JP3171732B2 - Manufacturing method of long composite building materials - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a long composite building material having a bottom such as a square gutter in which a reinforcing core is covered with a thermoplastic resin outer layer, and more particularly to a method for manufacturing a reinforcing core and an outer layer. The present invention relates to a product having improved peel resistance.

[Prior art]

[0002] As a gutter having increased durability compared to a hard vinyl chloride resin gutter, a sheath of a thermoplastic resin such as a vinyl chloride resin is provided on both sides of a reinforcing core material in which reinforcing fibers are fixed with a synthetic resin. Coated long composite building materials have been proposed. However, although the durability is increased by the reinforcing core material, there is a problem that cracks and delamination of the reinforcing core material easily occur due to impact. To solve this problem, Japanese Unexamined Patent Publication No. 2-184428 discloses a technique proposed to improve the above disadvantage. This is a long composite building material in which a long reinforcing core made of a reinforcing fiber fixed with a foamed synthetic resin is covered with a thermoplastic resin outer cover on both surfaces.

[0003]

However, in the above-mentioned long composite building material, peeling due to impact at the interface between the reinforcing fiber in the reinforcing core material and the thermoplastic resin fixing the reinforcing fiber can be suppressed. However, there has been a problem that the separation between the reinforcing core material and the thermoplastic resin of the outer skin cannot be sufficiently suppressed. Bending and impact may act on building materials depending on the usage form.
The reinforcing core and the outer skin may peel off. For example, in a corner gutter, as shown in FIG. 9, a cut is made in the end of the bottom surface b of the corner gutter a, and a cut portion c bent further downward is formed to perform a draining process. The core and the outer skin are easily peeled off. An object of the present invention is to solve such problems, and to more reliably prevent the reinforcing core material and the outer skin layer from peeling off due to bending or impact, and to improve the overall impact resistance and thermal stretchability. To provide a method for producing a long composite building material.

[0004]

Means for Solving the Problems In order to solve the above-mentioned problems, the present inventors have proposed a method for reducing the shear stress between the reinforcing core material and the outer skin layer when an impact or bending stress is applied.
It is conceived that the maximum elongation of the thermoplastic resin outer layer in the vicinity of the interface with the reinforcing core may be improved, and this can be achieved by coating the reinforcing core with a suitable material having a low elastic modulus. We have found and completed the present invention.

The preparation method of the elongate composite building material of claim 1, wherein the heat expandable thermoplastic resin is coated on both surfaces, fibers
After bending the reinforcing core material composed of the composite sheet into a building material shape having a bottom portion, the coating material is passed through a sizing mold having a passage having a cross-sectional building material shape while continuously taking up the cover, and the heat-foamable thermoplastic resin is formed. And a step of forming a non-foamed skin layer on the surface and a thermoplastic resin foamed layer having closed cells inside by foaming the inside while cooling the surface thereof. Which achieves the above object.

According to a second aspect of the present invention, there is provided a method for producing a long composite building material, wherein a heat-expandable thermoplastic resin is coated on both sides .
After bending a reinforcing core material made of a fiber composite sheet into a building material shape having a bottom, the coated body is passed through a crosshead mold having a passage having a cross-sectional building material shape while continuously taking up the cover, and the heat-foaming heat is applied. characterized by comprising the step of forming a thermoplastic resin foam layer having a substantially same time the thermoplastic resin extrusion-coating to the thermoplastic resin skin layer closed cells therein when the plasticity resin heated foamed Thereby, the above object is achieved.

[0007] The reinforcing core material used in the present invention is not particularly limited, and examples thereof include a fiber-reinforced thermoplastic resin composite sheet comprising reinforcing fibers and a thermoplastic resin.

The fiber composite sheet used as the reinforcing core material is, for example, glass fiber, carbon fiber, Kevlar fiber, polyamide fiber, polyester fiber or the like as the reinforcing fiber, and the thermoplastic resin is one which melts and softens upon heating. These materials and shapes are not particularly limited. The surface of the above-mentioned reinforcing fiber may be subjected to a surface treatment with a primer or a coupling agent or a surface modification treatment in order to improve the adhesiveness with the synthetic resin.

[0009] As the method of manufacturing the fiber composite sheet, for example, arranged at equal intervals reinforcing fiber bundle consisting of a large number of continuous monofilaments in a plurality of width direction, the tank powdery thermoplastic resin is flowing The reinforcing fiber bundle is opened into a monofilament by passing the reinforcing fiber bundle through a plurality of bars installed in the tank in the dense powder resin suspension portion in the tank, and the powder From the step of adhering, and thereafter, the step of laminating so that both ends of each fiber bundle overlap, the step of heating and melting the powder-adhered fibers in the heating section and the step of cooling and solidifying in the cooling section, For producing a fiber composite sheet.

[0010] As such a powdery thermoplastic resin, e.g., polyethylene, olefin polymers such as polypropylene, vinyl resins and copolymers thereof chloride, polyether sulfone, engineering plastics such as polyphenylene sulfide, these thermal A mixed resin of a plastic resin and a thermosetting resin can be used.

[0011] Next, the thermoplastic resin foam layer having closed cells. The thermoplastic resin foam layer having the closed cells, the thermoplastic resin, a pyrolytic foaming agent described later,
If necessary, a cross-linking agent is mixed, and the foaming agent and the cross-linking agent are formed by foaming in a mold the heat-foamable thermoplastic resin layer formed into a sheet while maintaining the temperature at which the crosslinking agent does not decompose. .

[0012] The sheet is treated by ionizing radiation or by a chemical method or by a cross-linking agent mixed as required.
Ri cause cross-linking. As for the degree of crosslinking, the gel fraction is 15-60%.
It is preferable that the foaming be performed in such a manner that uniform and high magnification foaming cannot be obtained outside this range. This cross-linking is performed to make the bubbles at the time of foaming fine and uniform. For example, when crosslinking polyvinyl chloride, a method of mixing acrylic polyfunctional monomers and crosslinking acrylic with peroxide, ultraviolet rays, electron beams, etc., triazine-based crosslinking agents, silicon-based crosslinking agents, vinylsilane-based crosslinking And a crosslinking method using an agent or the like.

[0013] The expansion ratio of the heat expandable thermoplastic resin layer is in the selection of regulatory or resin content of the foaming agent, although up to about 40 times can be expressed, preferably about 2 to 30 times. If the expansion ratio is lower than 2, the elongation is poor and the material becomes hard. If the expansion ratio is higher than 30, it is difficult to obtain a uniform foam layer. The thickness of the thermoplastic resin foam layer after foaming, 0 on one surface.
About 3 to 3 mm is preferable. Can not be sufficiently absorbed shear stress between the reinforcing core and the surface layer of the thermoplastic resin layer is less than 0.3 mm, more than 3mm the handling of the building material is deteriorated. 0.5 to 2 mm is more preferable.

[0014] As the foaming agent described above, and the degradation or condensation by heat well as to generate a gas, for example, azodicarbonamide, azobisisobutyronitrile, N,
N'-dinitrosopentamethylenetetramine, pp'-
Oxybisbenzenesulfonyl hydrazide, barium azodicarboxylate, trihydrazinotriazine, p-toluenesulfonyl hydrazide and the like can be mentioned.

[0015] Next, the thermoplastic resin layer. This is to maintain the appearance, weather resistance, rainwater flowability, stain resistance, and the like of the building material, and may be any commonly used resin, and is not particularly limited, and is appropriately selected depending on the purpose. In order to improve the adhesiveness between the foamed layer and the non-foamed thermoplastic resin layer, a primer layer and an adhesive layer may be provided. Still further product appearance, weather resistance, rainwater flowability, in order to improve the stain resistance and the like, on the thermoplastic resin layer, a non-foamed sheet may be further laminated.

After all, as the resin of the non-foamed thermoplastic resin layer or the foamed layer, any thermoplastic resin which can be melt-softened by heating can be used. For example, polyvinyl chloride, polyethylene, polypropylene, polystyrene, polyamide, polyethylene terephthalate, polybutylene terephthalate, polycarbonate, polyvinylidene fluoride, polyphenylene sulfide, polyphenylene oxide, polyether sulfone, polyether ether ketone and the like can be mentioned. Polyvinyl chloride, which is diversified as above, is also preferably used in the present invention.

Further, a copolymer or a graft resin or blend resin as a main component the above thermoplastic resins, for example, ethylene - vinyl chloride copolymers, vinyl acetate - ethylene copolymer, vinyl acetate - vinyl chloride copolymer And urethane-vinyl chloride copolymer, acrylonitrile-butadiene-styrene copolymer, acrylic acid-modified polypropylene, and maleic acid-modified polyethylene. Further, additives such as a stabilizer, a lubricant, a processing aid, a plasticizer, and a coloring agent and a filler such as talc, mica, and calcium carbonate can be added to these resins. The layer structure of the corner gutter will be described in detail in each embodiment described later, but the corner gutter in FIG.
At the upper ends of both side walls, ear portions 43, 43 forming a closed space are formed, and the outer layer made of thermoplastic resin is formed on the entire outer peripheral surface of the ear portions together with both the bottom and side wall portions. However, in some cases, the inner peripheral surface of the ear may be further covered.

[0018]

The long reinforcing core material obtained by the present invention maintains the rigidity of the building material, and the non-foamed thermoplastic resin layer on the surface maintains the appearance, weather resistance, rainwater flowability, stain resistance and the like of the building material. The foamed thermoplastic resin layer between the long reinforcing core material and the non-foamed thermoplastic resin layer has a low modulus of elasticity, and has a central reinforcing core material and a non-foamed thermoplastic resin layer on the surface during bending or impact. To reduce the shear stress acting between them and improve the peeling resistance. Also,
Since the cell structure of the foamed thermoplastic resin layer is closed cells, it prevents rainwater from entering the inside of the building material from the end of the reinforcing core material, and the durability of the building material is extremely good.

In the above-mentioned peeling resistance, a part to which bending or impact is applied may be specified depending on the shape and use condition of the building material, and in this case, only the bottom surface of the reinforcing core material or only a part of another portion is used. May be covered with a foamed resin. On the other hand, by forming a foamed thermoplastic resin layer on both sides of the reinforcing core material, the heat insulating effect of the foamed resin suppresses the temperature change of the reinforcing core material due to solar heat, reducing the thermal expansion and contraction of the building material, and the entire building material. Not only the impact resistance but also the thermal stretchability can be greatly reduced. The heat insulating property of a material is generally represented by thermal conductivity (kcal / mh ° C.), and the thermal conductivity of a thermoplastic resin is generally about 0.5 to 2.0. Although it varies depending on the magnification, it is generally 0.05 or less, and the heat insulating effect from the solar heat to the reinforcing core material is extremely good.

[0020] and heating while suppressing the foaming of the heat expandable thermoplastic resin, and the thermoplastic resin foam layer having a non-foamed skin layers and the internal closed cell surface by foaming inside while cooling the surface A method including a step of forming
A method having a step of forming a thermoplastic resin foam layer having a thermoplastic resin outer layer and closed cells therein by extrusion-coating the thermoplastic resin almost simultaneously with heat-foaming the heat-foamable thermoplastic resin, It enables continuous and efficient production of long composite building materials. Further, the adhesion between the reinforcing core material and the thermoplastic resin layer is also ensured.

[0021]

Hereinafter, a method of manufacturing a gutter will be described as a specific example of a building material, and an example of the present invention will be described in detail in comparison with a comparative example.
I will explain. Example 1 In FIG. 1, a square gutter has the entire cross-sectional structure of an enlarged view, 1 is a long reinforcing core material, and 2 and 2 are outer skin layers on both surfaces. The outer skin layers 2 and 2 are thermoplastic resin foam layers 2a and 2a and the thermoplastic resin layers 2b and 2 as skin layers, respectively.
b and the skin layers 2b,
2b is substantially cooled without foaming while being cooled.

[0022] The Sumitoi was prepared by the following method using the apparatus shown in FIG. In FIG. 2, 11 is a roll of the long reinforcing core material 1, 12 and 13 are heated foamable sheets serving as outer skin layers, 15 is a forming machine, and 16 is a sizing mold. Heated foamable sheets 12 and 13 are laminated on both sides of the long reinforcing core material 1 via heating rolls 17 and 18, are bent into a cross section of a square gutter by a forming machine 15, and pass through a sizing mold 16.

[0023] Here, the sizing die 16 having a cooling zone C by the heating zone H and the cooling pipe 20 by the heater 19. In the heating zone H, there is no expansion allowance, and the heated foam sheets 12 and 13 are heated while foaming is suppressed. In the cooling zone C, the cross section gradually increases in anticipation of the expansion allowance. However, the surfaces of the heat-foamable sheets 12, 13 are cooled, and the foaming temperature is not reached, and the non-foamed skin layers 2b, 2b (typically, having a thickness of 0.1 to 1 m)
m). The inside of the heat-foamable sheets 12, 13 is at or above the foaming temperature, and foams as much as the cross-sectional area increases. That is, a desired expansion ratio can be obtained by adjusting the mold clearance.

[0024] Here, the heat-foamable sheet 12 and 13 is obtained by the following method. Vinyl chloride resin 100
Powder of vinyl chloride resin containing 25 parts by weight of trimethylolpropane triacrylate, which is a reactive acrylic monomer, and 1.5 parts by weight of azodicarbonamide foaming agent uniform AZ (H) (Otsuka Chemical) based on parts by weight Was formed into a sheet by a twin-screw extruder, and the vinyl chloride resin was crosslinked by electron beam irradiation to obtain a heat-foamable vinyl chloride resin sheet having a thickness of 0.5 mm. The gel fraction of this vinyl chloride sheet was measured by the following method and found to be 55%. That is, the vinyl chloride sheet is cut into 3 cm squares,
The gelled portion was immersed in methyl ethyl ketone at 25 ° C. for 24 hours to elute the ungelled portion, and then dried. The value of the following equation was defined as the gel fraction. (Weight of undissolved resin / weight of resin before immersion) × 100

The reinforcing core 1 is made of glass fiber reinforced sheet.
(Thickness 0.5 mm, glass content 30 w%)
The heating rolls 17 and 18 are heated to 180 ° C., the heating zone H of the sizing mold 16 is heated to 220 ° C. (the time required for foaming is 20 seconds), the cooling zone is cooled to 50 ° C., and foaming including the skin layer is performed. The thickness after one side is 2 mm,
The test piece was cut to a length of 4 m by a cutting machine (not shown). At this time, 0.5 mm from the surface of the outer skin was an unfoamed skin layer (expansion ratio 3 times).

The method for producing the above glass fiber reinforced sheet is described below.
It is shown below. Glass roving (Nittobo # 4400: fiber diameter 23 μm, monofilament 400 as a reinforcing fiber)
Twelve (0 bundles) were uniformly arranged in the lateral direction, and the powder resin was dispersed and introduced into a flowing tank while passing through two guide bars. The flow surface in this tank has a width of 1100 m when all twelve rovings each having 4000 filaments having a fiber diameter of 23 μm are bundled in the width direction as monofilaments.
m.

After the roving is passed along the fluidized bed along the three bars installed in the tank, the roving is opened in a monofilament form and the powder is adhered thereto. The filament was drawn into a heating roll while narrowing the filament from both sides, and heated and melted at a roll temperature of 230 ° C. to obtain a glass fiber reinforced sheet. The molding speed was 2.0 m / min, and the average thickness of the molded product was 0.5 mm. As the powder, vinyl chloride resin: MA800S manufactured by Shin-Etsu Chemical Co. (average particle size: 15
0μ) was mixed with 1.5 phr of a stabilizer and 0.5 phr of a lubricant in a super mixer.

[0028] Example 2 3, the lower side of the outer skin layer 4 of the long reinforcing core 1 (the outer surface side of the trough) is foamed layer 2a and a layer of vinyl chloride resin of the multilayer consisting of skin layer 2b 2 And polyvinylidene fluoride /
It differs from Example 1 in FIG. 1 in that a polymethyl methacrylate laminated film 3 is laminated. That is, in FIG.
Heat-expandable vinyl chloride resin sheet 1 having a thickness of 0.5 mm
The heating rolls 17 and 1 heated to 180 ° C.
8 continuously drawn from a feed device using a practice
The glass fiber reinforced sheet used in Example 1 (thickness 0.5 mm,
At the same time as being laminated on both sides having a glass content of 30 w%) , a polyvinylidene fluoride / polymethyl methacrylate laminated film 3 (thickness: 50 μm: KFC AT-50Y manufactured by Kureha Chemical Industry Co., Ltd.) Laminated, heat-expandable metal sheet with a poly (vinylidene fluoride) resin layer on the outermost layer on one side (expansion ratio 3.6
Times). Subsequently, a test piece having a length of 4 m was obtained in the same process as in Example 1 shown in FIG.

[0029] In Embodiment 3 FIG. 5, Sumitoi are those having throughout the cross-sectional structure of the expanded view, 1 long reinforcing core member, 7 is the side of the outer skin layer. Each skin layer 7 of the thermoplastic resin foam layer 5
And in which ordinary thermoplastic resin layer 6 are laminated integrally.

[0030] The Sumitoi is manufactured by the following method using the apparatus shown in FIG. In FIG. 6, reference numeral 11 denotes a roll of the long reinforcing core material 1, reference numerals 25 and 26 denote a heat-foamable sheet serving as a first layer of an outer skin layer, reference numeral 28 denotes a forming machine, reference numeral 29 denotes a heating die, reference numeral 30 denotes a crosshead die, 31 is a cooling sizing mold and 32 is an extruder. Heat-expandable sheets 25 and 26 are laminated on both sides of the long reinforcing core material 1 via heating rolls 27, and are bent into a cross section of a square gutter by a forming machine 28, and a heating mold 29, a crosshead mold 30 and It passes through a cooling sizing mold 32. Heating mold 29 is heater 3
3 has an expanded cross-section passage for foaming from the cross-section passage heated and suppressed in foaming. Crosshead die 30 has a deployment channel 34 to the outer periphery of the thermoplastic resin foam layer 5 extends annularly form a thermoplastic resin layer 6 ordinary thermoplastic resin from the expansion passage 34 is pushed I do. The cooling sizing mold 32 has a cooling pipe 35.

[0031] Here, the long reinforcing core material 1 used in Example 1
Glass fiber reinforced sheet (thickness 0.5mm, containing glass
Amount of 30 w%) and a heat-expandable polyvinyl chloride resin sheet 25, 2 having a thickness of 0.2 mm obtained in the same manner as in Example 1.
6 was continuously pulled out from the payout machine using a roll 27 heated to 180 ° C. and laminated, and subsequently formed into a square gutter shape by roll forming 28 and passed through a heating mold 29 heated to 220 ° C. , after foaming the heating foamable sheet to the thermoplastic resin foam layer 5 of a single-sided thickness 0.5 mm,
0.5m per side by extruder with crosshead mold 30
a thermoplastic resin layer 6 of hard vinyl chloride resin is laminated on m,
The sample was cooled to about 50 ° C. by a cooling sizing mold 32, cut to a length of 4 m by a cutting machine, and a test piece (expansion ratio:
Times).

It should be noted, can also make extrusion lamination of non-foam thermoplastic resin foam just before the heating foamable thermoplastic resin sheet, in this case easily perform control of the thickness of the non-foamed layer, but
Extrusion lamination of a non-foamable thermoplastic resin with a crosshead mold may be performed during or immediately after the foaming of the heat-foamable thermoplastic resin sheet.

[0033] In Embodiment 4 FIG. 7, the portion of the bottom surface of Sumitoi is a thermoplastic resin foam layer 5 and the ordinary thermoplastic resin layer 8 is a skin layer 9 laminated, other portions, It has a structure in which ordinary thermoplastic resin layers 8 are laminated. The manufacturing method is as shown in FIG.
Heat-expandable vinyl chloride resin sheets 25 and 26 are narrowed,
The heating sizing mold 29, the crosshead mold 30, and the cooling sizing mold 31 are thickened by foaming only at the bottom of the square gutter. Used in Example 1 as long reinforcing core material 1
Glass fiber reinforced sheet (0.5mm thickness, glass content
30 w%). In the same manner as in Example 1, the length 4
m, a test piece having a cross section shown in FIG. 7 was obtained.

The coated chromate treated galvanized steel sheets of the acrylic primer is continuously withdrawn from Comparative Example 1 feeding machine (thickness 0.2 mm) was shaped into Sumitoi shape by roll forming, the crosshead die continues A hard vinyl chloride resin was extrusion-coated to a thickness of 0.5 mm on one side by an extruder having the above, cooled to about 50 ° C. by a cooling sizing mold, and cut into a length of 4 m by a cutter to obtain a test piece.

[0035] Glass fiber-reinforced sheet used in Example 1 in place of Comparative Example 2 Zinc-plated steel plate (thickness 0.5 mm, a glass content of 30 w%)
A test piece having a length of 4 m was obtained in the same manner as in Comparative Example 1 except for using. Using the test pieces obtained in Example 1 and Comparative Example 2, a falling ball impact test as shown in FIG. 8 was performed. In FIG. 8, reference numeral 50 denotes a gutter placed with its bottom face up,
A steel ball 51 having a weight of 1 kg was dropped from the height shown in Table 1. Table 1 shows the results.

[0036]

[Table 1]

[0037]

The long composite building material obtained according to the present invention has a low elastic modulus thermoplastic resin foam layer laminated on at least the bottom long reinforcing core material, so that the core can be subjected to impact or bending stress. The material and the surface resin are not easily separated. In particular, when the building material is a square gutter, surface resin cracking and surface resin peeling during draining of the corner gutter end are eliminated. Moreover, since the thermoplastic resin foam layer also functions as a heat insulating layer, the thermal stretchability is improved.

The method for producing a long composite building material of the present invention
It is capable of continuously stacking things, and is easily reinforced
Thermoplastic resin foam layer with closed cells is laminated on the core material
Building materials can be manufactured.

[Brief description of the drawings]

FIG. 1A is a cross-sectional view of a gutter obtained in Example 1. FIG. (b) of (a)
FIG.

FIG. 2A is a perspective view of an apparatus for manufacturing a gutter used in the first embodiment . (b) An enlarged sectional view of the sizing mold of (a).

FIG. 3 (a) is a cross-sectional view of a gutter obtained in Example 2 . (b) of (a)
FIG.

FIG. 4 is a perspective view of a main part of an apparatus for manufacturing a gutter used in a second embodiment .

FIG. 5 (a) is a sectional view of a gutter obtained in Example 3 . (b) of (a)
FIG.

FIG. 6A is a perspective view of an apparatus for manufacturing a gutter used in the third embodiment . (b) The principal part enlarged sectional view in (a).

FIG. 7 (a) is a cross-sectional view of a gutter obtained in Example 4 . (b) of (a)
FIG.

FIG. 8 is a layout diagram showing a falling ball test of a corner gutter.

FIG. 9 is a perspective view showing a draining process of a corner gutter.

[Explanation of symbols]

1 long reinforcing core member 2a thermoplastic resin foam layer 2b skin layer 2 skin layer 3 laminated film 4 skin layer 5 a thermoplastic resin foam layer 6 thermoplastic resin layer 7 skin layer 8 thermoplastic resin layer 9 outer skin layer 16 Sizing mold 30 Crosshead mold 41 Bottom

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 E04D 13/064-13/08

Claims (2)

(57) [Claims] 1. A method of bending a reinforcing core material made of a fiber composite sheet having both sides coated with a heat-foamable thermoplastic resin into a building material shape having a bottom portion, and continuously pulling the coated body to form a sectional building material. Passing through a sizing mold having a passage having a shape, and heating while suppressing the foaming of the heat-foamable thermoplastic resin, and foaming the interior while cooling the surface thereof to form a foam-free skin layer on the surface and the interior of the interior. Forming a foamed thermoplastic resin layer having closed cells. 2. After bending a reinforcing core material made of a fiber composite sheet having both sides coated with a heat-foamable thermoplastic resin into a building material shape having a bottom, the cross-section building material is continuously taken off while the coated body is continuously taken off. through the crosshead die in having a passage shape, having the the heat expandable thermoplastic resin is heated foamed extrusion coated at approximately the same time the thermoplastic resin and the thermoplastic resin skin layer closed cells therein A method for producing a long composite building material, comprising a step of forming a thermoplastic resin foam layer.