KR830000048B1 - Manufacturing method of lightweight plate-shaped composite material - Google Patents

Abstract

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Description

Manufacturing method of lightweight plate-shaped composite material

1 is a cross-sectional view of one embodiment of the reinforced foamed resin structural material of the present invention having both surface layers (1) and inner layers (2).

2 is a cross-sectional view of another embodiment of the material of the present invention having a double layer structure consisting of a foam layer (11) reinforced with fibrous mat and a foam layer (12) reinforced with a plurality of elongated fibers arranged in a specified direction.

3 is a cross-sectional view of another embodiment of the inventive material in which aggregate 23 is present in the foamed resin 22 which fills the voids in the honeycomb material 21.

Figure 4 is a view showing an embodiment of the present invention reinforced resin foam structure member manufacturing process.

5 is a view showing another structural material manufacturing process embodiment of the present invention.

6 and 7 are cross-sectional views of the surface layer structure employed in another embodiment of the present invention.

The foamed resin material of the present invention is used in many places, in particular can be used in thermal insulation, load walls, floors, benches, verandas, truck unloading, offshore containers, FRP ship interior materials.

The reinforced foamed resin material is described and described in detail in the drawings.

1 is a cross-sectional view of one embodiment of the material of the present invention, in which internal seal 2 enters between the two surface layers 1 to form a unit with the two surface layers. The surface layer 1 is made of a foamed resin reinforced with fibers, and the inner layer 2 is made of a honeycomb material 21 filled with foamed resin 22 in the voids of the honeycomb material 21.

2 is a cross-sectional view of another embodiment of the material of the present invention, in which a surface layer 1 having a double layer structure woven with a foam layer 11 reinforced with a fiber mat and a foam layer 12 reinforced with a plurality of long fibers is shown. have. Furthermore, the foam layer 11 reinforced with fibrous mats is arranged to be the outermost layer of the respective material, respectively.

3 is a cross-sectional view of yet another embodiment of the inventive material, in which aggregate 23 is in the resin filling the voids in the honeycomb.

Specific examples of the fibers constituting the surface layer of the present invention and having a function as a reinforcing material include highly impregnated materials made of glass fiber, natural fiber, synthetic fiber, metal fiber, carbon fiber and the like. These fibers may be used in the form of short fibers of 5 mm-10 cm in length, or may be used as long fibers of 10 cm or more, woven fabrics such as glass fabrics or fibrous networks, and layers of fibers arranged side by side on the same side, C Used as Chop-strand mat, continuous strand mat, glass paper, surf-ace mat and the like.

Glass paper and surface mats, not formed as weaving, are reinforcing materials made from short fibers of 2-10 cm.

The former is made by the so-called wet method using emulsion binders such as polyvinylacetate emulsions and polyacrylate emulsions.

The latter is made by the so-called dry process using a heat-melting process without the use of emulsion binders. Among these fibers, glass fibers are most suitable in terms of strength and the price of the article to be made. These fibers should be used on mats.

Preferred fibers should have a high impregnation force that can be impregnated with various liquids and then be spread out into layers and can be impregnated with effervescent thermosetting resin liquid with high permeability, which can only enter the inner fibrous layer by spraying liquid resin on the surface of the fibrous layer. In addition, it should be possible to fill the fibrous layer with the expansion of the resin solution foaming result. Thus, the fiber reinforced foam resin, in which the fiber is completely and evenly spread in the foamed resin, is used as the fiber which can be impregnated at a high concentration as described above, and the foaming thermosetting resin liquid is supplied by the simple spraying operation and the resin liquid is foamed, By curing, it can be easily obtained.

No special apparatus is required for impregnating the resin liquid by this method.

Such highly impregnated fibrous materials would have a porosity of 50-97% by volume and a porosity of 80-95% by volume. Glass cloths typically have 90% by volume voids.

A particular example that is most suitable as a high impregnated fibrous material may be made of continuous strand mat as described in US Pat. No. 3,394,046. The mat is made of one or several layers of continuous long glass fibers while rotating in the cavity, and then the fibers are first bonded to the fibers first bonded to the fibers to form a mat shape. Made by bonding.

Continuous strand mats have a much greater ability to penetrate and saturate into the resin liquid (compared to the case of strand strand mats and glass cloths), and the fibers disperse better into the foamed resin when the resin liquid is foamed and cured. Typically, this type of mat usually has a void volume of 85% by volume, depending on how tightly the fibers are layered. The foamed resin constituting the surface layer 1 and the foamed resin 22 used for the inner layer 2 may be the same or different. Two or more fibrous layers may also be superimposed and bonded to both sides of the honeycomb material as a surface layer. Usually the amount of fiber in the surface layer is in the range of 10-70% by volume, suitably 15-60% by volume.

The foamed synthetic resin used in the surface and inner layers is not particularly limited, but is convenient for producing cotton and plate-shaped products, such as heat resistance required for building materials, and is suitable for polyurethane, phenolic resins, unsaturated polyterresins, urea resins and melamine resins. Thermosetting resins such as epoxy resins are suitable.

Among these thermosetting resins, foamable thermosetting resin liquids that can be foamed and cured in a short time are particularly suitable for the present invention.

Representative examples of the polyester resins are esters obtained from the reaction between dibasic acids such as maleic acid and fumaric acid and dihydric alcohols such as ethylene glycol and diethylene glycol. As the urea resin, one produced by condensation of urea and aldehyde may be used, and the reaction product of epichlorohydrin and bis (4-hydroxyphenol) dimethylmethane may be used as the epoxy resin.

A particularly effective method for making the present structural agent is to use a foamable polyurethane resin solution, which provides a rigid polyurethane foam. Such foamable liquids include blowing agents, catalysts, foam control agents, and polyols and polyisocyanates mixed with them.

As polyols, polyester polyols and polyether polyols are used. Polyester polyols include dicarboxylic acids such as adipic acid, suberic acid, sebacic acid, phthalic acid, isophthalic acid and terephthalic acid, and ethylene glycol, 1,2-propylene glycol, 1,3-butylene glycol, 2,3 What is obtained from the condensation reaction between polyhydric alcohols, such as butylene glycol, dimethylene glycol, hexamethylene glycol, decamethylene glycol, trimethylol propane, trimethylol ethane, and grill serine, is used.

Polyether polyols include polyhydric alcohols such as glycerin, trimethyl propane, pentaerythritol, α-methylglucose, sorbitol, sucrose, ethylene oxide, 1,2-propylene oxide, 1,2-butylene oxide, 2, What is obtained by addition polymerization of alkylene oxides such as 3-butylene can also form a resin.

Examples of the isocyanate include tetramethylene isocyanate, hexamethylene diisocyanate, ethylene diisocyanate, xylene diisocyanate, 1,3,6-hexanetriisocyanate, phenylene diisocyanate, tolylene diisocyanate, chlorophenylenedi isocyanate, diphenylmethane diisocyanate, tri Pefemethane-4,4 ', 4 "-triisocyanate, xylene- (alpha), (alpha)'-diisocyanate, isopropyl benzene- 1, 4- diisocyanate.

As the blowing agent, low boiling point volatile liquids such as water or monofluoro-trichloro-methane, dichloro-difluoromethane, dichloro-tetrafluoroethane, monochloro-difluoromethane and the like are used. Silicone compounds or polysiloxane oxyalkylene compounds are used. Tertiary amines and tin compounds that are basic to the periodic table metals are commonly used as catalysts.

It is most suitable to provide a rigid polyurethane in such a resin liquid.

Any honeycomb material is suitable as the inner material of the present invention as long as it is a plate.

The honeycomb material may not necessarily have a honeycomb structure. The size of one compartment of the honeycomb material is approximately 5 mm-50 mm, suitably 8-20 mm, but is determined according to the size or shape of the formed structural material. This material has various designs such as hexagon, corrugation and cylinder.

Specific examples of honeycomb materials suitable for use in the present invention include paper honeycomb, thermosetting resins such as polyurethane, phenol resins, unsaturated polyester resins, epoxy resins, melamine resins, urea resins, and the like, and polystyrene, polyvinyl acetate, poly Paper honeycomb impregnated with a resin such as a thermosetting plastic resin emulsion or a solution such as acrylate, and a conventional honeycomb inner material commonly used for making an object having a sandwich structure such as a plastic honeycomb material and a metal honeycomb material are suitable. .

The thickness of the honeycomb structure is in the range of 5 mm-99 mm. The thickness of the material sheet from which the honeycomb inner member is made is approximately 0.1-2 mm, suitably 0.2-1 mm.

Further, in the present invention, aggregates may enter the foamed resin 22 filled with the voids of the honeycomb material 21 as shown in FIG. Specific examples of such aggregates include inorganic fillers such as calcium carbonate, talc, aluminum hydroxide and the like, and lightweight aggregates such as silica balun, pearl rock and glass balun and quartz powder.

Such aggregates are used to improve various physical properties such as, for example, the compressive strength of the resin foam forming the inner layer, and to lower the price of the product. This aggregate is used in an amount of 5-60% by volume of the volume occupied by the inner layer in the lightweight foamable resin material of the present invention.

The foamed resin material having a particularly good bending strength is preferably a foamed material reinforced with a high impregnation fiber mat, preferably a continuous strand mat, and a plurality of long fibers, preferably a large number, laid out in one or several directions as desired. It can be obtained by providing a double layer layer with the foam layer reinforced with glass fibers of the surface layer.

In the case of the continuous process shown in Figs. 4 and 5, the fibers are oriented in the advancing direction of the workpiece, whereby convenient and good mechanical properties can be obtained. There, the degree of improvement in bending strength is much greater than can be predicted from the amount of fiber used.

The long fibers used for the reinforcement of the foam layer 12 in the surface layer 1 are laid out and arranged in a constant direction, and include glass fibers, synthetic fibers, metal fibers, carbon fibers, and the like. When short fibers are used as long fibers, fibers with a thickness of 6-30 microns, suitably 9-20 microns, are laid on the honeycomb material at a rate of 50,000 -450,000 single fibers per meter. In particular, glass irradiation obtained by making several layers of glass fibers and then roughening them is suitable. Glass irradiation is placed on the honeycomb material at a rate of 50-300 glass irradiation per meter. One glass irradiation has 1,000-15,000 short fibers. The direction in which the long fibers are laid is usually the longitudinal direction of the manufactured product which matches the running direction in the continuous manufacturing process.

An embodiment of making another surface layer of the present invention is shown in FIGS. In the surface layer material of FIG. 6, the foamed resin is reinforced by a large number of long fibers 14 dispersed in the foamed resin and further reinforced by a fiber mat 13 supplied near one surface of the foamed resin. The foamed resin 15 in the surface layer of FIG. 7 is reinforced with a fiber mat 13 near both surfaces of the foamed resin.

The surface layer in the present invention has a thickness of 0.5-20 mm suitably 0.6-10 mm. The thickness of the fiber mat to reinforce the surface layer is 0.1-10 mm, suitably 0.2-7 mm, and the thickness of the long fiber reinforcement layer is about 0.1-10 mm preferably 0.2-8 mm. However, it will be apparent to the skilled person that these dimensions can be adjusted according to the size and shape of the structural material formed.

For example, such a surface layer can be easily made by first placing a fibrous mat filled with effervescent thermosetting resin liquid in the mold, then arranging the fibers filled with the resin liquid with a predetermined thickness thereon, and foaming and curing the resin liquid in the mold. have.

Another method involves placing a foamable thermosetting resin solution between two layers of the fibrous mat in which the same resin solution is added and placing it in a mold so as to be foamed and cured in the mold.

In order to obtain the structural agent of the present invention, the surface layer and the inner layer may be prepared separately (ie, impregnated, foamed, cured), and both are bonded together using an adhesive to form a monolith.

In this case, the adhesive preferably has a composition similar to that of the foamed resin. Polyisocyanate adhesives are well used. However, for the sake of simplicity, it is better to make the plate composite material of the present invention by the following method, in which the inner material is more firmly combined with the surface layer to form a monolith.

The honeycomb material enters between the two layers to form a layered material, and the foamable thermosetting resin liquid is supplied to the layered material, and then the resin liquid is foamed and cured to fill the voids of the honeycomb material with the foamed resin and At the same time, the fibers constituting the surface layer of the foamed resin produced are impregnated and coated. Thus, the surface layer and the inner layer are firmly combined into a single structure.

4, the highly impregnated continuous fibers 4, 4 '(e.g., continuous strand mat) are released from each reel and layered by guide rollers 42 and 42', respectively, in the direction of the arrow. An embodiment of the present invention is shown.

The honeycomb material is also arranged in the direction of the arrow to enter between the two fibrous layers 4 (4 '). Furthermore, the conveyor 8 supports and carries the honeycomb material.

These materials are conveyed to a forming passage 6 having a plate-shaped cross section. The passage 6 is composed of an endless belt 61 at an upper surface, an endless belt 61 'at a lower surface or a bottom thereof, and in particular, one endless belt covers both sides of the passage although not shown in the drawing. 62 and 62 'are guide rollers for the endless belts 61 and 61', respectively.

The passage may consist of only endless belts, but in order to obtain more uniform foaming and smoother product surface, it is more preferable that both walls, ceilings and floors are disposed.

The endless belt 61 ', which is the bottom of the passage 6, extends past the entrance of the passage in the direction opposite to the direction in which the honeycomb material proceeds, so that the layer of highly impregnated fiber 4', in which the honeycomb material forms the lower layer of the product. ) Provide a nesting place, which is supported by the belt 61 'and moved toward the passage inlet.

The foamable thermosetting resin liquid is supplied to the honeycomb material 21 through the resin liquid supply device 52 from above and filled in the voids of the honeycomb material before the fibers 4 forming the upper surface layer are supplied.

As these materials progress, the fibrous layer 4 is fed to the upper surface of the honeycomb material 21 and superimposed thereon to form a layer which enters the forming passage 6. In the passage 6, the belts 61 (61 ') and the side belts closely move the layer containing the resin.

Then, the foamable thermosetting resin solution is foamed in the forming passage (6). Due to the expansion resulting from the foaming, it is filled with the pore resin liquid of honeycomb structure, and at the same time, some resin liquid is uniformly penetrated into the fiber 4 (4 '). Due to the subsequent hardening of the resin solution, the honeycomb material 21 and the fibers 4 and 4 ', which are lumped with the resin solution, form a plate-shaped resin foam product in which the fiber is reinforced with a honeycomb material. The resulting product is ejected from the aisle by a roller conveyor or endless belt (not shown in this figure) and cut to size.

The molding passage 6 may include a heating device for promoting the foaming and curing of the resin liquid, and a cooling device for lowering the temperature after the foaming and curing phenomenon is completed.

The passage 6 is usually 2-20 m long, in which there is material 1-25 minutes. Suitable foaming temperatures are about 0-50 ° C, preferably 10-35 ° C.

Normal foaming is completed in 10 seconds-5 minutes, preferably 30 seconds-2 minutes. The curing temperature is usually about 40-150 ° C., preferably 60-120 ° C., and can be carried out in 1-20 minutes, preferably 2-10 minutes.

5, the endless belt 61 forms the upper surface of the forming passage 6, and the endless belt 63 forms the lower surface of the forming passage, and guide rollers 62 and (62) for each endless belt 61, 63 are formed. 64 shows an embodiment of another process of the present invention in which the side frame is disposed along both sides of the lower endless belt 63.

The endless belts 61 and 63 move in the directions indicated by the arrows. Furthermore, the endless belt 63 forming the bottom of the passage 6 is installed to extend past the inlet of the passage 6 to provide a good place to place the material to be molded.

Glass irradiation (3) (3 ') made of multiple layers of glass fibers is pulled from the roller (31) (31') through the guide rollers (32), (32 ') and (33) (34) in the direction of the arrow. It is arranged horizontally so as to have a parallel relationship while keeping constant intervals. A continuous strand mat 4, 4 ′ then enters the passage 6 through the guide rollers 42, 42 ′.

As described above, a combination of continuous strand mat and glass irradiation is used as the fiber material layer in the present invention. The continuous strand mat 4 used to form the upper surface layer and the continuous strand mat 4 'used to form the lower surface layer are arranged so as to be on the outermost surface, respectively.

On the other hand, the honeycomb material 21 is continuously supplied from the position higher than the forming passage 6 through the guide roller 34 to descend to the extension surface of the lower endless belt 63, and as a result, the downward angle This decreases, and the honeycomb material is not stuck near the inlet of the forming passage 6.

It is supported by the endless belt 63 in contact with the endless belt 63 near the inlet of the passage. The honeycomb material 21, glass irradiation 3, 3 ', and continuous strand mat 4, 4', respectively, proceed in the directions indicated by the arrows, and are supplied to form a unit when entering the forming passage. do.

The foamable thermosetting resin liquid is supplied from the foam liquid injection device 51 during the progress of the forming passage, i.e., when the honeycomb material is lifted from the endless belt 63 and is not in full contact with the belt.

The resin liquid supplied by the above method passes through the pores of the honeycomb material 21, falls on the fiber side on the endless belt 63, and then penetrates into the fiber.

At the same time, the resin liquid flows laterally into the space between the endless belt 63 and the fibrous layer and the honeycomb material 21 and spreads uniformly. Furthermore, the resin liquid flows gradually from the honeycomb material in the high position toward the honeycomb material supported by the endless belt 63 and is evenly distributed in the individual gaps forming the honeycomb structure of the honeycomb material 21. In the molding passage, foaming of the foamable thermosetting resin liquid with expansion occurs. Because of the expansion, the gap between the pores of the honeycomb structure and the fibrous material of the lower surface layer is completely filled with foamed resin, while the foamed resin liquid also penetrates into the fibrous material of the upper surface layer and causes the fiber to be embedded in the foam.

Then, a thermosetting resin solution foamable to make an elastic product 7 'of a resin foam reinforced with honeycomb material 21, glass irradiation 3, 3' and continuous strand mat 4, 4 '. Hardening occurs. The material 7 'thus obtained is pulled out of the outlet of the forming passage 6 by a device not shown in the figure and cut into a predetermined length.

As can be seen from the fourth and fifth degrees, the supply of the resin liquid can be performed before or after the supply of the fiber material 4 to constitute the upper surface layer of the honeycomb material. Thus, FIG. 5 shows an embodiment in which the resin liquid is supplied to the honeycomb material through the fiber material 4 from the upper position of the fiber material 4 after the fiber material is applied to the honeycomb material.

Suitable thickness of the structural material of the present invention is 10-100mm, specific gravity is 0.2-0.8, but other sizes and specific gravity may be obtained depending on the end use of the material. Lightweight foamed resin material of the present invention has the structure as described above, the surface layer is made of foamed resin reinforced with fiber material and the inner layer is a honeycomb material whose pores are filled with foamed resin, these layers are combined in one piece As a result, it is light and excellent in the required mechanical properties as a structural material such as compressive strength, bending strength and impact resistance.

In particular, the plate-like material of the present invention, due to the fiber-reinforced surface layer, can exhibit such an effect that the impact received is not only absorbed by the foamed resin, but also the biocrack is not expanded. Also, due to the presence of a foam layer reinforced with long fibers pulled in one or more directions, the plate material of the present invention can effectively exhibit strength such as bending strength, even though relatively small fiber amounts are used. Lighten the material with presence. In addition, the plate-like foamable resin material of the present invention is not only excellent in thermal insulation ability, waterproofness, chemical resistance, but also good workability.

The structural material of the present invention is usually plate-shaped. Therefore, the material of the present invention can be suitably used as a building material that is light, heat insulating, and requires high compressive strength.

In particular, they show their ability when used as insulation for house walls, flooring materials, materials for making ventinas and verandas, loading materials for trucks, materials for offshore containers, and interior materials for FRP ships. In order to be easy to use in such a field, it would be good to form a concave-convex structure for connection on both parallel sides of the structural member.

Furthermore, when the highly impregnated fiber material is used in the present invention, the fiber material does not need to be impregnated with the thermosetting resin liquid in advance, and the fiber material can be uniformly impregnated with the resin liquid through expansion by the foaming of the resin liquid supplied to the honeycomb material. .

Therefore, the process and apparatus for first impregnating the fiber material with the resin liquid are not necessary in the present invention. So, by the embodiment of the present invention, the foamed resin material having such excellent physical properties can be made simply and effectively.

Further, in the present invention, by supplying the honeycomb material and the thermosetting resin liquid in a special manner, it is possible to make a structural material in which the foamed resin is uniformly contained in each void of the honeycomb structure of the honeycomb material. Next, the present invention will be described in more detail with reference to Examples.

Example 1

450g / m2 in a box-shaped steel mold with two holes of 0.5mm in the upper mold for venting out the gas generated with a volume of 2cm (height) × 10cm (width) × 50cm (length) A continuous strand mat having a thickness of 1 mm having a thickness of 10 cm x 50 cm is cut and pulverized, and then 200 g of the expandable polyurethane is poured thereon to form a uniformly dispersed state.

The above-mentioned foamable polyurethane includes 150 parts by weight of crude diphenylmethane diisocyanate, 100 parts by weight of polyether polyol having four hydroxyl groups obtained by the addition reaction of propylene oxide, 1.5 parts by weight of distilled water, monofluro-trichloromethane It was obtained by mixing with a liquid composition composed of 5 parts by weight, 0.5 parts by weight of silicone oil, and 0.3 parts by weight of dibutyl tin dilaurate.

Next, a paper honeycomb material (Hatokore; manufactured by Honshu Paper Co., Ltd., having a specific gravity of 0.04 and a thickness of 0.6 mm of the constituent sheet) cut to a size of 18 mm and 10 cm x 50 cm was placed on a foamable polyurethane layer. Place the continuous strand mat as used above first and close the mold.

After the foaming of the resin liquid in the mold is almost completed, the mold is placed in a high temperature oven and the resin foam is heated to 120 ° C. for 10 minutes therein. The mold is then taken out of the oven, cooled with water and the resulting molding is taken out of the mold.

The material thus obtained has a plate-like structure and has a specific gravity of 0.28. The surface layer consisted of polyurethane foam reinforced with continuous strand mat (17,7% by volume) and its thickness was 1 mm.

The inner layer consisted of paper honeycomb and foam urethane. In addition, the bending strength and other properties are shown in Table 1.

Example 2

The same method as in Example 1 was used, except that two consecutive strands of 1 mm thickness were used (four mats in total) to form a double surface layer, and 225 g of foamable polyurethane was used instead of 200 g. A foamed water globe assembly was prepared. The specific gravity of the obtained material is 0.35, the physical properties are shown in Table 1.

Comparative Example 1

240 g of expandable polyurethane as used in Example 1 to uniformly blend the fibers with polyurethane on a glass roving (weight: 110 g) obtained by squeezing a length of 50 cm long glass fibers Sprayed.

The resultant glass irradiation was pushed into a tubular mold having an inner cross-sectional area of 10 cm x 2 cm and a length of 50 cm, with both ends broken. After the foaming is completed, the mold is placed in a high temperature oven and heated at a temperature of 120 ° C. for 10 minutes to allow the resin foam to harden. The mold obtained after cooling the mold is taken out of the mold.

The material thus obtained was substantially the same as the plate-shaped polyurethane foam reinforced by long glass fibers arranged in the longitudinal direction, and the specific gravity was 0.35. Its physical properties are also shown in Table 1.

TABLE 1

Example 3

450g / ㎠ weight in a mold with 2cm (height) × 10cm (width) × 50cm (length) and two holes with a diameter of 0.5mm on the top to let out the gas generated inside the mold. 10 mm x 50 cm of continuous strand mat (made by Asahi Fiberglass Co., Ltd.) having a thickness of 0.4 mm was cut and spread, and 10 glass irradiation pieces (total thickness of 0.6 mm) were squeezed to a length of 50 cm thereon. Each mat consisted of 60 strands, each strand corresponding to 200 bundles of bile fibers 9 μm thick.

Then, 200 g of expandable polyurethane was poured onto the glass to spread evenly.

The above-mentioned foaming functional polyurethane comprises 150 parts by weight of crude diphenylmethane diisocyanate, 100 parts by weight of polyether polyol having four hydroxyl groups obtained by the addition reaction of propylene oxide, 1.5 parts by weight of distilled water, monofluoro-trichloromethane 5 It is obtained by mixing with a liquid composition consisting of parts by weight, 0.5 parts by weight of silicone oil, and 0.3 parts by weight of dibutyl ilaurate.

Next, a paper honeycomb material (Hatokore, manufactured by Honshu Paper Co., Ltd.) cut to a size of 10 cm x 50 cm with a thickness of 18 mm was placed on a foamable polyurethane, and the same number of glass irradiation as above was arranged on it. Next, a continuous strand mat as described above is placed on the glass irradiation. Then close the mold.

After the foaming of the resin liquid in the mold is almost finished, the mold is placed in an oven and the resin foam is heated therein at a temperature of 120 ° C for 10 minutes. The mold is then taken out of the oven and cooled with water. The molding thus obtained is then taken out of the mold.

Thus, a resin foam material having a surface composed of foamed polyurethane reinforced with fibers (53.8% by volume) as shown in FIG. 2 is obtained. The obtained material has the following physical properties.

Specific gravity (accumulated by the method described in JISZ-2102) 0.36

Longitudinal bending strength (measured by the method described in JISZ-2113) 450㎏ / ㎠

Longitudinal bending modulus (measured by the method described in JISZ-2113) 3.8 × 10 ⁴ kg / ㎠

Compressive strength (measured by the method described in JISZ-2111) 40㎏ / ㎠

Example 4

Instead of 200 g of expandable polyurethane injected into the mold, 100 parts by weight of polyol (as used in Example 1), 1.5 parts by weight of distilled water, 10 parts by weight of monofluoro trichloromethane, 0.5 parts by weight of silicone oil, dibutyl 200 g of a mixture composed of 0.3 parts by weight of tin laurate and 150 parts by weight of purified diphenylmethane diisocyanate is 75 g of aggregate (glass-clay foam mainly composed of glass particles having a particle size of 2.5-5 mm and apparent specific gravity of 0.59). Except for using a liquid composition obtained by mixing with OK Raito) and Chichibu Concrete Industries, Ltd., a plate-shaped foam resin was prepared by the same method as in Example 3.

The obtained material had the following physical properties, which were measured in the same manner as described in Example 3.

Example 5

According to the process of FIG. 4, a resin foam structure was prepared. A continuous strand mat (product made by Asai Fiberglass Co., Ltd.) having a weight of 540 g / m 2 and a volume of 85% by volume was used as a fiber mat, and was composed of kraft paper having a thickness of 03 mm, 95% by volume, and an apparent density of 0.022. The honeycomb paper (Diacel manufactured by Shipp Nippon Shim Co., Ltd.) consisting of a hexagonal core material having a thickness of 18 mm and a width of 170 mm and a side of 12 mm was used as a honeycomb material.

The foamable polyylurethane as used in Example 1 was poured into the space of the honeycomb material in an amount of 800 g / min so that the three layers were made of four stainless steel endless belts to form a space of 170 mm wide and 20 mm high. Pass the forming passage 9 of the configured length 9m. After heating at 120 ° C. with a heater occupying about 3 mm in the middle of the forming passage 6, the material exits the passage by an endless belt at a rate of 1 mm / min and is cut into round saws.

The material thus obtained had a thickness of 20 mm and a width of 170 mm. It is 4.000 mm in length and has the following physical properties measured by the same method as the method measured in Example 1.

Example 6

According to the process of FIG. 5, a resin foam member was manufactured. The same strand mat, honeycomb material, and apparatus, ie endless belts and forming passages, as used in Example 5, and foamable polyurethane as used in Example 3 were used.

The glass irradiation used consisted of 60 strands layered with 2,000 short fibers 9 μm thick.

Eighteen glass irradiations were blown onto the honeycomb material and poured the resin liquid in an amount of 480 g / min.

The material thus obtained had a thickness of 20 mm, a width of 170 mm, and a length of 4,000 mm, the foamed resin layer reinforced with a mat having a thickness of 0.4 mm, and the resin layer reinforced with glass irradiation having a thickness of 0.6 mm.

The physical properties of this material are shown next.

While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to those skilled in the art that changes or modifications may be made without departing from the spirit or scope of the invention.

Claims (1)

The inner material of the honeycomb structure is disposed between two or more layers of the fibrous material, the foamable thermosetting resin solution is supplied to the pores of the honeycomb structure, and the obtained stratified material is introduced into a passage for forming, and in the passage A method of producing a lightweight plate-like composite material, characterized in that the foamable thermosetting resin solution supplied above is heated to foam the resin solution, thereby filling the pores of the honeycomb material and impregnating and coating the fiber material.

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