JPH0516274A - Laminated molding and molding method thereof - Google Patents
Laminated molding and molding method thereofInfo
- Publication number
- JPH0516274A JPH0516274A JP3176835A JP17683591A JPH0516274A JP H0516274 A JPH0516274 A JP H0516274A JP 3176835 A JP3176835 A JP 3176835A JP 17683591 A JP17683591 A JP 17683591A JP H0516274 A JPH0516274 A JP H0516274A
- Authority
- JP
- Japan
- Prior art keywords
- sheet
- thermoplastic resin
- molding
- resin layer
- fiber
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は、繊維強化熱可塑性樹脂
層の芯部と通気性装飾用表皮からなる多孔質積層成形品
およびその成形方法に関するものである。本発明による
多孔質積層成形品は、自動車の内装材、あるいは家庭電
気製品等のハウジング部品、家具等の産業用部品に広く
使用される。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a porous laminated molded article comprising a core portion of a fiber reinforced thermoplastic resin layer and a breathable decorative skin, and a molding method thereof. The porous laminated molded article according to the present invention is widely used for interior materials of automobiles, housing parts such as household electric appliances, and industrial parts such as furniture.
【０００２】[0002]
【従来の技術】最近、金属のプレス加工で製造されてい
た産業用部品が、比較的長い強化繊維と熱可塑性樹脂か
ら構成されている繊維強化熱可塑性樹脂のプレス成形品
に代替される傾向にある。繊維強化熱可塑性樹脂の特徴
は、加熱された繊維強化熱可塑性樹脂シート状成形素材
（以後該成形素材をシート状成形素材と称する）を、室
温あるいは加熱した成形型内に挿入し短時間で加圧成形
することにより複雑な成形品を製造することができ、さ
らにその成形品が高い強度を有し、軽量である点にあ
る。2. Description of the Related Art Recently, there has been a tendency that industrial parts manufactured by pressing metal are replaced by press-molded products of fiber-reinforced thermoplastic resin composed of relatively long reinforcing fibers and thermoplastic resin. is there. Fiber-reinforced thermoplastic resin is characterized in that a heated fiber-reinforced thermoplastic resin sheet-shaped molding material (hereinafter, the molding material is referred to as sheet-shaped molding material) is inserted into a molding die at room temperature or in a heated state and is added in a short time. A complicated molded product can be manufactured by pressure molding, and the molded product has high strength and is lightweight.
【０００３】さらに、繊維強化熱可塑性樹脂を膨脹させ
た多孔質成形品は、その剛性が製品肉厚の増加に伴い著
しく強化されるため、軽量化メリットが向上する。しか
して、抄造法（特公昭５２−１２２８３号公報、特公昭
５５−９１１９号公報）によるシート状成形素材の多孔
質成形品の製造方法（特開昭６０−１７９２３４号公
報、特開昭６２−１６１５２９号公報）が提案されてい
る。シート状成形素材は、抄造技術を応用して、直径３
〜３０μm φ、長さ３〜５０mmの強化繊維と熱可塑性樹
脂粉末を均一に分散して不織材料を製造し、この不織材
料を原料とし加熱、加圧を行いさらに冷却して製造され
る。Further, since the rigidity of the porous molded product obtained by expanding the fiber reinforced thermoplastic resin is remarkably strengthened as the product thickness increases, the merit of weight reduction is improved. Therefore, a method for producing a porous molded article of a sheet-shaped molding material by a papermaking method (Japanese Patent Publication No. 52-12283, Japanese Patent Publication No. 55-9119) (Japanese Patent Laid-Open Nos. 60-179234 and 62-62). No. 161529) has been proposed. The sheet-shaped molding material has a diameter of 3 by applying the papermaking technology.
It is manufactured by uniformly dispersing reinforcing fibers having a diameter of -30 μm and a length of 3 to 50 mm and a thermoplastic resin powder to produce a non-woven material, and using the non-woven material as a raw material, heating, pressurizing and further cooling. .
【０００４】抄造法で製造される不織材料は、強化繊維
がモノフィラメント（単一の繊維）の状態で分散し、ラ
ンダムに配向しているため非常にかさ高いという性質を
示す。不織材料の厚みは、強化繊維の含有量とその形
状、抄造条件により異なるが、シート状成形素材として
一般的に用いられる空隙を除去したシートに比べ１０倍
程度の厚みを有している。シート状成形素材は、成形前
にマトリックスである熱可塑性樹脂の軟化点または融点
以上に加熱されるが、熱可塑性樹脂の強化繊維に対する
結合力が弱まるため、強化繊維の残留応力が解放され、
元に戻ろうとするスプリングバックにより膨脹する。The non-woven material produced by the paper-making method has the property that it is very bulky because the reinforcing fibers are dispersed in the state of monofilaments (single fibers) and are randomly oriented. The thickness of the non-woven material varies depending on the content of reinforcing fibers, its shape, and papermaking conditions, but is about 10 times as thick as that of a sheet from which voids are generally used as a sheet-shaped forming material. The sheet-shaped molding material is heated before the softening point or melting point of the thermoplastic resin that is the matrix before molding, but the binding force of the thermoplastic resin to the reinforcing fibers is weakened, so that the residual stress of the reinforcing fibers is released.
It expands due to springback trying to return to its original state.
【０００５】多孔質成形品は、このシート状成形素材の
膨脹を利用して成形される。シート状成形素材は、一般
的には遠赤外線加熱炉で加熱されるが、その際に膨脹し
た加熱シート状成形素材を、成形型内に挿入し、目的と
する膨脹倍率を得る条件で加圧成形することにより、多
孔質成形品を製造する。A porous molded article is molded by utilizing the expansion of this sheet-shaped molding material. The sheet-shaped molding material is generally heated in a far-infrared heating furnace, and the expanded heated sheet-shaped molding material at that time is inserted into a molding die and pressed under the condition of obtaining a desired expansion ratio. A porous molded product is manufactured by molding.
【０００６】シート状成形素材の膨脹は、シートの表面
から始まり次第に熱が板厚中心部におよぶにつれて全体
的に膨脹し、それと共に断熱空気層が形成されるため熱
伝導率が低下する。シート表面では、強化繊維がスプリ
ングバックにより露出し、さらに熱可塑性樹脂がシート
の熱伝導率の低下に伴う局部加熱により劣化し、外観が
著しく悪化する。結果として、膨脹した加熱シート状成
形素材を加圧成形して得られる多孔質成形品の外観の低
下が、シート状成形素材の外観を受け継ぐために生じ
る。The expansion of the sheet-shaped molding material starts from the surface of the sheet and gradually expands as the heat reaches the central portion of the plate thickness, and a heat insulating air layer is formed with it, so that the thermal conductivity decreases. On the surface of the sheet, the reinforcing fibers are exposed by springback, and the thermoplastic resin is deteriorated by local heating due to the decrease in the thermal conductivity of the sheet, resulting in a marked deterioration of the appearance. As a result, the appearance of the porous molded article obtained by pressure-molding the expanded heated sheet-shaped molding material is deteriorated because the appearance of the sheet-shaped molding material is inherited.
【０００７】膨脹した加熱シート状成形素材の表面に、
装飾用表皮を積層し加圧成形するのと同時に両者を一体
化することにより積層成形品を得る方法は、多孔質成形
品の外観改良において非常に有効な手段である。積層成
形品の成形方法の一例を図１（ａ）に示した。シート状
成形素材１を遠赤外線加熱炉２内で加熱する。シート状
成形素材は、加熱により膨張し、強化繊維の露出３が多
くなる。通気性装飾用表皮５を、加熱されたシート状成
形素材４の上に重ねて成形型６内に挿入し、目的とする
膨脹倍率を得る条件で加圧成形するのと同時に両者を一
体化することにより多孔質積層成形品７を得る。しか
し、この方法で成形された多孔質成形品の繊維強化熱可
塑性樹脂層と通気性装飾用表皮の接着強度は、非常に弱
く実用的ではない。On the surface of the expanded heated sheet-shaped molding material,
A method of obtaining a laminated molded product by simultaneously laminating and press-molding the decorative skin and simultaneously integrating the two is a very effective means for improving the appearance of the porous molded product. An example of a method for molding a laminated molded product is shown in FIG. The sheet-shaped molding material 1 is heated in the far infrared heating furnace 2. The sheet-shaped molding material expands by heating, and the exposed portion 3 of the reinforcing fiber increases. The breathable decorative skin 5 is placed on the heated sheet-shaped molding material 4 and inserted into the molding die 6, and the molding is performed under the condition of obtaining a desired expansion ratio, and at the same time, the both are integrated. As a result, a porous laminated molded product 7 is obtained. However, the adhesive strength between the fiber-reinforced thermoplastic resin layer of the porous molded article molded by this method and the breathable decorative skin is very weak and not practical.
【０００８】積層成形品の繊維強化熱可塑性樹脂層と通
気性装飾用表皮の接着強度は、加圧成形時に装飾用表皮
内部へ熱可塑性樹脂が浸入し、固化して結合することに
よるアンカー効果により発現する。しかしながら図１
（ａ）の積層成形品の成形方法においては、加熱シート
の表面部の強化繊維の露出が多くなり、膨脹したシート
内部の熱可塑性樹脂は、均一に分散している強化繊維の
存在により流動が阻害され、加圧成形時にシート表面へ
しみ出し難くなる。このため、熱可塑性樹脂の表皮内部
への浸入量がごく僅かになり十分なアンカー効果が発現
しないため、繊維強化熱可塑性樹脂層と表皮の接着強度
は非常に弱くなる。The adhesive strength between the fiber-reinforced thermoplastic resin layer of the laminated molded product and the breathable decorative skin is determined by the anchor effect by the thermoplastic resin penetrating into the decorative skin during pressure molding and solidifying and bonding. Express. However, FIG.
In the method for molding a laminated molded article of (a), the exposed amount of the reinforcing fibers on the surface of the heating sheet is increased, and the thermoplastic resin inside the expanded sheet is flowed due to the presence of the uniformly dispersed reinforcing fibers. It becomes difficult to exude to the surface of the sheet during pressure molding. For this reason, the amount of the thermoplastic resin penetrating into the inside of the epidermis becomes very small and a sufficient anchor effect is not exhibited, so that the adhesive strength between the fiber reinforced thermoplastic resin layer and the epidermis becomes very weak.
【０００９】[0009]
【発明が解決しようとする課題】本発明は、抄造法で製
造されたシート状成形素材を用いて、通気性装飾用表皮
との接着強度の良好な多孔質積層成形品およびその成形
方法を提供するものである。DISCLOSURE OF THE INVENTION The present invention provides a porous laminate molded article having a good adhesive strength with a breathable decorative skin, and a molding method thereof, using a sheet-shaped molding material produced by a papermaking method. To do.
【００１０】[0010]
【課題を解決するための手段】本発明は、芯部が抄造法
による強化繊維含有量１０体積％以上の繊維強化熱可塑
性樹脂層で、通気性装飾用表皮と前記芯部との間にホッ
トメタルタイプの接着性フィルムを介在させて、加熱加
圧成形してなる繊維強化熱可塑性樹脂層が５〜７５体積
％の空隙を有する積層成形品、および抄造法による強化
繊維含有量１０体積％以上の繊維強化熱可塑性樹脂層を
芯部とし、加熱時に強化繊維の残留応力解放によるスプ
リングバックを利用して膨脹させ、通気性装飾用表皮と
前記芯部との間にホットメタルタイプの接着性フィルム
を介在させた状態で、成形用型を用いて加圧成形するこ
とにより、全体を一体化させることを特徴とする繊維強
化熱可塑性樹脂層が５〜７５体積％の空隙を有する積層
成形品の成形方法である。According to the present invention, a core is a fiber-reinforced thermoplastic resin layer having a reinforcing fiber content of 10% by volume or more produced by a papermaking method, and a hot air-permeable decorative skin is provided between the core and the core. A laminated molded product having a void of 5 to 75% by volume of a fiber-reinforced thermoplastic resin layer formed by heating and pressurizing with a metal type adhesive film interposed therebetween, and a reinforcing fiber content by a papermaking method of 10% by volume or more. Of the fiber-reinforced thermoplastic resin layer as a core part, which is expanded by utilizing springback by releasing residual stress of the reinforcing fiber at the time of heating, and a hot metal type adhesive film between the breathable decorative skin and the core part. Of a laminated molded article having a void of 5 to 75% by volume in which the fiber-reinforced thermoplastic resin layer is integrated by pressure molding using a molding die in a state in which Molding method A.
【００１１】本発明の積層成形品の成形方法の一例を図
１（ｂ）に示した。図１（ａ）と同様に、シート状成形
素材１を遠赤外線加熱炉２内で加熱する。さらに、加熱
されたシート状成形素材４と通気性装飾用表皮５との間
にホットメタルタイプの接着性フィルム８を介在させ
て、成形型６内に挿入し、目的とする膨脹倍率を得る条
件で加圧成形すると同時に両者を一体化することにより
多孔質積層成形品７を得る。An example of the method for molding the laminated molded article of the present invention is shown in FIG. 1 (b). Similar to FIG. 1A, the sheet-shaped molding material 1 is heated in the far infrared heating furnace 2. Furthermore, a hot metal type adhesive film 8 is interposed between the heated sheet-shaped molding material 4 and the breathable decorative skin 5 and inserted into the molding die 6 to obtain a desired expansion ratio. A porous laminated molded product 7 is obtained by pressure-molding at 1 and simultaneously integrating both.
【００１２】図１では、多孔質成形品の片側に通気性装
飾用表皮とホットメルトタイプの接着性フィルムを積層
して外観改良を行っているが、成形品用途に応じては、
その両側に通気性装飾用表皮とホットメルトタイプの接
着性フィルムを積層して外観改良を行うことができる。In FIG. 1, a breathable decorative skin and a hot-melt type adhesive film are laminated on one side of a porous molded article to improve the appearance.
A breathable decorative skin and a hot-melt type adhesive film may be laminated on both sides to improve the appearance.
【００１３】本発明では、多孔質積層成形品の表皮内部
への熱可塑性樹脂の浸入量不足による接着強度の低下
を、ホットメルトタイプの接着性フィルムの熱融着によ
り補うことで改善した。ホットメルトタイプの接着性フ
ィルムは、加熱されたシート状成形素材の熱により溶融
し、成形時の冷却により芯部の繊維強化熱可塑性樹脂層
と通気性装飾用表皮を固着させる。ホットメルトタイプ
の接着性フィルムは、繊維強化熱可塑性樹脂層に用いた
熱可塑性樹脂との相溶性、融点などから適宜選択するこ
とが望ましい。ホットメルトタイプ接着性フィルム素材
の代表的なものは、融点が８０〜１５０℃のＥＶＡ（エ
チレン−酢酸ビニル共重合体）、ＥＡＡ（エチレン−ア
クリル酸共重合体）、エチレン−アクリル酸アルキルエ
ステル共重合体、ポリエチレン、ポリアミド等である。
またこれらの２種類またはそれ以上の混合物をも含み、
これらには可塑剤、熱安定剤、光安定剤、充填材、染顔
料、増粘剤、加工助剤等を添加することもできる。ホッ
トメルトタイプの接着性フィルム厚みは、接着効果と経
済性により１５μm から５００μm とすることが望まし
く、さらに好ましくは３０μm から３００μm である。In the present invention, the decrease in the adhesive strength due to the insufficient penetration of the thermoplastic resin into the skin of the porous laminated molded article is improved by supplementing the hot-melt type adhesive film with heat fusion. The hot-melt type adhesive film is melted by the heat of the heated sheet-shaped molding material, and the fiber-reinforced thermoplastic resin layer of the core and the breathable decorative skin are fixed by cooling during molding. The hot-melt type adhesive film is preferably selected appropriately from the compatibility with the thermoplastic resin used for the fiber reinforced thermoplastic resin layer, the melting point and the like. Typical hot melt type adhesive film materials include EVA (ethylene-vinyl acetate copolymer), EAA (ethylene-acrylic acid copolymer), ethylene-acrylic acid alkyl ester copolymer having a melting point of 80 to 150 ° C. Examples include polymers, polyethylene, polyamides.
Also includes mixtures of two or more of these,
Plasticizers, heat stabilizers, light stabilizers, fillers, dyes and pigments, thickeners, processing aids and the like can be added to these. The thickness of the hot-melt type adhesive film is preferably 15 μm to 500 μm, more preferably 30 μm to 300 μm, in view of the adhesive effect and economy.
【００１４】本発明では、ホットメルトタイプの接着性
フィルムを用いることにより、多孔質成形品の成形と通
気性装飾用表皮による加飾を同時に実施することができ
るため、工程省略が実現する。さらに、通気性装飾用表
皮にホットメルトタイプの接着性フィルムを予め熱融着
によりラミネートされたものを用いることが、作業性の
観点から望ましい。このようなラミネート材は、自動車
の天井材、ドア材、リアパッケージ材、カーペット材等
に実用化されている。通気性装飾用表皮としては、天然
および合成繊維を素材とした織布、ニードルパンチ等を
行った不織布、起毛織布、編布、植毛布等を用いる。In the present invention, by using the hot-melt type adhesive film, the molding of the porous molded article and the decoration with the breathable decorative skin can be carried out at the same time, so that the steps can be omitted. Further, it is desirable from the standpoint of workability to use a hot-melt type adhesive film that is previously laminated by heat fusion on the breathable decorative skin. Such laminated materials have been put to practical use as automobile ceiling materials, door materials, rear package materials, carpet materials and the like. As the breathable decorative skin, a woven fabric made of natural or synthetic fibers, a non-woven fabric obtained by needle punching, a raised woven fabric, a knitted fabric, a flocked fabric, or the like is used.
【００１５】本発明における芯部の繊維強化熱可塑性樹
脂層の繊維含有量は、強化繊維のスプリングバックによ
る安定した膨脹が生じる１０体積％以上で、強化繊維と
熱可塑性樹脂との接着が可能で、繊維強化熱可塑性樹脂
の多孔質成形品としての強度を十分発現する４０体積％
以下とすることが望ましい。The fiber content of the fiber-reinforced thermoplastic resin layer of the core of the present invention is 10% by volume or more at which stable expansion due to spring-back of the reinforcing fibers occurs, so that the reinforcing fibers can be bonded to the thermoplastic resin. , 40% by volume that fully develops the strength of a fiber-reinforced thermoplastic resin as a porous molded article
The following is desirable.
【００１６】強化繊維としては、ガラス繊維、炭素繊
維、金属繊維のほかに無機繊維、有機繊維が用いられ
る。強化繊維の形状は、取り扱いの容易さと経済的な観
点により直径を３μm φ以上で、十分な強度を発現させ
るために３０μm φ以下にすることが好ましく、強度発
現の観点から繊維長を３mm以上で、均一な分散が可能な
５０mm以下にすることが望ましい。また強化繊維は、水
中での良好な分散を目的として親水性を向上するために
水溶性高分子、湿潤剤で、或いは強度発現を目的として
熱可塑性樹脂との接着性を向上するためにシランカプリ
ング剤等で、表面処理を行うことが望ましい。As the reinforcing fibers, inorganic fibers and organic fibers are used in addition to glass fibers, carbon fibers and metal fibers. The shape of the reinforcing fiber is preferably 3 μm φ or more in diameter from the viewpoint of easy handling and economical, and 30 μm φ or less in order to express sufficient strength. From the viewpoint of strength development, the fiber length is 3 mm or more. However, it is desirable that the thickness is 50 mm or less, which allows uniform dispersion. Further, the reinforcing fiber is a water-soluble polymer or a wetting agent for improving hydrophilicity for the purpose of good dispersion in water, or silane coupling for improving adhesiveness with a thermoplastic resin for the purpose of developing strength. It is desirable to perform surface treatment with an agent or the like.
【００１７】熱可塑性樹脂は、ポリエチレン、ポリプロ
ピレン、ポリスチレン、スチレン−ブタジエン−アクリ
ルニトリル共重合体、スチレン−アクリルニトリル共重
合体、ポリアミド、ポリカ−ボネート、ポリアセター
ル、ポリエチレンテレフタレート、ポリブチレンテレフ
タレート、ポリフェニレンオキシド、ポリスルホン、ポ
リフェニレンスルフィド等の樹脂であり、またこれらの
２種類またはそれ以上の混合物をも含み、これらに一般
的に用いられる可塑剤、熱安定剤、光安定剤、充填材、
染顔料、耐衝撃剤、増量材、核剤、加工助剤等を添加す
ることもできる。The thermoplastic resin includes polyethylene, polypropylene, polystyrene, styrene-butadiene-acrylonitrile copolymer, styrene-acrylonitrile copolymer, polyamide, polycarbonate, polyacetal, polyethylene terephthalate, polybutylene terephthalate, polyphenylene oxide, Resins such as polysulfone and polyphenylene sulfide, which also include a mixture of two or more of these, and which are commonly used for these plasticizers, heat stabilizers, light stabilizers, fillers,
It is also possible to add dyes and pigments, impact resistance agents, extenders, nucleating agents, processing aids and the like.
【００１８】多孔質成形品の空隙率は、シート状成形素
材の加熱時の膨脹倍率と加圧成形の条件により決定され
る。多孔質成形品の軽量化メリットを生かすためには、
その空隙率を増加させることが望ましいが、強度を発現
させるために強化繊維を熱可塑性樹脂で十分接着させる
必要があり、本発明の多孔質成形品の空隙率は、５〜７
５体積％とする。好ましくは、３０〜７０体積％であ
る。The porosity of the porous molded article is determined by the expansion ratio of the sheet-shaped molding material during heating and the conditions of pressure molding. To take advantage of the weight saving of porous molded products,
It is desirable to increase the porosity, but it is necessary to sufficiently bond the reinforcing fibers with a thermoplastic resin in order to express the strength, and the porosity of the porous molded article of the present invention is 5 to 7
5% by volume. It is preferably 30 to 70% by volume.
【００１９】抄造技術によるシート状成形素材の製造工
程の一例を図２に示した。直径３μm φ〜３０μm φ、
長さ３mm〜５０mmのガラス繊維等の強化繊維９と熱可塑
性樹脂粉末１０を分散槽１１内の水中に連続的に投入す
る。分散槽内では、強化繊維と樹脂粉末を均一に分散さ
せるために攪拌が行われ、さらにその分散液をポンプ１
２によりメッシュ状ベルトコンベア１３の上側に設置さ
れたヘッドボックス１４に供給する。ヘッドボックスの
下側に設置したウェットボックス１５内を負圧に保ち、
ヘッドボックス内の分散液の吸引、脱水を連続的に行い
強化繊維と熱可塑性樹脂粉末が均一に分散した複合体で
ある不織材料１６を製造する。この不織材料を、通風式
の熱風乾燥機１７で乾燥するのと同時に熱可塑性樹脂の
一部または全部を、その軟化点、もしくは融点以上に加
熱して溶融させ、冷却して強化繊維を熱可塑性樹脂で結
合した不織材料とする。さらに、ダブルベルトコンベア
式連続プレス１８で加熱加圧を行ない、さらに冷却して
シート状に成形し、最終的にはリールアップ１９を行う
か、加熱加圧成形に必要とされる寸法に応じた形状にカ
ッター２０で切断してシート状成形素材１を製造する。
シート状成形素材としては、不織材料をダブルベルトコ
ンベア式連続プレスで成形する際に、シート内の空隙を
完全に除去したもののほかに、空隙が存在しているもの
を提供することができる。An example of the manufacturing process of the sheet-shaped molding material by the papermaking technique is shown in FIG. Diameter 3 μm φ ~ 30 μm φ,
A reinforcing fiber 9 such as a glass fiber having a length of 3 mm to 50 mm and a thermoplastic resin powder 10 are continuously charged into water in a dispersion tank 11. In the dispersion tank, stirring is performed in order to uniformly disperse the reinforcing fiber and the resin powder, and the dispersion liquid is further pumped.
2 supplies to the head box 14 installed above the mesh belt conveyor 13. Keep negative pressure inside the wet box 15 installed under the head box,
The non-woven material 16 which is a composite in which the reinforcing fibers and the thermoplastic resin powder are uniformly dispersed is manufactured by continuously suctioning and dehydrating the dispersion liquid in the head box. This nonwoven material is dried by a ventilation type hot air dryer 17, and at the same time, a part or all of the thermoplastic resin is heated to its softening point or higher than its melting point to be melted and cooled to heat the reinforcing fiber. A non-woven material bonded with a plastic resin. Further, heating and pressurization is performed by the double belt conveyor type continuous press 18, further cooling and forming into a sheet, and finally reeling up 19 or according to the dimensions required for heating and pressurizing. The sheet-shaped molding material 1 is manufactured by cutting it into a shape with the cutter 20.
As the sheet-shaped molding material, there can be provided a material in which voids are present in addition to a material in which voids in the sheet are completely removed when a nonwoven material is molded by a double belt conveyor continuous press.
【００２０】本発明に用いるシート状成形素材は、強化
繊維のスプリングバックによる安定した膨張と、良好な
強度を発現させるために、強化繊維がモノフィラメント
の状態まで分散していることが望ましい。本発明では、
シート状成形素材として抄造技術による湿式法で製造さ
れたものを用いるが、乾式法（強化繊維と熱可塑性樹脂
粉末を直接混合または攪拌して分散を実施し、さらに加
熱加圧成形してシート状成形素材を製造する方法）によ
るシート状成形素材においても強化繊維の分散状態によ
り、適用が可能になる。In the sheet-shaped molding material used in the present invention, it is desirable that the reinforcing fibers are dispersed to a monofilament state in order to exhibit stable expansion of the reinforcing fibers due to springback and good strength. In the present invention,
The sheet-shaped molding material used is the one manufactured by the wet method by the paper-making technology, but the dry method (the reinforcing fiber and the thermoplastic resin powder are directly mixed or stirred to disperse, and further heat-pressed and molded into a sheet-shaped material. It can be applied also to a sheet-shaped molding material according to the method for producing a molding material) depending on the dispersed state of the reinforcing fibers.
【００２１】[0021]
【実施例】以下実施例を挙げて本発明を詳細に説明す
る。
実施例１
強化繊維として直径１０μm φ、長さ１３mmのガラス繊
維と、熱可塑性樹脂として、直径３mmφの球状ペレット
を機械粉砕し、その粉砕品をふるい分けにより７０mesh
（開口径０．２１２mm）から１０mesh（開口径１．７m
m）までに分級したポリプロピレン樹脂粉末を用いて、
抄造法によりガラス繊維含有量５０重量％（２６．０体
積％）とポリプロピレン樹脂５０重量％（７４．０体積
％）の組成で、目付け量が３０００ g/m2 の不織材料を
製造した。The present invention will be described in detail below with reference to examples. Example 1 A glass fiber having a diameter of 10 μm φ and a length of 13 mm as a reinforcing fiber and a spherical pellet having a diameter of 3 mmφ as a thermoplastic resin were mechanically crushed, and the crushed product was sieved to 70 mesh.
(Opening diameter 0.212 mm) to 10 mesh (Opening diameter 1.7 m
m) using polypropylene resin powder classified
A non-woven material having a composition of glass fiber content of 50% by weight (26.0% by volume) and polypropylene resin of 50% by weight (74.0% by volume) and a basis weight of 3000 g / m 2 was produced by a papermaking method.
【００２２】この不織材料１枚を用いて、ホットプレス
成形により板厚２．２mmのシート状成形素材を製造し
た。ホットプレス成形の成形条件は、予熱を２１０℃、
無負荷で５分間行い、つづいて圧力２０Kgf/cm2 で５分
間加圧し、冷却固化してシートを成形した。A sheet-shaped molding material having a plate thickness of 2.2 mm was manufactured by hot press molding using one of the nonwoven materials. The molding conditions for hot press molding are preheating at 210 ° C,
The operation was carried out for 5 minutes under no load, followed by applying a pressure of 20 Kgf / cm 2 for 5 minutes, followed by cooling and solidification to form a sheet.
【００２３】このシート状成形素材と厚み５０μm のホ
ットメルトタイプの接着性フィルムＥＶＡ（ＪＩＳ−Ｋ
−２５３１による軟化点１０８℃）、さらに通気性装飾
表皮として目付け量が２３０ g/m2 のポリエステル繊維
不織布を用いて、図１に示した方法で多孔質積層成形品
を成形した。即ち、シート状成形素材を１５×１５cmに
切断して、遠赤外線加熱炉で表面温度が２１０℃になる
まで加熱し、つづいて加熱されたシート状成形素材と通
気性装飾表皮の間にホットメルトタイプの接着性フィル
ムをはさんで、４０℃に温度調節された金型内に挿入
し、圧力１０Kgf/cm2 でプレス成形することにより多孔
質積層成形品を成形した。成形品の繊維強化熱可塑性樹
脂層の膨張倍率（繊維強化熱可塑性樹脂層の厚み／シー
ト状成形素材の厚み）は、金型のキャビティをスペーサ
ーで調節して１．５倍（空隙率３３体積％）になるよう
に設定した。This sheet-shaped molding material and a hot-melt type adhesive film EVA (JIS-K) having a thickness of 50 μm
Using a polyester fiber nonwoven fabric having a softening point of −2531 of 108 ° C.) and a basis weight of 230 g / m 2 as a breathable decorative skin, a porous laminated molded article was molded by the method shown in FIG. That is, the sheet-shaped molding material is cut into 15 × 15 cm and heated in a far-infrared heating furnace until the surface temperature reaches 210 ° C., followed by hot melt between the heated sheet-shaped molding material and the breathable decorative skin. A porous laminated molded article was molded by inserting the adhesive film of the type into a mold whose temperature was controlled at 40 ° C. and press-molding it at a pressure of 10 Kgf / cm 2 . The expansion ratio of the fiber-reinforced thermoplastic resin layer of the molded product (thickness of the fiber-reinforced thermoplastic resin layer / thickness of the sheet-shaped molding material) is adjusted to 1.5 times by adjusting the cavity of the mold with the spacer (porosity 33 volume). %).
【００２４】実施例２
実施例１と同じシート状成形素材、ホットメルトタイプ
の接着性フィルム、通気性装飾表皮を用いて、同様な方
法で膨張倍率２倍（空隙率５０体積％）の多孔質積層成
形品を成形した。Example 2 Using the same sheet-like molding material, hot-melt type adhesive film, and breathable decorative skin as in Example 1, a porous material having an expansion ratio of 2 (porosity 50% by volume) was prepared in the same manner. A laminated molded product was molded.
【００２５】実施例３
実施例１と同じシート状成形素材、ホットメルトタイプ
の接着性フィルム、通気性装飾表皮を用いて、同様な方
法で膨張倍率３倍（空隙率６６体積％）の多孔質積層成
形品を成形した。Example 3 Using the same sheet-shaped molding material, hot-melt type adhesive film, and breathable decorative skin as in Example 1, a porous material having an expansion ratio of 3 times (porosity 66% by volume) was formed in the same manner. A laminated molded product was molded.
【００２６】実施例４
実施例１と同じシート状成形素材、ホットメルトタイプ
の接着性フィルム、通気性装飾表皮を用いて、同様な方
法で膨張倍率４倍（空隙率７５体積％）の多孔質積層成
形品を成形した。Example 4 Using the same sheet-shaped molding material, hot-melt type adhesive film, and breathable decorative skin as in Example 1, a porous material having an expansion ratio of 4 times (porosity 75% by volume) was formed in the same manner. A laminated molded product was molded.
【００２７】実施例５
実施例１と同じシート状成形素材と、厚み５０μm のホ
ットメルトタイプの接着性フィルムＥＡＡ（ＪＩＳ−Ｋ
−２５３１による軟化点１０３℃）が実施例１で用いた
ポリエステル繊維不織布に予めラミネートされている通
気性装飾用表皮を用いて、実施例１と同様な方法で膨張
倍率２倍（空隙率５０体積％）の多孔質積層成形品を成
形した。Example 5 The same sheet-shaped molding material as in Example 1 and a hot-melt type adhesive film EAA (JIS-K) having a thickness of 50 μm were used.
Using the breathable decorative skin in which the softening point by −2531 of 103 ° C. was previously laminated to the polyester fiber nonwoven fabric used in Example 1, the expansion ratio was doubled (porosity 50 volume by the same method as in Example 1). %) Porous laminated moldings were molded.
【００２８】比較例
実施例１と同じシート状成形素材、通気性装飾表皮を用
いて、加熱されたシート状成形素材の表面に直接通気性
装飾表皮を積層して、膨張倍率１．５倍（空隙率３３体
積％）の多孔質積層成形品を成形した。（ホットメルト
タイプの接着性フィルムは使用しない。）
各々の多孔質積層成形品の繊維強化熱可塑性樹脂層と表
皮の接着強度を９０度剥離試験により測定し、結果を表
１に示した。Comparative Example Using the same sheet-shaped molding material and breathable decorative skin as in Example 1, the breathable decorative skin was laminated directly on the surface of the heated sheet-shaped molding material, and the expansion ratio was 1.5 times ( A porous laminated molding having a porosity of 33% by volume was molded. (A hot-melt type adhesive film is not used.) The adhesive strength between the fiber-reinforced thermoplastic resin layer and the skin of each porous laminated molded article was measured by a 90-degree peel test, and the results are shown in Table 1.
【００２９】[0029]
【表１】 [Table 1]
【００３０】実施例の多孔質積層成形品においては、良
好な接着強度が得られた。これは、ホットメルトタイプ
の接着性フィルムが、芯部の繊維強化熱可塑性樹脂層と
表皮の間で溶融、固化することにより良好な接着が実施
されたためである。剥離試験においては、表皮が破損し
ながら剥離（凝集破壊）したため試験後の剥離面に表皮
が多く残存していた。Good adhesive strength was obtained in the porous laminated molded articles of the examples. This is because the hot-melt type adhesive film was melted and solidified between the fiber-reinforced thermoplastic resin layer of the core and the surface skin to achieve good adhesion. In the peeling test, peeling (cohesive failure) occurred while the epidermis was damaged, and a large amount of epidermis remained on the peeled surface after the test.
【００３１】成形品の膨張倍率が大きくなるに従って
（実施例１〜４）、繊維強化熱可塑性樹脂層と表皮の接
着強度が低下する傾向にあるが、膨張倍率４倍（空隙率
７５体積％）においても表皮が接着していることが確認
された。積層成形品の膨張倍率は、金型のキャビティの
厚みをスペーサーで変更することにより設定した。膨張
倍率が大きくなるに従って、キャビティの厚みが大きく
なり成形圧力が低下する。成形圧力の低下は、強化繊維
が露出した繊維強化熱可塑性樹脂層の表面と表皮内部へ
の接着剤の浸入量の減少を引き起こし、アンカー効果が
低下する。As the expansion ratio of the molded product increases (Examples 1 to 4), the adhesive strength between the fiber reinforced thermoplastic resin layer and the skin tends to decrease, but the expansion ratio is 4 times (porosity 75% by volume). It was confirmed that the epidermis was adhered also in. The expansion ratio of the laminated molded product was set by changing the thickness of the cavity of the mold with a spacer. As the expansion ratio increases, the cavity thickness increases and the molding pressure decreases. The decrease in the molding pressure causes a decrease in the amount of the adhesive infiltrated into the surface of the fiber-reinforced thermoplastic resin layer where the reinforcing fibers are exposed and the inside of the skin, and the anchor effect is decreased.
【００３２】実施例５のように、接着性フィルムが予め
ラミネートされている表皮を用いた場合は、接着性フィ
ルムと表皮の切断、積層工程の簡略化ができ、作業性が
良好であった。また、繊維強化熱可塑性樹脂層と表皮の
接着強度も実施例２と同程度であることが確認された。
比較例では、繊維強化熱可塑性樹脂層に表皮が接着しな
かった。In the case of using the skin having the adhesive film preliminarily laminated as in Example 5, the adhesive film and the skin can be cut, the laminating process can be simplified, and the workability is good. It was also confirmed that the adhesive strength between the fiber-reinforced thermoplastic resin layer and the skin was about the same as in Example 2.
In the comparative example, the skin did not adhere to the fiber reinforced thermoplastic resin layer.
【００３３】[0033]
【発明の効果】本発明により、抄造法で製造されたシー
ト状成形素材を用いた多孔質積層成形品において、芯部
の繊維強化熱可塑性樹脂層と通気性装飾用表皮の間にホ
ットメルトタイプの接着性フィルムを介在させたことに
より両者間の接着強度が改良され、外観の良好な多孔質
積層成形品が得られた。本発明は、一般的な加熱加圧成
形に用いることができるが、圧空成形においても有益な
結果がもたらされる。INDUSTRIAL APPLICABILITY According to the present invention, in a porous laminated molded article using a sheet-shaped molding material manufactured by a papermaking method, a hot-melt type between the fiber-reinforced thermoplastic resin layer of the core and the breathable decorative skin. By interposing the adhesive film of No. 1 above, the adhesive strength between the two was improved, and a porous laminated molded product having a good appearance was obtained. The present invention can be used for general hot pressing, but also has beneficial results in pneumatic molding.
【図１】（ａ），（ｂ）は積層成形品の成形加工の一例
を示す概略図である。1A and 1B are schematic views showing an example of a molding process of a laminated molded product.
【図２】抄造技術によるシート状成形素材の製造工程の
一例を示す概略図である。FIG. 2 is a schematic view showing an example of a manufacturing process of a sheet-shaped molding material by a papermaking technique.
１ シート状成形素材 ２ 遠赤外線加熱炉 ３ 強化繊維のスプリングバックによる露出 ４ 加熱されたシート状成形素材 ５ 通気性装飾用表皮 ６ 成形型 ７ 多孔質積層成形品 ８ ホットメルトタイプの接着性フィルム ９ 強化繊維 １０ 熱可塑性樹脂粉末 １１ 分散槽 １２ ポンプ １３ メッシュ状ベルトコンベア １４ ヘッドボックス １５ ウェットボックス １６ 不織材料 １７ 熱風乾燥機 １８ ダブルベルトコンベア式連続プレス １９ リールアップ ２０ カッター 1 Sheet-shaped molding material 2 Far infrared heating furnace 3 Exposure due to springback of reinforcing fibers 4 Heated sheet material 5 Breathable decorative skin 6 Mold 7 Porous laminated molding 8 Hot melt type adhesive film 9 Reinforcing fiber 10 Thermoplastic resin powder 11 dispersion tanks 12 pumps 13 Mesh belt conveyor 14 head box 15 Wet Box 16 non-woven materials 17 hot air dryer 18 Double belt conveyor type continuous press 19 reel up 20 cutter
【手続補正書】[Procedure amendment]
【提出日】平成３年１２月２０日[Submission date] December 20, 1991
【手続補正１】[Procedure Amendment 1]
【補正対象書類名】明細書[Document name to be amended] Statement
【補正対象項目名】００２２[Name of item to be corrected] 0022
【補正方法】変更[Correction method] Change
【補正内容】[Correction content]
【００２２】この不織材料１枚を用いて、ホットプレス
成形により板厚２．２mmのシート状成形素材を製造し
た。ホットプレス成形の成形条件は、予熱を２１０℃、
無負荷で５分間行い、つづいて圧力２０kgf/cm2 で５分
間加圧し、冷却固化してシートを成形した。A sheet-shaped molding material having a plate thickness of 2.2 mm was manufactured by hot press molding using one of the nonwoven materials. The molding conditions for hot press molding are preheating at 210 ° C,
The operation was carried out for 5 minutes under no load, followed by pressurizing at a pressure of 20 kgf / cm 2 for 5 minutes, cooling and solidification to form a sheet.
【手続補正２】[Procedure Amendment 2]
【補正対象書類名】明細書[Document name to be amended] Statement
【補正対象項目名】００２３[Name of item to be corrected] 0023
【補正方法】変更[Correction method] Change
【補正内容】[Correction content]
【００２３】このシート状成形素材と厚み５０μm のホ
ットメルトタイプの接着性フィルムＥＶＡ（ＪＩＳ−Ｋ
−２５３１による軟化点１０８℃）、さらに通気性装飾
表皮として目付け量が２３０ g/m2 のポリエステル繊維
不織布を用いて、図１に示した方法で多孔質積層成形品
を成形した。即ち、シート状成形素材を１５×１５cmに
切断して、遠赤外線加熱炉で表面温度が２１０℃になる
まで加熱し、つづいて加熱されたシート状成形素材と通
気性装飾表皮の間にホットメルトタイプの接着性フィル
ムをはさんで、４０℃に温度調節された金型内に挿入
し、圧力１０kgf/cm2 でプレス成形することにより多孔
質積層成形品を成形した。成形品の繊維強化熱可塑性樹
脂層の膨張倍率（繊維強化熱可塑性樹脂層の厚み／シー
ト状成形素材の厚み）は、金型のキャビティをスペーサ
ーで調節して１．５倍（空隙率３３体積％）になるよう
に設定した。This sheet-shaped molding material and a hot-melt type adhesive film EVA (JIS-K) having a thickness of 50 μm
Using a polyester fiber nonwoven fabric having a softening point of −2531 of 108 ° C.) and a basis weight of 230 g / m 2 as a breathable decorative skin, a porous laminated molded article was molded by the method shown in FIG. That is, the sheet-shaped molding material is cut into 15 × 15 cm and heated in a far-infrared heating furnace until the surface temperature reaches 210 ° C., followed by hot melt between the heated sheet-shaped molding material and the breathable decorative skin. A porous laminated molded article was molded by sandwiching the adhesive film of the type into a mold whose temperature was controlled at 40 ° C. and press-molding it at a pressure of 10 kgf / cm 2 . The expansion ratio of the fiber-reinforced thermoplastic resin layer of the molded product (thickness of the fiber-reinforced thermoplastic resin layer / thickness of the sheet-shaped molding material) is adjusted to 1.5 times by adjusting the cavity of the mold with the spacer (porosity 33 volume). %).
【手続補正３】[Procedure 3]
【補正対象書類名】明細書[Document name to be amended] Statement
【補正対象項目名】００２９[Name of item to be corrected] 0029
【補正方法】変更[Correction method] Change
【補正内容】[Correction content]
【００２９】[0029]
【表１】 [Table 1]
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.5 識別記号 庁内整理番号 ＦＩ 技術表示箇所 Ｂ２９Ｌ 9:00 4Ｆ 31:58 4Ｆ (72)発明者 木村 隆夫 三重県四日市市東邦町１番地 三菱油化株 式会社四日市総合研究所内─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. 5 Identification number Reference number within the agency FI Technical display location B29L 9:00 4F 31:58 4F (72) Inventor Takao Kimura 1 Toho-cho, Yokkaichi-shi, Mie Mitsubishi Yuka Co., Ltd. Inside the Yokkaichi Research Institute
Claims (2)
体積％以上の繊維強化熱可塑性樹脂層で、通気性装飾用
表皮と前記芯部との間にホットメタルタイプの接着性フ
ィルムを介在させて、加熱加圧成形してなる繊維強化熱
可塑性樹脂層が５〜７５体積％の空隙を有する積層成形
品。1. The core has a reinforcing fiber content of 10 produced by a papermaking method.
A fiber reinforced thermoplastic resin layer having a volume% or more of a fiber reinforced thermoplastic resin layer, wherein a hot metal type adhesive film is interposed between the breathable decorative skin and the core, and heat and pressure molding is performed. Is a laminated molded article having voids of 5 to 75% by volume.
以上の繊維強化熱可塑性樹脂層を芯部とし、加熱時に強
化繊維の残留応力解放によるスプリングバックを利用し
て膨脹させ、通気性装飾用表皮と前記芯部との間にホッ
トメタルタイプの接着性フィルムを介在させた状態で、
成形用型を用いて加圧成形することにより、全体を一体
化させることを特徴とする繊維強化熱可塑性樹脂層が５
〜７５体積％の空隙を有する積層成形品の成形方法。2. The content of reinforcing fiber by the papermaking method is 10% by volume.
The above fiber reinforced thermoplastic resin layer is used as a core part and expanded by utilizing springback by releasing residual stress of the reinforcing fiber at the time of heating, and a hot metal type adhesive property is provided between the breathable decorative skin and the core part. With the film interposed,
The fiber-reinforced thermoplastic resin layer is characterized in that the whole is integrated by pressure molding using a molding die.
A method for molding a laminated molded article having voids of ˜75% by volume.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3176835A JPH0516274A (en) | 1991-07-17 | 1991-07-17 | Laminated molding and molding method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3176835A JPH0516274A (en) | 1991-07-17 | 1991-07-17 | Laminated molding and molding method thereof |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH0516274A true JPH0516274A (en) | 1993-01-26 |
Family
ID=16020671
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP3176835A Pending JPH0516274A (en) | 1991-07-17 | 1991-07-17 | Laminated molding and molding method thereof |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH0516274A (en) |
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1996026822A1 (en) * | 1995-03-01 | 1996-09-06 | Kawasaki Steel Corporation | Stampable sheet made by papermaking technique and method for manufacturing lightweight molded stampable sheet |
| JPH08230114A (en) * | 1995-03-01 | 1996-09-10 | Kawasaki Steel Corp | Paper machine-made stampable sheet, lightweight stampable sheet molding and lightweight stampable sheet skin-laminated product |
| WO2002064361A1 (en) * | 2001-02-15 | 2002-08-22 | Kawasaki Steel Corporation | Laminated resin material |
| JP2006115877A (en) * | 2004-10-19 | 2006-05-11 | Toray Ind Inc | Reproduced molding material and manufacturing method thereof |
| JP2011224968A (en) * | 2010-04-02 | 2011-11-10 | Hirotani:Kk | Method for manufacturing of interior member for vehicle |
| US8481156B2 (en) | 2007-12-28 | 2013-07-09 | Yamaha Hatsudoki Kabushiki Kaisha | Decorative sheet and decorated formed product |
| JP2021526984A (en) * | 2018-06-06 | 2021-10-11 | ハンファ アズデル インコーポレイテッド | Composite articles, including non-smooth films, and furnishings containing them |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS60179234A (en) * | 1984-01-06 | 1985-09-13 | ザ・ウイギンズ・テイ−プ・グル−プ・リミテツド | Fiber reinforced synthetic resin molded shape and manufacture thereof |
-
1991
- 1991-07-17 JP JP3176835A patent/JPH0516274A/en active Pending
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS60179234A (en) * | 1984-01-06 | 1985-09-13 | ザ・ウイギンズ・テイ−プ・グル−プ・リミテツド | Fiber reinforced synthetic resin molded shape and manufacture thereof |
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1996026822A1 (en) * | 1995-03-01 | 1996-09-06 | Kawasaki Steel Corporation | Stampable sheet made by papermaking technique and method for manufacturing lightweight molded stampable sheet |
| JPH08230114A (en) * | 1995-03-01 | 1996-09-10 | Kawasaki Steel Corp | Paper machine-made stampable sheet, lightweight stampable sheet molding and lightweight stampable sheet skin-laminated product |
| KR100225617B1 (en) * | 1995-03-01 | 1999-10-15 | 소데다 나오히코 | Stampable sheet made by papermaking technique and method for manufacturing lightweight molded stampable sheet |
| WO2002064361A1 (en) * | 2001-02-15 | 2002-08-22 | Kawasaki Steel Corporation | Laminated resin material |
| JP2006115877A (en) * | 2004-10-19 | 2006-05-11 | Toray Ind Inc | Reproduced molding material and manufacturing method thereof |
| US8481156B2 (en) | 2007-12-28 | 2013-07-09 | Yamaha Hatsudoki Kabushiki Kaisha | Decorative sheet and decorated formed product |
| JP2011224968A (en) * | 2010-04-02 | 2011-11-10 | Hirotani:Kk | Method for manufacturing of interior member for vehicle |
| JP2021526984A (en) * | 2018-06-06 | 2021-10-11 | ハンファ アズデル インコーポレイテッド | Composite articles, including non-smooth films, and furnishings containing them |
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| A02 | Decision of refusal |
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