JPS5944456A - Reinforcing synthetic resin molded product for building material - 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 synthetic resin molded products for building materials such as various pipes, rain gutters, corrugated plates, etc., comprising a thermosetting synthetic resin reinforcing layer supported by paper or fibers or both. The present invention relates to a thermosetting synthetic resin molded product having a structure in which a reinforcing layer (hereinafter simply referred to as a reinforcing layer) and a thermosetting synthetic resin coating layer are laminated and integrated.

Traditionally, synthetic resin molded products have been widely used for building materials such as those mentioned above, but the synthetic resin that is the substance of these molded products does not have mechanical strength such as impact resistance compared to other building materials (for example, metal). Since it has the disadvantages of poor strength and easy thermal deformation (including thermal contraction), iron plates, wire mesh, etc. are integrally enclosed within the thickness of the molded product to simultaneously strengthen it and prevent thermal deformation. This is generally done. When embedding and molding reinforcing cores made of iron plates or wire mesh, which are materials different from synthetic resin, it is difficult to process the process of applying appropriate surface treatment to the surface of the reinforcing core and applying an appropriate adhesive. There have been problems such as the fact that the reinforcing core is heavy, which increases the weight of the molded product itself, and that the reinforcing core at the cut end of the molded product is easily rusted and corroded.

The present invention has been made in view of the above, and is capable of preventing and reinforcing thermal deformation of a molded product by using a thermosetting synthetic resin layer supported on paper, fibers, or both as a reinforcing layer. To provide a new reinforced synthetic resin molded product for front building materials, which is characterized by the following features.

Embodiments of the present invention will be explained with reference to the drawings. Fig. 1 is a partially cutaway perspective view of a rain gutter in which a typical embodiment of the present invention is adopted;
The figure is a partially enlarged vertical sectional view taken along line I-1 in FIG. 1, and FIG. 3 is a partially cutaway perspective view of a pipe in which another embodiment of the present invention is adopted.
FIG. 4 is a partially enlarged vertical sectional view taken along line ff--■ in FIG. 3.

That is, the present invention provides a building material comprising a thermosetting synthetic resin reinforcing layer 2 supported on a base material 4 of one or two types of paper or fiber, and a thermosetting synthetic resin coating layer l laminated on at least one side of the thermosetting synthetic resin reinforcing layer 2. This is a reinforced synthetic resin molded product. As the paper for the base material, kraft paper, paperboard, Japanese paper, etc. are used, but if translucency is required, thin paper is appropriately selected. Fibers include inorganic fibers such as gawase fibers, carbon fibers, asbestos fibers, and gypsum fibers, or chopped or processed products of organic fibers such as surface-treated metal fibers, polyester μ fibers, nylon fibers, and polyvinyl fibers. Further, processed fiber products include woven fabrics, nonwoven fabrics, nets, mats, etc. The paper and the fibers can each be used alone as the base material m, or they can be appropriately combined to form the base material 4 as a hybrid. As the thermosetting synthetic resin for the reinforcing layer 2, one selected from phenol resin, melamine resin, polyester resin, and epoxy resin is suitably adopted, and as the thermosetting synthetic resin for the covering layer 1, polyester/l/resin, melamine, etc. Selected types of resins such as resins, epoxy resins, melamine-modified resins, mixed resins of epoxy resins and phenolic resins (e.g., resin raw material weight ratio: 8:2), mixed resins of diallyl phthalate resins and urethane resins, etc., are adopted. are used in appropriate combinations. This thermosetting synthetic resin coating layer 1 is a reinforcing layer 2 as described later.
Since it is positioned as an exterior part of a plastic, colorability and weather resistance are also important factors in selecting the resin.

To briefly explain the manufacturing process of the molded product of the present invention, the resin raw material of the thermosetting synthetic resin as the reinforcing layer 2 is a solution-type resin liquid or an emulsion-type resin liquid, and a base material is used. The composite is impregnated to form a thermosetting synthetic resin reinforcing layer 2, and molded using a mold or the like to form a semi-cured molded body 2', on one or both sides of the molded body 2'. The resin raw material of the thermosetting synthetic resin for the coating layer 1 is applied by spraying or dipping to form the thermosetting synthetic resin coating layer 1, which is integrally heated and cured to obtain the desired molded product.

1 and 2 show a rain gutter (eave gutter) in which thermosetting synthetic resin coating layers 1 are integrally laminated on both sides of a molded body 2'.

In the impregnation process of the base material 21, when paper and fiber chops or their processed products are combined to form the base material 1
．． The entire base material of these combinations may be immersed in the resin solution, but instead, only pure paper is impregnated with the resin solution, and paper impregnated with the resin while the fibers or their processed products are not treated with the resin. By laminating with paper, it is possible to transfer resin liquid from paper and make it as if it were a resin-impregnated fiber or a processed product thereof. In addition, the reinforcing layer 2 supported by the base material blade is a thermosetting synthetic resin layer as the covering layer 1, etc. After being laminated, the molded body 2' is cured by heating, so that the shape of the molded body 2' is maintained as it is, and adhesion at the interface between the two is reliably guaranteed. Furthermore, when the reinforcing layer 2 and the covering layer 1 are individually heat-cured, it may be selected as appropriate in the manufacturing process to use an adhesive at the interface between the two to improve adhesion. The above-mentioned molded body 2' can be obtained by a method such as press molding or low-μ molding, but the method of molding the molded product is not limited to this.
It is also possible to mold after laminating.

As mentioned above, the rain gutter illustrated in FIGS. 1 and 2 is made of a thermosetting synthetic resin supported by a base material 4 such as paper, fiber, or a hybrid of both. Since the reinforcing layer 2 is integrally laminated with the thermosetting resin coating layer 1.1 in a sandwich-like manner, the stiffness of the base material and the thermosetting properties of the reinforcing layer 2 and the coating layer 1.1 can be improved. This rain gutter has extremely high commercial value as it has strong toughness and excellent shape retention due to the synergistic effect with the rigidity of the synthetic resin, and has little thermal expansion and contraction. Moreover, since the base material 4 of the reinforcing layer 20 is made of paper or fiber, rainwater penetrates through the cut ends and rusts the core material, causing delamination, as in the case where a conventional iron plate or wire mesh is enclosed. There is no risk of damage, and there is no increase in weight. In addition, the thermosetting synthetic resin coating layer 1 is also positioned as an exterior part, so if you select a colorable surface resin and color it appropriately, you can obtain a full-covered rain gutter. If the base material 4 is made of resin and paper with a picture pattern drawn on it, it will be possible to create a rain gutter with a rich design.In this sense, the commercial value of the rain gutter will be further increased. Layer 1 also serves as an effective protective layer and improves weather resistance.

3 and 4 show another embodiment of the present invention, in which the molded product is a piping vibrator, and the coating layer 1 is laminated on one side, that is, on the outer surface of the pipe. In this case, as in the above example, the stiffness of the base material (■) and the rigidity of the thermosetting synthetic resin combine to provide mechanical strength and non-stretchability due to heat, which were not found in conventional pipes of this type. and excellent shape retention.

These characteristics are especially effective when used as a downpipe or a pipe.Additionally, it is lightweight and the cut end does not rust, so it is very effective. The value is extremely high. Of course, as in the above embodiments, the coating layer 1 may be appropriately colored to obtain a 7μ colored pipe, or the base material may be patterned paper to obtain a uniquely designed pipe.

Although not shown in the drawings, the same effects as described above can be expected if the present invention is applied to corrugated plates including so-called iron plate waves, slate waves, square waves, and other types of deformed waves.

It goes without saying that the base material of paper, fiber, etc. is not limited to a single layer, but multiple layers may be appropriately adopted as necessary (in the sense of further enhancing the reinforcing effect). Further, although the thermosetting synthetic resins for the reinforcing layer 2 and the covering layer 1 can be freely selected as mentioned above, depending on the combination of the two, it is possible that the two are completely the same. In this case, by laminating and integrating, the resin of the covering layer 1 is apparently supported on the base material together with the resin of the reinforcing layer 2, but the covering layer 1 is positioned as the exterior part of the reinforcing layer 2. Particularly weird.

That is, the covering layer 1 protects the reinforcing layer 2, and by coloring the resin of the covering layer 1, it is possible to completely hide the reinforcing layer 2 and give a colorful appearance. On the other hand, even if these two resins are different, since the resin for the covering layer 1 is applied while the resin for the reinforcing layer 2 is semi-cured and is heated and solidified as one, the adhesion at the interface between the two is completely guaranteed. Ru.

Furthermore, in each of the above embodiments, examples were explained in which the covering layer l was laminated integrally on both sides and one side of the reinforcing layer 2 for eaves gutters and pipes, respectively. Whether or not to do so is determined as appropriate depending on the intended use.

As described above, in the molded product of the present invention, a covering layer 1 of a thermosetting synthetic resin is laminated on both or one side of a reinforcing layer 2 of a thermosetting synthetic resin supported on a base material such as paper or fiber. Therefore, as a molded product, thermal expansion and contraction in the longitudinal and width directions is prevented as much as possible, mechanical strength such as bending strength, shear strength, and impact strength is reinforced, and shape retention is maintained well. It will be done. Also, compared to this type of molded product using iron plates, wire mesh, etc.
It is lightweight and inexpensive, and there is no risk of delamination due to rust. In addition, the molded product of the present invention can be said to have extremely high practicality and commercial value, since it has the added advantage of being able to select a molded product that is full-bodied and rich in design according to one's preference. .

Examples are listed below.

(Example) Two sheets of kraft paper with a thickness of 0.25 mm as a paper base material and one sheet of glass fiber nonwoven fabric with a thickness of 0.3 m are stacked between them and immersed in a polyester resin solution, aged, and then preheated to form a rain gutter shape. and preformed. Furthermore, diaryμ phthalate and urethane modified resin are sprayed on top of it to give an overall thickness of 1.
Finish hardened to 3m.

The obtained Ame 61 had extremely low expandability and thermal elasticity.

[Brief explanation of the drawing]

Fig. 1 is a partially cutaway perspective view of a rain gutter in which a typical embodiment of the present invention is adopted, Fig. 2 is a partially enlarged vertical sectional view taken along line 1-1 in Fig. FIG. 4 is a partially cutaway perspective view of a pipe in which the embodiment is adopted, and FIG. 4 is a partially enlarged vertical sectional view taken along line W4 in FIG. (Explanation of symbols) 1--Covering layer, 2--Reinforcing layer, Mu...Base material. ·that's all

Claims (1)

[Claims] 1. A reinforced synthetic resin molded product for building materials, consisting of a thermosetting synthetic resin reinforcing layer supported on one or both of paper and fiber base materials, and a thermosetting synthetic resin coating layer laminated on at least one side of the thermosetting synthetic resin reinforcing layer. .