JPS6222781B2 - - Google Patents

Description

Detailed Description of the Invention (Industrial Field of Application) The present invention is directed to continuously manufacturing a molded article by filling a cavity of a synthetic resin molding material with a fiber-reinforced foam. The present invention relates to a method for continuously producing synthetic resin molded articles.

(Objective of the invention) A synthetic resin molded body filled with fiber-reinforced foam has high rigidity, excellent heat insulation, no fear of corrosion, light weight and convenient handling, and the surface of the molded material. Because it has excellent properties such as being able to easily apply coloring or patterning such as woodgrain patterns,
It is extremely useful as a building material for sash, etc., or as a component for furniture, etc., and is expected to be in great demand.

The present invention aims to provide a novel manufacturing method for manufacturing such a useful molded article, and more specifically, the present invention aims to provide a novel manufacturing method for manufacturing such a useful molded article. Based on the principle of maximizing the use of fiber reinforcement, it is possible to continuously manufacture the molded body in a highly efficient manner, and it has an excellent energy-saving effect, and the manufacturing equipment can be configured simply, reducing manufacturing costs. The object of the present invention is to provide a method for continuously producing a synthetic resin molded body filled with a foam.

(Structure) The method for continuously producing a synthetic resin molded body filled with a fiber-reinforced foam according to the present invention (hereinafter referred to as the "manufacturing method") involves using a thermoplastic synthetic resin molding material having a cavity over the entire length in the longitudinal direction. A large number of long fibrous bodies are extruded from a mold of an extrusion molding machine, and a large number of long fibrous bodies are arranged in the longitudinal direction of the molding material in the hollow portion of the molding material which is in a high temperature and flexible state immediately after being extruded from the mold. Continuously supplying fiber bundles made by impregnating thermosetting liquid foamable resin between long fiber bodies,
Immediately thereafter, the molding material is introduced into a molding passage,
In the molding passage, the liquid foamable resin is foamed to fill the cavity with the foam, and at the same time, the long fibrous material is dispersed in the foam, and the molding material and the foam are hardened. This is a characteristic feature.

(Example) Examples of the present invention will be described below based on the drawings.

FIG. 1 illustrates a synthetic resin molded body (hereinafter referred to as molded body) 1 filled with fiber-reinforced foam manufactured by the manufacturing method of the present invention.
The molded body 1 has a thermosetting foam 5 filled in a cavity 3 of a molded material 2, and contains a large number of lengths oriented in the longitudinal direction of the molded material 2. The fibrous material 6 is dispersed therein.

2 and 3 illustrate a manufacturing apparatus for carrying out the manufacturing method of the present invention, in which 7 is a crosshead extrusion molding machine, 9 is a nozzle for supplying the fiber bundle 10, and 11 is a molding passage. , 12 is a collection device.

The extrusion molding machine 7 extrudes thermoplastic synthetic resin such as vinyl chloride in a molten state from a mold 13 at a high temperature (approx.
(approximately 150°C to 250°C) and is extruded as a flexible molding material 2. As shown in FIG. 4a, the molding material 2 is formed into, for example, a rectangular tube shape having a cavity 3 over its entire length in the longitudinal direction.

As shown in FIG. 3, the nozzle 9 is formed into a cylindrical shape consisting of an inner and outer double tube, and is connected to the extrusion molding machine 7.
The crosshead 15 and the mold 13 are provided perpendicularly to the center line of the cylinder. Note that a cooling medium is circulated between the inner and outer tubes in order to prevent the heat of the mold 13 from being transmitted into the nozzle 9.

From the inlet end 9a of the nozzle 9, a large number of long fibrous bodies 6 arranged in the longitudinal direction of the molding material 2 are ejected.
A bundle 16 of..., for example, a bundle of glass rovings is introduced, and a thermosetting liquid foamable resin 19, such as a liquid polyurethane resin, phenolic resin, or polyester resin, is introduced from a press-fit hole 17 provided near the inlet end 9a. is press-fitted, and the glass roving is uniformly impregnated with the liquid foamable resin 19 to form the fiber bundle 10. In addition, long fibrous material 6
In short, it is sufficient that it is in the form of continuous long fibers, and it may be a thread-like product made by entwining short fibers, a monofilament, or even a long narrow woven fabric or woven material.
The molded material 2 is reinforced together with the foam 5. As the long fibrous material 6, in view of its purpose, glass fiber can be particularly preferably used, as well as carbon fiber, synthetic fiber such as polyester, nylon, polyamide, polyolefin, natural fiber, stainless steel, aluminum, etc. It is also possible to use metal fibers such as. Also, these may be used in combination. Furthermore, the number of long fibrous bodies 6 to be used is determined depending on the desired rigidity of the molded body 1.

The fiber bundle 10 thus formed is then transported from the outlet end 9a of the nozzle 9 as shown in FIG. 4b.
It is continuously supplied to the cavity of the molding material 2 which is in a high temperature and flexible state. The liquid foamable resin 19 in the fiber bundle 10 is effectively cooled by the cooling medium while the fiber bundle 10 is passing through the nozzle 9, so that it is difficult to cause a foaming hardening reaction. As soon as it is supplied to the cavity 3 of the material 2, foaming begins rapidly. Note that the nozzle 9 may be insulated by wrapping a heat insulating material around it.

Immediately thereafter, the hot and flexible molding material 2 is introduced into the molding passage 11. As shown in FIG. 4c, the molding passage 11 consists of a lower mold 21 in which a passage groove 20 is recessed, and the passage groove 20.
The cross-sectional shape of the molding passage 11 is formed to be the same as the preset external shape of the molded body. Both the lower mold 21 and the upper mold 22 are formed as cylindrical bodies having an inner and outer double wall structure, and the cooling medium 18 is circulated between them. Note that the upper mold 22 is pressed by a pressing device (not shown) with a pressing force that can resist the foaming pressure of the foam. The injected liquid foamable resin 19 is
Since the molding material 2 is in a high temperature state, it rapidly foams at a portion near the entrance 11a (see FIG. 2) of the molding passage 11, rapidly filling the cavity 3 (FIG. 4c). Foaming is almost completed at the portion near the inlet portion 11a (FIG. 4d). As the foaming progresses, the long fibrous material 6... is dispersed, and at the same time as the foaming is completed, the long fibrous material 6...
are uniformly dispersed in the foam 5. Furthermore, since the molding passage 11 is cooled by the refrigerant as described above, the molding material 2 is gradually cooled and hardened while moving through the molding passage 11. From the outlet 11b of the molding passage 11, the solidified molded body 1, in which the cavity 3 of the molded material 2 is filled with the fiber-reinforced foam, is taken up by the taking-off device 12 and continuously produced. . The molded body 1 is led to a cutting device (not shown) in the next step, where it is cut into a predetermined length to form a product.

In the molding passage 11, as the liquid foamable resin 19 foams, the foam 5 forms on the side walls 23, 2 of the molding material 2, as shown in FIG. 4c.
3 toward the side surfaces 25, 25 of the molding passage 11, the molding material 2 has a shape corresponding to the cross section of the molding passage 11, that is, a preset molded body 1.
This means that it can be automatically molded into the following shape. Therefore, the molding passage 11 does not require a special device such as a bagulum device for making the molding material 2 conform to the cross-sectional shape of the molding passage 11.

Figure 5 shows a molded material 2 formed into an H-shaped cross section.
This figure shows a molded body 1 in which long fibrous bodies 6 are dispersed so as to be offset to the periphery of a cavity 3.
As shown in FIGS. 7 to 7, only the liquid foamable resin 19 is discharged from the outlet end 9b of the nozzle 9, and around the nozzle 9, there are a number of guide holes 27 for delivering the long fibrous material 6. ... is provided so as to simultaneously send out the liquid foamable resin 19 and the long fiber material 6, and the long fiber material 6 is densely attached around the liquid foamable resin 19 discharged from the nozzle 9. fiber bundle 10 with liquid foamable resin 19 impregnated between the long fibers 6...
is continuously supplied to the cavity 3 of the molding material 2, and by foaming the liquid foamable resin 19, the long fibrous material 6 is dispersed toward the periphery of the cavity 3 as described above. .

FIG. 8 shows that before the bundle 27 of long fibers 6 is introduced into the inlet end 9a of the nozzle 9, the bundle 27 is immersed in a tank 29 filled with liquid foamable resin 19. Fibrous body 6...liquid foamable resin 1 in between
Another example of impregnating No. 9 is shown below. As the liquid foamable resin, a thermosetting resin is used which takes a long time to harden and also has the property of starting foaming immediately upon heating.

As shown in FIG. 6, a slit-shaped guide hole 31 is provided at a suitable position around the nozzle 9 to pass through the crosshead 15 and the mold 13 and feed, for example, a strip-shaped metal plate 30 into the cavity 3. The metal plate 30 can also be used as a fixing substrate for fixing attached metal fittings and the like to the molded body 1 with screws.

In addition, in the molded body of the present invention, the molding material 2 can be formed into a pipe shape having various cross-sectional shapes.
The figure shows a molded body 1 formed by filling a cavity 3 of a molded material 2 formed into a double cylindrical shape with a fiber-reinforced foam.
shows. In order to manufacture the molded body 1, for example, as shown in FIG. The guide rod 32
A thermoplastic synthetic resin is extruded from a peripheral portion 35 separated by a distance of about twice the radius of to foam the liquid foamable resin. Note that the guide rod 32
The length of is set to such an extent that foaming of the liquid foamable resin is completed at its tip. The molded article of the present invention can also be formed as a gutter-like body having an opening 26 communicating with the cavity 3, as shown in FIG. The cavity 3 can be filled with the foam 5 .

(Effects of the Invention) The manufacturing method of the present invention supplies a fiber bundle in which a liquid foamable resin is impregnated between long fibers into a cavity of an extrusion molding material which is in a high temperature state. Due to the heat retention, the liquid foamable resin rapidly foams, and as a result of the foaming, the long fibers are dispersed in the foam in a preset state, such as a uniform state or a deviated state. As described above, according to the present invention, the foaming of the liquid foamable resin and the dispersion of the long fibrous material are completed within a very short time immediately after the molding material is introduced into the molding passage, so that the molded product can be manufactured very efficiently and continuously.

The manufacturing method of the present invention foams the liquid foamable resin by making the most effective use of the retained heat of the molding material, so a special heating furnace is not required for foaming the liquid foamable resin. Therefore, it has an excellent energy saving effect.

In addition, since a special heating furnace is not required, the molding line can be shortened, and the molding material can be automatically molded into the desired shape using foaming pressure in the molding passage, making it easier to mold the molding material. A vacuum device or the like for conforming to the cross-sectional shape of the molding passage becomes unnecessary. For this reason, the entire device becomes very simple, and the manufacturing cost of the product can be reduced.

In the manufacturing method of the present invention, since the molding material is molded using an extrusion molding machine, even if the molding material has a complicated shape, it can be molded extremely easily. In addition, since the foam can be reliably filled into the cavity of the molding material in close contact with each other, the molding material and the fiber-reinforced foam are completely integrated and tightly integrated, and a molded product with stable quality can be provided.

[Brief explanation of the drawing]

FIG. 1 is a partially cutaway perspective view showing an embodiment of the molded article according to the present invention, FIG. 2 is a plan view of an apparatus used in the manufacturing method according to the present invention, and FIG. 3 is an extrusion molded article in the apparatus. Cross-sectional view near the crosshead,
4a to 4d are cross-sectional views explaining the manufacturing process according to the present invention, FIG. 5 is a cross-sectional view showing another embodiment of the molded article according to the present invention, and FIG. FIG. 7 is a front view of the mold part of the extrusion molding machine, and FIG. 8 is a side view showing another example used in the manufacturing method according to the present invention. Figure, No. 9
The figure is a perspective view showing another embodiment of the molded article according to the present invention, FIG. 10 is a cross-sectional view of the vicinity of the crosshead showing the apparatus for manufacturing the molded article shown in FIG. 9, and FIG. 11 is the other example of the molded article. It is a perspective view showing an example of this. DESCRIPTION OF SYMBOLS 1... Molded object, 2... Molding material, 3... Cavity part, 5... Foam, 6... Long fibrous body, 7... Extrusion molding machine, 10... Fiber bundle, 11... For molding Passage, 13...Mold.

Claims (1)

[Claims] 1. Extrude a thermoplastic synthetic resin molding material having a cavity over the entire length in the longitudinal direction from a mold of an extrusion molding machine, and insert the molding material into the cavity in a high temperature and flexible state immediately after being extruded from the mold. , a large number of long fibrous bodies are arranged in the longitudinal direction of the molding material, and a fiber bundle made by impregnating a thermosetting liquid foamable resin between the long fibrous bodies is continuously supplied, and immediately thereafter, The molding material is introduced into a molding passage, the liquid foamable resin is foamed in the molding passage, the cavity is filled with the foam, and at the same time the long fibrous material is dispersed in the foam, and the molding A method for continuously producing a synthetic resin molded body filled with fiber-reinforced foam, characterized by curing the material and the foam.