JPS6224521Y2 - - Google Patents
Info
- Publication number
- JPS6224521Y2 JPS6224521Y2 JP1981131755U JP13175581U JPS6224521Y2 JP S6224521 Y2 JPS6224521 Y2 JP S6224521Y2 JP 1981131755 U JP1981131755 U JP 1981131755U JP 13175581 U JP13175581 U JP 13175581U JP S6224521 Y2 JPS6224521 Y2 JP S6224521Y2
- Authority
- JP
- Japan
- Prior art keywords
- unsaturated polyester
- polyester resin
- particles
- frp
- resin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
- 229920006337 unsaturated polyester resin Polymers 0.000 claims description 32
- 239000002245 particle Substances 0.000 claims description 30
- 239000000835 fiber Substances 0.000 claims description 13
- 239000012792 core layer Substances 0.000 claims description 12
- 229920005672 polyolefin resin Polymers 0.000 claims description 12
- 239000002344 surface layer Substances 0.000 claims description 11
- 239000011802 pulverized particle Substances 0.000 claims description 3
- 239000006260 foam Substances 0.000 description 14
- 239000010410 layer Substances 0.000 description 8
- 239000000463 material Substances 0.000 description 8
- 239000002131 composite material Substances 0.000 description 6
- 229920005989 resin Polymers 0.000 description 6
- 239000011347 resin Substances 0.000 description 6
- 239000011550 stock solution Substances 0.000 description 6
- 229920002554 vinyl polymer Polymers 0.000 description 6
- -1 polyethylene Polymers 0.000 description 5
- 239000004698 Polyethylene Substances 0.000 description 4
- 239000003365 glass fiber Substances 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 229920000728 polyester Polymers 0.000 description 4
- 229920000573 polyethylene Polymers 0.000 description 4
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 3
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical group C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 3
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 3
- 230000005484 gravity Effects 0.000 description 3
- PUPZLCDOIYMWBV-UHFFFAOYSA-N (+/-)-1,3-Butanediol Chemical compound CC(O)CCO PUPZLCDOIYMWBV-UHFFFAOYSA-N 0.000 description 2
- WFUGQJXVXHBTEM-UHFFFAOYSA-N 2-hydroperoxy-2-(2-hydroperoxybutan-2-ylperoxy)butane Chemical compound CCC(C)(OO)OOC(C)(CC)OO WFUGQJXVXHBTEM-UHFFFAOYSA-N 0.000 description 2
- VZCYOOQTPOCHFL-OWOJBTEDSA-N Fumaric acid Chemical compound OC(=O)\C=C\C(O)=O VZCYOOQTPOCHFL-OWOJBTEDSA-N 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 2
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 229920001577 copolymer Polymers 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000009408 flooring Methods 0.000 description 2
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000000178 monomer Substances 0.000 description 2
- 239000004745 nonwoven fabric Substances 0.000 description 2
- 229920000098 polyolefin Polymers 0.000 description 2
- 150000007519 polyprotic acids Polymers 0.000 description 2
- 229920002223 polystyrene Polymers 0.000 description 2
- 150000005846 sugar alcohols Polymers 0.000 description 2
- 229920003002 synthetic resin Polymers 0.000 description 2
- 239000000057 synthetic resin Substances 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- 239000013585 weight reducing agent Substances 0.000 description 2
- 229940058015 1,3-butylene glycol Drugs 0.000 description 1
- SBYMUDUGTIKLCR-UHFFFAOYSA-N 2-chloroethenylbenzene Chemical compound ClC=CC1=CC=CC=C1 SBYMUDUGTIKLCR-UHFFFAOYSA-N 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- LGRFSURHDFAFJT-UHFFFAOYSA-N Phthalic anhydride Natural products C1=CC=C2C(=O)OC(=O)C2=C1 LGRFSURHDFAFJT-UHFFFAOYSA-N 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 235000010724 Wisteria floribunda Nutrition 0.000 description 1
- YMOONIIMQBGTDU-VOTSOKGWSA-N [(e)-2-bromoethenyl]benzene Chemical compound Br\C=C\C1=CC=CC=C1 YMOONIIMQBGTDU-VOTSOKGWSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000001361 adipic acid Substances 0.000 description 1
- 235000011037 adipic acid Nutrition 0.000 description 1
- XYLMUPLGERFSHI-UHFFFAOYSA-N alpha-Methylstyrene Chemical compound CC(=C)C1=CC=CC=C1 XYLMUPLGERFSHI-UHFFFAOYSA-N 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- MPMBRWOOISTHJV-UHFFFAOYSA-N but-1-enylbenzene Chemical compound CCC=CC1=CC=CC=C1 MPMBRWOOISTHJV-UHFFFAOYSA-N 0.000 description 1
- 235000019437 butane-1,3-diol Nutrition 0.000 description 1
- JHIWVOJDXOSYLW-UHFFFAOYSA-N butyl 2,2-difluorocyclopropane-1-carboxylate Chemical compound CCCCOC(=O)C1CC1(F)F JHIWVOJDXOSYLW-UHFFFAOYSA-N 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000006482 condensation reaction Methods 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 229920006248 expandable polystyrene Polymers 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- 239000001530 fumaric acid Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 239000003562 lightweight material Substances 0.000 description 1
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 239000011259 mixed solution Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920006327 polystyrene foam Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- HJWLCRVIBGQPNF-UHFFFAOYSA-N prop-2-enylbenzene Chemical compound C=CCC1=CC=CC=C1 HJWLCRVIBGQPNF-UHFFFAOYSA-N 0.000 description 1
- 229920005604 random copolymer Polymers 0.000 description 1
- 239000012783 reinforcing fiber Substances 0.000 description 1
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 1
- 229920006312 vinyl chloride fiber Polymers 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Description
この考案は、繊維強化不飽和ポリエステル樹脂
（以下FRPと略する）軽量成形体に関する。さら
に詳しくは、従来のFRP成形体に比して軽量で
かつ製造容易なFRP軽量成形体に関する。
従来からFRP成形体は種々の構造材として広
く用いられている。そして用途によつてこれら
FRP成形体の軽量化が要求されるようになつて
きた。軽量化のためには通常成形体の素材として
発泡体を用いることが考えられるが、上記FRP
成形体について不飽和ポリエステル樹脂の発泡体
を作製することが困難なためほとんど適用されて
いない。
また、発泡容易な合成樹脂の発泡層にFRPを
積層させた複合成形体も知られているが、これら
は発泡体が全ての点で強度的に劣り軽量化可能で
あつてもFRP単独の成形体に比してことに厚み
方向の圧縮強度において欠点があつた。
この考案の考案者らはこれらの問題点を解消す
べく、発泡容易な合成樹脂の発泡粒子又はその粉
砕物をFRP成形体の不飽和ポリエステル樹脂層
内にFRPの構造材としての機械的強度を損なわ
ない程度（発泡粒子の機械的欠点が現われない程
度）多数含有させることにより軽量化を行なうこ
とを想着し、種々研究を行なつた。まず、通常よ
く用いられるポリスチレン発泡粒子を不飽和ポリ
エステル樹脂原液と混和し、硬化させて軽量の
FRP成形体の作製を種々の条件下で試みたが、
混和時に不飽和ポリエステル樹脂原液中に含まれ
るスチレンモノマーによつて発泡粒子又はその粉
砕物が溶融・収縮し発泡粒中の空気が逸散してし
まうため軽量のFRP成形体は得られなかつた。
この考案の考案者らは更に研究を行なつた結果、
発泡粒子としてポリスチレンではなくポリオレフ
イン系樹脂を特定量適用することにより所望の
FRP軽量成形体が得られることを見い出しこの
考案に到達した。
従来から、ポリスチレン発泡粒子を種々の接着
剤で固着して発泡体の強度を上昇させたり、熱可
塑性樹脂内に発泡体を含有させて該熱可塑性樹脂
にクツシヨン性を与え圧縮永久歪等の機械的性質
を改良することは知られているが、この考案のご
ときFRPをポリオレフイン系樹脂発泡体又はそ
の粉砕物との複合体は知られていない。さらに、
主としてFRPの軽量化を計るため、発泡困難な
不飽和ポリエステル樹脂内に気泡を保持させる媒
体としてのみ他の発泡体をFRPの構造材として
の機械的強度を損なわない程度含有させるという
技術思想は、上記従来の発泡粒子含有複合成形体
の技術思想とは全く異なるものである。
かくしてこの考案によれば繊維含有不飽和ポリ
エステル樹脂からなる二つの表面層の間に、ポリ
オレフイン系樹脂発泡粒子又はその粉砕物を多数
含有する不飽和ポリエステル樹脂からなるコア層
を一体に形成してなることを特徴とする繊維強化
不飽和ポリエステル樹脂軽量成形体が提供され
る。
以下添付の図面に基づきこの考案を詳しく説明
する。
第１図はこの考案のFRP軽量成形体の一具体
例を示す断面図である。第１図においてFRP軽
量成形板は、強化繊維であるポリエステル不織布
５を含有する不飽和ポリエステル樹脂４からなる
二つの表面層２（それぞれ約0.5〜６mmの厚み）
及びその間に一体に形成された、ポリエチレン発
泡粒子３を多数含有する不飽和ポリエステル樹脂
４からなるコア層１から構成されている。第２図
は、この考案の他の具体例を示す断面図である。
第２図においてFRP軽量成形板はコア層１とし
てポリエチレン発泡粒子の粉砕物３′を多数含有
する不飽和ポリエステル樹脂４を用いる以外、第
１図に示したと同様に構成されている。
この考案における発泡粒子又はその粉砕物に用
いるポリオレフイン系樹脂としては、ポリエチレ
ン、ポリプロピレン、エチレン−プロピレンラン
ダム共重合体、エチレン−酢酸ビニル共重合体、
エチレン−α−オレフイン−ポリエン共重合体等
が挙げられこれらは架橋されていてもよい。ま
た、これらの樹脂にビニル芳香族系樹脂が少なく
とも一部で化学的に結合したポリオレフイン系樹
脂も使用可能であり、例えば、ビニル芳香族系樹
脂としては、スチレン、α−メチルスチレン、エ
チルスチレン、クロロスチレン、ブロモスチレ
ン、ビニルトルエン等が好適に使用できる。
以上の種々のポリオレフイン系樹脂のうち、ポ
リオレフインが20〜80重量％、ビニル芳香族系樹
脂80〜20重量％のものが好ましく、ポリオレフイ
ンが40〜60重量％、ビニル芳香族系樹脂60〜40重
量％のものが発泡性とビニル芳香族のモノマーで
溶けないという点で最も好ましい。なお、発泡粒
子の発泡倍率は軽量化の点から大きければ大きい
程好ましく、通常20〜40倍程度が適当である。
この考案に用いる不飽和ポリエステル樹脂とし
ては、不飽和の多塩基酸と多価アルコールの縮合
反応によつて得られる樹脂とビニルモノマーとを
溶解してなる当該分野で公知のものが適用でき
る。これらのうち不飽和多塩基酸としては無水マ
レイン酸、フマル酸、アジピン酸、無水フタル
酸、イソフタル酸等が使用され、多価アルコール
としてはエチレングリコール、１，３−ブチレン
グリコール、ジエチレングリコール、プロピレン
グリコール等が使用される。
この考案の表面層に用いる繊維としては、ガラ
ス繊維、炭素繊維、ホウ素繊維、金属繊維、セラ
ミツク繊維、ポリエステル系繊維、塩化ビニル−
アクリロニトリル共重合体系繊維、ポリビニルア
ルコール系繊維等が挙げられる。これらのうち経
済性の点からはガラス繊維が好適である。しか
し、より軽量の複合成形体が得られる点、不飽和
ポリエステル樹脂と親和し易く表面強度が上昇す
る点等からポリエステル系繊維を用いるのが好ま
しく、ポリエステル不織布を用いるのが製造上取
り扱い易くより好ましい。
この考案の軽量成形体は、例えば触媒メチルエ
チルケトンパーオキサイドを混合した不飽和ポリ
エステル樹脂原液とポリオレフイン系樹脂発泡粒
子とを混和し、これを表面層となる繊維含有の未
硬化不飽和ポリエステル樹脂層上に供給し、更に
その上に対向する表面層となる繊維含有の未硬化
不飽和ポリエステル樹脂層を被覆し、その後全体
を不飽和ポリエステル樹脂の常温硬化によつて表
面層及びコア層を硬化一体化させることにより得
られる。
上記のごとき製造方法において、不飽和ポリエ
ステル樹脂原液と発泡粒子との組成割合は容積比
で発泡粒子が20〜80％程度であることが必要であ
る。20％より少ないと軽量化にほとんど役に立た
ず、80％より大きいと発泡粒子が隣同志で接した
り連続したりするので強度的欠陥が生じ適さな
い。
なお、この考案における発泡粒子又はその粉砕
物を多数含有する不飽和ポリエステル樹脂からな
るコア層としては、第１図又は第２図に示したご
とき均一に発泡粒子又はその粉砕物が分散された
構造に限定されるものではなく、第３図のコア層
のごとく、不飽和ポリエステル樹脂のみからなる
中央層６を有するものであつてもよい。この場
合、板状の成形体における曲げ強度がより良好と
なる等好ましい場合がある。
また、この考案における発泡粒子又はその粉砕
物として、顔料等で着色したものを用いて軽量成
形体を作製した場合、透明な不飽和ポリエステル
樹脂層を通して（第１図の矢印方向に相当）着色
模様が形成される。従つて種々の着色した発泡粒
子又はその粉砕物を所望模様となるように混和し
前記と同様に軽量成形体を作製することにより浮
彫りに見える美麗な模様が形成でき、化粧板とし
て好適に使用することができる。
この考案の軽量成形体は、そのコア層において
発泡体のごとき構造を有し、かつ従来の単独
FRP成形体とほぼ同程度の機械的強度を有す
る。そして発泡粒の発泡倍数や種類を変化させる
ことによつて所望の比重ことに従来のFRP成形
体よりも著しく軽量の成形体を簡便に得ることが
できる。また、空気含有媒体が発泡粒子又はその
粉砕物であるため独立気泡を有する発泡体的な性
質（耐水性等）を有している。さらに通常の発泡
体の作製に使用する発泡剤や発泡工程が不要であ
り、自由な形状にかつ簡便に製造できるため安価
である。
従つて、断熱ボード、床材、パレツト床敷材、
壁体、船舶構造材、浮子玩具、合成木材等の種々
の構造材的用途に有用である。
以下にこの考案の実施例を示す。
実施例 １
300×300×６mmのプレス型内に、ガラス繊維
（チヨツプドストランドマツト；商品名FEM−
450−04、富士フアイバーグラス(株)製；450ｇ／
m2）１プライを敷載し、これに不飽和ポリエステ
ル樹脂原液（商武名ポリマール8255P、武田薬品
工業(株)製）100重量部と触媒メチルエチルケトン
パーオキサイド（商品名カヤメツクＡ、化薬ヌー
リー(株)製）0.8重量部との混合液を被覆させた
（表面層）。次に不飽和ポリエステル樹脂が硬化前
に、上記不飽和ポリエステル樹脂原液100重量
部、触媒0.8重量部及びポリエチレン粒子40重量
％にポリスチレン60重量％が一部化学的に結合し
たポリオレフイン系樹脂の20倍発泡粒子（平均粒
径約６mm）とを均一に混和した液を流し込み（コ
ア層）、その上に前記と同じガラス繊維含有不飽
和ポリエステル樹脂を被覆（表面層）した後、形
締めをして硬化させて第１図に示すごとき複合成
形体を得た。
得られた複合成形体の全体の比重は0.83であり
厚みは5.8mm、表面層厚み約0.8mmであつた。
比較例として、同様なガラスマツト（450ｇ／
m2）を用い上記不飽和ポリエステル樹脂を５プラ
イ積層した比重1.36、厚み4.6mmのFRP成形体を
作製した。
構造材としての評価に用いる曲げ剛性試験を行
なつた結果を下表に示す。
This invention relates to a lightweight molded article made of fiber-reinforced unsaturated polyester resin (hereinafter abbreviated as FRP). More specifically, the present invention relates to a lightweight FRP molded body that is lighter and easier to manufacture than conventional FRP molded bodies. FRP molded bodies have been widely used as various structural materials. And depending on the use
There is a growing demand for lighter weight FRP molded bodies. In order to reduce weight, it is possible to use foam as the material for the molded body, but the above FRP
Regarding the molded product, it is difficult to produce a foamed product of unsaturated polyester resin, so it is hardly applied. Composite molded products are also known in which FRP is laminated on a foamed layer of easily foamable synthetic resin, but these molded products are inferior in strength in all respects and even though they can be made lighter, they cannot be made by molding FRP alone. Compared to the body, the compressive strength in the thickness direction was particularly poor. In order to solve these problems, the creators of this device added foamed particles of easily foamable synthetic resin or their crushed products to the unsaturated polyester resin layer of the FRP molded body to increase the mechanical strength of the FRP as a structural material. We came up with the idea of reducing the weight by including a large number of foam particles to the extent that they do not cause any damage (to the extent that mechanical defects of the foamed particles do not appear), and conducted various studies. First, commonly used polystyrene foam particles are mixed with an unsaturated polyester resin stock solution and cured to create a lightweight material.
We attempted to produce FRP molded bodies under various conditions, but
During mixing, the styrene monomer contained in the unsaturated polyester resin stock solution melts and shrinks the foamed particles or their pulverized product, causing the air in the foamed particles to escape, making it impossible to obtain a lightweight FRP molded product.
The creators of this idea conducted further research and found that
By applying a specific amount of polyolefin resin instead of polystyrene as foam particles, the desired result can be achieved.
We discovered that a lightweight FRP molded body could be obtained and came up with this idea. Conventionally, foamed polystyrene particles have been fixed with various adhesives to increase the strength of the foam, and foams have been incorporated into thermoplastic resin to impart cushioning properties to the thermoplastic resin, resulting in machines such as compression set. Although it is known to improve the mechanical properties, a composite of FRP with a polyolefin resin foam or a pulverized product thereof is not known as in this invention. moreover,
Mainly to reduce the weight of FRP, the technical idea is to include other foams only as a medium for holding air bubbles in unsaturated polyester resin, which is difficult to foam, to an extent that does not impair the mechanical strength of FRP as a structural material. This is completely different from the technical concept of the conventional composite molded article containing expanded particles. Thus, according to this invention, a core layer made of an unsaturated polyester resin containing a large number of foamed polyolefin resin particles or pulverized particles thereof is integrally formed between two surface layers made of a fiber-containing unsaturated polyester resin. A lightweight molded article made of fiber-reinforced unsaturated polyester resin is provided. This invention will be explained in detail below based on the attached drawings. FIG. 1 is a sectional view showing a specific example of the lightweight FRP molded article of this invention. In Fig. 1, the FRP lightweight molded plate has two surface layers 2 (each about 0.5 to 6 mm thick) made of unsaturated polyester resin 4 containing polyester nonwoven fabric 5, which is a reinforcing fiber.
and a core layer 1 made of an unsaturated polyester resin 4 containing a large number of polyethylene foam particles 3 integrally formed therebetween. FIG. 2 is a sectional view showing another specific example of this invention.
In FIG. 2, the FRP lightweight molded plate is constructed in the same manner as shown in FIG. 1, except that the core layer 1 is an unsaturated polyester resin 4 containing a large number of crushed polyethylene foam particles 3'. The polyolefin resin used for the foamed particles or their pulverized product in this invention includes polyethylene, polypropylene, ethylene-propylene random copolymer, ethylene-vinyl acetate copolymer,
Examples include ethylene-α-olefin-polyene copolymers, which may be crosslinked. Furthermore, polyolefin resins in which a vinyl aromatic resin is chemically bonded at least in part to these resins can also be used. For example, the vinyl aromatic resins include styrene, α-methylstyrene, ethylstyrene, Chlorostyrene, bromostyrene, vinyltoluene, etc. can be suitably used. Among the various polyolefin resins mentioned above, those containing 20 to 80% by weight of polyolefin and 80 to 20% by weight of vinyl aromatic resin are preferred, and those containing 40 to 60% by weight of polyolefin and 60 to 40% by weight of vinyl aromatic resin % is the most preferred in terms of foamability and non-dissolving vinyl aromatic monomer. Note that the expansion ratio of the expanded particles is preferably as large as possible from the viewpoint of weight reduction, and usually about 20 to 40 times is appropriate. As the unsaturated polyester resin used in this invention, those known in the art, which are obtained by dissolving a vinyl monomer and a resin obtained by a condensation reaction of an unsaturated polybasic acid and a polyhydric alcohol, can be used. Among these, maleic anhydride, fumaric acid, adipic acid, phthalic anhydride, isophthalic acid, etc. are used as unsaturated polybasic acids, and ethylene glycol, 1,3-butylene glycol, diethylene glycol, propylene glycol are used as polyhydric alcohols. etc. are used. The fibers used in the surface layer of this invention include glass fibers, carbon fibers, boron fibers, metal fibers, ceramic fibers, polyester fibers, and vinyl chloride fibers.
Examples include acrylonitrile copolymer fibers and polyvinyl alcohol fibers. Among these, glass fiber is preferred from the economic point of view. However, it is preferable to use polyester fibers because a lighter composite molded article can be obtained, and the surface strength increases due to their affinity with unsaturated polyester resins, and it is more preferable to use polyester nonwoven fabrics because they are easier to handle in production. . The lightweight molded article of this invention is produced by mixing an unsaturated polyester resin stock solution mixed with catalyst methyl ethyl ketone peroxide and foamed polyolefin resin particles, and then applying this mixture onto a fiber-containing uncured unsaturated polyester resin layer that serves as a surface layer. Then, a fiber-containing uncured unsaturated polyester resin layer that becomes the opposing surface layer is coated on top of the uncured unsaturated polyester resin layer, and then the surface layer and the core layer are cured and integrated by curing the unsaturated polyester resin at room temperature. It can be obtained by In the above manufacturing method, it is necessary that the composition ratio of the unsaturated polyester resin stock solution to the foamed particles is about 20 to 80% by volume of the foamed particles. If it is less than 20%, it is hardly useful for weight reduction, and if it is more than 80%, the foamed particles will come into contact with each other or be continuous, resulting in strength defects, which is not suitable. In addition, the core layer made of unsaturated polyester resin containing a large number of foamed particles or pulverized products thereof in this invention has a structure in which foamed particles or pulverized products thereof are uniformly dispersed as shown in FIG. 1 or 2. However, the present invention is not limited to this, and may include a central layer 6 made only of unsaturated polyester resin, as in the core layer shown in FIG. In this case, it may be preferable that the bending strength of the plate-shaped molded product becomes better. In addition, when a lightweight molded body is produced using foamed particles or their pulverized products colored with pigments, etc. in this invention, a colored pattern can be seen through the transparent unsaturated polyester resin layer (corresponding to the direction of the arrow in Figure 1). is formed. Therefore, by mixing various colored foamed particles or their pulverized products to form a desired pattern and producing a lightweight molded product in the same manner as described above, a beautiful pattern that appears in relief can be formed, making it suitable for use as a decorative board. can do. The lightweight molded product of this invention has a foam-like structure in its core layer, and is
It has almost the same mechanical strength as an FRP molded product. By changing the expansion ratio and type of foamed beads, it is possible to easily obtain a molded product with a desired specific gravity and significantly lighter weight than conventional FRP molded products. Furthermore, since the air-containing medium is foamed particles or a pulverized product thereof, it has properties (water resistance, etc.) like a foam having closed cells. Furthermore, it is inexpensive because it does not require a foaming agent or a foaming process that are used in the production of ordinary foams, and can be easily manufactured into any shape. Therefore, insulation boards, flooring materials, pallet flooring materials,
It is useful for various structural applications such as walls, ship structural materials, floating toys, and synthetic wood. Examples of this invention are shown below. Example 1 Glass fiber (chopped strand mat; trade name: FEM-
450-04, manufactured by Fuji Fiber Glass Co., Ltd.; 450g/
m 2 ) 1 ply, and 100 parts by weight of an unsaturated polyester resin stock solution (commercial name Polymer 8255P, manufactured by Takeda Pharmaceutical Co., Ltd.) and catalytic methyl ethyl ketone peroxide (trade name Kayametsuku A, Kayaku Nouri) were added to this. Co., Ltd.) was coated with a mixed solution of 0.8 parts by weight (surface layer). Next, before the unsaturated polyester resin is cured, 20 times more polyolefin resin is prepared by chemically bonding 100 parts by weight of the unsaturated polyester resin stock solution, 0.8 parts by weight of the catalyst, and 60% by weight of polystyrene with 40% by weight of polyethylene particles. A liquid uniformly mixed with foamed particles (average particle size of about 6 mm) is poured into the core layer (core layer), and the same glass fiber-containing unsaturated polyester resin as described above is coated on top of the liquid (surface layer), and then the shape is tightened. After curing, a composite molded body as shown in FIG. 1 was obtained. The overall specific gravity of the resulting composite molded product was 0.83, the thickness was 5.8 mm, and the surface layer thickness was approximately 0.8 mm. As a comparative example, similar glass mats (450g/
An FRP molded body having a specific gravity of 1.36 and a thickness of 4.6 mm was produced by laminating 5 plies of the above unsaturated polyester resin using the FRP molded product. The table below shows the results of a bending rigidity test used for evaluation as a structural material.
【表】
なお、実施例と比較例におけるたわみの比は
１：1.17であつた。
以上の結果から、この考案の実施例のものは軽
量であるにもかかわらず、比曲げ弾性率、たわみ
で著しく優れたものであつた。[Table] Note that the ratio of deflection in Examples and Comparative Examples was 1:1.17. From the above results, the examples of this invention were found to be extremely superior in specific flexural modulus and deflection, despite being lightweight.
第１図は、この考案の軽量成形体の一具体例を
示す断面図であり、第２図及び第３図はそれぞれ
他の具体例を示す断面図である。
１……コア層、２……表面層、３……ポリオレ
フイン系樹脂発泡粒子、３′……ポリオレフイン
系樹脂発泡粒子の粉砕物、４……不飽和ポリエス
テル樹脂、５……繊維、６……中央層。
FIG. 1 is a sectional view showing one specific example of the lightweight molded article of this invention, and FIGS. 2 and 3 are sectional views showing other specific examples, respectively. DESCRIPTION OF SYMBOLS 1... Core layer, 2... Surface layer, 3... Polyolefin resin foam particles, 3'... Pulverized product of polyolefin resin foam particles, 4... Unsaturated polyester resin, 5... Fiber, 6... central layer.
Claims (1)
つの表面層の間に、ポリオレフイン系樹脂発泡
粒子又はその粉砕物を多数含有する不飽和ポリ
エステル樹脂からなるコア層を一体に形成して
なることを特徴とする繊維強化不飽和ポリエス
テル樹脂軽量成形体。 ２ コア層におけるポリオレフイン系樹脂発泡粒
子又はその粉砕物の含有量が20〜80容量％であ
る実用新案登録請求の範囲第１項記載の軽量成
形体。[Claims for Utility Model Registration] 1. A core layer made of an unsaturated polyester resin containing a large number of expanded polyolefin resin particles or pulverized particles thereof is integrally formed between two surface layers made of fiber-containing unsaturated polyester resin. A lightweight molded article made of fiber-reinforced unsaturated polyester resin. 2. The lightweight molded article according to claim 1, wherein the content of expanded polyolefin resin particles or pulverized particles thereof in the core layer is 20 to 80% by volume.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP13175581U JPS5836127U (en) | 1981-09-03 | 1981-09-03 | Fiber-reinforced unsaturated polyester resin lightweight molded body |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP13175581U JPS5836127U (en) | 1981-09-03 | 1981-09-03 | Fiber-reinforced unsaturated polyester resin lightweight molded body |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS5836127U JPS5836127U (en) | 1983-03-09 |
| JPS6224521Y2 true JPS6224521Y2 (en) | 1987-06-23 |
Family
ID=29925321
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP13175581U Granted JPS5836127U (en) | 1981-09-03 | 1981-09-03 | Fiber-reinforced unsaturated polyester resin lightweight molded body |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS5836127U (en) |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5371172A (en) * | 1976-12-07 | 1978-06-24 | Japan Styrene Paper Corp | Light weight molded body |
| JPS5455088A (en) * | 1977-10-12 | 1979-05-01 | Mitsubishi Petrochem Co Ltd | Foamed resin composite molded article |
-
1981
- 1981-09-03 JP JP13175581U patent/JPS5836127U/en active Granted
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5371172A (en) * | 1976-12-07 | 1978-06-24 | Japan Styrene Paper Corp | Light weight molded body |
| JPS5455088A (en) * | 1977-10-12 | 1979-05-01 | Mitsubishi Petrochem Co Ltd | Foamed resin composite molded article |
Also Published As
| Publication number | Publication date |
|---|---|
| JPS5836127U (en) | 1983-03-09 |
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