JPH0729401B2 - Manufacturing method of reinforced eaves gutter - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing a fiber-reinforced resin eaves gutter having improved thermal expansion and contraction and rigidity.

(Prior Art) An eaves trough formed by extrusion molding a thermoplastic resin such as a vinyl chloride resin is widely used. However, since the eaves gutter of such a thermoplastic resin has a large thermal expansion and contraction and a small rigidity, it has the drawback that it is deformed due to temperature changes during the four seasons and day and night, and is easily cracked.

As eaves gutter which improved such defects, non-woven fabric and woven fabric,
Alternatively, a fiber-reinforced resin eaves trough is formed by impregnating a large number of glass rovings with a liquid thermosetting resin or a synthetic resin-based or rubber-based liquid adhesive to form a core material, and coating thermoplastic resin on both sides of the core material. Proposed (for example, the actual development 59-
63137 and Japanese Utility Model Publication No. 63-43309).

(Problems to be Solved by the Invention) In such a fiber-reinforced resin eaves trough, generally, a core material is once shaped into an eaves trough, and then this is introduced into a crosshead mold having eaves trough-shaped slits. It is manufactured by extrusion coating a thermoplastic resin on both sides of the material.

However, when using a crosshead mold with eaves trough-shaped slits, the core material of the gutter ear part tends to be biased or deformed due to resin pressure in this mold, and depending on the shape of the eaves gutter ear part, the core material Due to unevenness or deformation, the resin may be unevenly coated on the inner surface and the outer surface thereof, or the ear may be crushed or expanded.

In addition, there is a problem in the design of the mold and the molding of the eaves gutter such as backflow of resin in the mold when the core material of the gutter ear portion is biased. Further, in order to obtain eaves troughs having different sizes and shapes, a crosshead die having dimensions and shapes corresponding thereto is required, but a crosshead die having such eaves trough-shaped slits is expensive.

The present invention is to solve the above problems, and an object thereof is to easily manufacture a reinforced resin eaves trough in which a core material is uniformly coated with a thermoplastic resin, and thermal expansion and contraction and rigidity are improved. To provide a method.

(Means for Solving the Problem) A method for manufacturing a reinforced resin eaves gutter according to the present invention comprises laminating a core material formed by holding or impregnating a thermoplastic resin A on a reinforced fiber material, and a metal sheet or a metal mesh body. A thermoplastic resin B is coated on both sides of the composite core material configured as described above, and is bent into a eaves trough shape at a temperature equal to or higher than the softening points of the resin A and the resin B and lower than the melting temperature, Thereby, the above-mentioned object is achieved.

Hereinafter, the present invention will be described with reference to the drawings.

1 to 4 are explanatory views showing an example of the present invention.
In the figure, 14 is a composite core material, and 10 is a resin-coated composite core material. The resin-coated composite core material 10 is manufactured by coating the thermoplastic resin B on both surfaces of the composite core material 14. Also, composite core material 14
Is formed by laminating a sheet-shaped core material 12 and a metal sheet or a metal mesh body 13. Further, the core material 12 is formed by capturing, adhering or impregnating the thermoplastic resin A between the reinforcing fiber materials.

In FIG. 1, the composite core material 14 is introduced into the cross head mold 60 of the extruder 61 through the pinch roll 50 in a flat state, and the thermoplastic resin B is melt extruded on both surfaces of the composite core material 10 here. The resin-coated composite core material 10 is formed by coating. In this case, since the composite core material 14 has a flat sheet shape, extrusion coating by the crosshead mold 60 is easy.

Further, the cross-head mold 60 for extrusion-coating in a sheet shape as described above is relatively inexpensive.

Subsequently, the resin-coated composite core material 10 is passed through the pinch roll 70 and a known bending machine such as a roll forming device.
Introduced into 80, where it is heated to a temperature above the softening point of the resins A and B and below the melting temperature and bent into a eaves gutter shape. At a temperature lower than the softening points of the resins A and B, the rigidity is too high, and it becomes difficult to shape by bending. Conversely, resin A
At a temperature equal to or higher than the melting temperature of B and B, the rigidity is too small to be shaped by bending.

In the present invention, the softening point is the Vicat softening point measured according to JIS K 7206. In addition, the melting temperature is 1 mm nozzle diameter x 10 m length with a high flow tester.
m, piston pressure 150 kg / cm ² , temperature rise rate of 3 ° C / min. The temperature at which the flow value of the molten resin reaches 2 ml / sec. (Refer to JIS K 7210 for reference. reference).

Resin-coated composite core material 10 shaped like an eaves trough by bending
Is cooled and then taken up by a tensioning device 90 such as a caterpillar tensioner. In this way, the reinforced resin eaves gutter 100 as shown in FIG. 4 is manufactured. The gutter ear portion and the gutter body portion of the eaves trough 100 can be formed into various known shapes in addition to the shape shown in FIG.

The composite core material 14 is specifically manufactured by, for example, the method shown in FIG. In this example, many roving fibers 11 are used as the reinforcing fiber material.

In FIG. 2, a large number of roving fibers 11 are unwound from a bobbin, aligned in the longitudinal direction, and introduced into a fluidized bed 20 having a porous bottom plate 21. In the fluidized bed 20, a powdery thermoplastic resin A has a porous bottom plate due to gas pressure such as air.
It has been blown above 21 and kept in a floating state.

In the fluidized bed 20, there are generally guide bars or guide rolls.
22 is provided, the roving fiber 11 when passing through the guide bar or the guide roll 22, gas pressure such as air blown into the fluidized bed, static electricity generated in the resin powder in the fluidized bed, rubbing of the resin powder. By the rubbing effect, the roving fibers are separated and opened into monofilament units, and the resin powder penetrates between the monofilaments and is uniformly and sufficiently trapped and adhered.

The guide bar or guide roll 22 described above also promotes the opening of the roving fiber 11, but in order to further promote the opening, the guide bar or the guide roll having a threaded surface or a bulged central portion is formed. Is preferably used.

The roving fiber 11 is a fiber bundle composed of hundreds to thousands of continuous monofilaments, and rovings such as glass fibers, carbon fibers, aramid fibers, and ceramic fibers are preferably used. The diameter of the monofilament is preferably 1 to 50 μm. From the viewpoint of improving the thermal expansion and contraction and rigidity of the eaves gutter, the roving fiber 10 is generally preferably contained in the range of 20 to 60% by volume.

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

Numerous roving fibers with powdery resin A captured and attached
11 is aligned in a band and forms the core material 12. The strip-shaped core material 12 is formed in upper and lower two sheets, and a metal sheet (including foil-like one) or a metal mesh body (including perforated one) 13 such as steel or aluminum is sandwiched between the core material 12 and the heating and pressing roll. Threaded through 30. Here, the thermoplastic resin A is heated and melted, and subsequently cooled and wound up. In this way, the composite core material 14 is produced.

The heating and pressing roll 30 may be used for forming the core material 12. In this case, a core material is obtained in which the thermoplastic resin A is melt-impregnated between the reinforcing fiber materials.

As in the above example, a large number of roving fibers are used as a reinforcing fiber material, and this is introduced into a fluidized bed to capture and adhere the powdery thermoplastic resin A to the large number of roving fibers. In the meantime, the resin can be uniformly and sufficiently retained or impregnated. Further, in the resin-coated composite core material 14, since a large number of roving fibers 11 are arranged in the longitudinal direction, it is easy to perform bending processing in the eaves trough shape along the longitudinal direction. However, it is also possible to use a non-woven fabric or a woven fabric as the reinforcing fiber material and impregnate this with a thermoplastic resin solution or emulsion in an impregnation tank.

As the thermoplastic resin B, a resin that can be heat-sealed with the resin A is selected from the same resins as the thermoplastic resin A.
The resin A and the resin B may be the same resin. As the resin A and the resin B, a vinyl chloride resin is usually used.

In the above example, the thermoplastic resin B is melt-extruded and coated on both surfaces of the composite core material 14 to form the resin-coated composite core material 10, which is subsequently introduced into the bending machine 80 to be provided in the eaves gutter shape. Shaped However, as shown in FIG. 3, the thermoplastic resin B in a sheet form is laminated on both surfaces of the composite core material 14, and the thermoplastic resin B is passed between the heating extrusion rolls 40 to be heated and melted and integrated, whereby the resin-coated composite core is obtained. 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 eaves gutter shape.

(Function) Since the composite core material is constituted by laminating the core material formed by holding or impregnating the thermoplastic resin A between the reinforcing fiber materials and the metal sheet or the metal mesh body, thermal expansion and contraction by the core material. In addition to thermal stretchability and rigidity, bending workability is improved by the metal sheet or metal mesh body.

Further, when the thermoplastic resin B is coated on both surfaces of such a composite core material, the composite core material is flat and does not have a deformed portion such as a trough, so that the thermoplastic resin B is even on both surfaces of the composite core material. Easily coated.

When such a resin-coated composite core material is bent at a temperature not lower than the softening point of these resins and lower than the melting temperature,
Since both sides of the composite core material are coated with the thermoplastic resin B uniformly in advance, the gutter portion is not unevenly coated with the resin unlike the conventional method, and the gutter portion can be freely formed into a desired shape. It is possible to form

(Example) Hereinafter, the Example of this invention is shown.

Example First, a large number of glass rovings (# 4400: manufactured by Nippon Electric Glass Co., Ltd.) were introduced in a fluidized bed in parallel in the longitudinal direction as shown in FIG. 2, where they were blown up by air pressure and were in a floating state. A vinyl chloride-vinyl acetate copolymer blend powder (MA-800S: manufactured by Shin-Etsu Chemical Co., Ltd .; melting temperature 168 ° C) with an average particle size of 100 μm and a softening point of 70 ° C is captured and adhered to a thickness of about 0.2.
mm core material is made up and down, aluminum foil coated with acrylic adhesive (thickness: 0.05 mm) is sandwiched between them, and subsequently heated to 185 ° C with a heating and pressing roll to melt and press-bond the thickness. 0.4mm, width 400mm, glass roving content 30
A volume% composite core was formed.

This composite core material was introduced into the crosshead mold of the extruder as shown in FIG. 1, where the softening point of 75 ° C. was applied to both sides of the composite core material.
(TS-800E: manufactured by Tokuyama Sekisui Co., Ltd .; melting temperature: about 180 ° C.) was melt-extruded and coated at 185 ° C. to a thickness of about 0.4 mm. Subsequently, the fat-coated strip-shaped core material was introduced into a roll forming device (bending machine), heated to 75 ° C., and bent into an eaves trough shape as shown in FIG. The bending workability of the gutter ear part and the gutter body part was good.

(Effects of the Invention) As described above, according to the method of the present invention, the core material formed by holding or impregnating the thermoplastic resin A between the reinforcing fiber materials and the metal sheet or the metal mesh are laminated. The thermoplastic resin B is uniformly and easily coated on both surfaces of the composite core material.

In addition, such a resin-coated composite core material is used as resin A and resin B.
Since the resin is bent into the eaves gutter shape at a temperature equal to or higher than the softening point of the resin and lower than the melting temperature, the gutter ear portion 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, according to the method of the present invention, a fiber-reinforced resin eaves trough in which a thermoplastic resin is uniformly coated on the core material and thermal expansion and contraction and rigidity are improved can be easily produced, as compared with the conventional method.

In general, a vinyl chloride resin is used as the resin A and the resin B. In this case, even if the temperature rises to near the softening temperature of the vinyl chloride resin during use of the eaves gutter, the metal sheet or metal Since it is reinforced by the mesh body, it has an advantage that the residual stress of the resin at the time of bending is released and the resin is prevented from being deformed.

[Brief description of drawings]

FIG. 1 is an explanatory view showing an example of the method of the present invention, FIG. 2 is an explanatory view showing an example of a molding method of a composite core material, and FIG. 3 is an explanatory view showing an example of a molding method of 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. 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, 90 …… Tension device, 100
…… Fiber reinforced resin eaves trough, A …… thermoplastic resin for core material,
B ... Thermoplastic resin for coating.

Claims (1)

[Claims] 1. A thermoplastic resin B is provided on both surfaces of a composite core material formed by laminating a core material which holds or impregnates a thermoplastic resin A between reinforcing fiber materials and a metal sheet or a metal mesh body. And a method of manufacturing the reinforced eaves gutter, which comprises bending the same into a eaves gutter shape at a temperature equal to or higher than the softening points of the resin A and the resin B and lower than the melting temperature.