JPS5940100B2 - lightweight synthetic material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a lightweight synthetic material suitable for use in building materials and the like.

As a structural material, wood is known as an excellent material that is lightweight and strong.For example, light wood such as paulownia, which has a specific gravity of around 0.3, and cedar, pine, and cypress, which have a specific gravity of 0.4 to 0.6, are used. There are also heavy and durable woods such as lauan and apitone, which have a specific gravity of 0.6 to 0.8.

In general, the lighter the wood, the lower its strength. On the other hand, as a synthetic material, there is a synthetic resin foam reinforced with long glass fibers, which has properties similar to wood and is known to have improved water absorption and corrosion resistance. If the specific gravity is reduced to make it lighter, the strength will decrease.

In addition, there is a sandwich structure as a lightweight synthetic material.
For example, it is known to use an FRP board as the surface material and a synthetic resin foam or honeycomb material as the core material. This material has excellent strength, but since the surface is an FRP plate, there is a problem with impact resistance. Furthermore, among synthetic resin foams, sandwich structure foams are known in which the density of the surface layer is increased and the density of the center portion is decreased, but this has the disadvantage of low bending elasticity and easy bending, and low bending strength. Therefore, it is not suitable as a structural material. In view of the above points, the present invention was made with the purpose of providing a lightweight and strong synthetic material, and in particular, a synthetic material such as paulownia, which is lighter than commonly used woods such as cedar, pine, and cypress. The purpose is to provide a material that is lightweight, has strength equal to or higher than that of cedar, cypress, etc., and is resistant to impact.

That is, the gist of the present invention is to provide a synthetic resin foam reinforced with fibers in which the surface layer is made of glass fibers and a density of 0.09 to 0.
35g/cm3 of synthetic resin foam, and the middle layer consists of organic fibers with a density of 1.5g/(V7l3 or less) and a density of 0.5g/cm3.
Made of synthetic resin foam with a rating of 09 to 0.351/kun 3,
It is a lightweight synthetic material characterized by an overall density of 0.2 to 0.4y/CWL3. Next, the lightweight synthetic material of the present invention will be explained using the drawings. FIG. 1 is a sectional view showing an example of the lightweight synthetic material of the present invention, and in the same figure, a plate-shaped lightweight synthetic material is shown.

In the figure, A is a surface layer portion, and the surface layer portion A is composed of glass fibers and synthetic resin foam. The density of the synthetic resin foam is 0.09 to 0.359/(11M3
This density does not include the weight and volume of the glass fiber. The density of the synthetic resin foam is 0.
09f! /Cm3, the compressive strength and shear strength will decrease, and the compressive strength and bending strength of the synthetic material of the present invention will decrease, making it impossible to obtain the strength aimed at by the present invention. If it becomes too large, the weight ratio targeted by the present invention cannot be achieved. In addition, in order to obtain the above synthetic resin foam, it is preferable to use a thermosetting resin that is initially liquid and then hardens through reaction, and to give it foaming properties. is impregnated into the glass fiber bundle, and by foaming and curing it,
A synthetic resin foam in which glass fibers are uniformly dispersed is obtained. Examples of synthetic resins suitable for the present invention include hard polyurethane, unsaturated polyester resin, phenol resin, urea resin, melamine resin, pyranyl resin, and epoxy resin. Also, the length of glass fiber is 25mw.
! It is preferable to use the above-mentioned material, and from the viewpoint of workability, the thickness is preferably about 1 to 50 μm.

The glass fibers are preferably arranged in the longitudinal direction of the synthetic material of the present invention in the synthetic resin foam, but the arrangement is not limited to this, and the arrangement may be arranged randomly. . Further, in the present invention, it is preferable to use continuous long fibers, but those woven into a sheet shape, nonwoven fabric, or mat shape may also be used. Regarding the amount of glass fiber used in the surface layer A, if it is too small, it will be difficult to obtain sufficient strength, and if it is too large, workability and lightness will tend to be impaired. It is preferable to set it in the range of ~12%.

The thickness of the surface layer A is preferably in the range of 0.5 to 2 m1.

Next, B in FIG. 1 is an intermediate layer, and the intermediate layer B is composed of organic fibers and synthetic resin foam, and the organic fibers are made of an organic material with a density of 1.59/ClrL3 or less. fibers are used, and as synthetic resin foams,
For the same reason as in the surface layer A, its density is 0.
09~0.359/CT! A foam made into L3 is used.

Further, the synthetic resin foam is preferably one made from a thermosetting resin liquid imparted with foaming properties, as in the case of the surface layer part A.

Suitable organic fibers include, for example, fibers made from wool, rayon, polypropylene, vinylon, polyester, nylon 6, acrylic resin, and the like.

The organic fibers preferably have a length of 25 Tnm or more, and are preferably arranged in the longitudinal direction of the synthetic material of the present invention in the intermediate layer, but are not limited to this. The arrangement may be random. Further, in the present invention, it is preferable to use continuous long fibers such as single fibers or twisted fibers, but organic fiber materials woven into a sheet shape or made into a non-woven fabric may also be used. If the amount of the above-mentioned organic fiber used in the intermediate layer B is too small, the compressive strength and shear strength will tend to decrease, and the holding power of the nail when nailing is performed will tend to decrease. If the amount is too large, the lightness tends to be impaired, so the volume content is preferably in the range of 3 to 10%.

However, the synthetic material of the present invention has an overall density of 0.2, that is, a density when the surface layer A and the intermediate layer B are viewed integrally.
~0.49/CTlL3.

The overall density can be made within the above range by appropriately selecting the density of the synthetic resin foam of the surface layer A and the intermediate layer B, as well as the type and amount of the fiber material used therein.
Next, in order to produce the synthetic material of the present invention, glass fibers and organic fibers with a density of 1.5y/C7IL3 or less are each impregnated with a foaming resin liquid and arranged so that the organic fibers are in the inner layer. By foaming and curing the resin liquid, the foam alone becomes 0.
．． This is done by forming an integrally molded fiber-reinforced foam having a density of 0.09 to 0.359/CTIL3 and an overall density of 0.2 to 0.49/(:TfL3). The production may be carried out by the batch method,
It may also be carried out in a continuous manner.

FIG. 2 is a schematic diagram showing a preferred manufacturing method adopted for manufacturing the synthetic material of the present invention. In the figure, 1 and 2 are glass fibers, and 2 are organic fibers.

A large number of glass fibers 1, 12 and organic fibers 2 are pulled out through a guide roll 3, and then passed through a guide roll 3.
Proceeding in the same direction while being applied with appropriate tension by
It is sent to a collecting roll 6, where the organic fibers 2 are arranged so as to be laminated between the glass fibers 1 and 1'. In this state, the foamable resin liquid is sprayed from the foamable resin liquid tank 7, and the impregnating device 8 and the rubbing plate 9 are used to uniformly disperse and impregnate the foamable resin liquid between the fibers, and then the endless belt 11, 11', guide rolls 12, 12' of an endless belt, etc. are introduced into the molding passage 10, where the foamable resin liquid is foamed and hardened by heating etc. The composite material 13 of the present invention is obtained by integrally molding the composite material 13. The lightweight synthetic material of the present invention has the configuration as described above,
The surface layer is made of glass fiber and a synthetic resin foam of a specific density, and the middle layer is made of a specific organic fiber and a synthetic resin foam of a specific density, and the overall density is 0.2 to 0.49/cm3.
Although it is lightweight like paulownia wood, it has excellent mechanical strength such as compressive strength, bending strength, and shear strength required for structural materials, and is also water resistant and corrosion resistant. It has excellent properties, as well as excellent workability and nail holding power. Therefore, the lightweight synthetic material of the present invention is particularly suitable for use as a structural material such as a building material.

Next, examples of the present invention will be described.

Example 1 In a steel mold with a recess of 2cm deep, 10mm wide, 10mm long, 50mm long (711), 200 glass single fibers with a thickness of 9 mittalons were collected to form one strand, and 60 of these were collected for roping. Glass fibers 509 cut into lengths of 50 cTn were lined up in the longitudinal direction of the above mold, and on top of that, polypropylene split yarn (20,000 denier) with a density of 0.99/3 was placed at 50 cTn. The cut pieces were laid in the same manner as 279, and the same glass fiber 50y as above was laid on top of it.

Next, 100 parts by weight of propylene oxide addition polyether with a hydroxyl value of 4101 and 4 functional groups, 1 part by weight of silicone oil, 1 part by weight of water, 0.5 part by weight of dibutyltin dilaurate, and 120 parts by weight of diphenylmethane diisocyanate were mixed. 2809 The prepared foaming polyurethane resin liquid
The mixture was injected into the mold, the fiber material in the mold was well impregnated, and the mold was closed.

This was placed in a heating oven, heated at 120° C. for 30 minutes, taken out from the oven, cooled, and then taken out from the mold.

The density of the entire molded product is 0.4! l/C7! In L3, the surface layer was composed of glass fibers and urethane foam, and the middle layer was composed of polypropylene fibers and urethane foam. Also, the density of the foam in the surface layer is 0.39/C
m3, and the density of the intermediate layer foam was 0.39/cm3. The bending strength of this molded product is 610K'CT! 12. Bending elasticity is 4.9 x 104KI2. Compressive strength is 25K2.
It shows similar strength to cypress with a specific gravity of 0.5 to 0.6, and
Processing such as sawing and nailing was easy. Further, the water absorption rate was 0.2% or less, whereas that of Japanese cypress was 7%.

Example 2 Using a device similar to that shown in Fig. 1, 48 glass fiber ropes, the same as in Example 1, were used as the fiber material, and 24 ropes were placed vertically, with 24 ropes placed in the middle. Split polypropylene yarn 34 as in Example 1
The books were placed.

While the above fiber materials are being arranged and advanced, the same polyurethane resin liquid as used in Example 1 is sprinkled from the foaming resin liquid supply device, and the resin liquid is evenly impregnated and dispersed by thoroughly kneading with the impregnating device. The inner wall is made up of an endless belt, with a cross-sectional size of 170 mm x 17 mm and a length of 9
7n, the first 3 m area is kept at room temperature, the next 3 m area is heated to 110°C, and the remaining area is water-cooled. The resin was foamed and cured to integrate the fiber material and the resin, and was molded to match the cross-sectional shape of the molding passage. The molded product thus obtained is a plate-like product with a width of 170 mm and a thickness of 17 mm, the surface layer is composed of glass fiber and urethane foam, and the middle layer is composed of polypropylene split yarn and urethane foam. The overall density is 0.359//CT! L3, the density of the foam in the surface layer is 0
．． 29/Cf! L3, the density of the middle layer foam is 0.18
y/C! ! It was 13. In addition, the bending strength of the molded body is 4
50KiCT! L2, bending elastic modulus is 4.5 x 104K~
, the compressive strength is 18KνR2, and the specific gravity is 0.4-0.
Performance similar to No. 5 cedar board was obtained. Further, it was easy to process such as sawing and nailing.

[Brief explanation of drawings]

FIG. 1 is a sectional view showing an example of the lightweight synthetic material of the present invention, and FIG. 2 is a schematic diagram showing an example of the method for producing the lightweight synthetic material of the present invention. A: Surface layer part, B: Intermediate layer, 1, D: Glass fiber, 2: Organic fiber, T
...... Foaming resin liquid layer, 8... Impregnation device, 10... Molding passage, 11, 11'...
...Endless belt, 13...Lightweight synthetic material.

Claims (1)

[Scope of Claims] 1. In a synthetic resin foam reinforced with fibers, the surface layer is made of glass fibers and a synthetic resin foam with a density of 0.09 to 0.3 g/cm^3, and the middle layer is made of a synthetic resin foam with a density of 1. .5g/cm
Organic fibers below ^3 and density 0.09-0.35g/cm
Made of ^3 synthetic resin foam, the overall density is 0.2
~0.41/cm^3 A lightweight synthetic material. 2. The lightweight synthetic material according to claim 1, wherein the length of the glass fiber and organic fiber is 2.5 mm or more. 3. The lightweight synthetic material according to claim 1, wherein the glass fibers and organic fibers are continuous long fibers arranged in the longitudinal direction.