JPS6412205B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a resin reinforcing mat.

A series of FRP in which a long glass fiber reinforcement impregnated with liquid thermosetting resin (hereinafter referred to as uncured FRP) is moved in contact with a mold having a predetermined cross-sectional shape, and heated during this time to harden the resin. The molding method (hereinafter referred to as pultrusion molding method) is a suitable method for mass production of FRP.

In the pultrusion molding method, an appropriate tensioning device is installed at the exit of the mold, and by pulling the obtained product (FRP), uncured FRP is drawn into the mold, and it is brought into contact with the mold heated to a predetermined temperature. Move it through the mold in this state. The uncured FRP is molded into the same shape as the cross section of the mold, and then hardened.

While uncured FRP is stretched in contact with the mold, it receives tension due to frictional resistance with the mold, so the glass fiber reinforcement used in the pultrusion molding method has high tensile strength and does not tear due to friction with the mold. It needs to be something. As a glass fiber reinforcement with such properties, CSM (contained strand mat), which preferably has rovings arranged in the longitudinal direction, has been widely used, but when CM or CSM is used, The following difficulties arise.

(1) The mold is prone to wear due to friction with the CSM.

(2) The resulting FRP has a relatively small resin content on the surface, and sometimes there are areas where resin does not exist (pores), which tends to result in poor water resistance and weather resistance.

(3) The surface of the obtained FRP is relatively rough.

In order to solve these difficulties, it has been proposed to use a composite mat in which a surface material such as organic fiber non-woven fabric is closely integrated with the surface of CSM, but this method also has the following difficulties. . That is, when surface materials are bonded together by adhesive, resin does not pass easily through this bonded portion, and resin impregnation property decreases. When the surface material and CSM are bonded by needling, the needled fibers are exposed on the surface and the smoothness of the surface deteriorates.

The inventor of the present invention has arrived at the present invention as a result of repeated studies in order to solve these difficulties and obtain a method for bonding CSM and surface material without impairing the impregnating properties of the resin.

The present invention involves a step of stacking long glass fiber bundles in a non-directional manner to form a mat-like material, and using a mixture of a thermoplastic resin and a thermosetting resin as a binder in an amount of 4 to 9 wt%.
A process of heating the pine-like material to harden the thermosetting resin and softening the thermoplastic resin, and a step of heating the pine-like material to harden the thermosetting resin and softening the thermoplastic resin, and a step of heating the pine-like material to harden the thermosetting resin and softening the thermoplastic resin. The present invention relates to a method for producing a resin-reinforced mat, which includes the steps of stacking and pressing outer covering materials and bonding the mat-like material and the outer covering material.

Next, the present invention will be described in more detail with reference to the accompanying drawings.

1 is a pine-like material made of long glass fiber bundles such as CSM. As a glass fiber bundle, 9~
30 to 200 glass fibers of about 20μ, preferably 50
A bundle of about 100 fibers can be preferably used.
In the most preferred embodiment, continuous or 60
A mat can be produced by dropping and depositing glass fiber bundles cut into lengths of cm or more, preferably 100 cm or more on a conveyor moving at a rate of 200 to 600 gr/m ² . Note that the glass fiber bundles are deposited in a non-directionally curved shape.

2 is a surface material that has good ability to retain liquid resin.
Here, a surface material that has good ability to retain liquid resin is one that is at least as thick as the surface material, preferably 1.2 times the thickness of the surface material, when the surface composite material is immersed in 4000 cps of liquid resin and pulled up. This refers to a surface material that can maintain a state in which a resin of twice the thickness or more is attached for about 1 minute.

As the surface material having such properties, organic fiber nonwoven fabrics such as polyester, polypropylene, acrylic copolymers, BM (bonded mat), etc. can be suitably used, and polyester nonwoven fabrics are particularly suitable. As a surface material, the thickness is 0.1 to 2.
Use mm.

If the thickness is too large, poor resin impregnation is likely to occur, and if the thickness is too small, the surface material is likely to be torn to pieces during molding, and sufficient effects may be difficult to obtain.

3 is a small hole provided on the surface of the cover material 2.
In a preferred embodiment, the diameter of the pores is between 0.5 and 5.
mm, the distance between the centers of the small holes is 1-10 mm. By providing such small holes, when impregnating the resin reinforcing mat of the present invention with liquid thermosetting resin,
It is possible to improve the impregnation of the resin into the mat-like material.

In order to bond the surface material 2 and the pine-like material 1, a mixture of thermoplastic resin and thermosetting resin is added to the glass fiber bundles deposited on the conveyor as a bonding agent between the glass fiber bundles, and the resin mixture is The glass fiber bundle deposit to which 4 to 9 wt% has been added is passed through a heating furnace and heated to harden the thermosetting resin and soften the thermoplastic resin. The cover material is layered on the softened pine-like material of thermoplastic resin taken out from the heating furnace, and a pair of pressure rolls are used to press the two together to bond the cover material and the pine-like material using the softened resin. .

The resin reinforcing mat produced by the method of the present invention is extremely suitable as a reinforcing mat when FRP is produced by pultrusion molding after being impregnated with a liquid thermosetting resin. has the following excellent properties:

(1) Long glass fiber bundles are stacked in a loop shape in no direction, and a binder made of a mixture of thermosetting resin and thermoplastic resin is added to the fiber bundles and heated. As a result, the thermosetting resin is cured, and the glass fiber bundles are bonded together by the thermosetting resin while being deposited and having a relatively low bulk density. Then, the outer covering material is layered with the thermoplastic resin softened, and is pressed with pressure rollers until it reaches a predetermined thickness, and is then cooled to harden the thermoplastic resin, and at the same time the outer covering material is bonded. Ru. Therefore, it is possible to give the glass fiber bundle the desired bulk density. It is necessary to do it.
If clamping pressure is applied in such a state, the resin tends to adhere to the rolls and the rolls are likely to be worn out, making it impossible to obtain a product with a desired bulk density from an industrial perspective. ).

Moreover, when using the method of the present invention, the glass fiber bundles are also bonded together by the thermosetting resin, so that when impregnated with liquid resin, the glass fiber bundles are bonded together only by thermoplastic resin. The bonds between the glass fiber bundles do not loosen and fall apart.

(2) The surface material is applied to the glass fiber bundles and bonded with a binder that binds the glass fiber bundles. Therefore, as in the case of bonding using another adhesive,
The adhesive surface or adhesive does not deteriorate the permeability of the liquid thermosetting resin.

(3) A surface material made of non-woven fabric or the like is adhered to the mat-like object, and the mold and the mat-like object do not come into direct contact during pultrusion molding, so there is little wear and tear on the mold surface.

(4) Since the surface of the reinforcing mat produced by the method of the present invention is covered with a surface material that has good resin retention properties, the FRP obtained using this reinforcing material has a FRP with high resin content and good water resistance, corrosion resistance, and weather resistance can be obtained without forming cavities.

[Brief explanation of the drawing]

FIG. 1 is a plan view of a resin reinforcing mat manufactured by the method of the present invention, and FIG. 2 is a front view. In the figure, 1 indicates a pine-like material, 2 indicates a cover material, and 3 indicates a small hole.

Claims (1)

[Claims] 1. A process of stacking long glass fiber bundles in a non-directional manner to form a mat-like material, a process of adding 4 to 9 wt% of a mixture of a thermoplastic resin and a thermosetting resin as a binder,
A process in which the pine-like material is heated to harden the thermosetting resin and soften the thermoplastic resin, and a surface material that has good ability to retain liquid resin is layered on the surface of the pine-like material while the thermoplastic resin is softened. A method for producing a resin-reinforced mat, which includes the step of clamping and bonding a mat-like material and a surface material.