JP3910704B2 - Manufacturing method of fiber composite rain gutter - Google Patents

Description

【００４０】
この［表１］から明らかなように、本発明の各実施例で得られた製品は、比較例で得られた雨樋に比して、雨樋外側の表面を覆う加飾熱可塑性樹脂層の厚みが均一であり、また、その表面光沢度も保護フィルムの光沢度により自由に調整できることが確かめられた。
【００４１】
【発明の効果】
本発明の繊維複合雨樋の製造方法によれば、繊維強化熱可塑性樹脂シートに対して加飾された熱可塑性樹脂シートを、更にその表面に保護フィルムを積層した積層体を、雨樋形状に略賦形した後、樋内側表面に熱可塑性樹脂を押出被覆するから、成形工程において加飾面が損傷したりずれたりすることなく、任意の加飾が施され、しかもその表層の被覆厚さが均一な繊維複合雨樋を容易に製造することができる。
【図面の簡単な説明】
【図１】本発明の実施例１において用いた繊維強化熱可塑性樹脂シートの製造装置の模式的説明図である。
【図２】本発明の実施例１で用いた積層シートの製造装置の模式的説明図である。
【図３】本発明の実施例１で用いた積層シートの構造の説明図である。
【図４】本発明の実施例１で用いた雨樋の製造装置の模式的説明図である。
【図５】本発明の実施例１で得た繊維複合雨樋の断面図である。
【図６】本発明の実施例２で用いた繊維強化熱可塑性樹脂シートの製造装置の模式的説明図である。
【符号の説明】
１、７ 繊維強化熱可塑性樹脂シート
２ 保護フィルム
３ 加飾シート
４ 積層シート
１１ 流動槽
１２、２４ 加熱ロール
１３、２５ 冷却ロール
３１ アンコイラー
３２ フォーミングシュー列
３３ クロスヘッド金型
３４ 押出機
３５ 冷却サイジング金型
３６ 引取機
Ｃ 芯材層
Ｄ 加飾熱可塑性樹脂層
Ｉ 内層熱可塑性樹脂層[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a gutter for the fiber reinforced resin layer and the core layer.
[0002]
[Prior art]
Conventionally, PMMA (polymethacrylic acid) has been applied to the outer layer surface of the fiber reinforced core layer (the outer surface of the kite) in order to improve the thermal expansion / contraction suppression, weather resistance and impact resistance of a typical hard vinyl chloride rain gutter. A rain gutter having a structure in which a methyl) layer and a vinyl chloride layer are laminated on the inner layer surface has been proposed (Japanese Patent Laid-Open No. 6-10460).
[0003]
In this proposed technique, a fiber reinforced thermoplastic resin sheet as a core material layer is shaped into a rain gutter shape, and then a thermoplastic resin is extrusion coated on the inner layer surface side by a crosshead die, and further, PMMA on the outer layer surface side. The rain gutter having the above structure is obtained by extrusion coating.
[0004]
[Problems to be solved by the invention]
By the way, according to the rain gutter based on the above proposal, since the outer layer surface is covered with PMMA, it is easy to obtain coloring and high weather resistance. There is a problem that it is difficult to decorate with a pattern, a pattern, or embossing.
[0005]
In addition, even during the production, since there are two lamination extrusion processes using a crosshead die, process management is difficult, and it is difficult to control the uniform surface coating thickness, which is highly correlated with weather resistance. There is also.
[0006]
An object of the present invention, the surface layer can be easily subjected to decoration to also efficiently be produced without damaging the fiber composite gutter its decorative surface with easy structural control of the surface layer coating thickness It is to provide a method that can.
[0007]
[Means for Solving the Problems]
In the method for producing a fiber composite rain gutter according to the present invention, a decorated thermoplastic resin sheet is laminated on one side of a core layer composed of a thermoplastic resin and a reinforcing fiber, and further, a spider molding temperature is formed on the sheet. Then, after forming a laminated body made of a protective film made of a material that does not melt or decompose into a substantially rain gutter shape so that the laminated surface of the protective film is on the outer surface side of the protective film, it is introduced into an extrusion mold. Thus, a thermoplastic resin is extruded and laminated on the inner surface side of the gutter and the whole is shaped into a gutter shape .
[0008]
In the method for producing a fiber composite rain gutter according to the present invention, a decorated thermoplastic resin sheet is laminated on one side of a core layer composed of a thermoplastic resin and reinforcing fibers, and the surface of the thermoplastic resin sheet is further laminated. After the laminated body covered with a protective film is almost formed into a gutter shape, a thermoplastic resin is extrusion coated on the opposite side of the core layer to shape it into a gutter shape. The formed thermoplastic resin sheet is not damaged or shifted during molding, and process management including uniform surface layer coating thickness is easy, and a high quality rain gutter can be obtained with good reproducibility.
[0009]
Here, in the present invention, as a method for pre-decorating the thermoplastic resin sheet laminated on the core material layer, the surface is uneven by coloring or embossing roll etc. Ordinarily used sheet decorating methods such as those provided can be employed and are not particularly limited.
[0010]
Moreover, the clear layer may be further laminated | stacked on the thermoplastic resin sheet (henceforth a decorating sheet) to which this decoration was given previously, for protection of a surface layer.
[0011]
The material of the decorative sheet used in the present invention may be any material as long as it can be heat-sealed with the fiber reinforced thermoplastic resin sheet as the core material layer.
[0012]
Moreover , as for the thickness of this decorating sheet, 10-500 micrometers is desirable. When the thickness is less than 10 μm, it is difficult to impart sufficient concealing property, and it is easily broken during molding. When the thickness exceeds 500 μm, even if a protective film is laminated on the surface, the resin of the sheet flows due to heat and pressure during molding, and the pattern on the decorative surface is displaced, which is not preferable.
[0013]
In the present invention, the protective film laminated on the surface of the decorative sheet is for preventing the decorative sheet from being broken or displaced during molding, and is not fused with the decorative sheet. A thermoplastic resin film (sheet) having a higher melting temperature than the thermoplastic resin used for the decorative sheet, a nonwoven fabric, or the like is used.
[0014]
Since this protective film must be peeled off from the product after the rain gutter is formed or before the rain gutter construction, it is desirable to perform a mold release treatment on the contact surface side with the decorative sheet as necessary.
[0015]
Also, by providing fine irregularities on the contact surface of the protective film to the decorative sheet, the surface gloss of the resulting product can be suppressed, and if the contact surface with the decorative sheet is also embossed It is also possible to transfer the embossed shape to the surface of the product obtained.
[0016]
The thickness of the protective film is desirably 500 μm or less, and more desirably 200 μm or less. When the thickness exceeds 500 μm, it is difficult to shape the decorative sheet. When the thickness is 200 to 500 μm, the shape of the corner of the molded product may not be sharp.
[0017]
As the reinforcing fiber used in the fiber-reinforced thermoplastic resin sheet as the core layer in the present invention, glass fiber, inorganic fiber such as carbon fiber, organic fiber such as aramid fiber, etc., usually used for reinforcing plastic, and It is not particularly limited as long as it is a fiber that does not undergo thermal decomposition, melting, or the like during the molding. Also, the fiber diameter, fiber length, etc. are not limited.
[0018]
In addition, as the fiber form of this fiber reinforced thermoplastic resin sheet, a fiber reinforced in one direction is impregnated with resin, or a fiber reinforced knitted fiber is impregnated with resin. can do.
[0019]
This fiber reinforced thermoplastic resin sheet must not be stretched in the longitudinal direction (longitudinal direction of rain gutter) at the time of cocoon molding, and long fibers are used or a thermoplastic resin having a melting temperature higher than the cocoon molding temperature is reinforced. It is necessary to take measures such as impregnating the fiber.
[0020]
If a fiber reinforced thermoplastic resin sheet that is extensible in the transverse direction (cross-sectional direction of the gutter) is used, such as a fiber reinforced thermoplastic resin sheet in which the reinforced fibers are impregnated with resin, the final shaping will be performed. Even if the shaping prior to the introduction of the extrusion mold is insufficient, it is preferable that the inner surface coating resin is laminated in the mold in the transverse direction to obtain the desired shape. In that case, it is necessary to use the material extended | stretched to a horizontal direction also about a protective sheet.
[0021]
The thermoplastic resin that is extrusion coated onto the core material layer to form the inner surface of the gutter (flowing surface such as rainwater) may be any thermoplastic resin that can be extruded at or below the melting temperature of the protective film, The material is not particularly limited.
[0022]
The inner layer preferably has a coating thickness of 200 μm or more, and if it is less than 200 μm, the product is easily deformed.
[0023]
When the melting temperature of the matrix resin constituting the fiber reinforced thermoplastic resin sheet as the core material layer is higher than the wrinkle molding temperature (inner layer resin coating temperature), the inner layer resin thickness is desirably 500 μm or more. In this case, if the inner layer resin thickness is less than 500 μm, it is difficult to maintain the product shape during rain gutter molding.
[0024]
As for the laminated body (henceforth a laminated sheet) which laminated | stacked the fiber reinforced thermoplastic resin sheet, the decorating sheet, and the protective film used in the manufacturing method of this invention, it is desirable that each layer is heat-seal | fused mutually. 2. The laminate according to claim 1, wherein such a laminate is generally shaped into a product shape and then introduced into an extrusion mold, followed by extrusion coating with a thermoplastic resin on the inner layer surface side, followed by cooling and solidification. The fiber composite rain gutter according to the invention is obtained.
[0025]
In the production method of the present invention, any method can be adopted for shaping the laminated sheet as long as it is a method used for shaping the sheet, such as roll forming and shoe forming, and is not particularly limited. .
[0026]
If the laminated sheet has poor lateral stretchability, the product circumference and the shaped sheet circumference should be closely matched to the applicable circumference in the extrusion mold for coating and final molding. It is necessary to keep.
[0027]
【Example】
Examples of the present invention will be described below together with comparative examples.
[0028]
<Example 1>
(1) Production of Fiber Reinforced Thermoplastic Resin Sheet As schematically shown in FIG. 1, polyvinyl chloride (made by Tokuyama Sekisui Chemical Co., Ltd., tin laurate stabilizer and polyethylene lubricant at a polymerization degree of 800 is contained in the fluidized tank 11. Formulation) Powder P is contained and fluidized by air, and 16 bundles of glass fiber bundles (manufactured by Nitto Boseki, fiber system 23 μm, 4400 tex) F are drawn therein, and polyvinyl chloride powder P is placed between the glass filaments. After adhering, the polyvinyl chloride powder P is heated and melted with a heating roll 12 adjusted to 210 ° C., and then passed through a cooling roll 13, whereby a fiber-reinforced thermoplastic resin sheet 1 having a thickness of 0.8 m. And wound up on a winder 14.
[0029]
(2) Manufacture of laminated sheet As schematically shown in FIG. 2, rewind rolls 21, 22 and 23 are respectively provided with protective film 2, decorative sheet 3, and fiber reinforced thermoplastic resin manufactured in (1) above. The sheet 1 was wound, and the sheets 1 were laminated in this order and led to the next heating roll 24.
[0030]
As the protective film 2, a polyethylene terephthalate film (manufactured by Teijin, biaxially stretched, single-sided sandblasted product, thickness 38 μm, gloss 12%) was used. As the decorative sheet 3, a laminate of a transparent acrylic film (Mitsubishi Rayon, thickness 30 μm) and an acrylic film (Mitsubishi Rayon, thickness 65 μm) printed on the surface by gravure printing was used.
[0031]
The heating roll 24 is adjusted to a temperature of 150 ° C., pressurized with a linear pressure of 2 kg / cm, and then passed through a cooling roll 25, whereby a fiber reinforced thermoplastic film that becomes a core material layer as schematically shown in FIG. A laminated sheet 4 in which the decorative sheet 3 and the protective film 2 were sequentially laminated on one side of the resin sheet 1 was obtained, and wound around the winder 26.
[0032]
(3) Manufacture of rain gutter As shown schematically in FIG. 4 in a side view (A) and a plan view (B), the laminated sheet 4 produced in (2) is wound around an uncoiler 31 and the protective film 2 is used. After being guided to the forming shoe row 32 and shaped into a substantially rain gutter shape so that the covered surface becomes the outer surface side, the fiber reinforced thermoplastic resin sheet 1 is exposed at the same time as passing through the crosshead mold 33. Polyvinyl chloride resin is extruded and coated with a thickness of 0.5 mm from the extruder 34 on the inner surface side of the ridge, and then cooled and solidified by a cooling sizing die 35, taken by the take-up machine 36, and then cut to the required length. did.
[0033]
As shown schematically in FIG. 5, a sectional view and a partially enlarged view of the obtained product, a core material layer C made of a fiber reinforced thermoplastic resin and a decorative thermoplastic made of an acrylic resin covering the outer surface side of the bag. A fiber composite rain gutter comprising a resin layer D and an inner thermoplastic resin layer I made of a polyvinyl chloride resin covering the inner surface side of the gutter was obtained.
[0034]
<Example 2>
(1) Manufacture of fiber reinforced thermoplastic resin sheet As schematically shown in FIG. 6, carbon fiber (manufactured by Toho Rayon, fiber diameter: 7 μm) roving CF wound around a roll 61 is cut by a cutter 62 into a length of about 10 cm. At the same time, the heated roll which was opened by air from the air supply pipe 63 and mixed with the polyvinyl chloride powder P and dropped onto the conveyor belt 64 made of polytetrafluoroethylene and adjusted to 210 ° C. 65, the polyvinyl chloride powder P is heated and melted, and then passed through a cooling roll 66 to obtain a carbon fiber reinforced thermoplastic resin sheet 7 (thickness 0.7 mm), which is wound around a winder 67. I took it.
[0035]
(2) Production of Laminated Sheet A laminated sheet was produced using the same apparatus as in Example 1, and the same decorative sheet and protective film.
[0036]
(3) Production of rain gutter Extrusion coating using the same apparatus and the same thermoplastic resin as in Example 1 was performed to form a gutter.
[0037]
<Comparative example>
A rain gutter-shaped molded article was produced in the same manner as in Example 1 described in JP-A-6-10460.
[0038]
<Evaluation of Examples and Comparative Examples>
About the product obtained by the above Examples 1 and 2 and a comparative example, the cross section was observed with the microscope, respectively, and the coating thickness of the acrylic layer (decorative thermoplastic resin layer D) was measured.
Further, the glossiness on the outer side of the bottom surface was measured using a gloss meter. The results are summarized in [Table 1] below.
[0039]
[Table 1]

[0040]
As is apparent from [Table 1], the products obtained in the respective examples of the present invention have a decorative thermoplastic resin layer covering the outer surface of the rain gutter as compared with the gutter obtained in the comparative example. It was confirmed that the thickness of the film was uniform and the surface glossiness could be freely adjusted by the glossiness of the protective film.
[0041]
【The invention's effect】
According to the method for producing a fiber composite rain gutter of the present invention, a laminated body in which a thermoplastic resin sheet decorated with a fiber reinforced thermoplastic resin sheet is further laminated with a protective film on its surface is formed into a gutter shape. Since the thermoplastic resin is extrusion coated on the inner surface of the heel after approximately shaping, the decorative surface can be given any decoration without damaging or shifting in the molding process, and the coating thickness of the surface layer Can be easily produced.
[Brief description of the drawings]
FIG. 1 is a schematic explanatory view of an apparatus for producing a fiber-reinforced thermoplastic resin sheet used in Example 1 of the present invention .
FIG. 2 is a schematic explanatory view of a laminated sheet manufacturing apparatus used in Example 1 of the present invention .
FIG. 3 is an explanatory diagram of the structure of a laminated sheet used in Example 1 of the present invention .
FIG. 4 is a schematic explanatory view of a rain gutter manufacturing apparatus used in Example 1 of the present invention .
FIG. 5 is a cross-sectional view of the fiber composite rain gutter obtained in Example 1 of the present invention .
FIG. 6 is a schematic explanatory view of an apparatus for producing a fiber-reinforced thermoplastic resin sheet used in Example 2 of the present invention .
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1, 7 Fiber reinforced thermoplastic resin sheet 2 Protective film 3 Decorating sheet 4 Laminated sheet 11 Fluid tank 12, 24 Heating roll 13, 25 Cooling roll 31 Uncoiler 32 Forming shoe row 33 Crosshead die 34 Extruder 35 Cooling sizing gold Type 36 Take-up machine C Core material layer D Decorated thermoplastic resin layer I Inner layer thermoplastic resin layer

Claims (1)

A decorated thermoplastic resin sheet is laminated on one side of a core layer made of thermoplastic resin and reinforcing fibers, and a protective film made of a material that does not melt or decompose at the molding temperature is laminated on the sheet. After forming the laminated body into a substantially rain gutter shape so that the laminated surface of the protective film is on the outer surface side of the protective film, it is introduced into an extrusion die, and a thermoplastic resin is extruded and laminated on the inner surface side of the upper surface. And manufacturing the fiber composite gutter characterized by shaping the whole into a gutter shape.

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