JPH06114980A - High-strength panel and manufacturing method thereof - Google Patents

Abstract

(57) [Summary] [Object] The present invention is directed to a lightweight and high-strength panel used for concrete formwork panels, partition walls, and the like, and a method for manufacturing the same. [Structure] A fiber-reinforced material cloth is laminated on the upper and lower surfaces of a foam plate, and the laminate is integrated by impregnation and curing of a radically polymerizable liquid resin, and the fiber-reinforced material cloth on the upper and lower surfaces is foamed. A high-strength panel characterized by being connected by resin columns made of a cured product of a plurality of the resins, which penetrate the plate. A foam plate with through holes, at least the upper and lower surfaces of which were coated with a fiber-reinforced material cloth, was installed in the lower mold, and after closing the upper mold, a radically polymerizable liquid resin was injected under pressure into the mold. And a method for manufacturing a high-strength panel characterized by curing.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is intended to obtain a lightweight and high-strength panel used for concrete formwork panels, partition walls, etc. More specifically, two opposing fiber-reinforced thin plates are used. The present invention relates to a panel whose relative positions are solidified at predetermined intervals and a method for manufacturing the panel.

[0002]

2. Description of the Related Art Concrete formwork panels have heretofore mainly been made of veneer plywood. However, with the expectation of the appearance of panels other than wood, there is a method of laminating press molding a glass fiber-containing polypropylene sheet. Further, as another example, there is a so-called honeycomb plate obtained by adhering FRP thin plates prepared in advance on the upper and lower sides of a honeycomb (honeycomb) -shaped object having a height of 10 to 20 mm.

[0003]

The press-formed product made from the glass fiber-containing polypropylene sheet, when used as a concrete formwork panel, has been devised in its shape in consideration of cost reduction and weight reduction. Insufficient bending rigidity is unavoidable. Further, a honeycomb-shaped product sandwiched between two FRP plates is good in terms of its lightness and bending rigidity, but since it is expensive to manufacture, it is difficult to use as a concrete formwork panel in terms of price. It is used only for limited purposes. The present invention overcomes these shortcomings and provides a method for manufacturing a lightweight, stiff, and inexpensive manufacturing panel.

[0004]

[Means for Solving the Problems] Two F-shaped honeycombs are used.
The reason why the RP plates sandwiched between them have a large bending rigidity is that the relative positions of the two FRP plates are fixed by the honeycomb-shaped material. The above problem was solved by completing an integral molding method in which two fiber-reinforced plates are molded and at the same time, their relative positions are fixed.

That is, according to the present invention, the fiber-reinforced material cloth-like material is superposed on the upper and lower surfaces of the foam plate, and the laminate is integrated by impregnation and curing of the radical-polymerizable liquid resin. The object is a high-strength panel characterized by being connected by a plurality of columns penetrating the foam plate.
For example, there is one in which the fiber-reinforced material cloth is a glass fiber mat, the radically polymerizable liquid resin is unsaturated polyester, and the resin column is an impregnated molded cured product of the unsaturated polyester such as shirasu balloon or sawdust. Next, another invention is to install a foam plate with through holes, at least the upper and lower surfaces of which are coated with a fiber-reinforced material cloth, in the lower mold, and after closing the upper mold, radically polymerizing into the mold. This is a method for manufacturing a high-strength panel characterized by injecting a liquid resin under pressure and curing it. In this case, the resin is injected under pressure by using an upper mold and a lower mold.
It can also be done from the point.

The foamed plate having a large number of through holes used in the present invention may be used by appropriately punching a commercially available foamed plate of polyvinyl chloride, polypropylene or the like, or by making it a perforated plate when the foamed plate is made. You can either make it. The foam plate is not soluble in the liquid resin used, such as ordinary expanded polystyrene. It is possible to use a foam plate that is used as an insert material when handling the FRP fishing boat. The expansion ratio is about 15 to 50. The shape of the through holes scattered on the foam plate is not particularly limited, but is generally circular. The diameter of the through hole is 10 to 5
About 0 mm is suitable. The distance between the centers of the through holes is 5 to 20.
cm is preferable. In the present invention, geometrical existence patterns such as the size of the through holes and the center-to-center spacing are not regulated at all, but they are the mechanical force that the panel receives during use, the necessity of nailing the panel, the panel It should be decided considering how the panel is used, such as cutting and using, and the time and effort required for manufacturing the panel. The diameter and center interval of the through holes described above are examples suitable for concrete formwork panels. The through hole of the foam plate is a portion which becomes a pillar of resin for fixing the mutual positions of the fiber reinforced plates generated on both side surfaces of the foam plate after molding. The resin pillars, of course, correspond to the honeycombs of the honeycomb plate, but also serve as nailing locations for the panels. Since the pillars fix the mutual positions of the fiber-reinforced plate, it is not always necessary to bond the foamed portion of the foam plate and the fiber-reinforced plate.

That is, the foamed plate plays an important role as a mold for holding the position of the fiber-reinforced material cloth-like material and a column forming mold at the time of molding, but does not play any role as a concrete formwork panel after molding. . However, in the partition panel, the foam plate suppresses the convection of air and plays a role of heat insulation. It is not impossible to nail or screw the pillars in the panel even if the pillars are made of resin. However, in order to facilitate such operations, dry sawdust, dried wood chips, hollow powder such as shirasu hollow expanded powder (shirasu balloon), or organic foam particles should be placed in the through holes of the foam plate when preparing for molding. It can be done by filling. During molding, they are impregnated with resin to form columns. The filling in these through holes also serves to reduce the sink mark phenomenon on the panel surface due to the column portion due to the molding shrinkage of the resin. As the filler in the through hole, calcium carbonate, or glass short fibers or powder can be used. However, although they are effective in reducing the sink mark phenomenon, they cannot facilitate nailing and screwing.

As the liquid resin, an ionic polymerizable liquid resin such as a phenol resin or an epoxy resin can be used in principle in the same manner as the radical polymerizable resin of the present invention, but in view of the resin price and the molding speed, In consideration of practicality, the latter liquid resin is used in the present invention.

Examples of the radical-polymerizable resin include various α, β-ethylenically unsaturated polyesters, novolac type vinyl esters or bisphenol type vinyl esters having a (meth) acryloyl group at the terminal, and styrene or methacrylic acid as a reactive diluent solvent. The various urethane (meth) acrylates that are methylates can be mentioned as examples. In the production of the panel, a filler such as calcium carbonate may be present in the resin, but in such a case, the resin containing the filler, that is, the dope viscosity is preferably low. It is expected to be about 800 centipoise. In particular, when the column is filled with a filler prior to molding, the viscosity is preferably 300 centipoise or less in order to facilitate permeation and impregnation of the resin or dope into the column. To do this, select a liquid resin with a low viscosity, reduce the viscosity of the resin by appropriately using a reactive diluent solvent, and further add a filler such as calcium carbonate to the resin, if necessary, a viscosity reducing agent. ,
For example, if W-995 (manufactured by BIC Chemie Japan) is used in combination, a dope with a viscosity of 300 centipoise or less can be easily achieved.

A commercially available RTM is used as the fiber-reinforced material cloth.
The glass mats for are the most common. Glass fiber knits and fabrics, carbon fiber fabrics can also be used. Organic fiber woven fabrics such as vinylon, non-woven fabrics or felt-like materials can also be used. Regarding the selection of these reinforcing materials, the knowledge in ordinary RTM molding can be used as it is.

The liquid resin is cured by a peroxide catalyst which is a curing catalyst, a curing accelerator such as cobalt naphthenate which is a curing aid, and N, N'which is also a curing aid.
RTM is a combination of promoters such as dimethylaniline
It is common in law. Also in the present invention, the curing can be performed by utilizing the knowledge as it is. That is, for unsaturated polyesters, N, N'-dimethylaniline is used in combination with acetylacetone peroxide and cobalt naphthenate when it is necessary to further accelerate the curing. For vinyl ester, Percure K (a peroxide made by NOF CORPORATION) and cobalt naphthenate may be used in combination, and for a liquid resin containing urethane methacrylate, a combination of benzoyl peroxide and N, N′-dimethyltoluidine may be mentioned.

The mold release is carried out by applying an external mold release agent such as wax to the mold and mixing the liquid resin used with an internal mold release agent of, for example, a phosphoric acid ester, as in the case of ordinary RTM molding. Also, if the external release agent is selected, even if the internal release agent is not used, the release can be performed several times to about 10 times by applying the external release agent once, which is no different from the usual RTM method.

The number and position of the liquid resin injection ports or exhaust ports provided in the mold used for molding are determined based on the experience of ordinary RTM. As in the case of ordinary RTM molding, the method of injecting from one or several places of the upper mold or the lower mold is
In molding the panel of the present invention, the probability of success is not necessarily high. When the resin is molded from the side of the lower mold, that is, the resin is applied to the side surface in the thickness direction of the panel as in Example 2, the success rate of the molding is high even if there is only one injection port. However, if a mold having a pair of inlets and exhaust ports (at least four inlets / outlets) is provided in each of the lower mold and the upper mold as described below, the molding pass rate can be extremely high. That is, the idea that both sides of the panel are molded separately seems to be good.

Regarding molding, general procedures and the like will be given as examples. A mold coated with an external mold release agent is prepared, a glass mat is laid on the bottom surface of the cavity, and a foam plate having holes is placed thereon. Next, if necessary, each of the through holes is filled with a shirasu balloon, and a glass mat is laid on it and the upper mold is closed. Each of the lower mold and the upper mold is provided with a pair of resin injection port and exhaust port. Thus they stand almost perpendicular to the panel surface to be molded. The resin containing the curing system is supplied to both the lower mold and the upper mold. Eventually, resin will overflow from the exhaust port from either the lower mold or the upper mold. After overflowing an appropriate amount,
Close the outlet and wait for overflow from the other outlet. When the overflow comes out, flow an appropriate amount to finish the injection of the liquid resin.
After that, when the contents harden, the mold is removed.

The molding temperature is preferably room temperature to about 60 ° C. as is the case with ordinary RTM. In particular, when molding a panel such as a flat plate by room temperature molding, a resin type, an electroformed nickel type, or a metal type such as aluminum, which has been often used as a mold material, can be used, but it is the easiest. In order to prepare the mold, it is preferable to use plywood having FRP attached to both sides used in the production of the freezer. As a result, die manufacturing costs can be significantly reduced.

[0016]

[Function] A foamed plate having a large number of through holes is laid in a mold by stacking a layer of fiber reinforced cloth on the front surface and the back surface,
By injecting and hardening a liquid resin into it, a panel in which the relative positions of the two fiber reinforced plates are fixed by resin columns generated by the through holes can be manufactured by integral molding. This panel is as lightweight as a honeycomb plate, has a large bending rigidity, and has compression resistance, but since it is integrally molded, it can be manufactured at a cheap price that cannot be achieved with a honeycomb plate. Further, the column formed by the through hole is particularly easy to nail and has a holding property when it is a molded and hardened product containing a shirasu balloon or the like.

The present invention will be described in more detail with reference to the following examples. In addition, "%" is "% by weight".

[0018]

[Embodiment 1] An embodiment will be described with reference to FIGS.

On the bottom of the lower mold 1, a glass mat 2 (for example, 4
50 g / m ² ), and a thin paper 3 is laid on the glass mat 2 (having narrow sleeves around it as shown in FIG. 5). A large number of through holes 4 (for example, diameter 2
Foamed polypropylene plates 5 (for example, 45 times foamed, the foaming rate is not limited) having 0 mm and an interval of 10 cm) are stacked. The periphery of the glass mat 2 is bent to cover the periphery of the expanded polypropylene plate 5, and the edge portion 2a of the glass mat 2 is further bent to the upper surface of the expanded polypropylene plate 5 (FIG. 3). Next, the through holes 4 are filled with the shirasu balloons 6, respectively, the glass mat 7 is overlaid thereon, and the upper mold 8 is placed on the lower mold 1 to close the mold. The particle diameter of the Shirasu balloon 6 in the above was 5 to 150 μm, the average particle diameter was 40 μm, and the bulk specific gravity was 0.18.

The upper mold 8 is provided with a resin injection port 9 and an exhaust hole 10, and the lower mold 1 is also provided with a resin injection port and an exhaust hole corresponding to these positions (Note). Inlet and exhaust holes are not shown). Liquid resin (Yupica 4001A, α, β ethylenically unsaturated polyester with styrene monomer added and 100 centipoise at 25 ° C) was injected from the above two upper and lower injection ports with a RTM injection pump at a mold temperature of 27 ° C ( For example, 0.8 kg / cm ² ). In this way, the injection was stopped when the resin leaked from the upper and lower exhaust holes.

In the above, PR-M (hardening aid manufactured by Nippon Yupica) was dissolved in resin by 0.6% and placed in the resin storage tank of the RTM pump, and the curing catalyst was acetylacetone peroxide, which was used as a catalyst. Put it in a storage tank and add resin 10
The RTM pump was adjusted so that 1.0 part (volume) of the curing catalyst was mixed with 0 part (volume).

In the mold described above, the exhaust hole is higher than the inlet by about 10 cm. After leaving it for 1 hour, the upper mold was opened and the molded product 11 was taken out. The molded product 11 (panel) had a width of 90 cm, a length of 180 cm and a thickness of 12 cm, and a specific gravity of 0.45.

In the above description, the injection port is provided on one side of the upper mold and the lower mold, but by providing the flow gutter 12 as shown in FIG. 4 inside the injection port, the liquid resin can be easily fed. Can be

Both ends in the length direction of the panel are 7 cm × 7
After supporting with cm square timber, load 0-3200 in the center
When the g is applied, the sag in the center is 0,200g.
And 3200 g were 5 mm, 9.5 mm, and 12.5 mm, respectively.

On the other hand, a commercially available polypropylene panel having a width of 60 cm and a length of 180 cm and containing glass fiber has a height of 12
Since it has ribs of mm, assuming a thickness of 12 mm, the specific gravity is 0.6. It was supported in the same manner as above, and when the sag of the central part under the same conditions was measured, 32
mm, 47.5 mm and 57.5 mm.

Therefore, the panel of the present invention is
It was found to be lightweight and highly rigid.

[0027]

Second Embodiment Next, an embodiment will be described with reference to FIG.

An aluminum thick plate having a thickness of 25 mm and a width and a length of 50 cm was prepared for both the lower mold 1 and the upper mold 8. Separately height 12
A frame having a width of 45 mm and a width of 45 cm was formed by bending an iron plate having a thickness of 5 mm. Silicon rubber 13 having a width of 5 mm and a thickness of 1 mm was attached to the upper and lower surfaces of the iron frame 14 using a sealant. An iron pipe 15 having an outer diameter of 10 mm, an inner diameter of 8 mm and a length of 5 cm was welded to the center of one side of the iron frame 14 and used as a resin injection port 9. An exhaust hole 10 was similarly attached to the center of the side opposite to the inlet 9. The iron frame 14 was placed on a thick aluminum plate which was the lower mold 1. One piece similar to that shown in FIG. 5 having a sleeve of 45 cm × 45 cm and a width of 8 cm on each side thereof was cut out from a roll of a glass mat and placed in an iron frame 14. Next, add block (foamed polyethylene board made by Nippon Styrene Paper), expansion ratio 15 times,
Cut out 45 cm x 45 cm from a plate with a thickness of 10 mm,
Around the width of 2.5 cm, lines were drawn at intervals of 10 cm, and through holes having a diameter of 10 mm were opened at the intersections of the lines. The foamed plate having the through holes was put in an iron frame, the glass mat was folded as in Example 1, and the same glass mat cut into a size of 45 cm × 45 cm was placed on the glass mat. The mold was closed by placing an aluminum plate. As the liquid resin, Upica 4001A was used as it was. It is 1
It was 550 centipoise at 8 ° C. Mold temperature is 18 ℃
With an RTM infusion pump.

In the above, the curing aid PR-M in the resin is used.
Has a concentration of 0.7%, and Moldbits E is used as an internal release agent.
1.5% of Q-6 (phosphoric acid ester type manufactured by Accel Plastics Research Laboratories, USA) was added. The curing catalyst was acetylacetone peroxide, and the pump was adjusted to mix 1.25 with respect to the resin 100 in a volume ratio. The injection pressure was 0.3 kg / cm ² , and the resin solution was injected into the mold from the pump, and after 1 hour, the molded product was demolded. The obtained panel is fixed at both ends and is placed at the center of the panel.
Even when a load of 0 kg was applied, the deflection was about 5 mm and the specific gravity was 0.48. It was confirmed that this panel is lightweight and has a significantly high bending rigidity.

[0030]

[Comparative Example 1] A comparative example is the case in which the through-holes were not present in the foam plate in Example 2. Others are Example 2
A panel was manufactured in exactly the same manner as. Also 70 in the center
When a load of kg was applied, it was found that the deflection was 43 mm. Although the specific gravity of this product was 0.45, it was confirmed that the bending rigidity was significantly inferior to that of the panel of Example 2 above.

[0031]

According to the present invention, the fiber-reinforced cloth-like material is placed in layers on the upper and lower surfaces of the foam plate having a large number of through holes, and the whole is resin-reinforced. The effect is to obtain a lightweight and highly rigid panel made of a resin column that fixes the position.

Further, according to the manufacturing method of the present invention, there is an effect that a panel having high rigidity can be integrally molded in one step.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a panel of the present invention.

FIG. 2 is a partial vertical perspective view of a mold during a manufacturing process of the present invention.

FIG. 3 is a partially enlarged cross-sectional view of the same panel.

FIG. 4 is a partially enlarged cross-sectional view of the same mold.

FIG. 5 is a plan view of a glass mat with sleeves similarly used in the examples.

FIG. 6 is a partially enlarged sectional view of a mold of another embodiment.

[Explanation of symbols]

 1 Lower Mold 2, 7 Glass Mat 3 Paper 4 Through Hole 5 Foamed Polypropylene Plate 6 Shirasu Balloon 8 Upper Mold 9 Injection Port 10 Exhaust Hole 11 Panel 14 Iron Frame 15 Iron Pipe

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification number Internal reference number FI Technical display area E04G 9/00 7040-2E // B29K 67:00 105: 04 105: 08 B29L 9:00 4F

Claims (5)

[Claims] 1. A fiber-reinforced material cloth-like material is laminated on the upper and lower surfaces of a foam plate, and the laminate is integrated by impregnation and curing of a radically polymerizable liquid resin. A high-strength panel characterized by being connected by a plurality of resin columns made of a cured product of the resin, which penetrate the foam plate. 2. The high-strength panel according to claim 1, wherein the fiber-reinforced material cloth material is a glass fiber mat, and the radical-polymerizable liquid resin is unsaturated polyester. 3. The high-strength panel according to claim 1, wherein the resin column is a cured product obtained by impregnating and molding a radically polymerizable liquid resin of shirasu balloon, sawdust or organic foam particles. 4. A radical-polymerizable liquid resin is placed in the mold after a foam plate having through holes, at least the upper and lower surfaces of which are coated with a fiber-reinforced cloth, is installed in the lower mold and the upper mold is closed. A method for manufacturing a high-strength panel, which comprises injecting under pressure and curing the same. 5. The method for manufacturing a high-strength panel according to claim 4, wherein the pressure injection of the resin is carried out from at least two positions of an upper mold and a lower mold.