JPS6046022B2 - Method for manufacturing plate-shaped synthetic material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a plate-shaped synthetic material that is lightweight and has excellent strength and is suitable for use in building materials and the like.

Resin foams reinforced with fibers are well known as conventional synthetic materials, but they have drawbacks such as low surface strength and being susceptible to scratches, and low compressive strength that easily causes dents.

Sandwich structural materials are also known that have a resin foam as a core and an FRP plate as a surface material, but although this material can improve surface hardness, the compressive strength is low due to buckling in the core material layer. It had drawbacks such as being small because it was dented.

Also, a sandwich board is known in which an FRP board is used as the surface material and a honeycomb material is used as the intermediate layer, and these are bonded together. Peeling and warping are likely to occur between the
Also, the bending strength was not sufficient.

In view of the above-mentioned drawbacks, the present invention is a lightweight plate-like material that has a large surface strength, excellent wear resistance, high compressive strength, excellent bending strength, and excellent water resistance and chemical resistance. It was made with the purpose of providing.
That is, the gist of the present invention is that between two layers of fibrous material impregnated with a liquid resin that hardens in a short time to produce a resin,
A foaming resin liquid that foams and hardens in a short period of time to produce a resin foam is supplied to the voids of the honeycomb structure.The laminate, which is formed by narrowing the plate-shaped honeycomb material, is then transported using an endless belt. A plate-shaped synthetic material characterized in that the liquid resin is cured by being introduced into an enclosed molding passage, and the foamable resin liquid is foamed and cured, so that the fiber material and the plate-shaped honeycomb material are integrally formed. It consists in the manufacturing method.

The fiber material used in the present invention refers to fibers made from organic materials such as cotton, rayon, polyester, nylon, and polypropylene, and inorganic materials such as glass, carbon, and metal. It may be in the form of a thread, such as in the form of a thread, or it may be in the form of a cloth or sheet, such as a nonwoven fabric or a mat.

In view of strength, cost, ease of handling, etc., it is preferable to use glass fiber as the fiber material. Two types of the above-mentioned fiber materials are prepared in layers, and each layer is impregnated with a liquid resin. For example, unsaturated polyester resin,
Examples include uncured resin liquids such as melamine resin, epoxy resin, phenol resin, and urethane resin.

In addition, the plate-shaped honeycomb material used in the present invention has many polygonal, circular, or wavy through holes,
It refers to a plate-shaped body with a honeycomb structure that looks like a honeycomb cut into rings, and its material is not particularly limited, but it is preferably made of paper, resin-impregnated paper, or synthetic resin.

Then, a foamable resin liquid is supplied to the voids of the honeycomb structure in the plate-shaped honeycomb material, and the foamable resin liquid foams and hardens in a short time to produce a resin foam. Resin liquids are used, such as foamable urethane resins, unsaturated polyester resins, phenol resins, urea resins, melamine resins, pyranyl resins,
Examples include compositions such as epoxy resins. The method of the present invention will be explained below with reference to the drawings. FIG. 1 is a schematic diagram showing one example of the present invention. In the figure, numerals 1 and 1 are layers of fibrous material impregnated with liquid resin, and the fibrous material layer 1 is prepared as follows. That is, a large number of glass ropes 11 arranged parallel to the traveling direction are guided to the resin liquid tank 2 through a guide 21 and pressed by an impregnating roll 23 to harden in a short time to form a resin. The excess resin liquid is squeezed out with the pinch roll 24, and the sheet fiber 12 is let out from the rolled body in parallel with passing through the guide roll 26. roll 2
5 to be impregnated with resin liquid in the same manner and guided to the guide roll 27, where it is overlapped with the glass roping 11 to prepare the fiber material layer 1.

Note that the method of impregnating the fiber material layer 1 with the resin liquid in the present invention is not limited to the dipping method as described above, and other appropriate methods such as scattering and spraying may be employed. On the other hand, while the plate-shaped honeycomb material 3 is supported by the conveyor 6 and travels, the foamable resin liquid supply device 5 supplies the foamable resin to the voids of the honeycomb structure of the plate-shaped honeycomb material 3.

At this time, the bottom surface of the plate-shaped honeycomb material 3 is covered with a sheet material 4 so that the supplied foamable resin liquid does not flow out from the bottom. In this way, the sheet material 4 is used to prevent the supplied foamable resin liquid from flowing out from the bottom of the plate-shaped honeycomb material 3, and the sheet material 4 may be nonwoven fabric, cloth, or paper. A suitable sheet-like material such as a synthetic resin film or the like may be used. Further, the foamable resin liquid may be supplied to the bottom of the plate-shaped honeycomb material 3 covered with the fiber material layer 1, and in this case, it is not necessary to use the sheet material 4. Next, the plate-shaped honeycomb material 3 to which the foamable resin liquid has been supplied into the voids of the honeycomb structure prepared as described above is further advanced, and the fiber material 1 impregnated with the liquid resin is
, 1, and the "plate-shaped honeycomb material 3
The result is a laminate whose upper and lower surfaces are each coated with fiber material 1.

This laminate is led to a molding passage 7, where the liquid resin impregnated into the fiber material 1 hardens and the foamable resin liquid supplied to the voids of the honeycomb structure foams and hardens. The fiber material 1 and the plate-shaped honeycomb material 3 are pressed against the foaming pressure of the resin in the molding passage 7, and the resin is cured to form a saw body at the exit of the molding passage. A plate-like synthetic material 8 having a cross section that matches the cross-sectional shape is obtained. The forming passage 7 used in the present invention is surrounded by an endless belt 71, and as the laminate guided into the forming passage 7 passes, the endless belt By doing so, the resistance when passing through the forming passage 7 is reduced, and at the same time, the laminate is foamed while remaining stationary on the surface of the endless belt 71. Since the plate-like synthetic material 8 is molded, the dimensional stability and surface condition of the obtained plate-like synthetic material 8 are excellent.

72 in the figure is a guide roll for the endless belt 71. The surface of the plate-shaped synthetic material 8 obtained as described above is covered with a resin reinforced with a fiber material, and the inner layer includes a plate-shaped honeycomb material whose voids are filled with foamed resin. Some have a structure in which the surface material and the inner layer material are firmly bonded over the entire surface with resin. The plate-shaped synthetic material 8 has a large surface strength and excellent wear resistance, and has a honeycomb structure that reduces compressive strength.Furthermore, the surface plate and inner layer material are made of resin over the entire surface Because it is fixed and bonded, it also has excellent bending strength.

In addition, since the interior is filled with resin foam, even if a material with poor water resistance such as paper is used as the honeycomb plate material, it is possible to use a material with excellent water resistance and chemical resistance. You can get it. Since the method for producing a plate-shaped synthetic material of the present invention has the above-mentioned configuration, the surface thereof is covered with resin reinforced with fiber material, and the voids in the inner layer are filled with foamed resin. There is a plate-shaped honeycomb material that has a structure in which the surface material and the inner layer material are fixed and combined with resin over the entire surface, and has excellent surface strength, compressive strength, bending strength, etc., and is also wear resistant. It has excellent water resistance, chemical resistance, and light weight, making it possible to obtain a plate-shaped synthetic material suitable for use as a building material. Examples of the present invention will be described below.

Example 1 The plate-shaped honeycomb material is made of paper with a thickness of 250 microns and has a thickness of 15T! Rln, a vapor honeycomb material having a wavy honeycomb structure is used, and a nonwoven fabric made of polyester long fibers and having a thickness of about 70 microns and a basis weight of 20y1rr1 is brought into contact with the lower surface of the vapor honeycomb material. The process proceeded as shown in FIG. 1, and a foamable urethane resin liquid was sprinkled thereon and injected into the voids of the honeycomb structure.

The composition of the resin liquid is polyether polyol 1
0 Quantity Silicone oil 1 Water
It was a mixture of 1.0.5 dibutyltin dilaurate and 120 diphenylmethane diisocyanate.

The honeycomb material has a cross-sectional passage with a width of 170Tnm and a thickness of 17Tr0n, and the length is 9Tr1. The 3TrL from the inlet is at room temperature, and the next 3Tr1. was heated to 110'C and the remaining 3m was water cooled, and was introduced into a forming channel similar to that shown in Figure 1, while at the same time the honeycomb material was heated to 110'C and the remaining 3 m was water-cooled. A sheet of the same nonwoven fabric impregnated with resin liquid in the same manner as shown and 11 glass ropes (thickness 13
A large number of μ glass fibers are arranged as a strand,
Roping is made by pulling 58 of these strands together, and the weight per 1000TrL of roping is 9260.
It is f.

) was inserted, and the foamable urethane resin liquid was foamed and cured in the molding passage, and the resin liquid was cured. The above resin liquid contains 10 parts of unsaturated polyester resin and 0.0 parts of methyl ethyl ketone peroxide. Limeability and cobalt naphthenate 0. A composition consisting of a lumen was used. The product thus obtained has a thickness of 17 and a width of 170T.
! r! n plate-shaped, specific gravity 0.3\bending strength 680k91d1 bending modulus 4.8 x 101kgIc!
11 showed a compressive strength of 42k91d.

[Brief explanation of the drawing]

FIG. 1 is a schematic diagram showing one example of the present invention.

Claims (1)

[Claims] 1. Between two layers of fibrous material impregnated with a liquid resin that hardens in a short time to produce a resin, the material foams and hardens in a short time to produce a resin foam. The foamable resin liquid is supplied to the voids of the honeycomb structure, and the laminate in which the plate-shaped honeycomb material is narrowed is guided into a molding passage surrounded by an endless belt to harden the liquid resin. A method for manufacturing a plate-shaped synthetic material, characterized in that the foamable resin liquid is foamed and hardened while soaking, thereby integrating the fiber material and the plate-shaped honeycomb material. 2. The manufacturing method according to claim 1, wherein the fiber material is made of glass fiber.