JPH03180326A - Manufacture of sheetlike formed body - Google Patents

Abstract

PURPOSE:To form the formed body concerned without developing failures such as blister and the like by a method wherein air bubbles, which develop at the expansion and setting of resin liquid, and dispersingly passed through non-woven fabric. CONSTITUTION:A roll R, on which non-woven fabric 20 having the surface coated with synthetic resin excellent in weathering resistance such as acrylic resin or the like, is arranged above and endless belt 4. The non-woven fabric 20 is made of synthetic fiber or glass fiber and provided so as to face to the outer peripheral surface of an endless belt 4 under the condition that the coating layer C side locate at the outer surface of sheet-like formed body S. Through the rear surface of the non-woven fabric 20, the dispersing passage of air bubbles is ensured and the resin liquid impregnated so as to be integrally bonded with uncured formed body S. The resin liquid sets when the formed body S is formed, resulting in laminating the non-woven fabric 20 to the formed body S and preventing the former from separating from the latter. Air bubbles, which develop at the expansion and setting of the resin liquid, are dispersingly passed through the non-woven fabric or taken in the non-woven fabric, resulting in preventing blister from developing on the boundary surface of lamination.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for manufacturing a plate-shaped molded body suitable for building materials and the like.

(Prior art) Conventionally, a reinforcing fiber material such as glass fiber is impregnated with a foamed curable resin liquid, and the fiber material is continuously advanced in the longitudinal direction in a tapered shape and guided into a molding path. In this process, the applicant has foamed and hardened the resin liquid to form a lightweight plate-like molded product suitable for building materials and the like. First, let's talk about the manufacturing apparatus for this plate-shaped molded body in the fifth section.
This will be explained based on FIGS. 7 to 7.

When the continuous glass fiber bundles 1 are dispersed and arranged in a thin and wide state, when a foamed curable resin liquid such as polyurethane is jetted from the jetting machine 2, the fiber bundles 1 are
The foamed curable resin liquid is adhered to the fibers and further rubbed by the rocking plate 3, thereby uniformly dispersing the foamed curable resin liquid between each fiber. Such a continuous fiber bundle 1 enters a forming passage 8 surrounded by endless belts 4, 5 and side belts 6.7 whose inner peripheral surfaces are secured by slat chains 60.70,
Proceeds with endless belt 4.5 and side belt 6.7. The endless belt 4° 5 is supported with its inner circumferential surface in contact with a group of mold rollers 12 rotatably supported by the upper mold 10 and the lower mold 11, respectively, and the side belt 6° 7 is the upper mold lO and the lower mold 11
The inner peripheral surface of the wheel 14 is supported by being engaged with a slat chain 60, 70 which is rotatable in contact with the wheel 14 which is rotatably supported by a fixture 13 which is fixed to the wheel 14. As a result, the endless belt 4.5 and the side belts 6.7 can be easily rotated.

As a result, when the fiber bundle 1 is pulled by the tensioning machine 15, the foamed curable resin liquid contained in the fiber bundle 1 foams while traveling in contact with the endless belts 4, 5 and the side belts 6.7. and curing. During foaming, endless belts 4, 5 and side belts 6 are placed around the fiber bundle l.
．． Furthermore, a group of mold rollers 12 are in contact with the inner circumferential surfaces of the endless belts 4 and 5, and side belts 6
．． Since the slat chains 60 and 70 are engaged with the inner circumferential surface of the molding channel 7, the foamed resin liquid cannot exit the molding passage 8. Therefore, a plate-shaped molded body S can be manufactured based on the molding passage 8 defined by the outer surfaces of the endless belt 4.5 and the side belts 6.7 (Japanese Patent Publication No. 52-2421, Utility Model Publication No. 59-1982). 364
(See Publication No. 14).

When the plate-shaped molded body S formed in this manner is used outdoors, there is a problem in that it discolors or deteriorates due to the influence of ultraviolet rays. For this reason, a synthetic resin film is laminated on the surface of the plate-shaped molded body S (1983-
(See Publication No. 18442, Japanese Patent Publication No. 60-4774)
.

(Problem to be Solved by the Invention) By the way, when a synthetic resin film is laminated on the surface of the plate-shaped molded body S in this way, when the resin liquid is foamed and hardened at the interface between the plate-shaped molded body S and the synthetic resin film. The generated air bubbles may remain, resulting in defective products with blisters in the synthetic resin film.

The present invention has been made in view of the above-mentioned problems, and provides a method for manufacturing a plate-shaped molded body that can reliably mold a plate-shaped molded body without producing defective products.

(Means for Solving the Problems) The first manufacturing method of the present invention is to foam and harden a foamed curable resin liquid impregnated into a fiber material in a mold to form a plate-shaped molded body reinforced with the fiber material. When foaming and curing a foamed curable resin liquid, a nonwoven fabric is laminated on at least one surface of an uncured molded body, the nonwoven fabric is impregnated with a foamed curable resin liquid, and the resin liquid is foamed and cured. It is characterized by distributing and distributing the bubbles that are sometimes generated.

Further, a second manufacturing method of the present invention is a manufacturing method in which a foamed curable resin liquid impregnated into a fiber material is foamed and hardened in a mold to form a plate-shaped molded body reinforced with the fiber material, comprising: When foaming and curing the foaming curable resin liquid, a low-density nonwoven fabric and a high-density nonwoven fabric are laminated on at least one side of the uncured molded body, and a high-density nonwoven fabric is laminated on the outside of this low-density nonwoven fabric in order, and the foaming curable resin liquid is laminated on these nonwoven fabrics. It is characterized in that it is impregnated with a resin liquid and that air bubbles generated during foaming and curing of the resin liquid are distributed and distributed.

(Function) The foamed curable resin liquid impregnated with a reinforcing material such as glass fiber in the mold starts to foam and harden, and a plate-shaped molded product is formed. When this resin liquid foams and hardens, by placing a nonwoven fabric on at least one surface of the uncured molded body, the nonwoven fabric is integrally bonded to the uncured molded body, producing a molded body in which the nonwoven fabrics are laminated. I can do it. At this time, the air bubbles generated when the resin liquid is foamed and cured are dispersed through the nonwoven fabric or are accommodated in the nonwoven fabric, so that no blistering occurs at the laminated interface.

(Example) Embodiments of the present invention will be described below with reference to the drawings.

Note that the overall configuration of the device was previously explained in the section of the prior art, so a detailed explanation thereof will be omitted.

1 and 2 show a first embodiment of a plate-shaped molded body with excellent weather resistance and a manufacturing apparatus for molding this plate-shaped molded body S. FIG. In this manufacturing device, above the endless belt 4, a nonwoven fabric 2 whose surface is coated with a synthetic resin having excellent weather resistance, such as acrylic resin, etc.
A roll R of 0 is placed. Synthetic fibers or glass fibers are used as the nonwoven fabric 20, and the nonwoven fabric 20 is disposed so as to face the outer peripheral surface of the endless belt 4 so that the coating layer C side described above is located on the outer surface of the plate-shaped molded body S. There is.

This nonwoven fabric 20 ensures the dispersion and circulation of air bubbles on its back surface, and at the same time, the nonwoven fabric 20 is impregnated with resin liquid and is an uncured molded body S.
When the resin liquid is cured and molded body S is molded, it is laminated on the molded body S and peeling is prevented. , and this nonwoven fabric 20 has a weight of 100 to 200
g/bo, thickness is 0. Preferably, the diameter is 3 to 0.7 mm. Its weight is ioog/rrf.

If the thickness is less than 0.3 m, the resin liquid will easily infiltrate beyond the coating layer C even if coated with a weather-resistant resin, while the weight is 200 g/nf and the thickness is 0.1
If it is larger than tm, and the diameter of the roll R is constant, the length wound around the roll R becomes short and must be replaced frequently, which increases cost and deteriorates workability.

Further, the weather-resistant resin such as acrylic resin imparts weather resistance to the molded body S, and also prevents the foamed curable resin liquid from infiltrating beyond the non-woven fabric 20.

In the case of acrylic resin, the coating amount of this weather-resistant resin is preferably 150 to 300 g/%;
If it is less than 300 g/nf, the effect of improving weather resistance will be small and the resin liquid will easily leak beyond the nonwoven fabric 20 to its outer surface. This worsens the condition and makes it easier for swelling to occur.

Conventionally, a mold release agent is used to smoothly remove the molded body S from the molding passage 8, and since the surface of the molded body S is smooth, it has the disadvantage of being slippery; however, in this example, Since the nonwoven fabric 20 is laminated on at least one surface of the molded body S, that surface becomes a rough surface, which also has the advantage of being difficult to slip.

Further, although the nonwoven fabric 20 is coated with a weather-resistant resin in advance, the coating may be applied after molding.

Furthermore, FIGS. 3 and 4 show the second part of the plate-shaped molded body S.
Examples and a manufacturing apparatus for molding this plate-shaped molded body S are shown. In this manufacturing equipment, endless belt 4
A roll R5 of high-density nonwoven fabric 30 and a roll R2 of low-density nonwoven fabric 40 are arranged above. These nonwoven fabrics 30 and 40 are made of synthetic fibers or glass fibers, and are placed in contact with the outer surface of the endless belt 4 so that the low-density nonwoven fabric 40 and the high-density nonwoven fabric 30 overlap in this order on at least one side of the plate-shaped molded body S. Arranging the density nonwoven fabric 30,
A low-density nonwoven fabric 40 is disposed outside the nonwoven fabric 30.

This high-density nonwoven fabric 30 prevents the foamed resin liquid from infiltrating to the outside, and this high-density nonwoven fabric 30 has a weight of 150 to 300 g/po and a thickness of 0.2 to
0.4 mm is preferable, and if the weight is less than 150 g/rrf, the resin liquid tends to infiltrate;
If it is larger than 300 g/nr, the circulation of air bubbles will be poor and bulges will easily occur, and the roll diameter will become large, resulting in poor workability.

In addition, the low-density nonwoven fabric 40 is impregnated with the foamed resin liquid to firmly bind it, disperse the bubbles, lower the foaming pressure, and assist the leaching into the high-density nonwoven fabric 30. The low density nonwoven fabric 40 has a weight of 30
~80g/rrf and a thickness of 0.4~0.6ns are preferred. If the weight is less than 30g/rrf, the resin liquid will easily infiltrate, while if it is greater than 80g/nf, the permeability of the resin liquid will be poor, and the high-density nonwoven fabric 3
In addition to weakening the bond with 0, workability deteriorates.

At least the − side of the molded body S formed in this way,
That is, by applying an acrylic resin, which is a weather-resistant resin, to the outer surface of the high-density nonwoven fabric 30, the weather resistance of the molded body S is improved. In this case, similarly to the first embodiment, the surface corresponding to the outer surface of the high-density nonwoven fabric 30 is coated with a weather-resistant resin in advance, and the fiber material l impregnated with the foam-setting resin liquid is guided into the molding passage 8. It may be configured as follows.

Also in this second embodiment, since the nonwoven fabric is laminated on at least one surface of the molded body S, the rough surface thereof makes it difficult to slip.

In these embodiments, the mold is composed of a molding passage 8 formed by an endless belt 4.5 and a side belt 6.7, and this molding passage 8 is provided with a continuous reinforcement impregnated with a foamed curable resin liquid. The manufacturing method has been described in which the plate-shaped molded body S is continuously formed by supplying the reinforcing fiber material 1. It is also possible to adopt a manufacturing method in which the resin liquid is foamed and hardened in this mold to form plate-shaped molded bodies one by one.

(Effects of the Invention) As described above, according to the manufacturing method of the present invention, it is possible to disperse and distribute the air bubbles generated during foaming and curing of the resin liquid through the nonwoven fabric. A shaped body can be formed.

[Brief explanation of drawings]

The drawings illustrate an embodiment of the method for manufacturing a plate-shaped molded body according to the present invention, and FIG. 1 is a perspective view showing the molded body manufacturing apparatus of the first embodiment with some parts omitted, and FIG. A cross-sectional view of the molded body,
FIG. 3 is a partially omitted perspective view of the molded body manufacturing apparatus of the second embodiment, FIG. 4 is a sectional view of the molded body, and FIG. 5 is an overall perspective view schematically showing the molded body manufacturing apparatus. FIG. 6 is a sectional view showing a molding passage according to the prior art, and FIG. 7 is a plan view showing the molding passage according to the prior art with a portion omitted. 4.5...Endless belt 6.7...Side belt 20.30.40...Nonwoven fabric 8...Molding passage (molding mold) S...Plate-shaped molded body

Claims (1)

[Scope of Claims] 1) A manufacturing method in which a foamed curable resin liquid impregnated into a fiber material is foamed and hardened in a mold to form a plate-shaped molded body reinforced with the fibrous material, the method comprising: When foaming and curing the liquid, a non-woven fabric is laminated on at least one surface of the uncured molded body, the non-woven fabric is impregnated with the foam-curing resin liquid, and the air bubbles generated when the resin liquid is foam-cured are dispersed and distributed. A method for manufacturing a plate-shaped molded body. 2) A manufacturing method in which a foamed curable resin liquid impregnated into a fiber material is foamed and hardened in a mold to form a plate-shaped molded body reinforced with the fiber material, the method comprising: foaming and hardening the foaming curable resin liquid; , a low-density nonwoven fabric and a high-density nonwoven fabric are laminated on at least one surface of the uncured molded body, and a high-density nonwoven fabric is laminated on the outside of the low-density nonwoven fabric, and these nonwoven fabrics are impregnated with a foamed curable resin liquid, and the resin liquid is foamed. A method for producing a plate-shaped molded article, characterized in that air bubbles generated during curing are distributed and distributed.