JPS6367119A - Manufacturing method of reinforced plate-shaped body - Google Patents

Abstract

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

Description

DETAILED DESCRIPTION OF THE INVENTION [Object of the Invention] (Industrial Application Field) The present invention relates to a method for manufacturing a reinforcing plate-like body mainly composed of an inorganic fiber mat.

(Prior art) A plate-shaped body (hereinafter referred to as a "plate-shaped body") obtained by pressurizing and heating a fiber mat such as a glass fiber mat containing an uncured binder to harden the binder has sound absorption and heat insulation properties. It has excellent properties and is widely used as interior materials for buildings, vehicles, etc. In particular, glass fiber "plates" are characterized by their light weight.

However, "plate-shaped bodies" generally have the disadvantage of low mechanical strength, especially bending strength, and if a load is concentrated on one part during handling, they are likely to break or peel off in that part, and this tendency is The smaller the thickness and density of the "plate-shaped body", or the larger its dimensions, the more significant the problem becomes. In order to increase the mechanical strength of the "plate-like body", a method of reinforcing the "plate-like body" by bonding reinforcing members such as FRP or metal plates to the plate has been proposed (Utility Model Publication No. 53-14493 (see Publication No. 1), and has the following problems.

(1) The "plate-shaped body" and the reinforcing member are likely to separate.

(2) The weight per unit area of the "plate-like body" becomes large.

(3) When the "plate-like object" is a flat object, a fiber mat containing a reinforcing material and an uncured binder is layered, and the binder is cured by applying pressure and heat to form the "plate-like object." In addition, it can also be made into a "plate-like body" (hereinafter referred to as a "reinforced plate-like body") which is reinforced by being integrally combined with a reinforcing member.

(Hereinafter, this method will be referred to as the one-piece molding method.) However, if the "plate-like body" has a curved shape, it is difficult to manufacture a reinforced plate-like body by the one-piece molding method. It is necessary to mold the reinforcing members separately and attach them together, which not only complicates the manufacturing process, but also makes it difficult to perfectly match the shapes of the two, and there is a gap between the plate and the reinforcing member. The occurrence of peeling tends to cause a decrease in strength.

In order to solve these difficulties, the present invention has been developed by overlapping an uncured fiber mat containing a phenolic resin binder with a cloth-like material impregnated with a phenolic resin solution and then dried, and then applying pressure and heating to bind the phenolic resin. It has been found that suitable results can be obtained by curing and integrally bonding the mat and cloth-like material. (Hereinafter, this method will be referred to as the original invention) When the original invention is used, it is possible to move around a reinforcing plate-like body that is lightweight, has excellent heat insulation and sound absorption properties, and has sufficient strength. , it softens under pressure and heat and easily sticks to the mold used, making it necessary to clean the mold each time or apply a mold release agent to the mold.

(Problems to be Solved by the Invention) The present invention aims to solve the above-mentioned problems that the prior art had.

[Structure of the Invention] (Means for Solving the Problems) The present invention was made to solve the above-mentioned problems, and includes a first layer made of an uncured m-fiber mat containing a phenolic resin binder; A second layer made of a cloth-like material impregnated with a phenolic resin solution and then dried, and a third layer made of a film-like material are superimposed and heated under pressure to harden the phenolic resin, and the mat and the cloth-like material are combined. The present invention also provides a method for manufacturing a reinforcing plate-like body characterized by integrally bonding film-like materials.

Next, the present invention will be explained in more detail.

In the present invention, the uncured fiber mat containing a phenolic resin binder is obtained by spraying an aqueous phenolic resin solution onto inorganic fibers such as short glass fibers obtained by a centrifugal method, flame method, etc., and keeping the lower surface under reduced pressure. A mat obtained by depositing on a right hole conveyor can be preferably used.

The thickness of the inorganic TAA varies depending on the manufacturing conditions, but it is preferable to use a thickness of 3 to 15 mm.

As the phenolic resin binder, an aqueous solution of a water-soluble initial product (resol) rich in oxymethyl groups obtained by addition condensation of phenol and formaldehyde or its derivatives is suitable, and is used in the industrial production of glass fiber mats. Phenolic binders that can be used are preferably used.

It is appropriate that the binder solid content and water content contained in the wh fiber mat be 8 to 30 wt% and 3 to 10 wt%, respectively.

Also, the weight per unit area of N & fiber mat is "plate-like body"
This is determined depending on the purpose, size, etc. of the scale, but when using the method of the present invention, even when using a mat of about 400 gr/m', a reinforcing plate-like body having sufficient bending strength can be obtained as a scale.

As the cloth-like material, woven fabrics, non-woven fabrics, linter paper, kraft paper, etc. made of natural organic fibers such as cotton and hemp, synthetic organic fibers such as polyester, and glass fibers can be suitably used. In particular, cotton woven fabric, kraft paper, etc. are preferred.

As the phenol resin solution, a lower alcohol solution of resol is suitable.

A cloth material is impregnated with a predetermined amount of a phenol resin solution and then dried. It is appropriate that the degree of drying be at least dry to the touch or higher, preferably to such an extent that the resin loses its plasticity at room temperature.

If the degree of drying is insufficient, workability is poor, it takes a long time to harden the fabric, and industrial integral molding becomes difficult.

Industrially, a dried cloth can be efficiently obtained by passing a cloth impregnated with a predetermined amount of a phenolic resin solution through a drying oven maintained at a predetermined temperature.

During drying, the crosslinking reaction of the phenol resin progresses, resulting in a resitol (B stage) state.

The basis weight (weight per unit area) of the cloth-like material and the weight of the resin to be impregnated into the cloth-like material are determined according to the required degree of reinforcement (strength required for the reinforced plate-like material). Usually 40~100gr/m', 2(1~75gr/rr
f especially 75-85 gr/rrf each.

It is appropriate to set it at 50 to 70 gr/m''.

Examples of film-like materials include aluminum foil with a thickness of about 7 to 20 IL, kraft paper with a thickness of about 30 to 7!5 gr/rd,
A nonwoven fabric having a weight of 10 to 50 gr/g can be suitably used.

The film-like material may be used as a surface material, or the surface material may be further attached to the film-like material.

According to the present invention, it is possible to obtain a reinforcing plate-shaped body having sufficient strength at about 500 gr/rrr'.

The uncured fiber mat containing the aforementioned phenolic resin binder (hereinafter referred to as the main mat) and the phenolic resin impregnation,
A dried cloth-like material (hereinafter referred to as a dried cloth-like material) and a film-like material are stacked and pressed between a pair of pears and heated.

By heating, the phenolic resin contained in the dried cloth is once softened and then hardened. Therefore, the cloth-like material can be sufficiently plastically deformed before hardening, and therefore has good conformability to the mold and can be deep-drawn. At the same time that the resin contained in the dry cloth is cured by the crosslinking reaction, the resin contained in the mat is also cured by the crosslinking reaction. The resin contained in the dry cloth is B stage (Resol), and the resin contained in this mat is A stage (Resol).
And, even though this mat contains a considerable amount of water, and this mat has a larger weight per unit area and is thicker, both can be cured simultaneously in a short time. It has been found that the two are firmly and integrally bonded, and furthermore, the film-like material is also integrally bonded by the phenol resin contained in the dried cloth-like material, and no peeling occurs.

Heating temperature is 190-250℃, preferably 200-22℃
It is appropriate to set it to 0'C, and the required heating time is 40 to 1
It is about 20 seconds.

The density of the resulting "plate" is determined by the weight per unit area of the wooden mat and the distance between the upper and lower molds. The density is determined depending on the use of the "plate-like material", but it is usually 100 to 4.
00 kg/rn' is appropriate.

(Function) The phenolic resin contained in the dried cloth is softened by heating, allowing the dried cloth to be plastically deformed and conforms well to the mold.The phenol resin contained in the dried cloth and this mat is hardened. As a result of progressing simultaneously, the two become strongly integrated,
A sufficient reinforcing effect can be obtained without causing peeling. Since the dried cloth does not come into direct contact with the mold, the phenol resin contained in the dry cloth does not stick to the mold, and the phenol resin also firmly integrates the film, causing peeling. Not at all.

(Example 1) A binder containing an A-stage phenolic resin was sprayed on short glass fibers with an average diameter of 7 ends obtained by a centrifugal method, and the fibers were collected on a perforated conveyor whose lower part was kept under reduced pressure.
An uncured glass m-fiber mat having a QOgr/ln', a thickness of 15 ma, and containing 18 wt% of resin and 5 mat% of water as solid content was obtained.

A plain-woven cotton fabric (80gr/g) made of #40 cotton yarn with 68 warps and 60 wefts is impregnated with an alcoholic solution of A-stage phenolic resin, heated and dried, and B
A dry cloth containing 70 gr/m' of stage phenolic resin was obtained.

A mat with a size of 100 cm x 150 cm, a dry cloth-like material, and an aluminum foil with a thickness of 7 mm are stacked together and heated for 90 seconds in a pair of molds kept at 220 ° C to produce a mat with a curved shape, a thickness of 3 mm, and a bulk density of the mat. 130 kg/m
A reinforced plate-like body was manufactured.

The mat, cloth-like material, and aluminum foil are integrally bonded without peeling, and even if you hold one end of this reinforcing plate-like material by hand and support it horizontally, the degree of bending is slight and there will be no bending or peeling. It also did not occur. The weight of this reinforcing plate is 550
It was light in terms of gr/rn' and had good heat insulation and sound absorption properties.

Furthermore, during molding, the phenol resin did not adhere to the mold.

(Example 2) In place of the uncured glass am-rt of Example 1, 600
gr/m', resin content 13wt%, thickness 20m: I+
using a mat with a thickness of 0.111 Im instead of cotton cloth,
The dry fabric containing phenolic resin i 40 gr/m'' obtained using kraft paper of 75 gr/rrr' was prepared in the same manner as in Example 1 except that kraft paper of 33 gr7/rIf was used instead of aluminum foil. The results were obtained.

(Effects) A plate-like body that is lightweight, has excellent heat insulation and sound absorption properties, and has sufficient strength can be obtained. Furthermore, the phenol resin does not adhere to the mold, allowing smooth release from the mold, and has the effect of increasing the rigidity of the plate-shaped body.

Claims (5)

[Claims] (1) Layering a first layer made of an uncured fiber mat containing a phenolic resin binder, a second layer made of a cloth-like material impregnated with a phenolic resin solution and then dried, and a third layer made of a film-like material. A method for producing a reinforcing plate-like body, which comprises curing the phenol resin by heating and pressurizing the mat, and integrally bonding the mat, the cloth-like material, and the film-like material. (2) The method for manufacturing a reinforcing plate-like body according to claim 1, wherein the fiber mat is a glass fiber mat. (3) Glass fiber mat has a solid content of 8 to 30 wt%
3. The method for manufacturing a reinforcing plate-like body according to claim 2, characterized in that the reinforcing plate-like body contains a phenolic resin of: (4) Cloth-like material has a solid content of 20 to 75 g per 1 m^2
4. The method for manufacturing a reinforcing plate-like body according to claim 3, characterized in that the reinforcing plate-like body contains r phenolic resin. (5) A method for manufacturing a reinforcing plate-like pair according to claim 1, 2, 3, or 4, wherein the film-like material is a surface material.