JP6040166B2 - 曲げ剛性を備えた積層板、同積層板からの成形品、及びその製造方法 - Google Patents
曲げ剛性を備えた積層板、同積層板からの成形品、及びその製造方法 Download PDFInfo
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- JP6040166B2 JP6040166B2 JP2013549851A JP2013549851A JP6040166B2 JP 6040166 B2 JP6040166 B2 JP 6040166B2 JP 2013549851 A JP2013549851 A JP 2013549851A JP 2013549851 A JP2013549851 A JP 2013549851A JP 6040166 B2 JP6040166 B2 JP 6040166B2
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Images
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Description
本発明の一態様において、曲げ剛性を備えた成形品を製造する方法が設けられる。方法は、a)補強繊維を含む不織布の繊維マットを準備する工程と、b)不織布の繊維マットにニードル処理を施し、ニードル処理された不織布の繊維マットを得る工程と、c)少なくとも一枚の熱可塑性樹脂シートと少なくとも一枚の表面シートとを提供する工程とを含む。表面シートは、不織布から形成され、表面シートと樹脂シートとを、ニードル処理された不織布の繊維マットの少なくとも一方の側の平面上に配置し、これにより多層シートを得、熱可塑性樹脂は、表面シートの軟化温度T2及び補強繊維の軟化温度T3の両者より低い軟化温度T1を有する。方法は、更に、d)多層シートに加熱処理及び加圧処理を施し、これにより熱可塑性樹脂シートを溶融させ完全に含浸した積層板を形成する工程と、e)完全に含浸した積層板に冷却処理及び加圧処理を施し、これにより溶融した熱可塑性樹脂シートを固化し、5容量%を超えない空隙率を有する一体化した積層板を形成する工程とを含む。少なくとも工程c)乃至工程e)は、連続した工程として実施される。方法は、上記工程に続き、f)一体化した積層板の一部を提供し、同積層板の一部を軟化温度T1より高いが軟化温度T2及び軟化温度T3より低い温度に加熱し、これにより積層板の一部に含まれる熱可塑性樹脂を溶融させることにより、本体の厚みがこれに含まれる補強繊維のスプリングバック作用により増し、多孔質な積層板を形成する工程と、g)多孔質な積層板に加熱成型工程を施し、加熱成形された部分を形成する工程と、h)加熱成形された部分を冷却させ、これにより曲げ剛性を備えた成形品を形成する工程とを含む。本明細書において、繊維強化熱可塑性樹脂の技術分野において公知のように、用語「成形品」は「成形体」と交換可能に使用されるものとする。
補強繊維のマット及び表面シートのそれぞれを形成する繊維構造体を分断させることなく上記工程を実施するために、熱可塑性樹脂の軟化温度T1は、布繊維及び補強繊維それぞれの軟化温度T2及びT3のいずれより低くする必要がある。任意の繊維材料が軟化温度T2やT3より更に低い分解温度Tcを有する場合に、温度Tc未満の軟化温度T1を有する熱可塑性樹脂を選択する必要があるであろう。
好適な実施例を従属項に定義する。
特に好適な実施例において、積層板は300乃至2500g/m2の面積重量、特に、500乃至1800g/m2の面積重量を有する。
更に後述するように、成形により形成される成形体のコア層となる積層板の本体は、一枚の繊維マットから構成される。しかしながら、別例において、本体には、2つ以上の繊維マットが相互に隣接して設けられる。いくつかの実施例において、そのような繊維マットは、熱可塑性樹脂シートを間に挟むサンドイッチ方法にて配置される。異なる特性を備えた繊維マット群を含む複数の繊維マットを有することも可能である。多数の同様のものが、複数の表面シート及び熱可塑性樹脂シートの構造体に応用される。これらのシートは、片面の樹脂シート、両面の樹脂シート、二重の樹脂シートなどである。
まず、本発明の第1実施形態について図1〜3を参照して説明する。図1(a)に示すように、チョップガラス繊維容器1及び連続ガラス繊維容器2から引き出されたガラス繊維は、チョップタイプ繰出し装置3からチョップドガラス繊維として、且つ、連続タイプ繰出し装置4から連続ガラス繊維として、ネットコンベア5に供給される。これらは続いてニードルパンチ装置6で両面ニードルパンチ処理されて不織布の繊維マット7として搬出される。図示しない別例において、チョップドガラス繊維のみが、或いは連続ガラス繊維のみが使用される。
次に、第2〜16実施形態を第1実施形態との相違点を中心に説明する。
図6(a)に示す第13実施形態の第一重合体10においては、図5(c)に示す第9実施形態の第一重合体10に対応する本体11が、互いに重ねられた三枚の繊維マット7a,7b,7aをから実際になり、両繊維マット7aの材質と両繊維マット7a間の繊維マット7bの材質とが互いに異なる。例えば、両繊維マット7a間の繊維マット7bは第1実施形態と同様にチョップドガラス繊維や連続ガラス繊維からなる不織布であり、両繊維マット7aはガラス繊維以外例えば織物などを混ぜたりした繊維から形成される。
(1)積層板16,18及び成形体20,22において、ガラス繊維を主体とする繊維マット7,7a,7bを主体とする本体11内の空隙と、不織布の表面シート9内の空隙とにそれぞれ熱可塑性樹脂を含浸させたので、積層板16,18及び成形体20,22の強度を高めることができるとともに、その本体11の繊維マット7,7a,7bの外側に重ねた任意の表面シート9により手触りや外観を良くすることができる。しかも、その本体11の繊維マット7,7a,7b内の空隙に含浸させた熱可塑性樹脂と、任意の表面シート9内の空隙に含浸させた熱可塑性樹脂とが互いにつながるため、本体11の繊維マット7,7a,7bの外側に対する任意の表面シート9の接着強度を高めて表面シート9の非剥離性を向上させることができる。
Claims (16)
- 曲げ剛性を備えた成形品を製造する方法であって、
a)補強繊維を含む不織布の繊維マットを準備する工程と、
b)前記不織布の繊維マットにニードル処理を施し、前記ニードル処理された不織布の繊維マットを得る工程と、
c)少なくとも一枚の熱可塑性樹脂シートと少なくとも一枚の表面シートとを準備する工程であって、前記表面シートは、不織布から形成され、該表面シートと樹脂シートとを、前記ニードル処理された不織布の繊維マットの少なくとも一方の側の平面上に配置し、これにより多層シートを得、該熱可塑性樹脂は、該表面シートの軟化温度T2及び該補強繊維の軟化温度T3の両者より低い軟化温度T1を有する、前記少なくとも一枚の熱可塑性樹脂シートと少なくとも一枚の表面シートとを準備する工程と、
d)前記多層シートに加熱処理及び加圧処理を施し、これにより該熱可塑性樹脂シートを溶融させ完全に含浸した積層板を形成する工程と、
e)前記完全に含浸した積層板に冷却処理及び加圧処理を施し、これにより該溶融した熱可塑性樹脂シートを固化し、5容量%を超えない空隙率を有する一体化した積層板を形成する工程とを含み、
少なくとも工程c)乃至工程e)は、連続した工程として実施され、
上記工程に続く
f)前記一体化した積層板の一部を準備し、同積層板の一部を前記軟化温度T1より高いが前記軟化温度T2及び前記軟化温度T3より低い温度に加熱し、これにより前記積層板の一部に含まれる熱可塑性樹脂を溶融させることにより、本体の厚みがこれに含まれる補強繊維のスプリングバック作用により増し、多孔質な積層板を形成する工程と、
g)前記多孔質な積層板に加熱成形処理を施し、加熱成形された部分を形成する工程と、
h)前記加熱成形された部分を冷却させ、これにより曲げ剛性を備えた成形品を形成する工程とを含むことを特徴とする成形体の製造方法。 - 前記加熱成形工程は、所定の厚みを備えた少なくとも1つの小型化した領域と、該所定の厚みよりも大きな厚みを備えた少なくとも1つの拡張した領域とを形成する工程を含むことを
特徴とする請求項1に記載の方法。 - 曲げ剛性を備えた一体化した積層板を製造する方法であって、
a)補強繊維を含む不織布の繊維マットを準備する工程と、
b)前記不織布の繊維マットにニードル処理を施し、前記ニードル処理された不織布の繊維マットを得る工程と、
c)少なくとも一枚の熱可塑性樹脂シートと少なくとも一枚の表面シートとを提供する工程であって、前記表面シートは、不織布から形成され、該表面シートと樹脂シートとを、前記ニードル処理された不織布の繊維マットの少なくとも一方の側の平面上に配置し、これにより多層シートを得、該熱可塑性樹脂は、該表面シートの軟化温度T2及び該補強繊維の軟化温度T3の両者より低い軟化温度T1を有する、前記少なくとも一枚の熱可塑性樹脂シートと少なくとも一枚の表面シートとを提供する工程と、
d)前記多層シートに加熱処理及び加圧処理を施し、これにより該熱可塑性樹脂シートを溶融させ完全に含浸した積層板を形成する工程と、
e)前記完全に含浸した積層板に冷却処理及び加圧処理を施し、これにより該溶融した熱可塑性樹脂シートを固化し、5容量%を超えない空隙率を有する一体化した積層板を形成する工程とを含み、
少なくとも工程c)乃至工程e)は、連続した工程として実施されることを特徴とする積層板の製造方法。 - 前記補強繊維は、ガラス繊維、カーボン繊維、或いはこれらの混合物から選択されることを特徴とする請求項1乃至3のうちのいずれか一項に記載の方法。
- 前記表面シートは、ポリエチレンテレフタレート繊維を含み、前記熱可塑性樹脂はポリプロピレンであることを特徴とする請求項1または4に記載の方法。
- 曲げ剛性を備えた成形品であって、
補強繊維を含む少なくとも1つのニードル処理を施した不織布の繊維材料で形成されるコア層と、
前記コア層の少なくとも一方の側の平面上に接着される少なくとも一枚の表面層であって、不織布から形成される、前記表面層とを備え、
前記コア層と前記表面層との間、及びそれぞれの内部の空隙は、前記表面層の軟化温度T2及び前記補強繊維の軟化温度T3の両者より低い軟化温度T1を有する熱可塑性樹脂により含浸され、これにより前記表面層は、前記コア層に堅固に接着され、
前記成形品(20)は、5容量%を超えない空隙率、及び10乃至50重量%の補強繊維含有量を有することを特徴とする曲げ剛性を備えた成形品。 - 所定の厚みを備えた少なくとも1つの小型化した領域(15)と、該所定の厚みよりも大きな厚みを備えた少なくとも1つの拡張した領域(17)とを更に備え、同拡張した領域は、35乃至65容量%の空隙率を有することを特徴とする請求項6に記載の曲げ剛性を備えた成形品。
- 前記補強繊維は、ガラス繊維、カーボン繊維、或いはこれらの混合物から選択されることを特徴とする請求項6または7に記載の成形品。
- 前記表面シートは、ポリエチレンテレフタレート繊維を含み、前記熱可塑性樹脂はポリプロピレンであることを特徴とする請求項6乃至8のうちのいずれか一項に記載の成形品。
- 前記表面シートのうち少なくとも一枚は装飾性プリントが施されることを特徴とする請求項6乃至9のうちのいずれか一項に記載の成形品。
- 曲げ剛性を備えるとともに一体化された積層板であって、
補強繊維を含む少なくとも1つのニードル処理を施した不織布の繊維マット(7,7a,7b)で形成される本体と、
前記本体の少なくとも一方の側の平面上に接着される少なくとも一枚の表面シート(9)であって、不織布から形成される、前記表面シートとを備え、
前記本体と前記表面シートとの間、及びそれぞれの内部の空隙は、前記表面シートの軟化温度T2及び前記補強繊維の軟化温度T3の両者より低い軟化温度T1を有する熱可塑性樹脂(8)により含浸され、これにより前記表面シートは、前記本体に堅固に接着され、前記積層板は、300乃至6500g/m2の面積重量、10乃至50重量%の補強繊維含有量、及び5重量%を超えない空隙率を有することを特徴とする積層板。 - 前記積層板は300乃至2500g/m2の面積重量を有することを特徴とする請求項11に記載の積層板。
- 前記補強繊維は、ガラス繊維、カーボン繊維、或いはこれらの混合物から選択されることを特徴とする請求項11または12に記載の積層板。
- 前記表面シートは、ポリエチレンテレフタレート繊維を含み、前記熱可塑性樹脂はポリプロピレンであることを特徴とする請求項11乃至13のうちのいずれか一項に記載の積層板。
- 前記表面シートのうち少なくとも一枚は装飾性プリントが施されることを特徴とする請求項11乃至14のうちのいずれか一項に記載の積層板。
- 前記本体は、相互に隣接して設けられる少なくとも2つの前記繊維マットからなることを特徴とする請求項11に記載の積層板。
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CN103517798A (zh) | 2014-01-15 |
KR102015339B1 (ko) | 2019-10-23 |
JP2012152982A (ja) | 2012-08-16 |
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EP2668022B1 (en) | 2019-12-18 |
US20190039329A1 (en) | 2019-02-07 |
WO2012101192A1 (en) | 2012-08-02 |
EP2668022A1 (en) | 2013-12-04 |
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