JPS5865652A - Manufacture of laminate - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a laminate. More specifically, the present invention relates to a method for producing a laminate having high dimensional stability and fire retardant properties.

Laminated bodies made of hard plastics with a core material of 7 ohm are widely used as lightweight structural materials, insulation boards, insulation building materials, etc., and their usefulness is widely recognized. In addition, a method of using glass fiber 1* as a reinforcing material for hard plastic foam used as a core material has been proposed in order to meet strict requirements (such as structural strength, fire resistance, and dimensional stability). For example, Tokko Zhao Mo! No. 5-15226, Special Publication No. 1845-80! Examples include ``Bou No. 1'' and JP-A No. 52-11079. These methods require a special glass spear mt-
There are disadvantages such as the need to use special mt equipment for dispersion into the glass fiber tube core material, and the price of the finished product is high.
It's not too practical and I love it.

That is, a method for manufacturing a composite from mineral fiber, spongy material, and K has been proposed. In this sense, fibers and foams (sponge-like substances)
It can be evaluated as the most basic technique for compositing tubes. In this method, as described above, an arbitrary space is roughly filled with a waterfall of mineral fibers (glass fibers, in other words), and a foam material tube is added to this to fill the entire strainer of the fibers to form a composite.

Therefore, the mineral III fiber used is bulky, and there are problems in handling this IIIItIa.

In addition, there is a drawback that the foam and IIIt fibers cannot be evenly dispersed and tend to be unevenly distributed. Furthermore, voids ([
1) and has structural defects in the complex.

On the other hand, the so-called condensed cocoon t+#! This is a method of manufacturing panels by integrating polyurethane foam tubes by cross-distributing the tubes in various directions. This method is also described above (Tokuko Showi $5-1
No. 3224) and No. 3224), when a high loft mat is used, voids are generated in the core material of the panel due to the loft, and this has an essential structural defect.

Also, No. 4]1@l1852-110791 describes a part of a structural laminate product and its manufacturing method. This method uses glass 1lIII miscellaneous and special 1, i.e. Mod
ig11ani law (US 1iI1% permit 2609320) [
In this type of glass fiber mat, the glass fibers are parallel to the medium in the core material and are arranged in layers. Therefore, although the occurrence of voids is certainly small, it has drawbacks such as low dimensional stability as a laminate and low strength in the thickness direction. Also, this method & iMoaigxta
Only glass fiber produced by the ni method can be used, and this glass fiber manufacturing method has low productivity and is therefore uneconomical, so it is hardly produced today.

The present invention improves upon these drawbacks and provides a method for economically manufacturing high performance laminate tubes.

In other words, glass fiber pine, which is commonly used as a reinforcing material for the core material)1
In addition, it is possible to avoid the generation of l-ide, and to provide a high-performance laminate.

That is, in the method of manufacturing a laminate tube consisting of two parallel face materials and a core material of a hard plastic foam into which glass fibers are dispersed, the present invention has the following steps: 5- stacking glass fibers and adding a binder; A thin glass fiber mat tube can be formed into a mat shape, and one side of the glass fiber mat tube is defibrated by immersing it in a solvent that can dissolve the binder to remove at least a portion of the binder. 4 on the wood
This is a method for manufacturing a laminate, which is characterized in that a hard plastic 7 ohm material having self-foaming hardening properties is supplied onto the hard plastic foam material, and the material is foamed, and the other side material tube is supplied onto the hard plastic foam.

To obtain a low-loft, ie, non-bulky glass fiber mat, any bonding agent is generally used to secure the glass fibers. Glass fiber mats that are firmly bonded with a binder in this way are easy to handle and transport, but when used as a reinforcing material for the core material of a laminate, this glass fiber mat is uniformly distributed throughout the core material. In such a laminate, where the core material is not dispersed and is concentrated in a specific position of the core material, for example near the bottom surface, it is not possible to exhibit high dimensional stability, fire resistance, and high strength. Therefore, it is necessary to use as little binder as possible (Glass fiber pine) Option 6) However, if there is less binder, it will have a high loft,
In other words, it becomes a bulky and fluffy futon! 11 There are handling problems, and existing technologies such as Special Publication No. 1I84
This is a drawback in the manufacturing method of No. 5-50255.

Therefore, there has been a need to develop a method for use as a reinforcing material for the core material of glass IIIA mat laminates, which is thin and easy to handle and transport, and has a low loft property. As a result of intensive research on this point, the present invention was completed.

(i.e., thin, low-loft glass fiber pine made by stacking glass fibers and adding a binder to form a mat KlEII)
The present invention has been completed by devising a method t1 in which the ink is opened by immersion treatment with an appropriate tS agent.

A detailed explanation of the present invention will be given using 10Iii. 1st.
At step 211, the glass*a mat 4 is immersed in a solvent bath 21. The binder in the glass fiber mat is dissolved in solvent 5 while passing through the mesh type conveyor N125, or
or distended. The solvent impregnated in the mat is removed by the squeezing rolls 25 and 211i, and the mat is advanced through the upper pipe of the conveyor, and in the oven 27, the solvent adhering to the mat is removed and dried. is obtained. Further, the glass ll1 mat is adjusted to a predetermined temperature, for example #i20 to 2SIC, in a temperature adjusting air bath 29, and then supplied to the laminator.

Glass fiber mat 4 is WAK partially O which passes through 5 times of solvent.
The fi mixture will be dissolved or the swollen binder will be physically scraped off on the mesh conveyor, but all the binder must be removed! There isn't.

That is, while passing through the solvent 5, a slight tensile force acts on the glass fiber pine F in the direction of execution (tensile force is generated).
Therefore, the binder initially attached is 010- or more, preferably 1
By the time j20 to 50- have been removed and the fibers reach the laminator, the glass fiber pine F has been sufficiently defibrated. Although there are some differences depending on the type of glass fiber mat, K used in the laminate of the present invention is fully decomposed if the binder tube is removed for 10 seconds or more.

ζ0fllK L, solvent treated glass III
-The thickness of the mat has increased by 10 to 200- compared to the original thickness. In other words, the song became that much more bulky.
kru. However, since it becomes bulky on a series of manufacturing equipment,
There are some problems in handling and transportation.

Solvent-treated glass fiber mats are placed in a temperature-regulating air bath 2.
The 9th floor passer is placed on the lower surface material 2, and a self-foaming, hardening hard plastic sheet is placed on top of it.
[1] (Foamed mixture) 1 is discharged from the mixing head 11 and introduced into the laminator 12 together with the upper surface material 1. After being sufficiently cured in a keyer, it is cut into a predetermined size by a cutter 1i to obtain a laminate (product) 4 of a fixed length.

In addition, the discharged foaming mixture 1 and glass fiber mat are weighed in order to obtain a predetermined layer thickness at 14.15, so that the foaming mixture becomes uniform in thickness in the width direction and foaming After regulator 14f, atne/-
12 [Can be introduced.

By using the measuring roll (nip roll) 14,15t7, it is possible to even out the distribution of the foam mixture (make the thickness uniform), and also promote mutual dispersion of the glass mat 9- and the foam mixture. It's convenient because you can do that.

In the present invention, the time for impregnating the glass*fiber*1 in the solvent varies depending on the type of glass fiber*fiber*D, the basis weight, the amount of binder used, etc. Therefore, the length of the solvent tank should be determined depending on the tI glass fiber mat conveyance speed, that is, the manufacturing mode of the laminate. Wire mesh, e.g. S~10 mesh JLO stainless steel mesh TF! It is better to use a conveyor with a wire mesh, or optional OIA holes (5~10m1) on the stainless steel plate.
Open the opening 940mm, and the fleas should move sufficiently up and down the conveyor, causing slight friction between the conveyor and the glass fiber mat.Of course, the solvent should move and circulate.
A stirring device may be attached to the K11 agent in order to measure the solvent, and it is preferable to circulate the solvent by an appropriate method.

25.24 ki of solvent squeezing rolls Of course, one pair may be sufficient in some cases. snin hard tube chrome plated 10- Round steel rolls are sufficient, roll clearance (-Seki)
It is amazing that a distance of the same degree as 0 thickness, or even slightly less than thickness is better.

The temperature in the open 27 is good enough to supply sufficient ripening heat to volatilize the solvent attached to the glass fiber pine).
Therefore, an air bath at 50 to 100° C. is sufficient to achieve the goal of the present invention.

Glass fiber pine) oil 1m! An ordinary air bath using steam as a heat source is sufficient as the energy saving air bath. Since it is necessary to maintain a constant temperature KIia when contacting the foamed mixture 1 of Glass Wire Cone Mat Co., Ltd., 29 tubes are passed through.

Of course, it may be possible to adjust the temperature to a constant level while passing the Open 27 event, so this is a must in such cases! do not have.

The present invention involves soaking the glass fibers in a solvent to reduce binder prior to contacting and integrating the fiberglass mat with the foam mixture. Therefore, the solvent l1
This is an indispensable device for 11 companies.

The laminator that can be used for this shield-El' is a laminator that produces a hard medium 7 ohm laminate.
All can be used. For example dh Viki
ng lBjngin@aring CO, Henn
acks.

There are laminators commercially available from Kornylac and others. Of course, it is not limited to these
Either a double conveyor type or a single conveyor type can be used. A horizontal laminator, a direct laminator, or an inverse laminator can be used.

A glass fiber mat that can be used for the Kf of the present invention is a thin glass fiber mat that can be formed into a mat by stacking glass III-11 and adding a binder tube. Specifically, there are continuous strand mats, cheat strand mats, and bonded strand mats. The continuous strand mat is as shown in Utility Model Publication No. 4s-254. Also, the chisel strand mat is J-K5.
It is starved with R-1411. Of course, in addition to this, it is also possible to use 0 gas 1111 fiber mats.

The tI glass fiber basis weight depends on the intended use and thickness of the laminate, but generally 2G to 4Of/d, preferably 50 to 2001/d are used.

1g for this invention! The glass fiber mat that can be used must be thin, that is, it must have low F-F properties. The specific value of thickness is 20 mm or less, preferably 10 mm.
Conveniently, it is JarF. If it is thicker than 20 cm, it is out of the scope of the present invention, but it becomes bulky and inconvenient to handle. Preferably not.

As the binder for the glass fiber mat, any commonly used binder may be used, including polyester resins, phenol resins, epoxy resins, melamine resins, urethane resins, and the like. Thermosetting resin, thermoplastic resin II
Either O can be used. From these O,
Polyester resin is commonly used and is economically advantageous. In addition, the 112 dose of the binder is generally KCLS ~ 1°- for glass bonding, and the thickness of the root and pine trees, which generally use a large amount of binder, is less, that is, thin and firmly bonded. are doing.

Of course, it is convenient for manufacturing the laminate of the present invention that the surface WJ of the glass fiber is subjected to IIi image treatment by methods such as silane treatment, chromic acid treatment, and heat deoiling treatment. IA#'i, since the glass fiber mat is soaked in a solvent, these surface treatments HAt may not necessarily be carried out.

The glass fibers constituting the glass fiber mat for KtI of the present invention may be monofilaments, and
It can be a strand made up of several dozen main tubes, of course, M
A method in which s to 1 g of monofilaments are bundled may be used, as in the odiEZliani method.

It is not limited to the above example 0 as long as these glass fibers can be piled up and formed into a mat shape by adding a binder.

Any solvent that can be used in the present invention may be used as long as it dissolves and swells the binder for glass III and other substances.For example, methylene chloride, trichloroethylene, perchloroethylene, ttt trichloropethane, 14-xylene, toluene, methyl ethyl ketone, etc. Kameru.

It is best to use a solvent with a flash point as low as possible, or a solvent with low flammability that evaporates easily. 4 for this purpose! 1.1. t,)
Lichloroethane and the like are preferred.

The core material of the laminate used in the present invention, that is, the foam mixture,
This is a hard plastic foam that is self-expanding and hardening. Specific examples include hard urethane 7 ohm, urethane modified incyanurate 7 ohm, polyisocyanurate foam, carbodiimide 7 ohm, phenol foam, amideimide 7 ohm, and epoxy foam.

The first three are particularly superior in terms of practicality.

Surface materials that can be used for the f'AKR of this invention include metal foils such as iron foil, steel foil, aluminum foil, and copper foil, asbestos paper,
It can be made of laminated metal foil and asbestos paper, or non-woven fabric mainly made of glass fiber. Metal foil is rust-proof and corrosion-proof! t
It is also possible to add processed pipes such as degreasing, plating, and painting.
Design (gravure printing, embossing, etc.) [May be added.

Also, i1! In order to improve the contact with the surface material, it is preferable to paint the surface material with a brusher. This glass #I11 fiber is defibrated by immersion treatment in a matt T1 solvent and uniformly dispersed in the core material as a 111i reinforcing material. That is, the laminate produced by the method of the present invention uses glass 1jIItm mat as 80% of the reinforcing material, and the glass fibers are uniformly dispersed in the core material, are arranged in arbitrary directions, and are mutually three-dimensional. % mold meeting 4 where they intersect
Two. Moreover, there are no voids in the core material, and two parallel face materials are integrally formed with eight strips. Therefore, the laminate of the present invention has many features such as high dimensional stability, fire resistance, and high strength.

The features of the method of the present invention have been explained so far, and will be summarized below.

1) Since it is possible to use a thin glass edge line mat that is firmly fixed with a bonding agent, handling and transporting the glass 6M mat is easy. Further, the amount of glass fiber used can be changed arbitrarily.

(It is possible to progress from a low level to a high level of a brass tube containing 1m of tJ lath.) 2) As a glass fiber mat, most of the commercially available products are
can be used. Can be used in a wide variety of ways, including continuous strand mats, bonpunto mats, and chopped strand mats.

S) Glass fiber dissolution* Since the process is carried out while immersed in a solvent, there is no scattering of glass fiber powder, creating a good working environment.

4) A wide range of solvents can be selected.

5) The conventional i-nator can be used as is.

By adding a solvent immersion treatment device to the laminator, it becomes possible to manufacture glass*fiber-reinforced laminates.

6) Self-foaming, hardening hard plastic foam can be used as the core material, so it can be used depending on the purpose of the product.

17-- 7) For reasons such as 1), 4), 5), and 6) above,
The laminate f can be manufactured economically.

8) The laminate obtained by the present invention has many quality merits.

Next, the % length f of the laminate according to the present invention is summarized as follows.

1) Since the glass fibers are uniformly dispersed, it has high dimensional stability, especially at high temperatures, and has excellent heat resistance.

2) The glass fibers are uniformly dispersed and intersect three-dimensionally, resulting in high mechanical and structural strength.

S) Excellent fireproof performance and passes quasi-noncombustible material test.

4) Glass III! Compared to conventional laminates that do not use fibers, the surface material has a 1% smoothness and a good appearance.

5) Same as conventional laminates, it is lightweight, has high strength, and has excellent heat insulation properties.

6) Texture and design can be added by selecting the surface material,
Can be adapted to user preferences.

=18 - An example of a laminate according to the present invention is shown in Figure 3.4.5.6 m
'm is one using glass fiber pine)1 which is not subjected to solvent immersion treatment. Figure 3 shows an example using Bonpunto Mat 1 (Tosho), Figure 4 shows an example of using Bonpunto Mat 1 (Trussian Strand Pine), and
Continuous strand mats were used in 9 cases. It can be seen that both are uniformly dispersed in the core material.

Moreover, FIG. 6 shows a conventional example, and shows an example in which Continua, Strandmat) is used without being immersed in a solvent. It can be seen that the glass fibers are not uniformly dispersed in the core material.

Next, a uniform tube embodiment of the present invention will be explained. Of course, the invention is not limited to this example.

Example 1~S a) Preparation of glass fiber mat Continuous strand mat made by Asahi Fiberglass Co., Ltd. (area weight 150 f/d, binder usage amount tsij)
Ii - After being immersed in methylene chloride for about 1 minute and squeezing with a roll, the solvent was evaporated in an air bath at 50°C. The thickness of this glass fiber mat before the solvent immersion treatment is about 2s1, but after the immersion treatment it is about MW, which shows that the thickness is quite unrelated.

b) Hard plastic foam A urethane modified incyanure foam having the following formulation was used.

Two polio cases. . heavy 11i
ls silicone oil 40
Potassium acetate 4,8) IJ
/lolomonofluoromethane 155
Polymethylene Borifu-Nylene Polyink Anade 870
Book 1.2 Propylene glycol 1 - 40 mol of ethylene oxide as an initiator, 6 mol of propylene oxide, polyol with a primary hydroxyl group content of 75 and a hydroxyl value of 600 Toray Silicone Co., Ltd. BY-10-530 Book rate Japanese polyurethane #
K Co., Ltd. Millionate MR, Free Incyanate also has an emergency Fi of 31%.

C) Manufacture of polar layers Vikim Engineering 00, g
The laminate was manufactured using a horizontal laminator. That is, for direct exposure, use a 50 micrometer aluminum foil (apply a urethane-based primer coating on the surface that contacts the form. m! The cloth lid is approximately 5 f/d), and use
So 1! A laminate was produced using the urethane-modified incyanurate foam tube core as described in b) using a glass fiber mat prepared by IL.

Three types of am body were manufactured: 25 thick, 55 tone, and 45 square.

d) Testing method for laminates Performance test results were obtained according to the following test method, and the results are shown in Table 1.

7 Om Density...J Engineering 8 Mu 9514
Semi-flammability test・・・・・・・・・JIEI Mu
1321 Flame penetration relationship・・・・・・・・・American mining method dimensional stability test・・・・A13TM D 212
421- Comparative Example-1 A laminate was produced in the same manner as in Example 1, except that the twin lath M-fiber mat used in Example 1 was used without any solvent immersion treatment.

As shown in FIG. 6 of this laminate #i, the glass fiber mat is unevenly distributed in one place in the core material, and the appearance of the laminate is not good.

Table 1 shows the performance of the obtained laminate.

Example 4.5 Instead of glass fiber pine) 0 in Example 1, Chibutsu strand mat (basis weight 25Qt/d).

Amount of binder used α5-) The entire amount used was carried out in the same manner as in Examples 1 to 5.

A laminate with good appearance was obtained. Performance, test results tI! −
Mourning shown in 1.

Example 11A-&7 A laminate was produced in the same manner as in Example 1, except that a 7-ohm phenol tube was used in place of the 7-ohm urethane-modified incyanurate tube.

The formulation of phenol foam is as follows: 22 pieces of phenol resin/te D-4520 100
1 part hardening agent IF-20 1 0 trichloromonofluorometa/12 trichlorotrif 0 loethane 12 bottles Hardening agent for 7-kol resins manufactured by Dainippon Ink & Chemicals Co., Ltd. Examples-8 to 1Q St pigeon bodies were prepared in the same manner as in Example-1, using a continuous strand mat (fabric weight 801/d binder usage amount 21) instead of the glass-koji mat in Actual IkA Example-1. was manufactured.

The performance test results are shown in Table-1.

Example 11.12.13 Example - In place of the self-made aluminum foil in BK, electrolytic iron foil manufactured by Toyo Kohan Co., Ltd. (treated with zinc plating on both surfaces) was used. The results are shown in Table 1.

[Brief explanation of the drawing]

Figure 2 is a system of equipment suitable for carrying out the method of the present invention. #! Figure 44.5 shows a cross-sectional view of a laminate obtained according to the invention. No. 61#i shows a cross-sectional view of a laminate made by a conventional method. 1. Foaming mixture 2. Lower side material 5. Upper working surface material 4. Glass fiber mat & solvent
&Product (81 layers) 1t mixing head 12
Laminator Buddhist seal cutting 14. Ratio metering roll to tubular roll) 1 foam regulator 2 solvent tank! Conveyor 2 shim solvent squeezing roll 2 made for 2jA Messi
7 Open 2t @ air bath for temperature adjustment, five-purpose conveyor st agent condenser s2-solvent extraction valve
5. Connect the mackerel agent supply device 4 to the core material 44. Glass fiber 4244 surface material patent sponsor Kokoku Chemical Industry Co., Ltd.

Claims (1)

[Claims] In a method for manufacturing a laminate consisting of two parallel AM members and a core material of hard plastic foam in which glass fibers are dispersed, the glass fibers are stacked and a binder tube is added to form a mat-like K16E-shaped thin glass fiber. The mat is immersed in a solvent capable of dissolving the binder and at least a portion of the binder tube is removed with scissors.The glass fiber mat is defibrated and supplied onto one side of the material, and a self-foaming hardening material is applied thereon. A method of manufacturing a laminate, comprising: supplying a hard plastic 7 ohm material tube with a tube, foaming it, and supplying the other side material onto the hard plastic 7 ohm tube 41.