JP2011005724A - 樹脂シート積層鋼板 - Google Patents
樹脂シート積層鋼板 Download PDFInfo
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Abstract
【解決手段】金属板を包埋した樹脂シートの両面に鋼板を積層してなる樹脂シート積層鋼板であって、前記金属板に形成された複数の細孔部の体積率の合計が、前記金属板の全体積に対して30体積%以上であり、細孔間のバーの幅が、バー厚みの0.2倍以上かつ2倍以下であることを特徴とする樹脂シート積層鋼板である。
【選択図】図1
Description
ye=[(e1−E2)y1 2+(E2−E3)y2 2+E3h2]/[2((E1−E2)y1+(E2−E3)y2+E3h)] ・・・式(2)
ρ=[7.8(h−y2+y1)+ρ樹脂シート(y2−y1)]/h ・・・式(3)
E2=E金属板V金属板+E基材樹脂V基材樹脂 ・・・式(4)
ρ樹脂シート=ρ金属板V金属板+ρ基材樹脂V基材樹脂 ・・・式(5)
・作業性がよく、かつ経済的である。
・鋼板、前記金属板、樹脂シートを一度に圧着して積層するので、加熱しても樹脂シートと前記金属板や鋼板との線膨張率差に起因する収縮ずれを制御し易い。この結果、そりや密着性不良を防止し易い。
パンチング、エキスパンド、プレス加工、ハニカム製造加工により、冷延鋼板(JISG3141、SPCC)、Al箔(3003)、Al板(A1050P−H24 相当)及びSUS箔(SUS304)に表1の細孔部を有する金属板を製造した。なお、ハニカム製法加工では、Al箔、Al板及びSUS箔の上に、表3の接着剤1をプリントロールで条線状に塗布し、所定のサイズに裁断した。この後、条線状接着剤が半ピッチずれるように多数枚数重ね合わせ、250℃、1MPaで2分間加熱硬化させた。当該ブロックを所定厚みに水流ジェットを利用してスライスし、展伸してAl及びSUSハニカムを得た。
ユニチカ製PET(1346P)、東レ製PBT(トレコン1401)、宇部興産製6−ナイロン(1013A)、三井デシュポン製アイオノマー(ハイミラン1702)、JSR製エチレンブテンゴムEBMを原料にTダイス付押し出し機で(押し出し温度230〜250℃)、0.4〜0.7mm厚みのPET、PBT、PET/EBM/アイオノマー=90/10/10(質量比)としたアロイポリマー、ナイロンの各種樹脂シートを作成した。さらに、ホモPP(MFR=1.5g/10分、Tm=159℃)の樹脂シートを同様にして作成した(押し出し温度220℃)。
上記のポリエステル系樹脂シート、ナイロン及びPPシートを、20MPa、32℃の超臨界CO2を含侵した。圧力を解放した後、当該含侵ポリエステル、PPシートを各々260℃、200℃で加熱して発泡させた。加熱後、0℃まで冷却し、気泡の成長を停止させ、発泡シートを得た。含浸時間、加熱時間、冷却速度により発泡率、発泡径を制御し、ポリエステル及び6ナイロンの発泡樹脂シートを得た。樹脂シートの質量とサイズを測定して、比重ρ発泡を算出し、一方、発泡していない同樹脂(気泡のない同樹脂)の質量とサイズを測定して、比重ρ樹脂を算出し、発泡率=(ρ樹脂−ρ発泡)/ρ樹脂として求めた。気泡径は、発泡樹脂シートの断面を走査型電子顕微鏡で観察し、断面顕微鏡像を画像処理で2値化し、円の面積として置き換えた場合の直径である等価円直径の平均値で気泡径を算出した。平均気泡径は、50個の気泡径の平均値とした。また、最隣接気泡間距離も、前記画像を使用して、気泡の中心を結ぶ直線上の気泡周間の距離から最隣接気泡間距離を求めた。
鋼板(TFS、0.18mm、引張り破断伸び35%)、金属板、樹脂シート、鋼板の順に積層し、所定の温度・圧力で加熱圧着した。
上記樹脂シート積層鋼板から125×30mmの試験片を切り出し、エリクセン社製20T総合試験機の角型深絞り実験装置(r=100mm、BHF:2t(ブランクホールドフォース))にてU型ハット曲げ試験片を作成した。断面実態顕微鏡観察によりコア層のせん断破壊の有無、目視観察により皺発生の有無を評価した。また、樹脂シート積層鋼板の総板厚と同じ板厚の鋼板(上記鋼板と同一鋼種、引張り破断伸び35%)を用いて、同一条件で加工した試験片の幅と上記加工片の幅とを比較し、スプリングバックの大きさを次式で評価した(小さいほどスプリングバックが小さい)。
SR=(H鋼板−H樹脂シート積層鋼板)/H鋼板
Claims (5)
- 金属板を包埋した樹脂シートの両面に鋼板を積層してなる樹脂シート積層鋼板であって、
前記金属板に形成された複数の細孔部の体積率の合計が、前記金属板の全体積に対して30体積%以上であり、
前記細孔部間のバーの幅が、当該バーの厚みの0.2倍以上2倍以下であることを特徴とする、樹脂シート積層鋼板。 - 前記バーの幅が、当該バーの厚みの0.6倍以上1.3倍以下であることを特徴とする、請求項1に記載の樹脂シート積層鋼板。
- 前記樹脂シートの基材が、ナイロン、ポリエステルまたはこれらの発泡体からなることを特徴とする、請求項1又は2に記載の樹脂シート積層鋼板。
- 前記樹脂シート基材が、最隣接気泡距離が5μm以下である発泡体であることを特徴とする、請求項1〜3のいずれかに記載の樹脂シート積層鋼板。
- 前記樹脂シートと前記鋼板との間に、100〜160℃での貯蔵弾性率G’が0.05MPa以上100GPa以下である接着層が積層されることを特徴とする、請求項1〜4のいずれかに記載の樹脂シート積層鋼板。
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