JPS631418B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a synthetic resin molded product for building materials such as various rain gutters or corrugated plates, which comprises a thermosetting synthetic resin reinforcing layer impregnated and supported by paper or fibers or both. The present invention relates to a thermosetting synthetic resin molded product having a structure in which a reinforcing layer (hereinafter simply referred to as a reinforcing layer) and a thermosetting synthetic resin coating layer are integrally laminated.

Conventionally, synthetic resin molded products have been widely used as building materials such as those mentioned above, but the synthetic resin that is the substance of these molded products has mechanical strength such as impact resistance that is higher than other building materials (for example, metal). Because it has the disadvantages of being inferior and prone to thermal deformation (including thermal contraction), it is common to encapsulate iron plates, wire mesh, etc. within the thickness of the molded product to simultaneously strengthen it and prevent thermal deformation. It is being talked about. When embedding and molding reinforcing cores made of iron plates or wire mesh, which are materials different from synthetic resin, it is difficult to process the process of applying appropriate surface treatment to the surface of the reinforcing core and applying an appropriate adhesive. There is something
Problems such as the heavy reinforcing core increases the weight of the molded product itself, and the reinforcing core at the cut end of the molded product easily rusts and corrodes.

The present invention was made in view of the above, and prevents thermal deformation of rain gutters or corrugated plates by using a thermosetting synthetic resin layer impregnated and supported on paper or fibers or both as a reinforcing layer. To provide a novel reinforced synthetic resin molded product for building materials, which is characterized by being designed and reinforced.

Embodiments of the present invention will be illustrated and explained. FIG. 1 is a partially cutaway perspective view of an eaves gutter in which a typical embodiment of the present invention is adopted, FIG. FIG. 3 is a partially cutaway perspective view of a gutter pipe in which another embodiment of the present invention is adopted, and FIG.
It is a partially enlarged vertical cross-sectional view of the figure-line. That is, the present invention integrally laminates a thermosetting synthetic resin coating layer 1 on at least one side of a thermosetting synthetic resin reinforcing layer 2 impregnated and supported on a base material 21 of one or two types of paper or fiber. This is a reinforced synthetic resin molded product for building materials, which is made by molding it into rain gutters or corrugated sheets. As the paper for the base material 21, kraft paper, paperboard, Japanese paper, etc. are adopted, but if translucency is required, thin paper is appropriately adopted. In addition, the fibers used include inorganic fibers such as glass fibers, carbon fibers, asbestos fibers, and gypsum fibers, or chips of surface-treated metal fibers, or organic fibers such as polyester fibers, nylon fibers, and polyvinyl fibers, or processed products thereof. Furthermore, processed fibers include woven fabrics, nonwoven fabrics, nets, mats, and the like. The above-mentioned paper and fiber can each be used as the base material 21 alone, or they can be appropriately combined to form the base material 21 as a hybrid. As the thermosetting synthetic resin for the reinforcing layer 2, one selected from phenol resin, melamine resin, unsaturated polyester resin, and epoxy resin is appropriately adopted, and as the thermosetting synthetic resin for the covering layer 1, unsaturated polyester resin, melamine A selected type of resin, epoxy resin, melamine-modified resin, mixed resin of epoxy resin and phenol resin (e.g., resin raw material weight ratio 8:2), mixed resin of diallyl phthalate resin and urethane resin, etc. is adopted.
These are used in appropriate combination. This thermosetting synthetic resin coating layer 1 is positioned as an exterior part of the reinforcing layer 2 as described later, so it has colorability,
Weather resistance is also an important factor in selecting the resin.

To briefly explain the manufacturing process of the molded product of the present invention, the base material 21, paper or fiber, or both, is added to the solution-type resin liquid or emulsion-type resin liquid, which is the resin raw material of the thermosetting synthetic resin as the reinforcing layer 2. The composite is impregnated to form a thermosetting synthetic resin reinforcing layer 2, and molded with a mold or the like to form a semi-cured molded body 2', and the coating layer 1 is applied on one or both sides of this molded body 2'. A thermosetting synthetic resin coating layer 1 is formed by applying a resin raw material of a thermosetting synthetic resin by spraying or dipping, and this is integrally cured by heating to obtain a desired molded product. 1 and 2 show a rain gutter (eave gutter) in which thermosetting synthetic resin coating layers 1 are integrally laminated on both sides of a molded body 2'. In the step of impregnating the base material 21, when the base material 21 is made by combining paper and fiber chips or their processed products, the entire combined base material may be immersed in the resin liquid. By impregnating only pure paper with resin liquid, and laminating fibers or their processed products with resin-impregnated paper without resin treatment, the resin liquid is transferred from the paper, making it look like resin-impregnated fibers or fibers. It can also be made equivalent to the processed product. In addition, resin processing (sizing treatment) is applied to paper fibers during paper making.
In any case, the reinforcing layer 2 supported by the base material 21 is laminated with the thermosetting synthetic resin layer as the covering layer 1 and then heated and hardened, so that the shape of the molded body 2' is maintained as it is. At the same time, adhesion at the interface between the two is reliably guaranteed. Also, reinforcing layer 2
When heating and curing the and coating layer 1 individually, using an adhesive at the interface between the two to improve adhesion can be selected as appropriate from the viewpoint of the manufacturing process. still,
The above-mentioned molded body 2' can be obtained by a method such as press molding or roll molding, but the method of molding the molded product is not limited to this, and it is also possible to mold after laminating the coating layer 1.

As mentioned above, the rain gutter illustrated in FIGS. 1 and 2 has a reinforcing layer 2 of thermosetting synthetic resin supported by a base material 21 such as paper, fiber, or a hybrid of both. is the thermosetting resin coating layer 1,
1 and 2 are integrated in a sandwich-like manner, so it has strong toughness due to the synergistic effect of the stiffness of the base material 21 and the rigidity of each thermosetting synthetic resin of the reinforcing layer 2 and the covering layers 1 and 1. This rain gutter has excellent shape retention and little thermal expansion and contraction, making it extremely valuable as a product. Furthermore, since the base material 21 of the reinforcing layer 2 is paper or fiber, rainwater can penetrate through the cut ends and rust the core material, causing delamination, as in the case where conventional iron plates or wire mesh are enclosed. There is no such thing as occurring,
Moreover, there is no increase in weight. In addition, the thermosetting synthetic resin coating layer 1 is also positioned as an exterior part, so by selecting a resin that can be colored and coloring it appropriately, a colorful rain gutter can be obtained.
On the other hand, if this is made of transparent resin and paper with a picture pattern is used as the base material 21, it is possible to make a rain gutter rich in design, and from this point of view, the commercial value of the rain gutter can be further enhanced. In addition, the coating layer 1 becomes an effective protective layer and improves weather resistance.

FIGS. 3 and 4 show another embodiment of the present invention, in which the molded product is a gutter pipe, and the coating layer 1 is integrally laminated on one side, that is, on the outer surface of the pipe.
In this case, as in the above embodiment, the stiffness of the base 21 and the rigidity of the thermosetting synthetic resin combine to provide mechanical strength and non-stretchability due to heat, which are not found in conventional pipes of this type. Provides excellent shape retention. These remarkable performances are particularly effective when applied as a hard gutter or a pipe gutter. Furthermore, it is lightweight, the cut end does not rust,
etc. are added, so its value is extremely high. Of course, the coating layer 1 can be appropriately colored to make a colorful pipe, or the base material 21 can be made of patterned paper to create a uniquely designed pipe, as in the above embodiment.

Although not shown in the drawings, the same effects as described above can be expected if the present invention is applied to corrugated plates including so-called iron plate waves, slate waves, square waves, and various other deformed waves.

It goes without saying that the base material such as paper or fiber is not limited to a single layer, but multiple layers may be adopted as necessary (in the sense of further enhancing the reinforcing effect). Furthermore, although the thermosetting synthetic resins for the reinforcing layer 2 and the coating layer 1 can be freely selected as described above, depending on the combination of the two, the two may be of the same quality. In this case, by laminating and integrating, the resin of the covering layer 1 is apparently supported on the base material 21 together with the resin of the reinforcing layer 2, but the covering layer 1 acts as an exterior part of the reinforcing layer 2. There is no difference in its position. That is, the covering layer 1 protects the reinforcing layer 2, and by coloring the resin of the covering layer 1, it is possible to completely hide the reinforcing layer 2 and provide a colorful appearance. On the other hand, even if these two resins are different, the resin of the covering layer 1 is applied while the resin of the reinforcing layer 2 is semi-hardened and is heated and solidified as a whole, so the adhesion at the interface between the two is completely guaranteed. Ru.

Furthermore, in each of the above embodiments, the covering layer 1 is replaced by the reinforcing layer 2.
Examples of integrally laminated layers on both sides and one side have been described for eaves gutters and pipes, respectively, but whether the coating layer 1 is formed on both sides or one side of each building material is determined as appropriate depending on the usage.

As described above, the molded product of the present invention has a reinforcing layer 2 of thermosetting synthetic resin impregnated and supported on a base material 21 such as paper or fiber, and a covering layer 1 of thermosetting synthetic resin is integrally laminated on both or one side of the reinforcing layer 2 of thermosetting synthetic resin. Therefore, the molded product is prevented from stretching as much as possible in the longitudinal and width directions due to heat, and its mechanical strength such as bending strength, shear strength, and impact strength is reinforced, and its shape retention is maintained well. dripping Furthermore, compared to molded products of this type using iron plates, wire mesh, etc., it is lightweight and inexpensive, and there is no risk of delamination due to rust formation. In addition, the molded product of the present invention can be said to have extremely high practicality and commercial value since it has the added advantage of being able to select a molded product that is colorful and rich in design according to one's preference. .

Examples are listed below.

Example: Two sheets of kraft paper with a thickness of 0.25 mm as a paper base material and one sheet of glass fiber nonwoven fabric with a thickness of 0.3 mm are stacked between them and immersed in an unsaturated polyester resin solution, aged, and then preheated and preformed into the shape of a rain gutter. did. Further, diallyl phthalate and urethane modified resin were sprayed on top of this, and finished and hardened to a total thickness of 1.3 mm. The obtained rain gutter had extremely low shape retention and thermal expansion properties.

[Brief explanation of the drawing]

Fig. 1 is a partially cutaway perspective view of an eaves gutter in which a typical embodiment of the present invention is adopted, Fig. 2 is a partially enlarged vertical sectional view taken along the line of Fig. 1, and Fig. 3 is another embodiment of the present invention. FIG. 4 is a partial enlarged vertical sectional view taken along the line of FIG. 3. (Explanation of symbols), 1...Covering layer, 2...Reinforcement layer,
21...Base material.

Claims (1)

[Claims] 1. A thermosetting synthetic resin reinforcing layer impregnated and supported on one or two of paper or fiber base materials is laminated with a thermosetting synthetic resin coating layer on at least one side, and this is used as a rain gutter or a corrugated plate. A reinforced synthetic resin molded product for building materials.