JPH04201252A - Preparation of reinforced eaves gutter - Google Patents

Abstract

PURPOSE:To improve thermal expansion and contraction or rigidity by applying a thermoplastic resin B to both surfaces of a composite core material formed by laminating a core material wherein a thermoplastic resin A is held to or infiltrated in a reinforcing fiber material and a metal sheet or a metal reticulated body and applying bending processing to the coated core material within the temp. range from the softening temps. of the resins A, B to below the melting temps. thereof to form an eaves gutter shape. CONSTITUTION:A thermoplastic resin A is caught in, bonded to or infiltrated in a reinforcing fiber to form a core material 12 and a metal sheet or a metal reticulated body 13 is laminated to the core material 12 to constitute a composite core material 14 which is, in turn, introduced into the crosshead mold 60 of an extruder 61 in a flat state through pinch rolls 50 and a thermoplastic resin B is extruded herein to be applied to both surfaces of the core material 14 in a molten state to form a resin coated composite core material 10. Continuously, the resin coated composite core material 10 is introduced into a bending processing machine 80 through pinch rolls 70 and heated to temp. equal to or higher than the softening points of the resins A, B but below the melting temps. thereof to be formed into an eaves gutter shape by bending processing.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a fiber-reinforced resin eaves gutter with improved thermal expansion/contraction and rigidity.

(Prior Art) Eaves gutters made by extrusion molding thermoplastic resin such as vinyl chloride resin are widely used. However, such eaves gutters made of thermoplastic resin have large thermal expansion and contraction and low rigidity, so they have the disadvantage that they deform due to seasonal changes and temperature changes between day and night, and are prone to cracking.

As eaves gutters that have improved these drawbacks, non-woven fabrics, woven fabrics,
Alternatively, fiber-reinforced resin eaves gutters are made by impregnating a large number of glass rovings with liquid thermosetting resin, synthetic resin, or rubber-based liquid adhesive to form a core material, and coating both sides of the core material with thermoplastic resin. It has been proposed (for example, Jitkai Showa 5g
-63137 and Utility Model Publication No. 63-43309).

(Problems to be Solved by the Invention) Such fiber-reinforced resin eaves gutters are generally manufactured by first shaping a core material into the shape of an eaves gutter, and then introducing this into a crosshead mold having gutter-like slits to form the core material. It is manufactured by extrusion coating both sides of a thermoplastic resin.

However, when using a crosshead mold with gutter-like slits, the core material of the gutter ears tends to be biased or deformed due to resin pressure within the mold, and depending on the shape of the gutter ears, the core material may Due to deviation or deformation, the inner and outer surfaces may be coated with resin unevenly, or the ears may be crushed or expanded.

Furthermore, if the core material of the gutter ear portion is uneven, there are problems in designing the mold and molding the eaves gutter, such as backflow of resin within the mold. Further, in order to obtain eaves gutters of different sizes and shapes, crosshead molds of corresponding dimensions and shapes are required, but such crosshead molds having eave gutter-like slits are expensive.

The present invention solves the above problems, and its purpose is to easily manufacture reinforced resin eaves gutters whose core material is uniformly coated with thermoplastic resin and whose thermal expansion and contraction and rigidity are improved. The purpose is to provide a method.

(Means for Solving the Problems) The method for manufacturing a reinforced resin eaves gutter of the present invention includes laminating a core material made of a reinforced fiber material holding or impregnating thermoplastic resin A, and a metal sheet or a metal mesh. The composite core material is coated with thermoplastic resin B on both sides of the composite core material, and is bent into an eave gutter shape at a temperature higher than the softening point of resin A and resin B and lower than the melting temperature, The above objectives are thereby achieved.

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

1 to 4 are explanatory views showing an example of the present invention.

In the figure, 14 indicates a composite core material, and 10 indicates a resin-coated composite core material. This resin-coated composite core material 10 is manufactured by coating both surfaces of a composite core material 14 with thermoplastic resin B. Moreover, the composite core material 14 is constructed by laminating the sheet-like core material 12 and a metal sheet or metal mesh 13. Furthermore, core material 1
No. 2 is made by trapping, adhering, or impregnating thermoplastic resin A between reinforcing fiber materials.

In FIG. 1, the composite core material 14 is transferred to a crosshead mold 60 of an extruder 61 while being in a flat state after passing through a vinyl roll 50.
Here, the thermoplastic resin B is melt-extruded and coated on both sides of the composite core material 10, thereby forming the resin-coated composite core material 10. In this case, since the composite core material 14 is in the form of a flat sheet, extrusion coating using the crosshead mold 60 is easy.

Further, the crosshead mold 60 for extrusion coating in the form of a sheet is relatively inexpensive.

Subsequently, the resin-coated composite core material 10 is passed through a pinch roll 7.
0, the resin is introduced into a known bending machine 80 such as a roll forming device, where it is heated to a temperature above the softening point of the resins A and B but below the melting temperature, and bent into the shape of an eaves gutter. At temperatures lower than the softening points of resins A and B, the rigidity is too high and it becomes difficult to shape by bending. On the other hand, if the temperature is higher than the melting temperature of resins A and B, the rigidity will be too low and it will be difficult to shape the resin by bending.

In addition, in the present invention, the softening point is determined according to JIS K 7206.
It is the Vicat softening point measured according to .

In addition, the melting temperature was measured using a high-speed flow tester using a nozzle diameter of In + m x length of 10 mm, and a piston pressure of 1 to 50 k.
This refers to the temperature at which the flow value of the molten resin, measured under the conditions of g/cm2 and a heating rate of 3°C/min, reaches 2K/sec (see the reference test described in JIS K 7210).

Resin-coated composite core material 1 shaped into a gutter shape by bending
0 is cooled, and then passed through a tensioning device 9 such as a caterpillar tensioning machine.
It will be picked up at 0. In this way, a reinforced resin needle [100] as shown in FIG. 4 is manufactured. The shapes of the gutter ears and the gutter body of the eaves gutter 100 can be formed into various known shapes such as the shape shown in FIG.

Specifically, the above-mentioned composite core material 14 is manufactured by the method shown in FIG. 2, for example. In this example, a large number of roving fibers 11 are used as the reinforcing fiber material.

In FIG. 2, a large number of roving N fibers 11 are unwound from a bobbin, arranged in parallel in the longitudinal direction, and introduced into a fluidized bed 20 provided with a porous bottom plate 21.

In the fluidized bed 20, a powdered thermoplastic resin A is blown up above a porous bottom plate 21 by gas pressure such as air, and is maintained in a floating state.

A guide bar or guide roll 22 is generally provided in the fluidized bed 20, and when the roving fibers 11 pass through this guide bar or guide roll 22, the pressure of gas such as air blown up into the fluidized bed, the flow Due to the static electricity generated in the resin powder in the bed and the rubbing effect of the resin powder, the roving fibers are separated and opened into monofilament units, and the resin powder enters between the monofilaments and is evenly and sufficiently captured and attached. .

The guide bar or guide roll 22 described above also promotes the opening of the roving fibers 11, but in order to further promote this opening, the guide bar or guide roll has a threaded surface or a bulged central portion. It is preferable to use

The roving fiber 11 is a fiber bundle composed of several hundred to several thousand continuous monofilaments, and rovings of glass fiber, carbon fiber, aramid fiber, ceramic fiber, etc. are preferably used. The monofilament preferably has a diameter of 1 to 50 μm. The roving fiber 10 is generally preferably contained in a range of 20 to 60% by volume from the viewpoint of improving the thermal expansion and contraction and rigidity of the eaves gutter.

Further, as the powdered thermoplastic resin A, vinyl chloride resin, acrylic resin, olefin resin, engineering resin such as polyphenylene sulfide and polyether sulfone, etc. are used. The particle size of the thermoplastic resin A is generally about 10 to 300 μm.

A large number of roving fibers 11 to which powdered resin A has been captured and adhered are aligned in a band shape to form a core material 12. This belt-shaped core material 12 is formed into two pieces, one above the other, and between them there is a metal sheet (including a foil-like one) made of steel, aluminum, etc.
Or a metal mesh body (including one with perforations) 13 is sandwiched,
It is passed through a heated press roll 30. Here thermoplastic resin A
is heated and melted, subsequently cooled and rolled up. In this way, the composite core material 14 is created.

Note that the heated press roll 30 may be used to form the core material 12. In this case, a core material is obtained in which the thermoplastic resin A is melted and impregnated between reinforcing fiber materials.

As in the above example, when a large number of roving fibers are used as the reinforcing fiber material and the powdered thermoplastic resin A is captured and attached to the large number of roving fibers by introducing them into a fluidized bed, each monofilament of the large number of rovings is In between, the resin can be uniformly and sufficiently retained or impregnated. In addition, in the resin-coated composite core material 14, a large number of roving fibers 11
Since they are arranged in the longitudinal direction, it is easy to bend them into a gutter shape along the longitudinal direction.

However, it is also possible to use a nonwoven fabric or woven fabric as the reinforcing fiber material and impregnate it with a thermoplastic resin solution or emulsion in an impregnating bath.

As the thermoplastic resin B, a resin that can be thermally bonded to the resin A is selected from the same resins as the thermoplastic resin A described above.

Resin A and resin B may be the same resin. As resin A and resin B, vinyl chloride resin is usually used.

In the above example, thermoplastic resin B is applied to both sides of the composite core material 14.
was melt-extruded and coated to create a resin-coated composite core material 10, which was subsequently introduced into a bending machine 80 and shaped into an eave gutter shape. However, as shown in FIG. 3, sheet-shaped thermoplastic resin B is laminated on both sides of the composite core material 14, and this is passed between heated press rolls 40 to melt and integrate the resin-coated composite core. It is also possible to create the material 10 and introduce it into a bending machine in a separate process to shape it into an eave gutter shape.

(Function) The composite core material is constructed by laminating a core material in which thermoplastic resin A is held or impregnated between reinforcing fibers and a metal sheet or metal mesh, so that the core material can be thermally expanded and contracted. The metal sheets or meshes provide improved bending properties in addition to thermal stretchability and stiffness.

In addition, when both sides of such a composite core material are coated with thermoplastic resin B, the composite core material is flat and has no irregularly shaped parts such as gutter ears, so that the thermoplastic resin B is uniformly coated on both sides of the composite core material. Easily coated.

Furthermore, when such a resin-coated composite core material is bent at a temperature above the softening point of these resins and below the melting temperature,
Since thermoplastic resin B is uniformly coated on both sides of the composite core material in advance, the gutter ears are not unevenly coated with resin as in conventional methods, and the gutter ears can be shaped into the desired shape. It becomes possible to form

(Example) Examples of the present invention will be shown below.

First, a large number of glass rovings (#4400, manufactured by Nippon Electric Glass Co., Ltd.) were introduced into a fluidized bed in parallel in the longitudinal direction as shown in Figure 2, where they were blown up by air pressure and made into a floating state. A certain average particle size is 100μm, softening point is 70°
Blended powder of vinyl chloride-vinyl acetate copolymer (MA-C)
8005: Manufactured by Shin-Etsu Chemical Co., Ltd.; melting temperature 168°C) was captured and adhered to create two upper and lower core materials with a thickness of approximately 0.2 mm, and an aluminum foil (thickness 0.05 mm), and then heated to 185°C with heated press rolls and melted and pressed to a thickness of about 0.05 mm.
A composite core material having four cores, a width of 400 mb, and a glass roving content of 30% by volume was formed.

This composite core material was introduced into a crosshead mold of an extruder as shown in Fig. 1, and a vinyl chloride resin compound (TS-800E
: Manufactured by Tokuyama Block Company; melting temperature approx. 180°C) 185
Melt extrusion coatings were applied to a thickness of approximately 0.4 mm at <RTIgt;°C. Subsequently, the fat-coated belt-shaped core material was introduced into a roll forming device (bending machine), heated to 75° C., and bent into the shape of an eaves gutter as shown in FIG. The bendability of the gutter ears and the gutter body was good.

(Effects of the Invention) As described above, according to the method of the present invention, a core material formed by holding or impregnating thermoplastic resin A between reinforcing fiber materials and a metal sheet or a metal mesh body are laminated. Thermoplastic on both sides of the composite core material.

Resin B is uniformly and easily coated.

In addition, such a resin-coated composite core material can be mixed with resin A and resin B.
Since the bending process is carried out into the eaves gutter shape at a temperature above the softening point of the resin and below the melting temperature, the gutter ears can be freely formed into a desired shape. Furthermore, the size of the eaves gutter can be easily changed by simply changing the forming roller of the bending machine.

Therefore, compared to the conventional method, the method of the present invention can easily produce fiber-reinforced resin eaves gutters whose core material is uniformly coated with thermoplastic resin and whose thermal expansion and contraction and rigidity are improved.

Note that vinyl chloride resin is usually used as resin A and resin B, but in this case, even if the temperature rises to around the softening temperature of the vinyl chloride resin while the eaves gutter is in use, the metal sheet or metal Since it is reinforced by the net-like body, it has the advantage that residual stress in the resin during bending is released and deformation is prevented.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an explanatory diagram showing an example of the method of the present invention, FIG. 2 is an explanatory diagram showing an example of the method for molding a composite core material, and FIG. 3 is an example of the method for molding a resin-coated composite core material. FIG. 4 is a partially cutaway perspective view showing an example of an eaves gutter manufactured by the method of the present invention.

DESCRIPTION OF SYMBOLS 10... Resin coated composite core material, 11... Roving fiber, 12... Core material, 13... Metal foil, 14... Composite core material, 60... Crosshead mold, 80... - Bending machine, 9o... Tensile device, 100... Fiber reinforced resin needle wire, A... Thermoplastic resin for core material, B... Thermoplastic resin for coating.

Claims (1)

[Claims] 1. Both sides of a composite core material formed by laminating a core material in which thermoplastic resin A is held or impregnated between reinforcing fiber materials and a metal sheet or a metal mesh body are coated with thermoplastic resin B. A method for manufacturing a reinforced eaves gutter, which comprises bending this into an eave gutter shape at a temperature higher than the softening point of resin A and resin B and lower than the melting temperature.