JP2000204725A - Rain gutter and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a rain gutter which is excellent in impact resistance and rigidity, does not break or deform due to a temperature change, and can be manufactured from a low-cost, easy-to-composite material. SOLUTION: This rain gutter includes a base layer 1 formed by adding and dispersing reinforcing fibers to a thermoplastic resin, and a surface layer 2 covering the surface of the base layer 1. No. 1 was formed by adding and dispersing reinforcing fibers to a dispersion of polyester in a polyolefin.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rain gutter molded from resin and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventional rain gutters are generally formed of hard vinyl chloride resin. However, since the vinyl chloride resin has a high coefficient of linear expansion, it may be damaged or deformed by expansion and contraction due to temperature changes in summer, winter, day and night after being fixed to a building with a joint or the like.

[0003] A rain gutter comprising a metal plate core layer and a molded article in which both inner and outer surfaces of the core layer are coated with a synthetic resin has been proposed. If this rain gutter is used, it will not be damaged or deformed even if there is a temperature change, but corrosion of the metal plate may occur if rainwater enters from the cut surface.

Accordingly, a molded article in which a base resin composed of a polycarbonate resin and a reinforcing fiber, or a base resin composed of a polycarbonate resin, a polyester and a reinforcing fiber is coated with an AES resin or a blend resin of an AES resin and a polycarbonate resin. Is disclosed (Japanese Patent Laid-Open No. 9-228577). Since the rain gutter uses a polycarbonate resin having excellent impact resistance for the base material and the surface layer, it has excellent impact resistance and rigidity, and is not damaged or deformed even if it changes in temperature.

[0005]

However, the above-mentioned polycarbonate resin has a molding temperature of about 300 ° C., which is higher than the molding temperature of other resins, so that it is difficult to combine it with other resins. There was a problem. Another problem is that polycarbonate resins are expensive.

The present invention has been made in view of the above problems, and is made of a material which is excellent in impact resistance and rigidity, does not break or deform due to a temperature change, and is inexpensive and easy to compound. It is an object of the present invention to provide a rain gutter capable of carrying out.

[0007]

Means for Solving the Problems In order to solve the above-mentioned problems, the invention according to claim 1 provides a base material layer formed by adding and dispersing reinforcing fibers to a thermoplastic resin; A rain gutter having a surface layer covering the surface, wherein the base layer is formed by adding and dispersing reinforcing fibers to a dispersion of polyester in polyolefin.

According to a second aspect of the present invention, there is provided a rain gutter having a base layer formed by adding and dispersing reinforcing fibers to a thermoplastic resin, and a surface layer covering the surface of the base layer. hand,
The base material layer is formed by dispersing a composite material composed of a reinforcing fiber and a polyester and a reinforcing fiber in a polyolefin in which a polyester is dispersed.

The invention according to claim 3 is characterized in that an intermediate layer made of a resin that can be fused to both the base layer and the surface layer is provided between the two layers.

The invention according to claim 4 is characterized in that the surface layer is made of a highly weather-resistant resin.

[0011] In the invention according to claim 5, after the polyolefin and the polyester are melted in the barrel of the extruder,
The method is characterized in that the reinforcing fibers are supplied into the barrel of the extruder to disperse the reinforcing fibers, and then the melt in the barrel of the extruder is extruded.

According to a sixth aspect of the present invention, after the polyolefin, polyester and the composite material are melted in the barrel of the extruder, the reinforcing fibers are supplied into the barrel of the extruder to disperse the reinforcing fibers. And continuously extruding the melt in the barrel of the extruder.

[0013]

According to the first aspect of the present invention, since the base material layer is formed by adding and dispersing reinforcing fibers to a material obtained by dispersing polyester in polyolefin, the impact resistance and rigidity of the base material layer are improved. be able to.

According to the second aspect of the present invention, the base material layer is formed by dispersing a composite material composed of a reinforcing fiber and a polyester and a reinforcing fiber in a thermoplastic resin in which a polyester is dispersed in a polyolefin. Therefore, the impact resistance and rigidity of the base material layer can be further improved.

According to the third aspect of the present invention, since the intermediate layer made of a resin that can be fused to both the base layer and the surface layer is provided between the two layers, the base layer and the surface layer have compatibility with each other. Even in the case where it is not provided, it can be integrated through the intermediate layer.

According to the fourth aspect of the present invention, since the surface layer is made of a highly weather-resistant resin, the deterioration of the base material layer due to ultraviolet rays is suppressed.

According to the invention of claim 5, after the polyolefin and the polyester are melted in the barrel of the extruder,
Since the reinforcing fibers are supplied into the barrel of the extruder to disperse the reinforcing fibers, and then the melt in the barrel of the extruder is extruded, the rain gutter according to claim 1 or claim 3 is used. It can be easily manufactured.

According to the invention of claim 6, after the polyolefin, polyester and the composite material are melted in the barrel of the extruder, the reinforcing fibers are supplied into the barrel of the extruder to disperse the reinforcing fibers. And continuously extruding the melt in the barrel of the extruder.
Can be easily manufactured.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a gutter according to the present invention will be described below with reference to the drawings.

The rain gutter 1 shown in FIG. 1 has a substantially U-shaped cross section, and has a base layer 1 and a surface layer 2 covering the base layer 1.
And an intermediate layer 3 that fuses the base layer 1 and the surface layer 2 together when the layers are not compatible with each other. In the drawings, the thickness ratio is increased for easy understanding. In addition, the shape of the rain gutter is not particularly limited, and it is sufficient if the water on the roof can be collected and allowed to flow, and any shape other than that having a substantially U-shaped cross section as described above can be used. Good.

The base material layer 1 was obtained by adding a polyester to a polyolefin and further adding a reinforcing fiber in order to suppress the linear expansion coefficient of the molded product, and was melted and extruded in a barrel of an extruder. Things.

The polyolefin is not particularly limited as long as it is generally used for molding, such as polypropylene and polyethylene.

As the polyester, those having a melting point of less than 260 ° C., such as polyethylene terephthalate (hereinafter referred to as PET) and polybutylene terephthalate (hereinafter referred to as PBT), are preferable. Melting point 260 ° C
This is because in the above case, the polyolefin may be thermally decomposed.

In order to improve the interfacial adhesion strength between the polyolefin and the polyester, a compatibilizer such as a modified olefin may be added.

The reinforcing fibers are not particularly limited, as long as they are generally used for reinforcing thermoplastics, such as inorganic fibers such as carbon fibers and glass fibers, organic fibers such as aramid fibers and nylon fibers, and metal fibers. The reinforcing fiber has the effect of suppressing the linear expansion coefficient of the molded body as described above, but also has the effect of improving the rigidity of the molded body.

Further, in order to further reduce the expansion and contraction of the molded article and to reduce the expansion and contraction of the molded article, a composite material comprising a reinforcing fiber and polyester produced by a method described later may be added.

The other additives are not particularly limited,
The following are mentioned. A filler: Inorganic filler such as mica, talc, single talc, etc., and organic filler such as wood flour. B Flame retardants: Various halogen-based, non-halogen, and inorganic flame retardants. C antioxidants: hindered amines and the like. D modifier: deformed polyolefin and the like.

The surface layer 2 is preferably made of a highly weather-resistant resin, for example, a styrene-based copolymer resin such as an acrylic resin, an AES resin, or an AAS resin. PET, PBT, PC
There are no particular limitations on polyesters, polyamide resins, and combinations thereof, as long as they have thermoplasticity so that they can be coated and molded.

In addition, an acrylic resin or styrene such as AES is further provided on the outside of the surface layer 2 so as to be able to be joined to a gutter component using a solvent-based adhesive for PVC which is mainly used in current gutters. A polar amorphous resin such as a system resin may be coated.

Further, a pigment or an ultraviolet absorber may be further added to the resin of the surface layer 2 in order to prevent the transmission of ultraviolet light to the base material layer 1.

On the intermediate layer 3, a resin that can be fused to both the resin of the base layer 1 and the resin of the surface layer 2 is laminated. For example, PET or PBT as polyester for the base material layer 1,
When polypropylene or polyethylene is used as the polyolefin and a styrene-based copolymer resin such as an acrylic resin, an AES resin, or an AAS resin is used as the resin for the surface layer 2, the resin for the intermediate layer 3 is a styrene-ethylene-diene-styrene-based resin. Block copolymer, polyolefin elastomer, chlorinated polyolefin elastomer,
Alternatively, an unsaturated carboxylic acid derivative thereof, a mixture thereof, a polymer alloy containing them, or the like is used.

Next, a method of manufacturing the rain gutter will be described.
This will be described with reference to the drawings.

As shown in FIG. 2, the apparatus 10 for manufacturing a rain gutter includes a central layer extruder (extruder) 11 for melting and extruding a base resin, and a reinforcing fiber in a barrel 12 of the central layer extruder 11. Injection feeder 13 for supplying fiber, surface extruder 14 for extruding surface resin, intermediate layer extruder 15 for extruding intermediate layer resin, base resin and reinforcing fiber extruded from center layer extruder 11 and surface extrusion Mold 16 for molding the surface layer resin extruded from the extruder 14 and the intermediate layer resin extruded from the intermediate layer extruder 15, and cooling sizing for cooling the molded body extruded from the extrusion mold 16 while controlling the dimensions. The apparatus comprises a device 17, a take-off device 18 for taking the molded body, and a cutting device 19 for cutting the molded body to a required length.

In order to manufacture rain gutters by the apparatus 10, first, a composite material of a polyolefin such as polyethylene and a polyester such as PET, and a reinforcing fiber and a polyester described later is introduced into a barrel 12 of a center layer extruder 11 and a material layer. The chip 33 and other additives are supplied, and the base resin is extruded from the barrel 12 while being heated and melt-kneaded.

At this time, the fiber feed press-in feeder 1
From 3, the reinforcing fibers are supplied to the barrel 12 of the center layer extruder 11 so as to be uniformly dispersed and extruded together with the equipment resin and the like.

Then, the base resin extruded from the barrel 12 of the center layer extruder 11 is formed by an extrusion die 16.

Further, the surface resin is supplied to the surface extruder 14 so that the surface resin is extruded while being melted and kneaded.
At the same time, the intermediate layer resin is supplied to the intermediate layer extruder 15 so that the intermediate layer resin is extruded while being melted and kneaded, and the surface layer resin and the intermediate layer resin are integrally fused to the equipment layer resin.

Next, the size is controlled and cooled by the cooling sizing device 17, and the compact is taken out by the take-off device 18.

Finally, a desired rain gutter is manufactured by cutting the above-mentioned molded body into a required length with a cutting device 19.

As described above, according to the method shown in this embodiment, a molded body in which a thermoplastic resin of polyolefin and polyester is combined with a reinforcing fiber or the like is used as a base material layer, and a surface layer and an intermediate layer are further formed on the surface thereof. Can be manufactured by a simple method.

Next, a method for producing a composite material of reinforcing fibers and polyester will be described.

FIG. 3 shows an apparatus for producing a composite material of reinforcing fibers and polyester.

This apparatus receives an unwinder 21 for rewinding the coil of the reinforcing fiber 20, an extruder 23 for melting and extruding a polyester 22 such as PET, and a polyester 22 melted and extruded by the extruder 23. Heating bath 24 in which reinforcing fibers 20 are immersed, and polyester amount adjusting bar 25 for removing excess polyester 22 attached to reinforcing fibers 20.
And a cooling device 28 including a cooling roll 26 and a cooling air nozzle 27 for cooling and solidifying the polyester 22 entrained by the reinforcing fiber 20, and cutting the reinforcing fiber 20 having the polyester 22 solidified on the surface to form the reinforcing fiber 20 and the polyester. 22 and a pelletizer 30 for manufacturing a composite material chip 29.

In order to produce a composite material of the reinforcing fiber 20 and the polyester 22 by using this apparatus, first, the polyester 22 such as PET is melted and extruded by the extruder 23 and supplied to the heating bath 24. Then, the reinforcing fiber 20 is immersed in the molten polyester 22 in the heating bath 24 by passing the coil of the reinforcing fiber 20 such as carbon fiber through the rewinding heating bath 24 using the rewinding machine 21.

Next, the excess polyester 22 adhering to the reinforcing fibers 20 is removed by a polyester amount adjusting bar 25, and entrained by the reinforcing fibers 20 using a cooling device 28 including a cooling roll 26 and a cooling air nozzle 27. Is cooled and solidified. Then, the reinforcing fiber 20 having the polyester 22 solidified on the surface is cut by the pelletizer 30 to produce a chip 29 of a composite material of the reinforcing fiber 20 and the polyester 22.

[0046]

EXAMPLES The following experiments were performed to confirm the effects of the present invention. <Embodiment 1> Using the apparatus shown in FIG.
ET (Mitsubishi Rayon-based diamond night PA-200) 10
vol% added polypropylene (Grand Polypropylene B701 manufactured by Grand Polymer Co., Ltd.), kneaded by raising the resin temperature to about 250 ° C., and carbon fiber chop (Vesfight HTA-C manufactured by Toho Rayon) as a reinforcing fiber.
6-SR) from the feeder 13 for feeding fibers.
vol%. At this time, the resin temperature dropped to 230 ° C. Acrylic resin (Orograss HF1-10 manufactured by Sumitomo Chemical Co., Ltd.) was used for the resin of the surface layer, and SEBS (Tuftec H1041 manufactured by Asahi Kasei Corporation) was used for the resin of the intermediate layer. The sheet was extruded from No. 15 and laminated on the base material layer, and formed into a U-shape by an extrusion die 16. The resin temperature in the extrusion mold dropped to 220 ° C. The thickness of the base layer is about 1.5 mm, the thickness of the intermediate layer is about 0.05 mm, and the thickness of the surface layer is about 0.1 mm. <Example 2> Glass fiber (CS manufactured by Nitto Boss Co., Ltd.)
PE946: average fiber diameter 23 mm, average fiber length 4 mm)
The procedure was the same as in Example 1 except for using. <Example 3> AES resin (Sumitomo A & L) was used as the surface resin.
Except for using Unibright UB-400). <Example 4> AES resin (Sumitomo A & L) was used as the surface resin.
Except for using Unibright UB-400). <Example 5> Maleic anhydride-modified polypropylene resin (Admer QB550 manufactured by Mitsui Petrochemical) 5 as a compatibilizer
%, Except that% was added. <Example 6> Maleic anhydride-modified polypropylene resin (Admer QB550 manufactured by Mitsui Petrochemical) 3 as a compatibilizer
%, Except that% was added. <Embodiment 7> Using the apparatus shown in FIG. 3, molten PET (Dianight PA-200 manufactured by Mitsubishi Rayon) was supplied from an extruder 23.
Is supplied to the heating bath 24 and carbon fibers (Vesfight HTA-C6-S manufactured by Toho Rayon Co., Ltd.) are used as reinforcing fibers in the rewinding machine 21.
R) 40 rubbings are aligned and passed through the heating bath 24 to be immersed in the molten PET in the heating bath 24.
mm, removes excess PET, cools and solidifies the molten PET entrained by the carbon fibers using a cooling device 28 including a cooling roll 26 and a cooling air nozzle 27, and the like. Cut the carbon fiber solidified on the surface into about 5 mm square to produce a composite material chip of the reinforcing fiber and the polyester.

Next, PET (Mitsubishi Rayon-based diamondite PA-20) was fed to the center layer extruder 11 by the apparatus shown in FIG.
0) Chip 10 vol of composite material of polypropylene (Grand Polypro B701 manufactured by Grand Polymer Co., Ltd.) to which 5 vol% is added, and the above-mentioned reinforcing fiber and polyester
%, Melted and kneaded, and used as a reinforcing fiber carbon fiber chop (Vesfight HTA-C6-S manufactured by Toho Rayon)
R) 5 vol. From the fiber feed push feeder 13
%, And an acrylic resin (Oroglass HFI-10 manufactured by Sumitomo Chemical Co., Ltd.) was used as the resin for the surface layer.
, And laminated on a base material layer, and formed into a U-shape by an extrusion die 16. <Example 8> Glass fibers (Nitto Boss CS
PE946: average fiber diameter 23 mm, average fiber length 4 mm)
Example 7 was the same as Example 7 except that was used. <Example 9> Maleic anhydride-modified polypropylene resin (Admer QB550 manufactured by Mitsui Petrochemical) 5 as a compatibilizer
%, Except that% was added. Example 10 Maleic anhydride-modified polypropylene resin (Admer QB550 manufactured by Mitsui Petrochemical) as a compatibilizer
Comparative Example 1 was the same as Example 1 except that PET was not added except that 5% was added. <Comparative Example 2> The same operation as in Example 2 was performed except that PET was not added. <Comparative Example 3> The same operation as in Example 5 was performed except that PET was not added. <Comparative Example 4> The same operation as in Example 6 was performed except that PET was not added.

The molded body obtained as described above was evaluated by a high-speed maximum tensile stress (tensile speed: 2 m / sec), a tensile strength, and a coefficient of linear expansion (TMA, average of 40 ° C. to 70 ° C.).

As a result, the result as shown in FIG. 4 was obtained.

That is, when Example 1 and Comparative Example 1 are compared, a remarkable increase in high-speed tensile maximum stress (400 kgf-m
m to 1600 kgf-mm), and the tensile strength also increased (from 18,000 kg / cm ² to 20,000).
kg / cm ² ). Similar effects were obtained by comparing Example 2 with Comparative Example 2, Example 5 with Comparative Example 3, and Example 6 with Comparative Example 4. Therefore, it was confirmed that the impact resistance and the rigidity can be improved by adding PET to the polyolefin.

Further, comparing Example 1 and Example 7, the maximum tensile stress at high speed increased (1600 kgf-mm).
From 1750 kgf-mm), the tensile strength increased (2
0000 kg / cm ² to 24000 kg / cm ² ). Therefore, it was confirmed that the impact resistance and the rigidity can be further improved by adding the composite material of the reinforcing fiber and the polyester to the base material layer.

[0052]

As described above, according to the first aspect of the present invention, a base layer formed by adding and dispersing reinforcing fibers to a thermoplastic resin, and a surface layer covering the surface of the base layer are provided. In the rain gutter, the base material layer is characterized by being formed by adding and dispersing reinforcing fibers to a material obtained by dispersing polyester in polyolefin, so that the impact resistance and rigidity of the base material layer are Can be improved.

According to the second aspect of the present invention, there is provided a rain gutter having a base layer formed by adding and dispersing reinforcing fibers to a thermoplastic resin and a surface layer covering the surface of the base layer. hand,
The base material layer is characterized by being formed by dispersing a reinforcing material and a composite material composed of a reinforcing fiber and a polyester in a polyolefin dispersed polyester, impact resistance of the base material layer, The rigidity can be further improved.

According to the third aspect of the present invention, the intermediate layer made of a resin that can be fused to both the base layer and the surface layer is provided between the two layers. Even when there is no compatibility, they can be integrated via the intermediate layer.

According to the fourth aspect of the present invention, since the surface layer is made of a highly weather-resistant resin, the deterioration of the base layer caused by ultraviolet rays is suppressed.

According to the invention of claim 5, after the polyolefin and the polyester are melted in the barrel of the extruder,
Since the reinforcing fibers are supplied into the barrel of the extruder to disperse the reinforcing fibers, and then the melt in the barrel of the extruder is extruded, the rain gutter according to claim 1 or claim 3 is used. It can be easily manufactured.

According to the invention of claim 6, after the polyolefin, polyester and the composite material are melted in the barrel of the extruder, reinforcing fibers are supplied into the barrel of the extruder to disperse the reinforcing fibers. And continuously extruding the melt in the barrel of the extruder.
The rain gutter according to any of the above can be easily manufactured.

[Brief description of the drawings]

FIG. 1 is a sectional view of a rain gutter according to the present invention.

FIG. 2 is a schematic plan view of an apparatus for manufacturing a rain gutter according to the present invention.

FIG. 3 is a schematic side view of an apparatus for producing a composite material of a reinforcing fiber and a polyester added to a rain gutter according to the present invention.

FIG. 4 is a table showing the results of examples of the fiber composite molded article according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base material layer 2 Surface layer 3 Intermediate layer

Continued on the front page F-term (reference) 4F100 AD11A AD11H AG00H AK01A AK01B AK01C AK03A AK07B AK12C AK12J AK27C AK27J AK41A AK42A AK75C AK75J J AK80C AL05A AL07B BA02 BA03 BA07 BA10 DABBAA BAJ BA10 BAK BAG

Claims (6)

[Claims] 1. A rain gutter comprising: a base layer formed by adding and dispersing reinforcing fibers to a thermoplastic resin; and a surface layer covering the surface of the base layer, wherein the base layer is A rain gutter formed by adding and dispersing a reinforcing fiber to a polyolefin in which polyester is dispersed. 2. A rain gutter comprising a base layer formed by adding and dispersing reinforcing fibers to a thermoplastic resin, and a surface layer covering the surface of the base layer, wherein the base layer is A rain gutter formed by dispersing a reinforced fiber and a composite material comprising a reinforced fiber and a polyester in a dispersion of a polyester in a polyolefin. 3. The gutter according to claim 1, wherein an intermediate layer made of a resin that can be fused to both the base layer and the surface layer is provided between the two layers. . 4. The rain gutter according to claim 1, wherein the surface layer is made of a highly weather-resistant resin. 5. After the polyolefin and the polyester are melted in the barrel of the extruder, the reinforcing fibers are supplied into the barrel of the extruder to disperse the reinforcing fibers, and then the reinforcing fibers are dispersed in the barrel of the extruder. The method for manufacturing a rain gutter according to claim 1, wherein the melt is extruded. 6. After extruding a polyolefin, a polyester, and the composite material in a barrel of an extruder, supplying reinforcing fibers into a barrel of the extruder to disperse the reinforcing fibers. The method according to any one of claims 2 to 4, wherein the melt in the barrel is extruded.