JPS58134740A - Sanderutsch board and its manufacturing method - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a novel sanderch board having various characteristics such as high strength, high rigidity, and excellent water resistance, and a method for manufacturing the same. In more detail, the fiber-reinforced thermosetting resin (hereinafter referred to as "l") is made of an inorganic particle layer bonded to each other with a binder mainly composed of a thermoplastic resin as a core material.
A sheet of uncured l'' It P is placed on both sides of a sandwich board with a layer (abbreviated as l' This article relates to a method of manufacturing a sandwich board consisting of:

Since Sanderutsch plate was developed by the Aircraft Structures Department, Aizuki 1fX, it has been widely used in vehicles, ships, and even building materials due to its structural freedom and benefits. I am in a situation where I am exposed. The Sandwich Board of HL) combines thin upper and lower surface materials with load-bearing strength with a lightweight and relatively soft core material, increasing structural efficiency to obtain large bending rigidity. .

Surface materials of sanderch boards currently in practical use include plywood, metal plates, Fl (P boards, asbestos slate boards, etc.), and core materials include synthetic resin foam, honeycomb or hunisch structures made of cardboard and metal plates, There are chipboards such as wood chips, thermoplastic resin sheets, etc., and there are a huge number of them because they are combined to make a practical sandwich board.Among these, the sandwich board that is currently most widely used is made of aluminum. IA is a combination of plywood, etc., and a (-)-nicum structure made of synthetic resin foam or cardboard. However, products that use metal plates as surface materials have poor chemical resistance and are relatively heavy. Generally, it is an expensive material.On the other hand, plywood is inherently inferior in water resistance and chemical resistance even if water-resistant veneer is used, so there are restrictions on outdoor use. Although it has the advantage of using synthetic resin foam as a monomer, it is limited in its use in which high-grade dried lumber is used as an anhydrous material due to its reduced compressive strength, shear strength, elastic modulus, etc. In addition, those using a cardboard honeycomb structure have a water resistance of y (cannot withstand outdoor use).

Therefore, a sanderch board using an inorganic hollow body as a core material, which has high strength, high elastic modulus, and excellent water resistance and chemical resistance, has been proposed. For example, in ``Compilation of Edge Material Technology (Published by Industrial Technology Center, Page Otsutoto)'' r(), an attempt was made to use a molded product of perlite, which is a type of inorganic hollow body, as a core material, but the inventors et al. After considering rj
1 Perlite bonded with an inorganic adhesive such as water glass □, epoxy resin 1, unsaturated polyester tree 11 TF, etc. Even if a non-Germany board was constructed by laminating the K F lt P layer as a surface material, the core material was too brittle and a high level of strength could not be obtained.

In view of the above-mentioned current state of sanderch boards, in order to develop a new sanderch board that overcomes the above-mentioned drawbacks, we aim to develop a new sanderch board that is lightweight, has high strength, high modulus of elasticity, and has excellent water resistance and chemical resistance. The present invention was achieved as a result of research into an inexpensive and easy manufacturing method. That is, the present invention provides a sanderch board whose core material is an inorganic particle layer bonded with a binder containing a thermoplastic resin as a main component and whose surface material is a fiber-reinforced thermosetting resin layer, and a method for manufacturing the same. be.

Examples of the inorganic particles used in the present invention include gravel, glass peas, coal granules, and inorganic foam particles. In the present invention, inorganic foam particles having pores are particularly preferred. Such inorganic foam particles include pearlite made by firing and foaming pearlite, pinestone, obsidian, etc., Shirasu balloons made by firing and foaming shirasu, natural products such as volcanic pumice, alumina, silica, borax, and synthetic glass. , particles made of artificially foamed cement, etc.

It is particularly preferable that these inorganic particles have an average particle size of o,3I11 or more. If the average grain size is 0.3 F or more, the density as a core material becomes high, or the penetration of l. There is a loop.

In the present invention, it is most preferable to use obsidian pearlite, which is 0.3111! It is easy to obtain particles with a relatively large particle size, the inside of the particle has a so-called honeycomb structure where primary foamed particles are gathered, so it has high strength, and the particle surface is smooth and it is easy to apply a binder. Due to reasons such as ease of use.

Heat used as a binder in the present invention・γi1.
I-type resins include polyolefin resins, polystyrene resins, polyvinyl chloride resins, polyester resins, polyester resins, etc. Among them, polyolefin resins have high toughness and are inexpensive. Preferred are resins and their co-compounds or modified products.

Polyolefin resins include polyethylene, polypropylene, polybutene/polymethylpentene/fX, and copolymers of these include ethylene-vinyl acetate copolymer and ethylene-ethyl acrylate copolymer. .

These modified products include maleic anhydride modified products and acrylic acid modified products.

The above thermoplastic resins can be used alone or in combination of two or more, and in order to increase the bonding strength with the inorganic foam, a small amount of emulsion adhesive or thermosetting resin can be used in combination. is also valid.

20 parts by weight of these binders per 100 parts by weight of the inorganic foam.
It is preferable to use up to 300 parts by weight. If it is less than 20 parts by weight, the binding strength may be insufficient and the strength of the product may decrease, while if it is used in excess of 300 parts by weight, no significant increase in strength can be expected and it may become uneconomical. There is a ha.

FRP is basically composed of a thermosetting resin such as unsaturated polyester or epoxy as a base material and a reinforcing material such as glass fiber 111□ or carbon fiber, and there are various molding methods. The sanderch board of the present invention can be manufactured by a method of bonding FRP already formed into a plate shape to a core material using an adhesive, but it is more preferable to increase the strength of the bonded part and improve productivity. The molding method involves applying uncured thermosetting resin and reinforcing material directly to both sides of the core material, heating it at room temperature or under pressure, and curing it under pressure, allowing some of the thermosetting resin to penetrate into the core material and integrating it. There is a way to do it. Although the conventional hand lay-up method and spray-up method can also be applied to this method, it is inexpensive, has good productivity, and has appropriate permeability.
Sheet molding compound C and below, “sM
The most preferred method is to use an uncured sheet-like material called cJ (abbreviated as cJ). In general, SMC is a mixture of a vesicular polyester resin liquid containing a hardening agent, chopped strands of glass fiber, and an inorganic filler such as calcium carbonate in approximately equal amounts and formed into a sheet.・Normal kneading is made by hardening it under heat and pressure using a mold called a dodai.

In the present invention, a sanderch board is manufactured by applying SMC to both sides of the core material and applying heat and pressure to allow the resin liquid and filler of the SMC to appropriately penetrate into the pores, so it has excellent strength and A product with elastic modulus is obtained.

The viscosity of the SMC used in this case (the viscosity of the resin liquid containing the filler excluding glass fibers) is in the range of 100,000 to 1,000,000 poise, preferably 200,000 to 10,000 poise. If it is outside this range, there is a concern that the resin liquid may penetrate into the pores of the core material too much or not sufficiently, making it impossible to obtain a sanderch board with excellent strength.

The amount of FRP used for the core material (that is, the relationship between the thickness of the core material and the thickness of FRP) is selected as appropriate depending on the application and required performance, but the thickness ratio is 10% of the core material.
It is preferable to set F l(P, 2 to jO with respect to 0).

In general, the larger the thickness ratio of FRP, the higher the strength and elastic modulus. Therefore, when high performance is required, )・When using the knot lay-up method, multiple coats are applied, while 8MC When used, measures such as stacking multiple sheets on top of each other are taken.

Next, an embodiment of the method for manufacturing a sanderch board according to the present invention will be described.

First, the process of bonding the inorganic particles of the core material using a binder can be carried out during the process of laminating the core material and FRP, but in general, in order to obtain a product with stable quality, inorganic particles are bonded in advance using a binder. It is preferable to use a core material that is preformed into a plate-shaped body or the like, which is bonded together using a binder. For this purpose, thermoplastic resin powder can be used to electrostatically attach the needles to the inorganic particles, but after covering the inorganic particles with a small amount of sticky substance, the adhesive force can be used. Not only is it possible to attach a larger amount of powder by attaching thermoplastic resin powder, but also the bonding force between inorganic particles and thermoplastic resin is increased, especially when adhesive is used for sticky substances. A desirable core material can be obtained. Next, the mixture to which the thermoplastic resin powder is attached is heated to a temperature above the melting (softening) point of the resin, and then cooled and molded. At this time, it is preferable to apply some pressure.

As a method for forming the core material, there is a method in which a mold is filled with a composite mixture and then hardened and molded, and a method in which a plate-shaped body is continuously manufactured using a double belt conveyor type molding machine is also available.

Next, in the step of laminating FRP to the core material, it is possible to use the conventional method of laminating pre-formed FRP plates using adhesive, but as mentioned above, it is possible to use uncured FRP. It is preferable to apply by a hand-laid coating method or a spray-up method, or to form a sanderch board by laminating SMC and then heating and pressurizing it. When using SMC,
SM on the front and back sides is
By feeding the core material between C and heating and pressurizing it, it is possible to continuously manufacture sanderch boards. In the manufacturing method of the present invention, in particular, by using SMC, applying an inorganic foam having pores as the core material, and providing appropriate ventilation holes, a part of the resin content of uncured FRP permeates into the core material. 1, the strength, □... is particularly improved.

As is clear from the above description, the core material constituting the sanderch board of the present invention is composed of inorganic particles with excellent strength, water resistance, and chemical resistance, and a thermoplastic resin with excellent toughness. The wood takes advantage of its soft characteristics.

Furthermore, by molding the core material of the present invention to have ventilation holes, it is not only lightweight, but the 12RP layer is laminated so that a portion of its resin permeates into the ventilation holes, making it extremely lightweight. The strength and rigidity of the sanderch board becomes extremely high.

Furthermore, in the present invention, a sandwich panel can be manufactured easily and with high productivity by applying uncured FRP sheets whose viscosity has been properly adjusted to both sides of the core material and applying heat and pressure to the sheets.

Hereinafter, the sandwich board of the present invention will be specifically explained with reference to examples, and the contents of each material used for kneading are as follows: ◇ Inorganic lightning foam 1: 11111 Obsidian pani, light quotient s r' Fuyorite, manufactured by Fuyorite Co., Ltd. Binders and binding aids: High-density polyethylene trademark: ``Stafrene Elf♂O'', 8 Seki Kagaku Co., Ltd. epoxy resin, Mikata Petrochemical Epoxy Co., Ltd. trademark: ``Epomic VR-/30AJ'', 0 parts by weight liquid polybutene ' Trademark "Nisseki Volipden LV-3; OJ Manufactured by Nisseki Chemical Co., Ltd. FR, P Material: Unsaturated polyester resin Trademark manufactured by Nippon Shokubai Chemical Co., Ltd. "Evolac Peroxide Glass Fiber Chopped 9 Strand Mat Trademark rMc-
600 to 8MC trademark "Polymer Matte" manufactured by J Nittobo Co., Ltd. Otsu 09LA J ) Manufactured by Takeda Pharmaceutical Company In addition, the bending strength and elastic modulus shown in the examples were determined by a three-point bending test under the following conditions.

Testing machine: Shimadzu Autograph DSL-2000 Temperature: ,
20'C test speed: Specimen thickness / 2 (mm 1 minute) Specimen width = SOn Span: 200 questions Example / Obsidian pearlite with an average particle size of about ram is used as the inorganic foam, and this / 00 ilj 1 was mixed with 0 parts by weight of high-density IW polyethylene powder and adhered to the particle surface. This was filled into an aluminum mold once and heated from the outside at 230°C for 5 minutes to form a L17 Mijho plate.

Next, a glass fiber chopped strand mat is placed on the surface using this as a core material, impregnated with unsaturated polyester resin by feather coating, and cured at room temperature to form a surface material with a thickness /
, six FRP layers were formed.

A similar FRP layer is formed on the back side to create a Santoi reference example. A polyvinyl chloride foam with a thickness of JO is used as the core material.
The surface material was formed in exactly the same manner as in Example/1 to create a sanderch board. The bending strength of this is 4', 3 ky
/ am, and the flexural modulus was 70 Yu/d.

Example 2 A core material with a thickness of 10III+ was molded using the same method as in Example/, and F with a thickness of 10III+ was formed on the front and back sides of this material using the same method as in Example/.
1 (, 1) layer was formed to create a sandwich plate. The bending strength of this was II'i/, the bending elastic modulus was 270 kg7 m.

Reference Example: A hard polyurethane foam with a thickness of 10111 mm was used as the core material 5, and the surface material was formed in the same manner as in Example 2.
I created a sandwich board. Stiff bending strength is 0.7
θkg/am, and the flexural modulus was j3yu/sn.

Example 3 20 parts by weight of epoxy resin was mixed and coated with 10xI'' part of obsidian pearlite, which is the same as in Example.
00 parts by weight of high density polyethylene powder was mixed and deposited. This was filled into an aluminum mold with many slits, and loaded into a steam molding machine commonly used for molding expanded polystyrene etc.
lI! Hold for 2 minutes under water vapor pressure of a to obtain a thickness of 20
A plate of IIm was molded.

Next, this was used as a core material, and one 5MCf sheet was sandwiched on each side of the core material, and the 5MCf was held in a heat press for 3 minutes at 3j'C for g minutes to create a γ7 German plate.The bending strength of this ke/, Heyanagi/Otori♂, and the bending elastic modulus was /OtsuOyu/d.

Reference Example 3 Molding was attempted using foamed polyvinyl chloride with a thickness of 20III for the core material and the surface material in the same manner as in Example 3, but S
When the MC was heated, the core material softened and collapsed, and no sanderch board was obtained.

Example 4 A core material having a thickness of 10 mm was prepared in the same manner as in Example 3, and SMC was laminated thereon in the same manner as in Example 3. The bending strength of this is 3.2 to 9/fin, and the bending modulus is 300 to 9/
It was a proverb.

Example J Obsidian pearlite with an average particle size of 7 companies was mixed and coated with 10 parts by weight of epoxy resin, and 100 parts by weight of high-density polyethylene powder was mixed and adhered thereto to create a core material with a thickness of 10IIll. A sandwich board was created in the same manner as above. The bending strength of this is! , Okg/1131. Flexural modulus of elasticity tdj00ka/m
Mix and coat the weight part of epoxy resin and this! O parts by weight of high-density polyethylene was mixed and deposited, and a plate with a thickness of 20 mm was molded in the same manner as in Example 3. Next, three sheets of It (SMC) were sandwiched between the two sides of the sheet and held under slight pressure for 75 minutes at /3!;'C for 75 minutes to create a sanderch board.

The bending strength of this is 1'fke A/yu/shoulder, the bending elastic modulus is/)
It was Okg/in.

Example 7 Average particle size of approximately 7/7 using dragon obsidian pearlite
00 parts by weight to 70 parts by weight of liquid polybutin were mixed and coated, and 20,111 parts of high-coverage polyethylene was mixed and adhered thereto, and a plate with a thickness of 20 dragons was prepared in the same manner as in the example. SMC was laminated using stiffness as a core material in the same manner as in Example B. What is the bending strength of this? The bending elastic modulus was Q kg/my2.

Comparative Example / A seam of obsidian pearlite 1001 with an average particle diameter of about s2 ml was mixed and coated with 700 parts by weight of epoxy resin, /!
The epoxy resin was held for O'CKj minutes to harden, and a plate with a thickness of 0 was formed. SMC was laminated on this in the same manner as in Example 3. The bending strength of this is O0 Otsujyu/d,
The flexural modulus was 730 Yu/m.

patent applicant Japan Petrochemical Co., Ltd. representative person

Claims (1)

[Claims] (1) f1 bonded with a binder containing a thermoplastic resin as a main component
A sanderch board with an fc inorganic particle layer as a core material and a fiber-reinforced thermosetting resin layer as a surface material. (2) The sanderch board according to claim 1, wherein the inorganic particles are inorganic foamed particles. (3) The sanderch board according to claim 1, wherein the inorganic foamed particles are obsidian pearlite. The sandwich board according to claim 2. (4) The sandwich board according to claim 7, 2 or 3, wherein the thermoplastic resin is a polyolefin. (5) The sandwich board is made of mainly thermoplastic resin in advance. A method for manufacturing a sanderch board, characterized by placing uncured fiber-reinforced thermosetting resin sheets on both sides of a core material made of an inorganic particle layer bonded with a binder as an ingredient, and bonding them under heat. (6) 135. The method for manufacturing a sandwich board according to claim 135, wherein the resin component of the uncured fiber-reinforced thermosetting resin sheet has a viscosity of 700,000 to 100,000 voids.