JPH086235B2 - Lightweight composite material and manufacturing method thereof - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight composite material suitable as a building material, a construction material and the like and a method for producing the same.

[0002]

2. Description of the Related Art Porous materials such as foamed resins are widely used as building materials, construction materials, core materials, etc.
It is known to incorporate reinforcing fibers such as glass fibers to increase strength.

[0003]

Conventionally, porous materials have been
It is produced by mixing a resin such as polyurethane or polystyrene with a foaming agent to foam, or by mixing a hollow filler such as a glass balloon, but the prior art has the following problems. (1) When a foamable resin liquid is used, when a foaming agent is mixed with the resin, foaming starts within a short time, so the pot life is short. Therefore, the resin and the foaming agent are sprayed from different nozzles to mix them, but it is difficult to mix them uniformly, and the quality tends to vary. (2) The strength of the porous material has a close relationship with the density,
Increasing the strength requires increasing the density. Therefore, it is difficult to obtain a porous material having a sufficiently low density and a large strength. The present invention solves the above-mentioned problems of the prior art, has high strength, low density, and little variation in quality,
An object of the present invention is to provide a lightweight composite material which is easy to manufacture and a manufacturing method thereof.

[0004]

In order to achieve the above-mentioned object, in the present invention, a mat-like material comprising a continuous glass fiber bundle deposited as a porous material in a curved shape, It is a composite material formed of a thermoplastic resin impregnated in a mat-like material, and a thermoplastic resin film is formed on the surface of the glass fiber bundles forming this composite material, and the fiber bundles are A lightweight composite material is used which is characterized in that it is thermoplastically bonded and has a large number of voids formed by expansion due to the elastic repulsion of the mat-like material between the fiber bundles. A step of depositing a curved shape to form a mat-like material, a step of applying a thermoplastic resin melt to the mat-like material and compressing it to form a compressed composite material, while the thermoplastic resin is in a molten state Solution of compressive force And to produce a lightweight composite material by forming a large number of void portions is inflated compression composite material by an elastic repellent force of the mat-like material.

Next, the present invention will be described more specifically. As a continuous glass fiber bundle, a sizing agent is attached to glass fibers having an average diameter of 6 to 30 µ, preferably 10 to 23 µ pulled out from a bushing, and 20 to 400, preferably 30 to
Weight per 1,000 m (gr) of 200 bundles
It is suitable to use those having an A of 5 to 200, preferably 10 to 100. As the sizing agent, a coupling agent such as aminosilane is 0.05 to 1.5 wt%, preferably 0.1 to 1 wt%, and a lubricant such as a nonionic lubricant is 0.05 to 0.5 wt%. Preferably 0.1-0.3
wt%, 0.5-10 wt% of film forming agent such as unsaturated polyester emulsion, preferably 1-8 wt%
%, And the amount added to the glass fiber is 0.2 to 2.0 wt% as a solid content, preferably 0.5.
It is suitable to be set to about 1.5 wt%. It was found that the effect of the present invention can be further enhanced by using such a glass fiber bundle.

The mat-like material of the present invention is, for example, Jpn.
Using the apparatus described in No. 234, the bundled glass fiber bundle can be suitably manufactured by directly dropping and depositing it on a moving conveyor. Alternatively, the glass fiber bundle is once wound as a cake, heated and dried,
It can also be produced by pulling it out from the cake, dropping it on a moving conveyor, and depositing it.

When the glass fiber bundle is dropped on the conveyor, it is deposited in a curved shape to form a mat-like material. At this time, the deposition amount is 100 to 4,000 gr / m.
² , preferably 200 to 2,000 gr / m ² .

A thermoplastic resin that has been heated and melted is added to and impregnated into such a mat-like material. The thermoplastic resin is not particularly limited, but PE, PP, PET, NY, PB
Suitable results could be obtained by using T, PPS, AS and the like. It is desirable that the amount of the thermoplastic resin added is determined so that the weight of the glass fiber bundle is 15 to 85 wt%, preferably 30 to 75 wt% of the total weight of the glass fiber bundle and the thermoplastic resin. The method of applying the thermoplastic resin is not particularly limited, and the melt of the thermoplastic resin can be jetted from the nozzle toward the mat-like material, and the thermoplastic resin film is layered on the mat-like material and heated and melted. However, the resin in a molten state extruded by an extruder may be impregnated.

A mat-like material provided with a thermoplastic resin is pressed and compressed to obtain a compressed composite material. Cleavage pressure is determined experimentally so that the mat-like material is sufficiently compressed and bubbles are not substantially left in the compressed composite material. 45 mats used
0gr / m thickness when applying a load of 40Gr / m ² when the ^second basis weight 1.3Mm～5mm, preferably 1.
It is suitable to select it so as to be 5 to 3.5 mm. The compression can be carried out by using a press, but it can also be carried out by applying a tensile force to the mat-like material provided with the thermoplastic resin and allowing the mat-like material to pass through a die having a predetermined thickness.

The compressive force is released while the thermoplastic resin is in the molten state. Due to the elastic repulsive force of the mat-like material, the compressed composite material expands in the thickness direction, and a large number of voids are generated. In a compressed state, the thermoplastic resin adheres to the surface of the glass fiber bundle by accommodating and releasing the pressure, and when the compressed composite material expands, voids are uniformly formed between the fiber bundles and the surface of the fiber bundle is heated. A uniform coating of a plastic resin is formed, and the fiber bundles are bonded together by a thermoplastic resin, so that a lightweight composite material having high porosity (low density) and high strength can be obtained.

[0011]

[Function] A continuous glass fiber bundle is formed into a curved shape and deposited into a mat-like material, and a thermoplastic resin melt is applied to the mat-like material and compressed to form a compression composite material, in which the thermoplastic resin is melted. During that time, the compression force is released, and the elastic composite of the mat-like material expands the compression composite material to form a large number of voids, and at the same time, the thermoplastic resin is adhered to the surface of the glass fiber bundle, By combining fiber bundles, a homogeneous lightweight composite material having high strength and low density can be obtained.

[0012]

Example: 0.2% by weight of γ-aminopropyltrimethoxysilane (coupling agent), 0.2% by weight of nonionic lubricant, and unsaturated polyester emulsion (forming a film) on glass fiber with an average diameter of 18μ drawn from a bushing. 0.8% as a solid component of a sizing agent containing 5 wt%
A glass fiber bundle having a weight of 40 gr per 1,000 m was obtained by bundling 60 fibers by adding t%. This glass fiber bundle is dropped onto a conveyor to form a curved shape and deposited.
A mat-like material having a thickness of 50 gr / m ² and a thickness of 5.8 mm was obtained.
The mat-like material had a thickness of 3 mm when a load of 40 gr / cm ² was applied. A melt of PP was applied at a rate of 1,200 gr / m ² to 4 sheets of the composite mat-like material, and pressed to make the thickness 2 mm. Then, the compression force is released to obtain a density of 0.3 gr / cm ³ and a thickness of 1
A homogeneous lightweight composite material having a bending strength of 0 mm and a bending strength of 150 kg / cm ² was obtained.

[0013]

EFFECT OF THE INVENTION A lightweight composite material having a low density and a high strength can be obtained.

[0014]

[Brief description of drawings]

FIG. 1 is a side view of a compressed composite material.

FIG. 2 is a side view of a lightweight composite material.

[Explanation of symbols]

 1 glass fiber bundle 2 resin 3 glass fiber bundle integrated with resin 4 void

Claims (2)

[Claims] 1. A composite material formed of a mat-like material composed of continuous glass fiber bundles that are deposited in a curved shape and a thermoplastic resin impregnated in the mat-like material. In addition, a thermoplastic resin coating is formed on the surface of the glass fiber bundles constituting this composite material, the fiber bundles are adhered to each other with a thermoplastic resin, and the fiber bundles are formed by elastic repulsion of a mat-like material. A lightweight composite material having a large number of voids. 2. A step of depositing a continuous glass fiber bundle in a curved shape to form a mat-like material, a step of applying a thermoplastic resin melt to the mat-like material and compressing it to form a compressed composite material, and heat. A method for producing a lightweight composite material, wherein a compression force is released while the plastic resin is in a molten state, and the elastic composite material of the mat-like material expands the compression composite material to generate a large number of voids.