JPH0732465A - Overhung or deep-drawn molded item made of fiber-reinforced thermoplastic resin and manufacture thereof - Google Patents
Overhung or deep-drawn molded item made of fiber-reinforced thermoplastic resin and manufacture thereofInfo
- Publication number
- JPH0732465A JPH0732465A JP18009893A JP18009893A JPH0732465A JP H0732465 A JPH0732465 A JP H0732465A JP 18009893 A JP18009893 A JP 18009893A JP 18009893 A JP18009893 A JP 18009893A JP H0732465 A JPH0732465 A JP H0732465A
- Authority
- JP
- Japan
- Prior art keywords
- thermoplastic resin
- fiber
- reinforced thermoplastic
- sheet
- resin layer
- 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.)
- Withdrawn
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
の張り出しまたは深絞り成形品に関するものである。本
発明の成形品は、自動車の内・外装材、家庭電気製品等
のハウジング、家具等の産業用部品に広く使用すること
ができる。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a stretched or deep-drawn molded product of a fiber-reinforced thermoplastic resin. INDUSTRIAL APPLICABILITY The molded product of the present invention can be widely used for interior / exterior materials of automobiles, housings for 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、加熱軟化された繊維強化熱可塑性樹脂シート状成形
素材（以後、該繊維強化熱可塑性脂樹シート状成形素材
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・冷却固化することに
より複雑な成形品を得ることができ、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. The characteristic of the fiber reinforced thermoplastic resin is that a heat-softened fiber reinforced thermoplastic resin sheet material (hereinafter, the fiber reinforced thermoplastic resin sheet material is referred to as sheet material) is heated at room temperature or heated. A complicated molded product can be obtained by inserting it into a mold and pressing and cooling and solidifying in a short time, and the molded product has high strength and is lightweight.
【０００３】シート状成形素材の製造方法は、乾式およ
び湿式法に大別されるが、代表的な方法は、乾式法
（ラミネート法）：複数本の強化繊維（ローピング）で
構成されている強化繊維マットに熱可塑性樹脂を積層
し、ダブルベルトコンベア式連続プレス機のスチールベ
ルト間に挿入し、加熱・加圧を行い、さらに冷却固化し
てシート状成形素材を製造する方法（特開昭４８−８０
１７２号公報、特開昭５２−４０５５８号公報、特開昭
５５−７７５２５号公報）、湿式法（抄造法）：抄造
技術を応用して直径３〜３０μｍφ、長さ３〜５０mmの
強化繊維と熱可塑性樹脂粉粒体を均一に分散して不織材
料を製造し、この不織材料を中間素材とし加熱・加圧・
冷却固化してシート状成形素材を製造する方法（特公昭
５２−１２２８３号公報、特公昭５５−９１１９号公
報）である。The method for producing a sheet-shaped molding material is roughly classified into a dry method and a wet method. A typical method is a dry method (lamination method): reinforcement composed of a plurality of reinforcing fibers (roping). A method for producing a sheet-shaped molding material by laminating a thermoplastic resin on a fiber mat, inserting it between steel belts of a double-belt conveyor-type continuous pressing machine, heating and pressurizing, and further cooling and solidifying (JP-A-48). -80
172, JP-A-52-40558, JP-A-55-77525), wet method (papermaking method): a reinforcing fiber having a diameter of 3 to 30 μmφ and a length of 3 to 50 mm by applying a papermaking technique. Thermoplastic resin particles are evenly dispersed to produce a non-woven material, and this non-woven material is used as an intermediate material for heating, pressing,
This is a method of producing a sheet-shaped molding material by cooling and solidifying (Japanese Patent Publication No. 52-12283 and Japanese Patent Publication No. 55-9119).
【０００４】これらのシート状成形素材を熱可塑性樹脂
の融点または軟化点以上に加熱して、金属のプレス加工
で広く行われている張り出しまたは深絞り成形すること
は、低い成形圧力で大型製品が成形でき、さらに装飾用
表皮との一体成形が可能となるため優れた効果が得られ
る。しかし、この方法では次のような問題点が生じる。Heating these sheet-shaped molding materials to a temperature above the melting point or softening point of the thermoplastic resin and subjecting them to overhanging or deep-drawing, which is widely used in metal stamping, produces large products with low molding pressure. Since it can be molded and can be integrally molded with the decorative skin, excellent effects can be obtained. However, this method has the following problems.
【０００５】張り出し成形とは、クランプにより固定さ
れた素材の伸び、つまり素材の表面積の増加により立体
を形成する成形方法である。張り出し成形の成形性は、
如何に深い成形ができるかで評価され、素材の伸び量が
大きくなるに従って成形性が向上する。深絞り成形は、
素材が金型内に移動して立体が成形されるため、素材の
伸び量の他に破断荷重が重要となる。深絞り成形は、一
般的に張り出し成形に比べて深い成形が可能となるが、
素材の破断荷重が非常に小さい場合は素材が成形途中で
破断し、成形性が低下する。繊維強化熱可塑性樹脂の張
り出しまたは深絞り成形において良好な成形性を得るた
めには、加熱されたシート状成形素材が、大きな伸び量
と高い破断荷重を有することが必要となる。The stretch forming is a forming method in which a material fixed by a clamp is expanded, that is, the surface area of the material is increased to form a solid. The moldability of overhang molding is
It is evaluated by how deep the molding can be done, and the moldability improves as the elongation of the material increases. Deep drawing is
Since the material moves into the mold to form a solid, the breaking load is important in addition to the amount of elongation of the material. Deep drawing generally enables deeper forming than extrusion forming,
If the breaking load of the material is very small, the material breaks during molding and the moldability decreases. In order to obtain good moldability in overhanging or deep drawing of a fiber-reinforced thermoplastic resin, it is necessary that the heated sheet-shaped molding material has a large elongation amount and a high breaking load.
【０００６】従来の繊維強化熱可塑性樹脂の張り出しま
たは深絞り成形の一例を図２に示した。シート状成形素
材９は、一般的には遠赤外線加熱炉６内で熱可塑性樹脂
の融点または軟化点以上に加熱される。加熱されたシー
ト状成形素材を、成形型７に設置されたクランプ（しわ
押え）８により保持し、加圧・冷却固化することにより
繊維強化熱可塑性樹脂張り出しまたは深絞り成形品１０
を得る。An example of conventional overhanging or deep drawing of a fiber reinforced thermoplastic resin is shown in FIG. The sheet-shaped molding material 9 is generally heated in the far infrared heating furnace 6 to a temperature equal to or higher than the melting point or softening point of the thermoplastic resin. A heated sheet-shaped forming material is held by a clamp (crease retainer) 8 installed in a forming die 7, and is pressed and cooled to be solidified, whereby a fiber-reinforced thermoplastic resin overhang or a deep-drawn molded product 10 is obtained.
To get
【０００７】この成形では、シート状成形素材に欠陥が
ある場合は、その部分が局部的に破断し成形性の低下原
因となる。抄造法によって製造されたシート状成形素材
は、強化繊維と熱可塑性樹脂が緻密にしかも均一に分散
しているため問題となる欠陥が少なく、良好な成形性を
得ることができる。In this molding, if there is a defect in the sheet-shaped molding material, that portion is locally broken, which causes deterioration of moldability. Since the reinforcing fibers and the thermoplastic resin are densely and uniformly dispersed in the sheet-shaped molding material produced by the paper-making method, there are few problematic defects and good moldability can be obtained.
【０００８】しかしながら、大きな変形を必要とする深
い成形品または複雑な成形品では、シート状成形素材の
伸び量と破断荷重が不足するため安定した成形性を得る
ことは難しくなる。図２の成形品では、縦壁部１１が水
平部１２に比べて大きく変形する。シート状成形素材
は、マトリックス樹脂が溶融または軟化しているため
に、成形時の張力がシート全体で一定せず局部的に大き
く変形し、素材の破断１３による成形不良が発生する。However, in a deep molded product or a complicated molded product which requires a large deformation, it is difficult to obtain stable moldability because the elongation amount and the breaking load of the sheet-shaped molding material are insufficient. In the molded product of FIG. 2, the vertical wall portion 11 is deformed more than the horizontal portion 12. In the sheet-shaped molding material, since the matrix resin is melted or softened, the tension at the time of molding is not constant in the entire sheet and is locally largely deformed, causing a defective molding due to the fracture 13 of the material.
【０００９】また加熱されたシート状成形素材の表面で
は、熱可塑性樹脂の溶融または軟化により強化繊維に対
する結合力が弱まり、強化繊維が元に戻ろうとするスプ
リングバックにより元のシートの板厚以上に膨張する。
この膨張したシート状成形素材の表面では強化繊維が多
数露出し、続いて加圧・冷却固化して成形するため、強
化繊維が成形品の表面に露出したままとなり外観低下が
生じる（１４）。On the surface of the heated sheet-shaped molding material, the binding force to the reinforcing fibers is weakened by the melting or softening of the thermoplastic resin, and the reinforcing fibers try to return to their original state. Expands.
A large number of reinforcing fibers are exposed on the surface of the expanded sheet-shaped molding material, and subsequently, they are pressed, cooled, and solidified to be molded, so that the reinforcing fibers remain exposed on the surface of the molded product and the appearance is deteriorated (14).
【００１０】[0010]
【発明が解決しようとする課題】本発明は、成形性、外
観の優れた繊維強化熱可塑性樹脂の張り出しまたは深絞
り成形品およびその成形方法を提供する。DISCLOSURE OF THE INVENTION The present invention provides a stretched or deep-drawn molded product of a fiber-reinforced thermoplastic resin excellent in moldability and appearance, and a molding method thereof.
【００１１】[0011]
【課題を解決するための手段および作用】本発明の要旨
とするところは次の通りである。 （１）単一の繊維に分散した強化繊維と熱可塑性樹脂か
らなる繊維強化熱可塑性樹脂の片面または両面に、接着
性素材を介して前記繊維強化熱可塑性樹脂の成形温度よ
り高い融点または軟化点を有する熱可塑性樹脂層が積層
されてなり、繊維強化熱可塑性樹脂の密度が理論密度以
下であることを特徴とする繊維強化熱可塑性樹脂張り出
しまたは深絞り成形品。Means and Actions for Solving the Problems The gist of the present invention is as follows. (1) A melting point or a softening point higher than the molding temperature of the fiber-reinforced thermoplastic resin via an adhesive material on one or both sides of a fiber-reinforced thermoplastic resin composed of a reinforcing fiber dispersed in a single fiber and a thermoplastic resin. And a fiber-reinforced thermoplastic resin having a density equal to or lower than the theoretical density.
【００１２】（２）前記繊維強化熱可塑性樹脂層の片面
に接着性素材を介して前記繊維強化熱可塑性樹脂の成形
温度より高い融点または軟化点を有する熱可塑性樹脂が
積層され、他方の片面に装飾用表皮が積層されてなり、
繊維強化熱可塑性樹脂層の密度が理論密度以下であるこ
とを特徴とする上記（１）に記載の繊維強化熱可塑性樹
脂張り出しまたは深絞り成形品。(2) A thermoplastic resin having a melting point or a softening point higher than the molding temperature of the fiber reinforced thermoplastic resin is laminated on one surface of the fiber reinforced thermoplastic resin layer via an adhesive material, and the other surface is laminated on the other surface. The decorative skins are laminated,
The fiber-reinforced thermoplastic resin overhang or deep-draw molded product according to the above (1), wherein the density of the fiber-reinforced thermoplastic resin layer is not more than the theoretical density.
【００１３】（３）単一の繊維に分散した強化繊維と熱
可塑性樹脂からなる繊維強化熱可塑性樹脂の片面または
両面に、接着性素材を介して前記繊維強化熱可塑性樹脂
の成形温度より高い融点または軟化点を有する熱可塑性
樹脂フィルムを積層し、加熱・加圧・冷却固化してシー
ト状成形素材とし、さらに該シート状成形素材を加熱し
た後、張り出しまたは深絞り成形することを特徴とする
繊維強化熱可塑性樹脂張り出しまたは深絞り成形品の成
形方法。(3) A melting point higher than the molding temperature of the fiber-reinforced thermoplastic resin through an adhesive material on one or both sides of the fiber-reinforced thermoplastic resin consisting of the reinforcing fiber dispersed in a single fiber and the thermoplastic resin. Alternatively, it is characterized in that a thermoplastic resin film having a softening point is laminated, heated, pressed and cooled to solidify into a sheet-shaped molding material, and the sheet-shaped molding material is further heated, and then stretched or deep-drawn. Molding method for fiber-reinforced thermoplastic resin overhang or deep-draw molding.
【００１４】（４）単一の繊維に分散した強化繊維と熱
可塑性樹脂からなる繊維強化熱可塑性樹脂の片面に、接
着性素材を介して前記繊維強化熱可塑性樹脂の成形温度
より高い融点または軟化点を有する熱可塑性樹脂フィル
ムを積層し、加熱・加圧・冷却固化してシート状成形素
材とし、さらに該シート状成形素材を加熱した後、前記
熱可塑性樹脂フィルムが積層されていない該シート状成
形素材の表面に装飾用表皮を重ね合わせて、張り出しま
たは深絞り成形することを特徴とする上記（３）に記載
の繊維強化熱可塑性樹脂張り出しまたは深絞り成形品の
成形方法。(4) A melting point or a softening point higher than the molding temperature of the fiber-reinforced thermoplastic resin via an adhesive material on one side of a fiber-reinforced thermoplastic resin composed of a reinforcing fiber and a thermoplastic resin dispersed in a single fiber. A thermoplastic resin film having dots is laminated, heated, pressed and cooled to solidify to form a sheet-shaped molding material, and the sheet-shaped molding material is further heated, and then the thermoplastic resin film is not laminated on the sheet-shaped molding material. The method for forming a fiber-reinforced thermoplastic resin overhanging or deep-drawing molded article according to (3) above, wherein a decorative skin is superposed on the surface of the molding material, and overhanging or deep-drawing is performed.
【００１５】本発明の繊維強化熱可塑性樹脂張り出しま
たは深絞り成形品およびその成形方法の一例を図１に示
した。本発明の繊維強化熱可塑性樹脂張り出しまたは深
絞り成形品１は、繊維強化熱可塑性樹脂層２と繊維強化
熱可塑性樹脂の成形温度により高い融点または軟化点を
有する熱可塑性樹脂３、さらに必要に応じて装飾用表皮
４から構成されている。FIG. 1 shows an example of a fiber-reinforced thermoplastic resin overhanging or deep-drawn molded product of the present invention and a molding method thereof. The fiber-reinforced thermoplastic resin overhang or deep-drawn molded product 1 of the present invention comprises a fiber-reinforced thermoplastic resin layer 2 and a thermoplastic resin 3 having a high melting point or a softening point depending on the molding temperature of the fiber-reinforced thermoplastic resin, and further, if necessary. It is composed of a decorative skin 4.
【００１６】繊維強化熱可塑性樹脂層２は、単一の繊維
に分散した強化繊維が熱可塑性樹脂中に均一に分散して
いる。熱可塑性樹脂層３は、成形時に溶融または軟化せ
ず繊維強化熱可塑性樹脂層２の全面を覆っているために
強化繊維の露出を抑え、良好な成形品外観を得ることが
できる。さらに本発明の成形品に塗装を施すことは、よ
り一層の外観向上につながり自動車、産業機械等の外装
部品への適用が可能になる。また、加熱されたシート状
成形素材に装飾用表皮４を重ね合わせて一体成形するこ
とにより、自動車内装材等の用途に応じた成形品を効率
的に成形することができる。In the fiber reinforced thermoplastic resin layer 2, reinforcing fibers dispersed in a single fiber are uniformly dispersed in the thermoplastic resin. Since the thermoplastic resin layer 3 does not melt or soften during molding and covers the entire surface of the fiber-reinforced thermoplastic resin layer 2, it is possible to suppress the exposure of the reinforcing fibers and obtain a good appearance of the molded product. Furthermore, applying a coating to the molded product of the present invention leads to a further improvement in appearance and can be applied to exterior parts such as automobiles and industrial machines. In addition, by superimposing the decorative skin 4 on the heated sheet-shaped molding material and integrally molding the molded material, it is possible to efficiently mold a molded product according to the application such as an automobile interior material.
【００１７】本発明の繊維強化熱可塑性樹脂張り出しま
たは深絞り成形品の成形方法を以下に説明する。図１に
は、片面に繊維強化熱可塑性樹脂の成形温度より高い融
点または軟化点を有する熱可塑性樹脂層を有し、他方に
装飾用表皮を設けて一体成形する方法を示した。The method for forming the fiber-reinforced thermoplastic resin overhanging or deep-drawing molded article of the present invention will be described below. FIG. 1 shows a method in which a thermoplastic resin layer having a melting point or a softening point higher than the molding temperature of the fiber reinforced thermoplastic resin is provided on one surface, and a decorative skin is provided on the other surface to integrally mold the thermoplastic resin layer.
【００１８】本発明のシート状成形素材５は、抄造法に
より製造された強化繊維と熱可塑性樹脂粉粒体からなる
不織材料の片面に、接着性素材を介して高融点または高
軟化点の熱可塑性樹脂フィルムを重ね合わせ、加熱・加
圧・冷却固化することにより製造される。このシート状
成形素材５は、一般的には遠赤外線加熱炉６内で繊維強
化熱可塑性樹脂の成形温度（マトリックス樹脂の融点ま
たは軟化点以上）まで加熱される。高融点または高軟化
点の熱可塑性樹脂層３は、加熱時に溶融または軟化せず
繊維強化熱可塑性樹脂層２の全面を安定して覆ってお
り、強化繊維の露出を完全に防いでいる。さらに、加熱
されたシート状成形素材の高融点または高軟化点の熱可
塑性樹脂を積層していない表面に成形品の用途に応じた
装飾用表皮４を重ね合わせ、これらの積層体を成形型７
に設置し、必要に応じてクランプ８により保持して加圧
・冷却固化することにより本発明の繊維強化熱可塑性樹
脂張り出しまたは深絞り成形品１を成形する。The sheet-shaped molding material 5 of the present invention has a high melting point or a high softening point through an adhesive material on one side of a non-woven material composed of reinforcing fibers and thermoplastic resin powder particles manufactured by a papermaking method. It is manufactured by stacking thermoplastic resin films, heating, pressurizing, and cooling to solidify. This sheet-shaped molding material 5 is generally heated in a far infrared heating furnace 6 up to the molding temperature of the fiber-reinforced thermoplastic resin (above the melting point or softening point of the matrix resin). The thermoplastic resin layer 3 having a high melting point or a high softening point does not melt or soften during heating and stably covers the entire surface of the fiber-reinforced thermoplastic resin layer 2 to completely prevent the reinforcing fibers from being exposed. Further, a decorative skin 4 according to the intended use of the molded product is superposed on the surface of the heated sheet-shaped molding material on which the thermoplastic resin having the high melting point or the high softening point is not laminated, and the laminate is formed into a molding die 7
The fiber-reinforced thermoplastic resin overhang or the deep-drawn molded product 1 of the present invention is molded by holding it with a clamp 8 and pressing and cooling to solidify it as required.
【００１９】張り出し成形品は、シート状成形素材およ
び装飾用表皮をクランプにより固定し、それらの伸びに
より成形品が成形される。深絞り成形品は、シート状成
形素材および装飾用表皮が金型内に引き込まれて成形品
が成形される。In the overhang molding, the sheet-shaped molding material and the decorative skin are fixed by a clamp, and the molding is molded by their elongation. The deep-drawing molded product is formed by drawing the sheet-shaped molding material and the decorative skin into the mold.
【００２０】本発明の成形方法では、高融点または高軟
化点の熱可塑性樹脂層および装飾用表皮が存在している
ことにより、張り出しおよび深絞り成形の成形性が著し
く向上する。従来の成形では、シート状成形素材の欠陥
と複雑な成形品における局部的な変形が成形性の低下に
結びついていた。これは、加熱されたシート状成形素材
のマトリックス樹脂が溶融または軟化しているために、
成形時の張力がシート全体で一定せず、局部的に大きな
変形が生じるとその部分から素材の破断が起こるからで
ある。In the molding method of the present invention, since the thermoplastic resin layer having a high melting point or high softening point and the decorative skin are present, the moldability of overhanging and deep drawing is remarkably improved. In conventional molding, defects in the sheet-shaped molding material and local deformation in complicated molded products have led to deterioration in moldability. This is because the matrix resin of the heated sheet-shaped molding material is melted or softened,
This is because the tension at the time of molding is not constant in the entire sheet, and if a large local deformation occurs, the material breaks from that portion.
【００２１】本発明では、高融点または高軟化点の熱可
塑性樹脂層および装飾用表皮が延伸されながら成形が進
行する。高融点または高軟化点の熱可塑性樹脂層および
装飾用表皮は、成形時の張力を保持しシート全体に伝え
る役割を果たすことから、繊維強化熱可塑性樹脂層の欠
陥の影響を低減し、さらに複雑な成形品における局部的
な変形を緩和することにより、素材の伸び量を増加させ
る。また、繊維強化熱可塑性樹脂層は、両者に補強され
た状態で変形するため破断荷重も同時に向上する。結果
として、張り出し成形で重要となる素材の伸び量と、深
絞り成形で重要となる破断荷重の両方が改善され、良好
な成形性が得られる。In the present invention, molding proceeds while the thermoplastic resin layer having a high melting point or high softening point and the decorative skin are stretched. The thermoplastic resin layer with a high melting point or high softening point and the decorative skin play a role of retaining the tension during molding and transmitting it to the entire sheet, reducing the influence of defects in the fiber-reinforced thermoplastic resin layer and making it more complicated. The amount of elongation of the material is increased by mitigating the local deformation of the molded product. Further, since the fiber-reinforced thermoplastic resin layer is deformed while being reinforced by both, the breaking load is simultaneously improved. As a result, both the amount of elongation of the material, which is important in stretch forming, and the breaking load, which is important in deep drawing, are improved, and good formability is obtained.
【００２２】本発明の成形素材は、図１の予め高融点ま
たは高軟化点の熱可塑性樹脂フィルムが積層されたシー
ト状成形素材の他に、成形時の加熱に先立って抄造法に
より製造された強化繊維と熱可塑性樹脂粉粒体からなる
不織材料（またはシート）の片面または両面に、接着性
素材を介して高融点または高軟化点の熱可塑性樹脂フィ
ルムを重ね、あるいは加熱された前記不織材料（または
シート）の片面または両面に、接着性素材を介して別に
加熱した高融点または高軟化点の熱可塑性樹脂フィルム
を重ねることによって調整することもできる。The molding material of the present invention is manufactured by a paper-making method prior to heating during molding, in addition to the sheet-shaped molding material in which a thermoplastic resin film having a high melting point or a high softening point is preliminarily laminated as shown in FIG. A thermoplastic resin film having a high melting point or a high softening point is laminated on one or both sides of a non-woven material (or sheet) composed of reinforcing fibers and thermoplastic resin powder particles through an adhesive material, or the above-mentioned non-woven material is heated. It can also be adjusted by laminating a thermoplastic resin film having a high melting point or a high softening point, which is separately heated via an adhesive material, on one side or both sides of the woven material (or sheet).
【００２３】本発明では、一般的に成形圧力１００kgf/
cm2 以下で張り出しまたは深絞り成形が実施される。図
１は、雄雌型による張り出しまたは深絞り成形について
示しているが、真空、圧空、またはその併用による成形
においても、本発明の張り出しまたは深絞り成形の効果
が適用でき、良好な成形性および成形品外観が得られ
る。In the present invention, the molding pressure is generally 100 kgf /
Overhanging or deep drawing is carried out at a cm 2 or less. Although FIG. 1 shows the overhanging or deep drawing by the male and female dies, the effect of the overhanging or deep drawing of the present invention can be applied to the molding by vacuum, compressed air, or a combination thereof, and good moldability and The appearance of the molded product is obtained.
【００２４】本発明では、ラミネート法による繊維強化
熱可塑性樹脂においても、高融点または高軟化点の熱可
塑性樹脂層および装飾用表皮の補強効果により素材の伸
び量および破断荷重が向上して成形性が改良され、強化
繊維の成形品表面への露出が抑えられて良好な成形品外
観を得ることができる。According to the present invention, even in the fiber-reinforced thermoplastic resin produced by the laminating method, the thermoplastic resin layer having a high melting point or a high softening point and the reinforcing effect of the decorative skin improve the elongation amount and breaking load of the material to improve the moldability. Is improved, the exposure of the reinforcing fibers to the surface of the molded product is suppressed, and a good molded product appearance can be obtained.
【００２５】繊維強化熱可塑性樹脂層の強化繊維含有量
は、強化繊維の補強効果が現れる５体積％以上で、強化
繊維と熱可塑性樹脂との接着が可能で機械的性質を十分
発現する４０体積％以下とすることが好ましい。The reinforcing fiber content of the fiber-reinforced thermoplastic resin layer is 5% by volume or more at which the reinforcing effect of the reinforcing fiber appears, and 40 volume at which the reinforcing fiber and the thermoplastic resin can be bonded and mechanical properties are sufficiently exhibited. % Or less is preferable.
【００２６】繊維強化熱可塑性樹脂層の強化繊維含有量
が１０体積％以上の場合は、シート状成形素材の加熱時
に繊維強化熱可塑性樹脂層が強化繊維のスプリングバッ
クにより板厚方向に膨張する。この膨張したシート状成
形素材を成形型内に挿入し、成形型内のクリアランスを
膨張したシート厚み以下で、かつ繊維強化熱可塑性樹脂
層に内包する空隙を残す範囲に設定して加圧、冷却固化
することにより、繊維強化熱可塑性樹脂層が膨張した多
孔質成形品を成形することができる。この成形品では、
膨張により面積当たりの強度、弾性率は低下するが、重
量一定で成形品の厚肉化を図ることができ、断面係数を
増加させることができる。従って、成形品荷重が板厚の
２乗に、曲げ剛性が板厚の３乗に比例し機械的性質が著
しく向上する。When the reinforcing fiber content of the fiber-reinforced thermoplastic resin layer is 10% by volume or more, the fiber-reinforced thermoplastic resin layer expands in the plate thickness direction due to the springback of the reinforcing fibers when the sheet-shaped molding material is heated. This expanded sheet-shaped molding material is inserted into a mold, and the clearance in the mold is set to a range that is equal to or less than the expanded sheet thickness and that leaves a void to be included in the fiber reinforced thermoplastic resin layer. By solidifying, a porous molded article in which the fiber reinforced thermoplastic resin layer has expanded can be molded. In this molded product,
Although the strength per unit area and the elastic modulus decrease due to the expansion, the molded product can be made thicker with a constant weight, and the section modulus can be increased. Therefore, the load of the molded product is proportional to the square of the plate thickness and the bending rigidity is proportional to the cube of the plate thickness, and the mechanical properties are remarkably improved.
【００２７】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、用途によっ
てはこれらの混合物が用いられる。強化繊維の形状は、
直径が取り扱いの容易さと経済的な観点により３μｍ以
上で、十分な強度を発現させるために３０μｍ以下にす
ることが好ましく、繊維長は強度発現の観点から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。As the reinforcing fibers, glass fibers, carbon fibers, metal fibers, as well as inorganic fibers, organic fibers, and mixtures thereof may be used depending on the application. The shape of the reinforcing fiber is
The diameter is preferably 3 μm or more from the viewpoint of easy handling and economically, and is preferably 30 μm or less in order to exhibit sufficient strength. The fiber length is 3 mm or more from the viewpoint of strength development, and 50 mm capable of uniform dispersion. The following is desirable.
【００２８】また湿式法で使用する強化繊維は、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、湿潤剤等で表面処理を行うことが望ましく、
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
るためにシランカップリング剤等で、表面処理を行うこ
とが望ましい。The reinforcing fiber used in the wet method is preferably surface-treated with a water-soluble polymer, a wetting agent or the like in order to improve hydrophilicity for the purpose of good dispersion in water.
It is desirable to perform a surface treatment with a silane coupling agent or the like in order to improve the adhesiveness with the thermoplastic resin for the purpose of expressing strength.
【００２９】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
ロニトリル共重合体、スチレン−アクリロニトリル共重
合体、ポリメチルメタクリレート、ポリアミド、ポリカ
ーボネート、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、ポリ弗化ビニリデン、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、ガラス繊維等の強化
繊維による補強効果が発揮されやすい点で結晶性樹脂
が、また結晶性樹脂の中でもポリエチレン、ポリプロピ
レン等のポリオレフィンが好んで使用される。さらに、
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。熱可塑性樹脂の形状は、ペレ
ット、パウダー、フレーク、繊維状のものを適宜選択し
て使用する。The thermoplastic resin includes polyethylene, polypropylene, polystyrene, styrene-butadiene-acrylonitrile copolymer, styrene-acrylonitrile copolymer, polymethylmethacrylate, polyamide, polycarbonate, polyacetal, polyethylene terephthalate, polybutylene terephthalate, polyphenylene oxide, It is a resin such as polyvinylidene fluoride, polysulfone, polyphenylene sulfide, etc., and crystalline resin is preferred because it is easy to exert the reinforcing effect by the reinforcing fiber such as glass fiber, and among the crystalline resins, polyolefin such as polyethylene and polypropylene is preferred. used. further,
Plasticizers, heat stabilizers, light stabilizers, which are commonly used in these, including mixtures of two or more of these,
Fillers, dyes and pigments, impact resistance agents, extenders, nucleating agents, processing aids and the like can also be added. The shape of the thermoplastic resin is appropriately selected from pellets, powders, flakes, and fibrous shapes.
【００３０】繊維強化熱可塑性樹脂に積層する高融点ま
たは高軟化点の熱可塑性樹脂は、フィルム状で用いるこ
とが取扱いが容易で好ましく、繊維強化熱可塑性樹脂の
成形温度より高い温度で溶融または軟化を開始するもの
を選択する必要がある。熱可塑性樹脂は、繊維強化熱可
塑性樹脂層のマトリックス樹脂より融点または軟化点が
３０℃以上高いものを選択することが望ましい。熱可塑
性樹脂として、繊維強化熱可塑性樹脂層のマトリックス
樹脂との融点または軟化点の差が３０℃未満のものを選
択した場合は、繊維強化熱可塑性樹脂の成形温度と重な
り、熱可塑性樹脂層が溶融または軟化して強化繊維が成
形品表面に露出する現象が起こるので、本発明の効果が
期待できなくなる。The thermoplastic resin having a high melting point or a high softening point to be laminated on the fiber-reinforced thermoplastic resin is preferably used in the form of a film because it is easy to handle, and is melted or softened at a temperature higher than the molding temperature of the fiber-reinforced thermoplastic resin. You have to choose what to start with. It is desirable to select a thermoplastic resin having a melting point or softening point higher by 30 ° C. or more than the matrix resin of the fiber reinforced thermoplastic resin layer. When the thermoplastic resin having a difference in melting point or softening point from the matrix resin of the fiber-reinforced thermoplastic resin layer of less than 30 ° C. is selected, the molding temperature of the fiber-reinforced thermoplastic resin overlaps with the thermoplastic resin layer. Since the phenomenon that the reinforcing fibers are exposed on the surface of the molded product due to melting or softening occurs, the effect of the present invention cannot be expected.
【００３１】繊維強化熱可塑性樹脂層のマトリックス樹
脂としてポリオレフィンを用いるときは、ポリオレフィ
ンとの融点または軟化点の差、フィルムへの成形性等の
点から、ポリアミド、ポリエステル、ポリカーボネー
ト、ポリメチルメタクリレート等を選択することが好ま
しい。When polyolefin is used as the matrix resin of the fiber-reinforced thermoplastic resin layer, polyamide, polyester, polycarbonate, polymethylmethacrylate, etc. are selected from the viewpoints of difference in melting point or softening point with polyolefin, moldability into film and the like. It is preferable to select.
【００３２】表層部に着色または塗装による意匠性、耐
熱性、表面硬度、耐摩耗性等の向上を必要とする場合は
異なる樹脂との混合物、または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、加工助剤等を添加したフィルム
を用いることができ、さらに異なる樹脂の多層フィルム
を用いてもよい。When it is necessary to improve the designability, heat resistance, surface hardness, abrasion resistance, etc. by coloring or coating the surface layer, a mixture with a different resin, or a plasticizer generally used for these, heat stability Films containing agents, light stabilizers, fillers, dyes and pigments, impact resistance agents, extenders, nucleating agents, processing aids and the like can be used, and multilayer films of different resins may be used.
【００３３】熱可塑性樹脂フィルムの厚みは、用途によ
り０．０１〜１mmの範囲で適宜選択する。フィルム厚み
が０．０１mm未満では、強化繊維の凹凸が成形品の表面
に影響し、１mm超過では、成形品の板厚当たりの強度が
低下し、経済性も悪くなる。The thickness of the thermoplastic resin film is appropriately selected within the range of 0.01 to 1 mm depending on the application. When the film thickness is less than 0.01 mm, the unevenness of the reinforcing fibers affects the surface of the molded product, and when it exceeds 1 mm, the strength per plate thickness of the molded product decreases and the economical efficiency deteriorates.
【００３４】さらに無機フィラーを添加した熱可塑性樹
脂フィルムを使用することもできる。添加する無機フィ
ラーとしては、炭酸カルシウム、タルク等の微粒子状フ
ィラー、マイカ等のフレーク状フィラー、チョップドガ
ラス繊維、ロックウール繊維等の繊維状フィラーを用い
る。無機フィラーは、熱可塑性樹脂との接着性を向上す
るために、シランカップリング剤等で表面処理を行うこ
とが望ましい。無機フィラーの種類は、用途に応じて適
宜選択するものとし、前記無機フィラーの２種類以上の
混合物を添加してもよい。無機フィラーの添加量は、安
定したフィルム成形が可能な３０体積％以下とすること
が望ましい。It is also possible to use a thermoplastic resin film further containing an inorganic filler. As the inorganic filler to be added, particulate fillers such as calcium carbonate and talc, flaky fillers such as mica, fibrous fillers such as chopped glass fibers and rock wool fibers are used. The inorganic filler is preferably surface-treated with a silane coupling agent or the like in order to improve the adhesiveness with the thermoplastic resin. The kind of the inorganic filler is appropriately selected according to the application, and a mixture of two or more kinds of the inorganic filler may be added. The amount of the inorganic filler added is preferably 30% by volume or less, which allows stable film formation.
【００３５】高融点または高軟化点の熱可塑性樹脂層
は、何らかの方法で繊維強化熱可塑性樹脂層と接合させ
る必要がある。本発明で用いる接着性素材とは、接着性
樹脂等、またはフィルムラミネートに使用する接着剤等
のことである。The high melting point or high softening point thermoplastic resin layer must be bonded to the fiber reinforced thermoplastic resin layer by some method. The adhesive material used in the present invention is an adhesive resin or the like, or an adhesive or the like used for film lamination.
【００３６】繊維強化熱可塑性樹脂層のマトリックス樹
脂としてポリオレフィンを用いるときは、接着性樹脂と
して不飽和カルボン酸またはその誘導体（酸無水物、エ
ステル、アミド、イミド、金属塩等）でグラフト変性さ
れたポリプロピレン、不飽和カルボン酸またはその誘導
体でグラフト変性されたエチレンコポリマー（エチレン
−酢酸ビニルコポリマー、エチレン−アクリル酸エステ
ルコポリマ−、エチレン−アクリル酸コポリマー等）
や、これらに炭化水素エラストマー（ブチルゴム等）を
添加したものを挙げることができ、さらにこれらの２種
類またはそれ以上の混合物を使用することもできる。When polyolefin is used as the matrix resin of the fiber reinforced thermoplastic resin layer, it is graft-modified with unsaturated carboxylic acid or its derivative (acid anhydride, ester, amide, imide, metal salt, etc.) as the adhesive resin. Ethylene copolymer graft-modified with polypropylene, unsaturated carboxylic acid or its derivatives (ethylene-vinyl acetate copolymer, ethylene-acrylic acid ester copolymer, ethylene-acrylic acid copolymer, etc.)
Alternatively, a hydrocarbon elastomer (butyl rubber or the like) added thereto may be mentioned, and a mixture of two or more of these may also be used.
【００３７】接着性樹脂は、高融点または高軟化点の熱
可塑性樹脂層と繊維強化熱可塑性樹脂層間に設けられ、
繊維強化熱可塑性樹脂層のマトリックス樹脂と共に溶融
し、冷却により両者を固着する。接着性樹脂は、フィル
ム状で用いることが取扱いが容易で好ましく、またその
厚みは接着効果と経済性により５〜５００μｍとするこ
とが望ましく、さらに１０〜１００μｍとすることが好
ましい。The adhesive resin is provided between the thermoplastic resin layer having a high melting point or high softening point and the fiber-reinforced thermoplastic resin layer,
It melts together with the matrix resin of the fiber reinforced thermoplastic resin layer and is fixed by cooling. The adhesive resin is preferably used in the form of a film because it is easy to handle, and the thickness thereof is preferably 5 to 500 μm, more preferably 10 to 100 μm in view of the adhesive effect and economy.
【００３８】高融点または高軟化点の熱可塑性樹脂フィ
ルムと接着性樹脂フィルムを予めラミネートした多層フ
ィルムを使用することにより、成形工程のハンドリング
性が改善される。多層フィルムは、フィルムのラミネー
ト方法として一般的な押し出しラミネート、共押し出し
ラミネート、さらには接着剤を介したラミネートにより
製造される。例えば、ポリアミド／無水マレイン酸変性
ポリプロピレンの押し出しラミネートフィルム、ポリア
ミド／無水マレイン酸変性ポリプロピレンの共押し出し
ラミネートフィルム、ポリアミド／無水マレイン酸変性
ポリプロピレン／ポリプロピレンの共押し出しラミネー
トフィルム、ポリアミド／接着剤／ポリプロピレンのド
ライラミネートフィルム等が挙げられる。By using a multilayer film obtained by previously laminating a thermoplastic resin film having a high melting point or a high softening point and an adhesive resin film, the handling property in the molding process is improved. The multilayer film is manufactured by extrusion laminating, coextrusion laminating, or laminating via an adhesive, which is a general method for laminating films. For example, polyamide / maleic anhydride modified polypropylene extruded laminated film, polyamide / maleic anhydride modified polypropylene coextruded laminated film, polyamide / maleic anhydride modified polypropylene / polypropylene coextruded laminated film, polyamide / adhesive / polypropylene dry film Laminate films and the like can be mentioned.
【００３９】本発明において、無機フィラーおよび染顔
料を含有した熱可塑性樹脂層を、繊維強化熱可塑性樹脂
層と、透明または半透明の高融点または高軟化点の熱可
塑性樹脂層および接着性素材層の間に設けることは、成
形品の意匠性の向上につながる。無機フィラーとして
は、炭酸カルシウム、タルク等の微粒子状フィラーを使
用し、さらに熱可塑性樹脂は繊維強化熱可塑性樹脂層の
マトリックス樹脂と同じものを使用することが一般的で
ある。この場合もフィルム状で用いることが取扱いが容
易で好ましく、その厚みは、０．１〜１mmとすることで
所望の意匠性を向上させることができる。無機フィラー
および染顔料の添加量は、安定したフィルム成形が可能
な３０体積％以下とすることが望ましい。In the present invention, a thermoplastic resin layer containing an inorganic filler and a dye / pigment, a fiber reinforced thermoplastic resin layer, a transparent or translucent thermoplastic resin layer having a high melting point or a high softening point, and an adhesive material layer. If it is provided between the two, it improves the design of the molded product. As the inorganic filler, it is common to use a particulate filler such as calcium carbonate or talc, and the thermoplastic resin is generally the same as the matrix resin of the fiber reinforced thermoplastic resin layer. Also in this case, it is preferable to use it in the form of a film because it is easy to handle, and the desired designability can be improved by setting the thickness to 0.1 to 1 mm. The addition amount of the inorganic filler and the dye / pigment is preferably 30% by volume or less, which allows stable film formation.
【００４０】この無機フィラーおよび染顔料を含有した
熱可塑性樹脂層は、溶融粘度が増大しているので、加熱
されたシート状成形素材においても繊維強化熱可塑性樹
脂層を安定して覆うことができ、強化繊維を隠ぺいする
働きをするので、成形品の意匠性がさらに向上する。Since the thermoplastic resin layer containing the inorganic filler and the dye / pigment has an increased melt viscosity, it is possible to stably cover the fiber-reinforced thermoplastic resin layer even in the heated sheet-shaped molding material. Since it works to hide the reinforcing fibers, the design of the molded product is further improved.
【００４１】装飾用表皮は、通気性表皮として天然およ
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、さらに非通気性表
皮としては平滑または布，皮模様等のシボ付け加工が施
されたプラスチックシートまたはフィルム、金属粉末を
混入したり、金属をコーティングしたプラスチックシー
トまたはフィルム等を用いる。また、これらの装飾用表
皮にポリエチレン発泡体、エチレン−プロピレンコポリ
マー発泡体、エチレン−酢酸ビニルコポリマー発泡体、
ウレタン発泡体等の多孔質シートをラミネートしたもの
を使用することもできる。装飾用表皮と繊維強化熱可塑
性樹脂層の接合は、装飾用表皮の融着、ホットメルトタ
イプ接着性樹脂フィルムまたは接着剤を介在させた接着
により行う。The decorative skins are woven fabrics made of natural and synthetic fibers as breathable skins, non-woven fabrics obtained by needle punching, raised woven fabrics, knitted fabrics, flocked fabrics, and smooth or non-breathable skins. A plastic sheet or film having a textured finish such as cloth or leather pattern, a metal sheet mixed with metal powder, or a metal-coated plastic sheet or film is used. Moreover, polyethylene foam, ethylene-propylene copolymer foam, ethylene-vinyl acetate copolymer foam, and these decorative skins,
It is also possible to use a laminate of porous sheets such as urethane foam. The decorative skin and the fiber-reinforced thermoplastic resin layer are joined by fusing the decorative skin, bonding with a hot-melt type adhesive resin film or an adhesive.
【００４２】[0042]
【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 強化繊維として水溶性高分子、湿潤剤、シランカップリ
ング剤で表面処理された直径１０μｍ、長さ１３mmのガ
ラス繊維、さらに熱可塑性樹脂として、直径３mm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
１．７mm）までに分級したポリプロピレン樹脂粉粒体
（融点：１６５℃）を使用した。The present invention will be described in detail with reference to the following examples. Example 1 A glass fiber having a diameter of 10 μm and a length of 13 mm which was surface-treated with a water-soluble polymer, a wetting agent, and a silane coupling agent as a reinforcing fiber, and a spherical pellet having a diameter of 3 mm as a thermoplastic resin was mechanically crushed, A polypropylene resin powder (melting point: 165 ° C.) was used, which was classified from 70 mesh (opening diameter 0.212 mm) to 10 mesh (opening diameter 1.7 mm) by sieving the ground product.
【００４３】抄造法によりガラス繊維含有量４０重量％
（１９体積％）とポリプロピレン樹脂６０重量％（８１
体積％）の組成で、坪量（面積当たりの重量）が２００
０g/ｍ2 の不織材料を製造した。この不織材料では、ガ
ラス繊維が単一の繊維に近い状態でポリプロピレン樹脂
粉粒体と共に均一に分散していた。Glass fiber content of 40% by weight according to the papermaking method
(19% by volume) and polypropylene resin 60% by weight (81
Volume%) and basis weight (weight per area) is 200
0 g / m 2 of non-woven material was produced. In this non-woven material, the glass fibers were uniformly dispersed together with the polypropylene resin powder particles in a state close to a single fiber.
【００４４】高融点または高軟化点の熱可塑性樹脂フィ
ルムおよび接着性樹脂フィルムとして、ポリアミド（ナ
イロン６６：融点２６５℃）フィルム（厚み８０μｍ）
と無水マレイン酸をグラフトさせた変性ポリプロピレン
樹脂フィルム（厚み３０μｍ）が予めラミネートした多
層フィルムを用いた。As a thermoplastic resin film having a high melting point or a high softening point and an adhesive resin film, a polyamide (nylon 66: melting point 265 ° C.) film (thickness: 80 μm)
A multilayer film was used in which a modified polypropylene resin film (thickness 30 μm) grafted with and maleic anhydride was previously laminated.
【００４５】不織材料の片面に接着性樹脂フィルムが接
するように多層フィルムを重ね合わせ、さらに、それら
の両面に鏡板として平滑な表面のステンレス鋼板（板厚
２mm）を重ね合わせて、２１０℃に温度設定された加熱
プレス盤内に挿入し、圧力２kgf/cm2 の加圧下で不織材
料の中心部温度が１９０℃以上に昇温するまで、約５分
間予熱した。この温度で、ポリプロピレン樹脂、接着性
樹脂は十分溶融し、ポリアミド樹脂は溶融していなかっ
た。続いて、圧力２０kgf/cm2 で３分間加圧し、さらに
積層体を冷却プレス盤に挿入し、圧力５kgf/cm2 で約５
分間、加圧、冷却し、鏡板を取り外して、板厚１．８mm
のシート状成形素材を成形した。A multilayer film is laminated on one side of the non-woven material so that the adhesive resin film is in contact with the non-woven material, and a stainless steel plate (plate thickness: 2 mm) having a smooth surface is laminated on both sides of the non-woven material to 210 ° C. It was inserted into a temperature-controlled heating press machine and preheated under a pressure of 2 kgf / cm 2 for about 5 minutes until the temperature of the central portion of the nonwoven material increased to 190 ° C. or higher. At this temperature, the polypropylene resin and the adhesive resin were sufficiently melted, and the polyamide resin was not melted. Then, pressurize at a pressure of 20 kgf / cm 2 for 3 minutes, insert the laminated body into a cooling press machine, and apply a pressure of 5 kgf / cm 2 for about 5 minutes.
For 1 minute, pressurize and cool, remove the end plate, plate thickness 1.8 mm
The sheet-shaped molding material of was molded.
【００４６】張り出しおよび深絞り成形性の定量的な評
価として、図３に示した成形評価を行った。シート状成
形素材５を２１０×２１０mmに切断し、遠赤外線加熱炉
内で３分間加熱した。この時のシート状成形素材の表面
温度は約２００℃で、繊維強化熱可塑性樹脂層のポリプ
ロピレン樹脂は溶融しているが、ポリアミド層は溶融せ
ずガラス繊維の露出を完全に抑えていることが確認され
た。ポリアミドフィルムが積層されていない表面は、多
くのガラス繊維の露出が確認された。The molding evaluation shown in FIG. 3 was carried out as a quantitative evaluation of the overhanging and deep drawing formability. The sheet-shaped forming material 5 was cut into 210 × 210 mm and heated in a far infrared heating furnace for 3 minutes. At this time, the surface temperature of the sheet-shaped molding material was about 200 ° C., and the polypropylene resin of the fiber-reinforced thermoplastic resin layer was melted, but the polyamide layer was not melted and the exposure of the glass fiber was completely suppressed. confirmed. It was confirmed that many glass fibers were exposed on the surface on which the polyamide film was not laminated.
【００４７】加熱されたシート状成形素材５を、直径１
５０mmの穴が切り抜かれた架台１５の上にポンチ１６側
がポリアミドフィルムの積層されていない表面になるよ
うに設置し、さらに架台と同様に直径１５０mmの穴が切
り抜かれた平板のクランプ８により固定した。続いて、
固定されたシート状成形素材を、直径５０mmのポンチ１
６で張り出しを行い、シート状成形素材の張り出し量
（ポンチの下降量）と、ポンチに設置したロードセル１
７により成形時の荷重を測定した。最大荷重時の張り出
し量を張り出し成形性の指標として、さらに最大荷重を
材料の破断荷重として深絞り成形性を評価した。成形品
外観は、ポリアミド層の表面粗度を測定し中心線平均粗
さ（Ｒａ）で評価した。結果を表１に示した。The heated sheet-shaped molding material 5 is
The punch 16 side was placed on the pedestal 15 in which a hole of 50 mm was cut out so that the surface of the punch 16 was not laminated with polyamide film, and was fixed by a clamp 8 of a flat plate in which a hole of 150 mm in diameter was cut out similarly to the pedestal. . continue,
Punch 1 with a diameter of 50 mm from the fixed sheet-shaped molding material
6 is used for overhanging, and the amount of overhanging sheet material (downward amount of the punch) and the load cell 1 installed on the punch
7, the load at the time of molding was measured. Deep drawing formability was evaluated using the amount of overhang at the maximum load as an index of the overhang formability, and the maximum load as the breaking load of the material. The appearance of the molded product was evaluated by measuring the surface roughness of the polyamide layer and measuring the center line average roughness (Ra). The results are shown in Table 1.
【００４８】実施例２ 実施例１の不織材料の両面に、実施例１のポリアミド／
変性樹脂・多層フィルムを接着性樹脂側が接するように
重ね合わせ、実施例１と同様に板厚１．９mmのシート状
成形素材を成形した。さらにこのシート状成形素材を用
いて、実施例１と同様に成形性の評価を行った。成形品
外観は、表面粗度を測定し中心線平均粗さ（Ｒａ）で評
価した。結果を表１に示した。Example 2 On both sides of the nonwoven material of Example 1, the polyamide of Example 1 /
The modified resin / multilayer film was laminated so that the adhesive resin side was in contact, and a sheet-shaped molding material having a plate thickness of 1.9 mm was molded in the same manner as in Example 1. Further, using this sheet-shaped molding material, the moldability was evaluated in the same manner as in Example 1. The appearance of the molded product was evaluated by measuring the surface roughness and measuring the center line average roughness (Ra). The results are shown in Table 1.
【００４９】実施例３ 実施例１のシート状成形素材と装飾用表皮との一体成形
における成形性の評価を行った。装飾用表皮としては、
皮膜様が施された厚み０．５mmポリ塩化ビニルシートに
３mmのエチレン−プロピレンコポリマー発泡体（融点１
３７℃、発泡倍率１５倍）がラミネートされた多層表皮
を用いた。Example 3 The moldability in integral molding of the sheet-shaped molding material and the decorative skin of Example 1 was evaluated. As a decorative skin,
3 mm ethylene-propylene copolymer foam (melting point 1
A multilayer skin laminated with 37 ° C. and a foaming ratio of 15 times was used.
【００５０】シート状成形素材を、実施例１と同様に加
熱し、加熱されたシート状成形素材のポリアミドフィル
ムが積層されていない表面に、発泡体が接するように多
層表皮を重ね合わせ、ポリアミド層がポンチ側になるよ
うに架台・クランプで固定して成形性の評価を行った。
成形品外観は、ポリアミド層の表面粗度を測定し中心線
平均粗さ（Ｒａ）で評価した。結果を表１に示した。The sheet-shaped molding material was heated in the same manner as in Example 1, and a multilayer skin was superposed so that the foam was in contact with the surface of the heated sheet-shaped molding material on which the polyamide film was not laminated. The moldability was evaluated by fixing with a pedestal and clamp so that was on the punch side.
The appearance of the molded product was evaluated by measuring the surface roughness of the polyamide layer and measuring the center line average roughness (Ra). The results are shown in Table 1.
【００５１】実施例４ 実施例１のシート状成形素材と装飾用表皮との一体成形
における成形性の評価を行った。装飾用表皮としては、
坪量２３０g/ｍ2 のポリエステル繊維不織布を用いた。
また、接着性樹脂フィルムとして、厚み２０μｍのエチ
レン−酢酸ビニルコポリマー・フィルムを用いた。Example 4 The moldability in the integral molding of the sheet-shaped molding material and the decorative skin of Example 1 was evaluated. As a decorative skin,
A polyester fiber non-woven fabric having a basis weight of 230 g / m 2 was used.
An ethylene-vinyl acetate copolymer film having a thickness of 20 μm was used as the adhesive resin film.
【００５２】シート状成形素材を、実施例１と同様に加
熱し、加熱されたシート状成形素材のポリアミドフィル
ムが積層されていない表面に、接着性樹脂フィルム、ポ
リエステル繊維不織布を重ね合わせ、ポリアミド層がポ
ンチ側になるように架台・クランプで固定して成形性の
評価を行った。成形品外観は、ポリアミド層の表面粗度
を測定し中心線平均粗さ（Ｒａ）で評価した。結果を表
１に示した。The sheet-shaped molding material was heated in the same manner as in Example 1, and the adhesive resin film and the polyester fiber non-woven fabric were superposed on the surface of the heated sheet-shaped molding material on which the polyamide film was not laminated to form a polyamide layer. The moldability was evaluated by fixing with a pedestal and clamp so that was on the punch side. The appearance of the molded product was evaluated by measuring the surface roughness of the polyamide layer and measuring the center line average roughness (Ra). The results are shown in Table 1.
【００５３】比較例１ 実施例１の不織材料にフィルム積層を行わず、実施例１
と同様にシート状成形素材を成形した。さらにこのシー
ト状成形素材を用いて、実施例１と同様に成形性の評価
を行った。加熱されたシート状成形素材の表面は、多く
のガラス繊維の露出が確認された。成形品外観は、表面
粗度を測定し中心線平均粗さ（Ｒａ）で評価した。結果
を表１に示した。Comparative Example 1 The non-woven material of Example 1 was not film laminated and
A sheet-shaped molding material was molded in the same manner as in. Further, using this sheet-shaped molding material, the moldability was evaluated in the same manner as in Example 1. It was confirmed that many glass fibers were exposed on the surface of the heated sheet-shaped molding material. The appearance of the molded product was evaluated by measuring the surface roughness and measuring the center line average roughness (Ra). The results are shown in Table 1.
【００５４】実施例は、比較例に比べて張り出し試験時
の最大荷重、張り出し量が向上していることが確認され
た。実施例の溶融していないポリアミド層および装飾用
表皮は延伸されながら張り出されており、両者は張力を
シート全体に伝える役割を果たしている。溶融している
繊維強化熱可塑性樹脂層は、両者に補強された状態で変
形するため、局部的な破断が起こり難くなる。結果とし
て、比較例に比べて欠陥の影響、局部的な変形が緩和さ
れ張り出し量が増加する。最大荷重は、ポリアミド層お
よび装飾用表皮の変形抵抗により増加する。実施例で
は、張り出し成形性で重要となる素材の伸び量と、深絞
り成形性で重要となる素材の破断荷重が改善され、良好
な成形性が得られる。It was confirmed that the maximum load and the amount of overhang in the overhang test were improved in the examples as compared with the comparative examples. The unmelted polyamide layer and the decorative skin of the example are stretched and bulged out, and both play a role of transmitting tension to the entire sheet. Since the molten fiber-reinforced thermoplastic resin layer is deformed while being reinforced by both, local breakage is less likely to occur. As a result, the influence of defects and local deformation are alleviated and the amount of overhang is increased as compared with the comparative example. The maximum load increases due to the deformation resistance of the polyamide layer and the decorative skin. In the examples, the elongation amount of the material, which is important for the stretch formability, and the breaking load of the material, which is important for the deep drawability, are improved, and good formability is obtained.
【００５５】中心線平均粗さで比較した成形品外観は、
実施例が比較例に比べて著しく改善されていることが確
認された。実施例では、加熱されたシート状成形素材の
表面がポリアミド層で覆われ、ガラス繊維の露出が抑え
られていた。成形品は、この状態を凍結して成形される
ため良好な外観が得られる。The appearance of molded products compared by center line average roughness is
It was confirmed that the example was significantly improved as compared with the comparative example. In the examples, the surface of the heated sheet-shaped molding material was covered with the polyamide layer, and the exposure of the glass fiber was suppressed. Since the molded product is frozen in this state and molded, a good appearance can be obtained.
【００５６】[0056]
【表１】 [Table 1]
【００５７】[0057]
【発明の効果】本発明の繊維強化熱可塑性樹脂張り出し
または深絞り成形品では、高融点または高軟化点の熱可
塑性樹脂層および装飾用表皮の補強効果により素材の伸
び量、破断荷重が向上して成形性が改良される。また、
強化繊維の露出が抑えられ良好な成形品外観が得られ
る。INDUSTRIAL APPLICABILITY In the fiber-reinforced thermoplastic resin overhanging or deep-drawing molded article of the present invention, the elongation amount and breaking load of the material are improved by the reinforcing effect of the thermoplastic resin layer having a high melting point or a high softening point and the decorative skin. Formability is improved. Also,
The exposure of the reinforcing fibers is suppressed, and a good molded product appearance is obtained.
【図１】本発明の繊維強化熱可塑性樹脂張り出しまたは
深絞り成形品およびその成形方法の一例を示す概略図。FIG. 1 is a schematic view showing an example of a fiber-reinforced thermoplastic resin overhanging or deep-drawn molded product of the present invention and a molding method thereof.
【図２】従来の繊維強化熱可塑性樹脂張り出しまたは深
絞り成形品およびその成形方法の一例を示す概略図。FIG. 2 is a schematic view showing an example of a conventional fiber-reinforced thermoplastic resin overhanging or deep-drawing molded product and its molding method.
【図３】実施例、比較例で行った張り出し試験方法を示
す概略図。FIG. 3 is a schematic diagram showing an overhang test method performed in Examples and Comparative Examples.
１ 本発明の繊維強化熱可塑性樹脂張り出しまたは深
絞り成形品 ２ 繊維強化熱可塑性樹脂層 ３ 高融点または高軟化点の熱可塑性樹脂層 ４ 装飾用表皮 ５ 本発明のシート状成形素材 ６ 遠赤外線加熱炉 ７ 成形型 ８ クランプ ９ 従来のシート状成形素材 １０ 従来の繊維強化熱可塑性樹脂張り出しまたは深絞
り成形品 １１ 成形品の縦壁部 １２ 水平部 １３ 素材の破断 １４ 強化繊維の露出 １５ 架台 １６ ポンチ1 Fiber Reinforced Thermoplastic Resin Overhang or Deep Drawing Molded Product 2 of the Present Invention 2 Fiber Reinforced Thermoplastic Resin Layer 3 High Melting Point or High Softening Point Thermoplastic Resin Layer 4 Decorative Skin 5 Sheet Forming Material of the Present Invention 6 Far Infrared Heating Furnace 7 Mold 8 Clamp 9 Conventional sheet molding material 10 Conventional fiber reinforced thermoplastic resin overhang or deep drawing molded product 11 Vertical wall part 12 of molded product 12 Horizontal part 13 Material break 14 Exposed reinforcing fiber 15 Stand 16 Punch
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.6 識別記号 庁内整理番号 ＦＩ 技術表示箇所 Ｂ２９Ｌ 22:00 (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. 6 Identification code Internal reference number FI Technical indication location B29L 22:00 (72) Inventor Takao Kimura 1 Toho-cho, Yokkaichi-shi, Mie Mitsubishi Petrochemical Co., Ltd. Yokkaichi Research Institute
Claims (4)
性樹脂からなる繊維強化熱可塑性樹脂層の片面または両
面に、接着性素材を介して前記繊維強化熱可塑性樹脂の
成形温度より高い融点または軟化点を有する熱可塑性樹
脂層が積層されてなり、繊維強化熱可塑性樹脂層の密度
が理論密度以下であることを特徴とする繊維強化熱可塑
性樹脂張り出しまたは深絞り成形品。1. A melting point higher than the molding temperature of the fiber reinforced thermoplastic resin via an adhesive material on one or both sides of a fiber reinforced thermoplastic resin layer composed of a reinforced fiber dispersed in a single fiber and a thermoplastic resin. Alternatively, a fiber-reinforced thermoplastic resin overhang or a deep-draw molded product, characterized in that a thermoplastic resin layer having a softening point is laminated, and the density of the fiber-reinforced thermoplastic resin layer is not more than the theoretical density.
着性素材を介して前記繊維強化熱可塑性樹脂の成形温度
より高い融点または軟化点を有する熱可塑性樹脂層が積
層され、他方の片面に装飾用表皮が積層されてなり、繊
維強化熱可塑性樹脂層の密度が理論密度以下であること
を特徴とする請求項１記載の繊維強化熱可塑性樹脂張り
出しまたは深絞り成形品。2. A thermoplastic resin layer having a melting point or a softening point higher than the molding temperature of the fiber reinforced thermoplastic resin is laminated on one surface of the fiber reinforced thermoplastic resin layer with an adhesive material interposed between the one surface and the other surface. The fiber-reinforced thermoplastic resin overhang or deep-draw molded product according to claim 1, wherein the decorative skin is laminated and the density of the fiber-reinforced thermoplastic resin layer is not more than the theoretical density.
性樹脂からなる繊維強化熱可塑性樹脂の片面または両面
に、接着性素材を介して前記繊維強化熱可塑性樹脂の成
形温度より高い融点または軟化点を有する熱可塑性樹脂
フィルムを積層し、加熱・加圧・冷却固化してシート状
成形素材とし、さらに該シート状成形素材を加熱した
後、張り出しまたは深絞り成形することを特徴とする繊
維強化熱可塑性樹脂張り出しまたは深絞り成形品の成形
方法。3. A melting point higher than the molding temperature of the fiber-reinforced thermoplastic resin on one or both sides of a fiber-reinforced thermoplastic resin composed of a reinforcing fiber dispersed in a single fiber and a thermoplastic resin, or an adhesive material. A fiber characterized by laminating a thermoplastic resin film having a softening point, heating, pressurizing and cooling to solidify into a sheet-shaped molding material, and further heating the sheet-shaped molding material, and then subjecting it to overhanging or deep drawing. Molding method for reinforced thermoplastic resin overhang or deep-draw molding.
性樹脂からなる繊維強化熱可塑性樹脂の片面に、接着性
素材を介して前記繊維強化熱可塑性樹脂の成形温度より
高い融点または軟化点を有する熱可塑性樹脂フィルムを
積層し、加熱・加圧・冷却固化してシート状成形素材と
し、さらに該シート状成形素材を加熱した後、前記熱可
塑性樹脂フィルムが積層されていない該シート状成形素
材の表面に装飾用表皮を重ね合わせて、張り出しまたは
深絞り成形することを特徴とする請求項３に記載の繊維
強化熱可塑性樹脂張り出しまたは深絞り成形品の成形方
法。4. A melting point or softening point higher than the molding temperature of the fiber reinforced thermoplastic resin via an adhesive material on one side of a fiber reinforced thermoplastic resin composed of a reinforced fiber dispersed in a single fiber and a thermoplastic resin. The thermoplastic resin film having the above is laminated, heated, pressurized and cooled to solidify to form a sheet-shaped molding material, and the sheet-shaped molding material is further heated, and then the sheet-shaped molding in which the thermoplastic resin film is not laminated. The method for forming a fiber-reinforced thermoplastic resin overhang or deep-draw molded product according to claim 3, wherein a decorative skin is superposed on the surface of the raw material, and the overhang or deep-draw molding is performed.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP18009893A JPH0732465A (en) | 1993-07-21 | 1993-07-21 | Overhung or deep-drawn molded item made of fiber-reinforced thermoplastic resin and manufacture thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP18009893A JPH0732465A (en) | 1993-07-21 | 1993-07-21 | Overhung or deep-drawn molded item made of fiber-reinforced thermoplastic resin and manufacture thereof |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH0732465A true JPH0732465A (en) | 1995-02-03 |
Family
ID=16077401
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP18009893A Withdrawn JPH0732465A (en) | 1993-07-21 | 1993-07-21 | Overhung or deep-drawn molded item made of fiber-reinforced thermoplastic resin and manufacture thereof |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH0732465A (en) |
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