JPH02265744A - Continuous composite molding and manufacture thereof - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a long composite molded article with excellent durability and a method for producing the same.

(Prior Art) Building materials such as rain gutters are molded into long lengths from thermoplastic resin such as vinyl chloride resin and are widely used.

However, such thermoplastic resin molded articles have large thermal expansion and contraction and low rigidity, and therefore have the disadvantage that they are easily deformed due to the seasons and changes in temperature between day and night, and are prone to cracking.

As a molded product that improves these drawbacks, a core material in which a large number of continuous long fibers such as glass roving are fixed with a thermoplastic resin such as acrylic resin is coated with a thermoplastic resin such as vinyl chloride resin. A long eave gutter composite molded body has been proposed.
(See Publication No. 09).

Such long eaves gutter composite molded products are usually produced by impregnating a large number of continuous long fibers with a liquid thermoplastic resin adhesive to form a core material, and introducing this core material into the crosshead mold of an extruder. It is manufactured by melt extrusion coating the thermoplastic resin.

(Problem to be Solved by the Invention) However, when a long composite molded article is manufactured by such a method, the strength of the core material is directional because the long fibers are oriented in one direction, and the heat resistance of the core material is Therefore, the resin pressure inside the crosshead mold causes the core material to flow and deform or break, making it difficult to obtain a uniform product.

In addition, the impact resistance of the obtained molded product is not sufficient, and
There is also the problem that deformation increases when used at high temperatures.

The present invention solves the above problems, and aims to improve deformation due to thermal expansion and contraction, rigidity, impact resistance,
It is an object of the present invention to provide a long composite molded article having improved heat resistance, uniformity, and excellent durability, and a method for producing the same.

(Means for Solving the Problems) The elongated composite molded article of the present invention comprises at least two core materials in which a large number of continuous long fibers are fixed with a thermoplastic resin.
Another core material in which long fibers similar to those described above are fixed with a thermoplastic resin having a higher melting point than the above resin is bonded to form a composite core material, and this composite core material is integrally coated with a thermoplastic resin. It is characterized by

Furthermore, the method for producing a long composite molded article of the present invention includes introducing a large number of continuous long fibers into a fluidized bed and impregnating them with a powdered thermoplastic resin to produce at least two sheets of resin-impregnated fiber material.
Another resin made by introducing long fibers similar to those described above into a fluidized bed and impregnating them with a powdered thermoplastic resin having a melting point higher than that of the resin is placed between the at least two resin-impregnated fiber materials. The method is characterized in that a composite core material is formed by thermocompression bonding of impregnated fiber materials, and this composite core material is introduced into a crosshead mold of an extruder, and a thermoplastic resin is melt-extruded and coated thereon to integrate the composite core material.

The present invention will be described below with reference to the drawings.

FIGS. 1 and 2 show an example of the elongated composite molded article of the present invention.

In FIG. 1, A is a long composite molded body shaped like an eaves gutter, 10 is a composite core material, and 20 is a thermoplastic resin integrally coated on the composite core material 10.

As shown in FIG. 2, the above-mentioned composite core material IO is made of a similar material as above, between two core materials 10° and 10' in which a large number of continuous long fibers 11 are fixed with thermoplastic resin 12. Long fiber 11
a thermoplastic resin 1 having a melting point higher than that of the resin 12;
3 and another core material 10'' is bonded.

As the long fibers 11, rovings such as glass fibers, carbon fibers, alumina fibers, and aramid fibers are suitably used. Expansion and contraction are the main problem, and when a large number of these rovings are arranged continuously in the longitudinal direction, the coefficient of linear expansion of the obtained molded article closely matches the theoretical value.

The long fibers 11 can theoretically be contained up to 90% by volume of the thermoplastic resin 12 or 13, but usually 60% by volume.
It is preferable to use it within a range of % by volume or less. Long fiber 11
If the amount exceeds 60% by volume based on the thermoplastic resin 12 or 13, cracking and delamination are likely to occur due to impact.

The thermoplastic resin 12 that fixes the large number of long fibers 11 is vinyl chloride resin such as polyvinyl chloride, vinyl chloride-ethylene copolymer, vinyl chloride-acrylic copolymer, vinyl chloride-urethane copolymer, etc. , acrylic resin,
Olefin resins such as polyethylene and polypropylene are used.

Further, the thermoplastic resin 13 fixing the long fibers 11 similar to the above is a thermoplastic resin having a melting point higher than that of the resin 12, such as polyamide resin, polycarbonate resin, chlorinated vinyl chloride resin, Fluorine-based resins such as tetrafluoroethylene-hexafluoroethylene copolymer, engineering resins such as polyphenylene sulfide and polyether sulfone, and the like are used.

The thermoplastic resin 12 and the thermoplastic resin 13 are usually combined to have a high compatibility and to be able to be thermally bonded.

Further, as the thermoplastic resin 20 coated on the composite core material 10, a resin similar to the above-mentioned thermoplastic resin 12 and a combination that can be thermally fused with the thermoplastic resin 12 is usually used. For example, when the elongated composite molded body A is an eaves gutter, a vinyl chloride resin with good weather resistance is preferably used as both thermoplastic resins 12 and 20.

Note that when the thermoplastic resin 20 contains fillers with a small coefficient of linear expansion, such as inorganic salts such as calcium carbonate, metal powders such as aluminum, short glass fibers, and wood powder, the coefficient of linear expansion with the composite core material 10 increases. This is preferable because the difference in .

In this way, the elongated composite molded article A of the present invention is constructed.

FIGS. 3 and 4 are schematic diagrams showing an example of the method for manufacturing the elongated composite molded article A of the present invention.

In FIG. 3, a large number of continuous long fibers 11 such as glass rovings are unwound from a bobbin, arranged in the longitudinal direction, and introduced into a fluidized bed 30 having a porous bottom plate 31. The long fibers 11 are usually defibrated by a defibrator 32 before being introduced into the fluidized bed 30 or within the fluidized bed 30 .

In the uppermost and lowermost fluidized beds 30, powdered thermoplastic resin 12 is blown up by air pressure above a porous bottom plate 31 and kept in a floating state. The particle size of the powdered thermoplastic resin 12 is generally about 10 to 200 microns. Then, a large number of long fibers 11 introduced into the uppermost and lowermost fluidized beds 30 are each impregnated with powdered thermoplastic resin 12 in a suspended state, resulting in two resin-impregnated fiber materials (10'), (10') is created. These two resin-impregnated fiber materials (10°) and (10') ultimately constitute the core material lO° of the composite molded body A.

Further, long fibers 11 similar to those described above are introduced into a fluidized bed 30 in the center similar to those described above, and are impregnated with a powdered thermoplastic resin 13 having a melting point higher than the resin 12, and other resin-impregnated fibers are added. The particle size of the powdered thermoplastic resin 13 is generally about 10 to lOOμ.The other resin-impregnated fiber material (10") is finally made into a composite molded product. A core material 10″ is constructed.

The other resin-impregnated fiber material (10'') is stacked between the two resin-impregnated fiber materials (10') and (10°) and passed through a pair of heated pinch rolls 40, where the thermoplastic resin Steps 2 and 13 are melt-bonded, and at least two resin-impregnated fiber materials (10'), (10°) and another resin-impregnated fiber material (10'') are thermocompression bonded.

In this case, since the thermoplastic resin 13 in the other resin-impregnated fiber material (10") has a high melting point and is difficult to melt,
Preferably, the resin 13 is melted and bonded by heating with I.

Note that the pair of heating pinch rolls 40 may be arranged in one set or in plural sets. In the figure, two sets are arranged. If the thermoplastic resins 12 and 13 are not completely melted and bonded, they are subsequently passed through a heating furnace 50 equipped with an infrared heater, etc., where the thermoplastic resins 12 and 1 are melted.
3 is completely fused.

In this way, a composite core material lO is formed in which another core material 10'' is bonded between the two core materials 10' and 10''.The composite core material 10 is once rolled up as shown in the figure. Alternatively, the arrangement of the pair of heating pinch rolls 40 and the heating furnace 50 may be reversed, and the two sheets of resin-impregnated fiber material (10'), (10'), another resin-impregnated fiber material (10'') is layered and heated in a heating furnace 50, where the thermoplastic resins 12 and 13 are melted and bonded, and then a pair of pinch rolls 40 You can also heat and press it.

Next, as shown in FIG. 4, the composite core material 10 is heated and softened by a heating forming device 60 to form eaves gutters, corrugated plates,
It is formed into a desired shape such as a deck material, and then cooled by a cooling forming device f61. It is preferable that the composite core material 10 formed into a desired shape is cooled by the cooling forming device 61 as described above because it can be smoothly introduced into the next crosshead mold. The core material 10 does not necessarily need to be cooled.

The composite core material 10 thus shaped is then introduced into the crosshead mold 70 of the extruder 71, where the thermoplastic resin 20 is melted and extruded from the crosshead mold 70.
is coated on the entire surface of the composite core material 10. At this time, the thermoplastic resin 12 in the composite core material 10 is softened or melted in the crosshead mold 70, and the thermoplastic resin 13 is not melted even though it is softened. The thermoplastic resin 20 is integrated over the entire surface of such a composite core material 10.

The length of the land portion of the crosshead mold 70 is determined by the extrusion temperature,
The gap is appropriately determined depending on the extrusion speed, the resin used, etc., and the gap is designed to have a desired shape, and is formed into a desired shape such as eaves troughs, corrugated plates, decking materials, etc.

Thereafter, the surface is finished by a sizing device 80 consisting of a cooling mold or the like, cooled, and taken out by a tensioning device F90 such as a caterpillar tensioning machine to produce a long composite molded product A.

In addition, in top peeling, - other core materials 10'' are adhered between the two core materials 10' and 10° to form the composite core material 10.
We have explained the case where three or more core materials 10' are formed, and between the three or more core materials 10 degrees,
A composite core material 10 formed by bonding two or more other core materials 10'' may also be used.

(Function) In the long composite molded article of the present invention, a large number of continuous long fibers are fixed with a thermoplastic resin to constitute at least two core materials and another core material. Long fibers have a small linear expansion coefficient and high rigidity.

Moreover, the long fibers of the other core material are fixed with a thermoplastic resin having a higher melting point than the resin of the two core materials, and the other core material is bonded between at least two core materials. Since the composite core material is formed by adding the other core material, heat resistance and impact resistance are improved.

In addition, in the method for manufacturing a long composite molded body of the present invention,
Since a large number of continuous long fibers are introduced into a fluidized bed and impregnated with a powdered thermoplastic resin, impregnation is easily performed.

Moreover, the composite core material formed in this way has good heat resistance, so even if it is introduced into the crosshead mold of an extruder, it will not absorb the heat of the thermoplastic resin melted and extruded from the crosshead mold. This prevents the core material from flowing and deforming or breaking due to extrusion pressure.

Then, due to the heat and extrusion pressure of the thermoplastic resin melted and extruded from the crosshead mold, the thermoplastic resin is strongly pressed against the composite core material and is firmly bonded and integrated.

(Example) Examples and comparative examples of the present invention are shown below.

In this example, the elongated eaves/gutter composite molded body shown in FIGS. 1 and 2 was manufactured by the method shown in FIGS. 3 and 4.

First, a large number of glass rovings (14400, manufactured by Nittobo) 11 are arranged in the longitudinal direction and introduced into the fluidized bed 3o, where they are defibrated and blown up by air at a pressure of 2.5 kg/oJ to form powder in a suspended state. PVC resin compound (average particle size 100μ, melting point 180°C) (TK-
400 (manufactured by Shin-Etsu Chemical Co., Ltd.) 12 to prepare two sheets of resin-impregnated fiber material (10") with a thickness of about 0.2mm, a width of 300mm, and a glass roving content of 30% by volume.

Similarly, the glass roving 11 was impregnated with powdered nylon 66 (average particle size 100μ, melting point 225'C) (Zytel 101: manufactured by DuPont) 13 to a thickness of about 0.
Another sheet of resin-impregnated fibrous material (10") with a width of 300 am and a glass roving content of 30% by volume was prepared.

Between the two sheets of resin-impregnated fiber material (10'),
Another sheet-shaped resin-impregnated fiber material (10"), which had been heated to 300°C in advance in a preheating furnace 41 to melt and adhere the resin 13, was
Stack the sheets and heat them with a heated vinyl roll 4 with a surface temperature of 200℃.
The resin 12 was passed through a heating furnace 50 to be heated to 200° C. to be completely melted, and taken off with a take-off pinch roll 51 to form a composite core material 10.

This composite core material IO was heated and softened by a forming device 60 maintained at a temperature of 170° C., shaped into a square eaves gutter shape, and then cooled. Subsequently, the shaped composite core material 10 was introduced into a crosshead mold 70 of an extruder, and the surface thereof was melt-extruded and coated with a vinyl chloride resin compound 20 to a thickness of 0.5 m at 185°C. .

Next, a sizing device 80 performs surface finishing,
It was cooled and taken out by a tensile machine 90 to produce a long eave gutter composite molded body A with a thickness of 1°5. The line speed at this time is 3
-7 minutes. The crosshead mold 70 described above had a land length of 200 mm and a rectangular gutter-like gap.

Thermal stretchability, impact resistance, and extrusion moldability of this eave gutter composite molded article were evaluated using the following methods. The results are shown in Table 1.

(1) A heat-stretchable eaves gutter molded body is cut into a length of 4 m to make a test piece, placed in a thermostatic chamber, the length Lto at 20°C is measured, and then the temperature is raised to 60°C. Length Li2 at 60°C
was measured, and the linear expansion coefficient α was calculated using the following formula. α-(L!
OLto)/(40('C)XLz.).

(2) Create a test piece by cutting the impact-resistant eaves gutter molding into 20mm x 20+++s, and test this test piece with a DuPont impact tester.
, s b was dropped, and the impact strength was measured from the falling distance at which the test piece was damaged.

(3) The heat-resistant eaves gutter molded body was cut into a 4-length test piece, which was left in an oven at 80°C for 5 hours, and its deformation state was observed.

(4) Create a test piece by cutting the rigid eaves gutter molded body into 150III in the longitudinal direction and 2511 in the width direction.
911, the longitudinal bending modulus of the test piece was measured. Note that the measurement temperature was 60°C.

(5) Deformation and tearing of the composite core material occurred when the extrudable composite core material was introduced into the crosshead mold of the extruder and the vinyl chloride resin compound was coated on the surface by continuous melt extrusion for 5 hours. The condition was observed.

Group 1 In Example 1, powdered polycarbonate (average particle size 70μ, melting point 240μ) was used instead of powdered nylon 66.
The procedure was the same as in Example 1, except that Naugatac 300-10 (Naugatac 300-10) was used.

The obtained eave gutter composite molded product was evaluated for thermal stretchability, impact resistance, and extrusion moldability. The results are shown in Table 1.

4 Hiyoshi JLL In Example 1, sheet-shaped resin-impregnated fiber material (10')
The same procedure as in Example 1 was carried out except that . However, in this case, the thickness of the composite core material is approximately 0.6 as in Example 1.
All to awi! ffL The obtained eave gutter composite molded product was evaluated for thermal stretchability, impact resistance, and extrusion moldability. The results are shown in Table 1.

Table 1 Note that the observation results of extrusion moldability in Examples 1 and 2 are as follows:
No deformation or tearing of the composite core material occurred during the 5-hour melt extrusion coating. On the other hand, in Comparative Example 1, a tear occurred in the composite core material approximately 30 minutes after the start of extrusion, and the thickness of the obtained eave gutter composite molded product was non-uniform at the portion where the composite core material was torn.

(Effects of the Invention) As described above, the long composite molded article of the present invention has small thermal expansion and contraction, improved deformation and rigidity, and further improved impact resistance and heat resistance, and can be used for long periods in environments with severe temperature changes. It has excellent durability, with no deformation, cracking, or delamination even when used.

In addition, the method for producing a long composite molded article of the present invention has good impregnation properties with a thermoplastic resin into a large number of long fibers (in addition, the composite core material may flow and deform during melt-extrusion coating or break). The composite core material and the thermoplastic resin coated thereon are firmly fused and integrated, and a long composite molded product having uniform thickness and excellent durability can be obtained.

[Brief explanation of drawings]

FIG. 1 is a partially cutaway perspective view showing an example of the elongated composite molded article of the present invention, and FIG. 2 is an enlarged view of the portion (A) in FIG. 1. FIGS. 3 and 4 are schematic diagrams showing an example of the method for manufacturing the elongated composite molded body of the present invention. A... Long composite molded body, 10... Composite core material, IO''
... Core material, 10'... Other core material, (10')...
Resin-impregnated fiber material, (10")...Other resin-impregnated fiber material, 11...Long fiber, 12...Thermoplastic resin fixing the long fiber, 13...Fixing the long fiber 20... Thermoplastic resin coated on composite core material, 30... Fluidized bed, 40... Heating pinch roll, 41... Preheating furnace, 50... ·heating furnace,
60... Heat forming device, 70... Crosshead mold of extruder, 80... Sizing device, 90...
...Tension device.

Claims (1)

[Claims] 1. Between at least two core materials in which a large number of continuous long fibers are fixed with a thermoplastic resin, long fibers similar to those described above are made of a thermoplastic resin having a higher melting point than the resin. A composite core material is formed by adhering another core material fixed with a thermoplastic resin, and the composite core material is integrally coated with a thermoplastic resin. 2. A large number of continuous long fibers are introduced into a fluidized bed and impregnated with powdered thermoplastic resin to form at least two sheets of resin-impregnated fiber material, and between the at least two sheets of resin-impregnated fiber material, the above-mentioned A composite core material is formed by thermocompression bonding with another resin-impregnated fiber material made by introducing long fibers similar to the above into a fluidized bed and impregnating them with a powdered thermoplastic resin having a melting point higher than that of the above resin. A method for producing a long composite molded article, which comprises introducing the composite core material into a crosshead mold of an extruder, melt-extruding the thermoplastic resin thereon, and integrating the composite core material.