product as a fiber-reinforced foamed resin molded product. Of course, depending on the product specifications, processing other than cutting at both ends may be required.

In place of the spacer 23 of the second embodiment described above, a hook is provided in the molded portion 24 of the lower die 20 so that the cut end of the glass roving 22 is hooked and held. Or glass roving 22
It is also possible to adopt a configuration in which the end portion is directly attached to and held on the inner wall surface of the molded portion 24 with an adhesive tape or the like.
In the above description, the foaming-curable resin stock solution 11 is sprayed every time one stage of the glass roving 22 is put into the molding unit 24. To form a multi-layered state, and a nozzle 3 may be inserted from a part of the side wall of the molding portion 24 to spray the foaming curable resin stock solution 11 between each stage of the glass roving 22. In this case, the nozzle 3 may be attached to an arm or the like that can swing in the horizontal direction and used.

In addition to the above first and second embodiments and their modified examples, the long fibers and the stock solution of the foam-curable resin used in the present invention differ of course depending on the molded product, and the above-mentioned glass roving or urethane foam is used. Stock solutions and the like are merely examples.

[0038]

EXAMPLES AND COMPARATIVE EXAMPLES Hereinafter, a molded article produced by a method and apparatus according to examples of the present invention will be compared with a molded article produced by a conventional method and apparatus.

Examples: Raw materials used Glass fiber: Glass roving No. 2200 (2.2 g / m) manufactured by Asahi Fiber Glass Co., Ltd., Number of glass rovings used: 364, Number of times of folding: 5 times, Foam curable resin stock solution: Urethane foam stock solution FRU-AQ500 manufactured by Nisshinbo Industries, Ltd. Molded product 200 × 200 × 2000 (mm) In this example, the glass content was 40% and the specific gravity was 0.5.
It is intended to manufacture a molded article having a value of
The urethane foam stock solution was sprayed every time it was drawn into the round mold. Comparative Example 1: Production method Batch method Raw material used Glass fiber: continuous strand mat (600 g / m ² ) manufactured by Asahi Fiber Glass Co., Ltd.
Number of strand mats used: 67 (glass content 40
%), Foam-curable resin stock solution: Nisshinbo Industries, Ltd. urethane foam stock solution FRU-AQ500 Molded product 200 × 200 × 2000 (mm) In this example, impregnation was inferior when molded to a thickness of 200 mm, so that glass As a result of examining the content rate, 25
% Was found to be the limit, and the number of strand mats used was reduced as in Comparative Example 2 below. Comparative Example 2: Production method Batch method Raw material used Glass fiber: Continuous strand mat (600 g / m ² ) manufactured by Asahi Fiberglass Co., Ltd.
Number of strand mats used: 42 (glass content 25
%), Foam-curable resin stock solution: Nisshinbo Industries, Ltd. urethane foam stock solution FRU-AQ500 molded product 200 × 200 × 2000 (mm) Comparative Example 3: Production method Continuous method Raw material used Glass fiber: Asahi Fiberglass Co., Ltd. Glass roving No. 2200 (2.2 g / m), number of used: 1274, foam-curable resin stock solution: Nisshinbo Industries, Ltd.
Urethane foam stock solution FRU-AQ500 Molded product 70 × 200 × 2000 (mm) In this example, the molded product thickness is 200 mm and the glass content is 40.
%, The equipment that can use the number of glass rovings required for the percentage (3640) is large and nonexistent, so the thickness of the molded product and the number of glass rovings used were reduced.

Table 1 below shows a comparison of physical properties between the molded article according to the embodiment of the present invention and the molded article according to the conventional method.

[Table 1] As shown in this table, the method of the present invention is basically a batch method, but the molded product according to the embodiment of the present invention has a greater bending strength and bending Young than the conventional batch-type molded product. Rate and excellent physical properties equivalent to those of the conventional continuous molding. Further, the same glass content could be achieved by using about one-tenth of the glass roving roll as compared with the molded article according to the conventional continuous method.

[0041]

Since the method and apparatus for producing a fiber-reinforced foamed resin molded article according to the present invention are as described above, a molded article having the same physical properties as a molded article produced by a conventional method called a continuous method is used. The number of long fiber rolls such as glass rovings used for obtaining can be made very small compared to the continuous method, and it is very simple and space-saving compared to the production equipment for implementing the conventional continuous method. Equipment is sufficient, and there is an effect that it is possible to mold a thick molded product in one time in a narrow space. In addition, since a thick molded product can be molded in a single operation, there is no need for an adhesive operation and associated operations, and there is also an effect that a molded product of uniform quality can be obtained even with a thick product.

Further, the method and the apparatus for producing a fiber-reinforced foamed resin molded article according to the present invention have a very good impregnation property with a foam-curable resin stock solution as compared with molded articles produced by a conventional production method called a batch method. In addition to being able to mold thick products without uneven distribution of fibers, it is possible to produce molded products with excellent bending strength and flexural Young's modulus, which are the most important performances from the application of this type of molded product. It has the effect of becoming.

[Brief description of the drawings]

FIG. 1 is a side sectional view (A) showing a first embodiment of a manufacturing apparatus for a fiber-reinforced foamed resin molded article according to the present invention, and FIG.
It is sectional drawing (B).

FIGS. 2A and 2B are a side sectional view (A) and a sectional view taken along a line BB in a state where a first glass roving is set and a foaming curable resin stock solution is poured in the manufacturing apparatus of FIG.

3A and 3B are a side cross-sectional view and a BB cross-sectional view of a state in which a second glass roving is set and a foaming curable resin stock solution is poured in the manufacturing apparatus of FIG.

FIG. 4 is a view illustrating a process of setting the glass roving twice and pouring the foaming curable resin stock solution in the manufacturing apparatus of FIG. 1;
A side sectional view (A) of a state in which the upper mold is covered and pressed,
It is BB sectional drawing (B).

FIG. 5 is a side sectional view showing a second embodiment of the apparatus for producing a fiber-reinforced foamed resin molded article according to the present invention.

6 (A) is a side sectional view showing a state in which a first-stage glass roving is set and a foaming-curable resin stock solution is poured in the manufacturing apparatus of FIG. 5; FIG. FIG. 7B is a side cross-sectional view (B) of a state in which the dispersing of the stock solution has been completed, and the upper mold has been put on and pressed.

[Explanation of symbols]

 1, 20 Lower die 2, 21 Upper die 3 Nozzle 4 Pull-in guide 4a Pull-in roller pair 5 Spacer 6, 22 Glass roving 7 Jig 8, 24 Lower die forming portion 9 Upper die side portion 10, 25 Upper die pressing Unit 11 Foam curable resin stock solution 20a Lower mold bottom surface 20b Lower mold side surface unit 23 Spacer 23a, 23b Plate material forming spacer 26 Spacer block

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[Procedure amendment]

[Submission date] February 6, 1998

[Procedure amendment 1]

[Document name to be amended] Drawing

[Correction target item name] Figure 2

[Correction method] Change

[Correction contents]

FIG. 2

[Procedure amendment 2]

[Document name to be amended] Drawing

[Correction target item name] Figure 3

[Correction method] Change

[Correction contents]

FIG. 3

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification symbol FI // B29K 105: 04 B29C 67/14 G 105: 08 309: 08 B29L 9:00 (72) Inventor Akihiro Takitaku Adachi-ku, Tokyo 1-1-18-1, Sakaemachi Nishiarai Nisshin Spinning Co., Ltd. Tokyo Plant

Claims (14)

[Claims] A step of arranging a bundle of long fibers, such as glass rovings, of a predetermined amount substantially uniformly dispersed in a mold having a predetermined cross-sectional shape to form a multilayer, and Spreading a foaming-curable resin stock solution, and foaming and curing the sprayed foaming-curable resin stock solution in the molding die to form a molded body having a desired thickness and the like. A method for producing a fiber-reinforced foamed resin molded product. 2. The method according to claim 1, wherein the dispersing step is repeated a plurality of times after disposing all required layers in the multi-layering step, or after disposing one or an appropriate number of layers. A method for producing a fiber-reinforced foamed resin molded article. 3. The method for producing a fiber-reinforced foamed resin molded article according to claim 2, wherein the bundle of long fibers is cut in advance into an appropriate length according to the arrangement in the molding die. . 4. An end portion of the cut long fiber bundle is hooked or held by a hook or a spacer or the like combined with the molding die, or is adhered to and held by an inner wall surface of the molding die with a tape or the like. The method for producing a fiber-reinforced foamed resin molded article according to claim 3, characterized in that: 5. The method according to claim 1, wherein the bundle of long fibers is a series over the entire length of the length to be arranged in the mold, and the bundle of long fibers is turned at least once to form a multilayer. The method for producing a fiber-reinforced foamed resin molded article according to claim 2. 6. The method according to claim 5, wherein the bundle of long fibers is drawn into the mold at least once from outside the mold, and the drawing is performed at least once to form a multilayer. A method for producing a fiber-reinforced foamed resin molded article. 7. The method according to claim 5, wherein the long fiber bundle is folded back a predetermined number of times outside the molding die, and then the folded long fiber bundle is mounted in the molding die. A method for producing a fiber-reinforced foamed resin molded article. 8. The method for producing a fiber-reinforced foamed resin molded product according to claim 5, wherein said bundle of long fibers is folded in said molding die a desired number of times. 9. A mold having a predetermined cross-sectional shape and having at least one end face opened, and a direction extending from the opened end face side into the mold and perpendicular to the direction of drawing. One or more pull-in means for pulling a bundle of long fibers such as a predetermined amount of glass rovings which are substantially uniformly spread, and a foaming curable resin stock solution is sprayed on the bundle of drawn long fibers in the mold. Means, and a lid for holding the bundle of long fibers and the sprinkled foaming curable resin stock solution at a desired thickness, and compressing the bundle of long fibers and the sprinkled foaming curable resin stock solution to a desired thickness. An apparatus for producing a fiber-reinforced foamed resin molded product, wherein the foamed curable resin stock solution is foamed and cured in the molding die in the above state. 10. In order for the drawing-in means to spread the bundle of long fibers substantially uniformly in a direction orthogonal to the drawing direction of the forming die, regular irregularities are formed on an edge side where the bundle of long fibers is hooked. 10. A comb-like, lattice-like or ring-like guide member having a shape portion is included.
For manufacturing fiber-reinforced foamed resin molded products. 11. A roller-like member reciprocally movable in the drawing direction into the molding die so that the drawing-in means wraps around the bundle of long fibers passed through the guide member and draws the bundle into the molding die. 2. The method according to claim 1, further comprising:
No. 0, an apparatus for producing a fiber-reinforced foamed resin molded article. 12. A mold having a predetermined cross-sectional shape and having at least one open side, and both ends of a bundle of long fibers such as a glass roving previously cut to an appropriate length in accordance with the arrangement in the mold. Holding means, means for spraying the foaming curable resin stock solution on the bundle of long fibers in the molding die, and the bundle of long fibers and the foaming curable resin stock solution sprayable which can be installed on the opening surface And a lid body for holding a desired thickness of the foamed curable resin stock solution in the mold while the bundle of long fibers and the spread foamed curable stock solution compressed to a desired thickness. An apparatus for producing a fiber-reinforced foamed resin molded article characterized by being cured. 13. A spacer for holding both ends of the long fiber bundle in a plate-like or frame-like shape, which can be inserted into the mold from the opening surface and forms a space between the long fiber bundles. The apparatus for producing a fiber-reinforced foamed resin molded article according to claim 12, wherein the apparatus also serves as: 14. A means for holding both ends of the bundle of long fibers, wherein the means for holding the two ends of the bundle of cut long fibers is hooking means such as a hook disposed in the molding die so as to hook the end of the bundle of long fibers or the cut length. 14. The apparatus for producing a fiber-reinforced foamed resin molded article according to claim 13, wherein said means is a sticking means such as a tape for sticking an end portion of a fiber bundle to an inner wall surface of said mold.