JPH0416334B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention is a synthetic resin molded product for building materials such as rain gutters, pipes, corrugated plates, flat plates, etc., which is integrally enclosed within the thickness of the molded product, and which improves the thermal and mechanical strength of the molded product. The present invention relates to a new multipurpose sheet that is widely used as a reinforcing core material that functions as a supplement, as an interior and exterior material for various types of fittings, and as a packaging material for industrial products.

Conventionally, in order to prevent thermal deformation and thermal expansion and contraction of the above-mentioned synthetic resin molded products for building materials and to increase mechanical strength such as impact resistance and shear resistance, metal reinforcing materials such as iron plates or wire mesh have been used within the thickness of the molded products. It was widely practiced to store them in one piece. However, when embedding these metal reinforcing materials, which are materials different from synthetic resin, in order to strengthen the interlayer adhesion with the synthetic resin, the surface of the reinforcing material must be appropriately treated and This requires a cumbersome process of applying adhesive, and such reinforcing materials are generally heavy, which increases the weight of the molded product itself, offsetting the lightweight nature of synthetic resin. In addition,
This has included problems such as the fact that the reinforcing material on the cut end surface of the molded product is easily rusted and corroded.

In Japanese Patent Application No. 57-064346, the present applicant proposed a construction material for construction materials in which a thermosetting synthetic resin reinforcing layer supported on a paper base material is integrally integrated in a sandwich-like manner within the thickness of a thermoplastic synthetic resin molded product. We provided reinforced synthetic resin molded products. The reinforcing layer of such a molded product is effective in supplementing the thermal and mechanical strength of the molded product due to the combination of the stiffness unique to the paper base material and the rigidity of the thermosetting synthetic resin, and is lightweight. Since there is no concern about rusting, it has become highly valued as a way to eliminate the above problems, but the thermosetting synthetic resin that is the substance of the reinforcing layer is coated with vinyl chloride. It has slightly poor adhesion with thermoplastic synthetic resins such as resins, and although it has high rigidity, it lacks flexibility.
Therefore, it was undeniable that some insufficiency remained in the impact strength of the molded product.

The present inventors conducted further research in view of the above, and found that when thermosetting synthetic resin, synthetic rubber, and thermoplastic synthetic resin are supported on a paper base material, the excellent rigidity of thermosetting synthetic resin and the synthetic rubber It has been discovered that the flexibility of thermoplastic resin and the good adhesion of thermoplastic synthetic resin to vinyl chloride resin etc. are organically combined to maintain excellent properties that can eliminate the above problems. The present invention was made based on this knowledge,
By integrally laminating glass net, organic fiber net, etc. on the above-mentioned paper base material, the suitability of the above-mentioned molded product as a reinforcing core material is further improved, as well as interior and exterior materials for various fittings (sliding doors, screens, etc.) In addition, it can be used as a packaging material in the manufacturing and transportation process of IC packages by integrating wire mesh, punched metal, etc. in place of the above-mentioned glass nets and organic fiber nets. The present invention aims to provide a valuable multi-purpose sheet that can be widely used for other purposes.

That is, the gist of the multipurpose sheet of the present invention is that it is formed by integrally laminating a paper base material carrying thermosetting synthetic resin, synthetic rubber, and thermoplastic synthetic resin, and a porous reinforcing material. As the base material, linter paper, Japanese paper, and mixed paper of linter, pulp, and organic or inorganic fibers are preferably used because of their excellent impregnability with resin liquid, as described later. Linter paper is paper made using only linters (additives such as colorants, waterproofing agents, and preservatives are included as appropriate), and it is softer than normal paper and is commonly used in Western paper. This is a porous paper used. Additionally, Japanese paper is widely known, but it is similar to the above linter paper in that it is porous. Furthermore, the above-mentioned mixed paper is made by mixing linter, pulp, and organic fibers such as vinylon or inorganic fibers such as glass fibers in an appropriate ratio in a beating machine, and the pulp or the above-mentioned fibers are intertwined with the linter to form porous pores. Despite its high quality, it has a unique tenacity.
On the other hand, the resin supported on this paper base material is
First, thermosetting synthetic resins include phenol resin, melamine resin, epoxy resin, urea resin, unsaturated polyester resin, diallyl phthalate resin, urethane resin, etc., and synthetic rubbers include butadiene acrylonitrile (NBR), butadiene styrene, etc.
Examples of the thermoplastic synthetic resin include vinyl acetate resin, acrylic resin, polyvinyl alcohol, polyvinyl chloride, and modified resins thereof. also,
As the reinforcing material, a glass net, an organic fiber net typified by vinylon, a wire net, a punched metal, or the like may be used as appropriate depending on the purpose.

In supporting the above resin on a paper base material,
Add a solution or emulsion of thermoplastic synthetic resin to the above synthetic rubber latex at a solid content ratio (weight).
Mix the mixture so that the ratio is 80:20 to 20:80, and then mix the solution or emulsion of the thermosetting synthetic resin to this mixed solution and impregnate the paper base material with it. Because it is porous, the resin liquid penetrates deeply into each pore, and when it is left to dry, the resin intertwines with the porous structure of the paper base material and becomes one, in effect supporting the resin on the paper base material. It turns out. The ratio of each resin etc. constituting this resin is 10 to 60 parts by weight of the thermosetting synthetic resin and 60 to 10 parts by weight of the mixture of synthetic rubber and thermoplastic synthetic resin in the above ratio to 100 parts by weight of the paper base material. It is desirable to achieve the desired performance for various uses described later, and in order to achieve this desired ratio, the viscosity, concentration, surface tension, etc. of the impregnating resin liquid are adjusted as appropriate. In addition, some types of thermosetting synthetic resins are difficult to be compatible with other synthetic resins, but in such cases, after impregnating the paper base material with the resin liquid of the thermosetting synthetic resin, By impregnating the above mixture, the same performance as above can be imparted.

On the other hand, in order to laminate a porous reinforcing material such as glass net onto a paper base material carrying resin, the two are pressed together using a normal heat press, but it is necessary to ensure strong mutual adhesion. In order to do this, it is desirable to carry out this process while the resin is uncured, or if the resin is to be laminated after being cured, an acrylic adhesive may be used as appropriate.

The thus obtained sheet has the stiffness of the paper base material, the rigidity of the thermosetting synthetic resin, and the toughness of the porous reinforcing material, and the above-mentioned metal is used as the reinforcing core material of the synthetic resin molded product. It has a mechanical strength comparable to that of synthetic reinforcement materials, and has flexibility and flexibility due to synthetic rubber and thermoplastic synthetic resin, making it highly workable. is integrally enclosed within the thickness of the rain gutter and is used to reinforce the rain gutter. FIG. 1 is a partially cutaway perspective view and a partially enlarged cross-sectional view of this rain gutter, in which 1 is a core material layer made of the above-mentioned sheet, 10 is a paper base material on which resin is supported, 11 is a glass net, and 2 is a vinyl chloride resin. (PVC resin)
The covering layer by T indicates a semicircular rain gutter, respectively. This rain gutter T is manufactured by forming the sheet into a semicircular shape using a roll forming machine, and then extruding and fixing heat-softened PVC resin on both sides of the sheet using a cross-die extruder. Since the sheet has flexibility as described above, its moldability is good, and the properties of the thermoplastic synthetic resin in the resin are exhibited at the interface with the PVC resin forming the covering layers 2, 2. PVC resin is glass net 11,1
Since the glass nets 11, 11 are firmly adhered to the paper substrate 10 through the holes 1 and sandwiched therebetween, the sheet does not require any prior treatment. also,
The rain gutter T effectively prevents thermal deformation and expansion/contraction due to the excellent reinforcing effect of the paper base material 10 of the core material layer 1 and the glass net 11, and also has the bending resistance required for a rain gutter. It has sufficient mechanical strength such as shearing force, and due to the flexibility (cushionability) of synthetic rubber, this type of rain gutter has unprecedented impact resistance strength. Furthermore, since the core material layer 1 is made of the above-mentioned non-metallic sheet, it will not rust, and therefore corrosion will progress from the cut end like in conventional rain gutters using metal reinforcing materials, and eventually There is no fear that the whole thing will rot away. In addition, since the sheet is lightweight, the rain gutter T
The lightweight nature of PVC resin, which is the substance of PVC resin, can be utilized as is, providing great benefits in terms of ease of handling and transportability. In the figure, glass nets 1 are placed on both sides of the paper base material 10.
Although we have shown an example in which 1 and 11 are laminated, it is also possible to use only one side, and it is also possible to use organic fiber nets such as vinylon instead of glass nets. It is obvious that when applied as a reinforcing core material for synthetic resin molded products, such as corrugated plates and various types of pipes, the same properties as described above can be imparted to the respective products.

In the above, an example was described in which the above-mentioned sheet was applied as a reinforcing core material layer for a synthetic resin molded product for building materials such as rain gutters, but it is also possible to use this sheet alone as an interior and exterior material for various types of fittings. In other words, fusuma is a traditional fitting that is indispensable to Japanese architecture, but in recent years,
In order to prevent damage caused by children's mischief, the underlayment was made of plywood or other board material, and traditional fusuma paper was used as the upper covering, or Western-style wallpaper was placed on one side, making it possible to double the partition between Japanese and Western rooms. Partition fittings and other fittings appeared and became widely used in condominiums and modern houses. However, such fittings are generally heavy, the feel when opening and closing them is far from that of traditional fusuma, and the soft feel of the fusuma paper is marred by the plywood on the bottom. had. However, in the sheet according to the present invention,
After using washi paper as the paper base material and supporting the resin, draw an appropriate picture pattern on one side and laminate glass net or organic fiber net on the other side, and then attach it to the conventional sliding frame as a top layer. The sheet is strong and effective in preventing breakage, and also takes advantage of the unique texture of washi paper, and is lightweight, so you can enjoy the atmosphere of traditional Japanese sliding doors when you open and close it. In addition, if you want to use a fitting that can be used in both Japanese and Western rooms, you can obtain the same effect by using a sheet adjusted like Western-style wallpaper on one side, and it fits very well in modern houses. If used as a sliding door, the traditional style of fusuma can be completely maintained. Note that for such indoor applications, it is necessary to mix a flame retardant or the like into the impregnated resin liquid to make it flame retardant.

Another example of an application in which the unique toughness and flexibility of the sheet can be effectively utilized is as a core material for the sole of an athletic shoe. Athletic shoes are required to be lightweight and have soles that have cushioning properties and appropriate hardness, and recently synthetic resin foams have been widely used as soles. Although foam has sufficient cushioning properties, it does not have the appropriate hardness to cushion the impact from the ground, so it is necessary to use some kind of core material. However, the reality is that there are almost no materials that are flexible, lightweight, and unbreakable.In this sense, the above-mentioned sheet meets these requirements, and when used in combination with synthetic resin foam to form the sole of a shoe, it is a very good material. You can get athletic shoes.

Furthermore, when wire mesh, punched metal, or the like is used as a reinforcing material, antistatic properties are imparted to the sheet due to its conductivity. The adsorption of dust due to static electricity during the manufacturing and transportation process of IC packages has a very large effect on its performance, and great care must be taken in packaging materials, etc., but such sheets are strong, lightweight, and inexpensive. In addition, it has antistatic properties, making it extremely suitable as a packaging material for such IC packages.

As mentioned above, the sheet according to the present invention has an extremely wide range of uses, but the sheets shown in FIGS. 2 to 4 are suitable for such uses.
It is also possible to use them in the manner shown in the figures, which further increases their suitability. That is, in FIG. 2, a glass net 11 is laminated on one side of a paper base material 10 carrying resin, and the glass net 1
A film 12 made of soft vinyl chloride resin, ethylene vinyl acetate resin, acrylic resin, etc.
(thickness 0.03-0.1mm) is coated. When this film 12 is applied as a core material of a synthetic resin molded product, this film 12 functions as an adhesive layer that stably fixes the coating resin to the paper base material 10, and when it is used as an interior and exterior material for fittings as described above. is effective in protecting the glass net 11 and preventing the net 11 from peeling off. Furthermore, when used as a core material for shoe soles, voids are formed between the paper base material 10 and the film 12 due to the holes in the glass net 11, which imparts cushioning properties and makes it even more suitable as a core material for shoe soles. increase In addition, when covering the film 12, unnecessary air tends to accumulate between it and the paper base material 10, so
It is desirable that the film 12 be provided with a large number of fine holes 121.

FIG. 3 shows a glass net 1 on both sides of a paper base material 10.
1 and 11 are laminated and the surfaces thereof are further covered with the above-mentioned films 12 and 12, and further reinforcing effect by the glass nets 11 and 11 is expected.

FIG. 4 shows a multilayer laminate of a paper base material 10 and a glass net 11, which doubles the properties of each material and is appropriately adopted as a core material of a molded product requiring higher mechanical strength. Even in this case, film 1
It is obvious that strong interlayer adhesion may be obtained by interposing 2 between each layer, and micro holes (not shown) may also be made in the paper base material 10 itself during lamination. If this is done, the inclusion of air between the layers can be avoided and even stronger adhesion can be achieved.

It should be noted that other kraft paper, paperboard, etc. can also be used as the paper base material.Also, in the above example, the paper base material was impregnated with a resin liquid to support the resin, It is also possible to obtain similar sheets by performing the process in liquid. Furthermore,
You are free to color or draw patterns on the resin or paper base material as appropriate, and if you use transparent resin as the coating resin, you can use it not only as the above-mentioned fittings, but also as a reinforcing core for molded products. This picture pattern etc. is utilized optically and contributes to further increasing the commercial value of the molded product.

Further details will be given below with reference to Examples.

Example 1 (a) Paper base material: Linter paper with a thickness of 0.4 mm was prepared.

(b) Resin liquid...NBR latex and methyl methacrylate resin solution with a solid content ratio (weight) of 60
A resin liquid was obtained by mixing the phenol resin solution so that the solid content thereof was 25 parts by weight based on 40 parts by weight of the solid content of the above-mentioned mixed solution.

(c) Impregnation in resin liquid... When the paper base material of (a) was impregnated with the resin liquid of (b) and aged, the resin was impregnated and supported on the paper base material in a semi-cured state.

(d) Lamination of glass net...Glass net is placed on one side of the paper base material in (c) and heat pressed (160-180℃, 2
A sheet was obtained in which the resin was integrally supported on the paper base material and the glass net was firmly fixed. The paper base material supporting this resin is made of 100 parts by weight of the paper base material and 25 parts by weight of the phenol resin.
It had a composition of 24 parts by weight of NBR and 16 parts by weight of methyl methacrylate resin.
The obtained reinforcing core material was molded into a semicircular shape, and heat-softened vinyl chloride resin was coated on both sides with a thickness of 0.4 mm.
A semicircular rain gutter with a total thickness of 1.2 mm was obtained by extruding and combining the parts to a total thickness of 1.2 mm. This rain gutter had excellent shape retention against heat, strong interlayer adhesion, and was extremely tough.

Example 2 Japanese paper was substituted for the linter paper in Example 1 and impregnated and laminated in the same manner to form a sheet with an appropriate pattern drawn on it, and this was stretched over the fusuma frame to obtain a fusuma. These fusuma were extremely strong and could not be easily torn by children's pranks, and they had the texture of traditional fusuma.

Example 3 During the lamination of the glass net in Example 1, an 0.04 mm thick acrylic resin film with a large number of micropores was placed on the surface of the glass net and thermocompression bonded at the same time. When this was applied to the core material of rain gutters or sliding doors, the interlayer adhesion was further increased or its suitability was further improved.

Example 4 A sheet was obtained in the same manner as in Example 1 except that the reinforcing core glass net consisting of a paper substrate impregnated with a modified resin and glass net was replaced with a wire net of 0.15 mm in wire diameter and 7 meshes. When this sheet was used as a packaging material for an IC package, no static electricity was generated and there was almost no dust adhering to the IC package.

Furthermore, in each of these examples, we considered the practicality of the above applications by appropriately substituting paper base materials, resins, etc., or by creating multilayer laminates, but it was found that the same or better effectiveness than the above was obtained. Ta.

As described above, the multipurpose sheet of the present invention is lightweight, inexpensive, strong, and also flexible, and when applied to the various uses mentioned above, it brings many benefits to each of them. This is an extremely practical sheet.

[Brief explanation of drawings]

FIG. 1 is a partially cutaway perspective view and partially enlarged sectional view showing an example in which the sheet of the present invention is applied to a rain gutter, and FIGS. 2 to 4 are longitudinal sectional views showing other embodiments. Explanation of symbols, 1...Reinforcement core material, 10...Paper base material,
DESCRIPTION OF SYMBOLS 11... Glass net, 12... Film, 2... Covering layer, T... Rain gutter.

Claims (1)

[Scope of Claims] 1. A multipurpose sheet comprising a paper base material carrying thermosetting synthetic resin, synthetic rubber, and thermoplastic synthetic resin, and a reinforcing material, which are integrally laminated. 2. The sheet according to claim 1, wherein the paper base material is linter paper. 3. The sheet according to claim 1, wherein the paper base material is Japanese paper. 4. The sheet according to claim 1, wherein the paper base material is a mixed paper made of linter, pulp, and organic or inorganic fibers. 5. The sheet according to claim 1, wherein the reinforcing material is a glass net. 6 Claim 1 in which the reinforcing material is a wire mesh
Sheet with section description. 7. The sheet according to claim 1, wherein the reinforcing material is an organic fiber net. 8. The sheet according to claim 1, wherein the reinforcing material is a punched metal.