JPH08224793A - Manufacture of fiber reinforced resin molding - Google Patents
Manufacture of fiber reinforced resin moldingInfo
- Publication number
- JPH08224793A JPH08224793A JP7056653A JP5665395A JPH08224793A JP H08224793 A JPH08224793 A JP H08224793A JP 7056653 A JP7056653 A JP 7056653A JP 5665395 A JP5665395 A JP 5665395A JP H08224793 A JPH08224793 A JP H08224793A
- Authority
- JP
- Japan
- Prior art keywords
- material layer
- thermoplastic resin
- resin
- fiber
- state
- 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- Withdrawn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、強化繊維と熱可塑性樹
脂マトリックスとからなる繊維強化樹脂成形品を製造す
る為の有用な方法に関するものであり、殊に良好な吸
音特性と高剛性を兼ね備えた繊維強化樹脂成形品を製
造する為の方法に関するものである。尚本発明によって
得られる方法の成形品は、上記、の性能によって、
主として自動車分野においてこれらの特性が必要とされ
る部品、例えばエンジンルームや車体下部のノイズシー
ルドやアンダーシールドとして有効に利用できるもので
ある。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a useful method for producing a fiber-reinforced resin molded article composed of a reinforcing fiber and a thermoplastic resin matrix, and particularly, having a good sound absorbing property and a high rigidity. And a method for producing a fiber-reinforced resin molded product. Incidentally, the molded article of the method obtained by the present invention, by the above performance,
It can be effectively used as a component that requires these characteristics mainly in the automobile field, for example, as a noise shield or an under shield in the engine room or the lower part of the vehicle body.
【０００２】[0002]
【従来の技術】強化繊維と熱可塑性樹脂マトリックスと
からなる繊維強化樹脂成形品は、安価でしかも優れた機
械性質を有しており、またリサイクル性に優れていると
いった特徴を有していることから、近年その使用量が様
々な分野で急速に増大してきている。特に、自動車や家
電業界では、環境保護という観点から、できるだけ環境
に優しい樹脂材料を使用する傾向をその基本姿勢として
打ち出している。こうした状況の下で、ガラス繊維で強
化されたポリプロピレン成形品（ガラス繊維強化樹脂複
合材料）は、非常に注目されている代表的な繊維強化樹
脂成形品である。ところで自動車等の車体下部に取りつ
けられるアンダーシールドは、特に良好な吸音特性が要
求される。この様なアンダーシールドとしては、従来で
は鉄板の様な金属部材を基板とし、その一方側表面に、
ガラス繊維マットをアルミ箔等で包み込んだ吸音性部材
を接着剤等で固定したものが用いられていた。しかなが
ら現在では、環境保護という観点から、上記の様な繊維
強化樹脂成形品をアンダーシールド用の素材として適用
しようとする傾向にある。2. Description of the Related Art A fiber-reinforced resin molded product composed of a reinforcing fiber and a thermoplastic resin matrix is characterized by being inexpensive, having excellent mechanical properties, and being excellent in recyclability. Therefore, in recent years, the amount used has been rapidly increasing in various fields. In particular, in the automobile and home electric appliances industries, from the viewpoint of environmental protection, the tendency to use environmentally friendly resin materials as much as possible has been established as its basic stance. Under such circumstances, a polypropylene molded product reinforced with glass fiber (glass fiber reinforced resin composite material) is a typical fiber reinforced resin molded product that has received a great deal of attention. By the way, an undershield attached to the lower portion of a vehicle body of an automobile or the like is required to have particularly good sound absorbing characteristics. As such an under shield, conventionally, a metal member such as an iron plate is used as a substrate, and one side surface thereof is
A sound absorbing member in which a glass fiber mat is wrapped with aluminum foil or the like and fixed with an adhesive or the like has been used. However, at present, from the viewpoint of environmental protection, there is a tendency to apply the above-mentioned fiber-reinforced resin molded product as a material for an undershield.
【０００３】繊維強化樹脂成形品は、安価で錆びにく
く、しかもリサイクル性に優れているという利点を有し
ている反面、前記アンダーシールドとして要求される基
本的な特性である吸音機能については全く備えていな
い。従って、この様な成形品をアンダーシールド用の素
材として利用する際には、該成形品はあくまでも基板と
しての機能を期待し得るに止まり、その表面に上記と同
様のガラス繊維マットをアルミ箔等で包み込んだ吸音性
部材を接着剤等で接合した状態でアンダーシールドとし
て使用することになる。Fiber-reinforced resin molded products have the advantages of being inexpensive, resistant to rust, and excellent in recyclability, but on the other hand, they are completely equipped with a sound absorbing function which is a basic characteristic required for the undershield. Not not. Therefore, when such a molded product is used as a material for an undershield, the molded product can only be expected to function as a substrate, and a glass fiber mat similar to the above is used on the surface thereof such as an aluminum foil. The sound-absorbing member wrapped in the above will be used as an undershield in the state of being joined with an adhesive or the like.
【０００４】何れにしてもアンダーシールドは、基板の
表面にガラス繊維マットを主たる構成素材とする吸音性
部材を張り付けたものであるから、こうした構成から必
然的に生じてくる問題として、下記の如き様々な難点が
指摘される。 （１）基板に吸音性部材を接着剤等で張り付けなければ
ならないので、接合作業が煩雑で手数を要し、生産効率
の低下やコストアップの問題は避けられない。 （２）ガラス繊維マット等の張り付け作業時等にガラス
繊維の破断片が飛散し、作業者の皮膚を刺激したり環境
汚染を生じる。 （３）アンダーシールドを回収してリサイクルしようと
すると、夫々の構成素材であるアルミ箔、ガラス繊維マ
ット、基板を一旦分離しなければならず、その作業が非
常に煩雑で分別回収費用が嵩むため、工業規模でのリサ
イクルは殆ど行なわれていない。 上記欠点のうち殊に（３）のリサイクル性の問題は、産
業廃棄物の低減や有価資源の有効利用という観点から、
産業界で大きな問題となっている。In any case, since the undershield is formed by sticking a sound absorbing member mainly made of glass fiber mat on the surface of the substrate, the following problems are inevitably caused by such a structure. Various difficulties are pointed out. (1) Since the sound absorbing member has to be attached to the substrate with an adhesive or the like, the joining work is complicated and troublesome, and the problems of reduced production efficiency and increased cost cannot be avoided. (2) Fragments of glass fibers are scattered during sticking work of a glass fiber mat or the like, which may irritate the operator's skin or cause environmental pollution. (3) When recovering and recycling the undershield, the aluminum foil, the glass fiber mat, and the substrate, which are the respective constituent materials, have to be separated once, and the work is extremely complicated and the separate collection cost increases. However, recycling on an industrial scale is rarely performed. Among the above drawbacks, the problem of recyclability (3) is, from the viewpoint of reduction of industrial waste and effective use of valuable resources,
It has become a big problem in industry.
【０００５】尚、上記の様な吸音性部材の上下面に樹脂
フィルム等を張り付けた材料を一回の成形で得られる技
術についても提案されているが（例えば、特公平６−２
９７６号，特開平１−２８５４３２号，特開平５−３１
１５５５号等）、この様にして得られた成形品は、高剛
性という特性を十分に満足しているものではなく、アン
ダーシールド用の素材として利用できない。A technique has been proposed in which a material obtained by sticking a resin film or the like on the upper and lower surfaces of the sound absorbing member as described above can be obtained by a single molding (for example, Japanese Patent Publication No. 6-2.
976, JP-A-1-285432, and JP-A-5-31
No. 1555, etc.), the molded product thus obtained does not sufficiently satisfy the characteristic of high rigidity and cannot be used as a material for undershielding.
【０００６】[0006]
【発明が解決しようとする課題】本発明は、こうした状
況のもとでなされたものであって、その目的は、良好な
吸音特性と高剛性を兼ね備え、エンジンルームや車体下
部のノイズシールドやアンダーシールドとして有効に利
用することのでき、しかもリサイクル性にも優れた繊維
強化樹脂成形品を簡単な手順で生産性良く製造すること
のできる方法を提供することにある。SUMMARY OF THE INVENTION The present invention has been made under these circumstances, and its purpose is to combine good sound absorption characteristics with high rigidity, and to provide a noise shield and an undercarriage in the engine room and the lower part of the vehicle body. It is an object of the present invention to provide a method capable of effectively manufacturing a fiber-reinforced resin molded product that can be effectively used as a shield and is excellent in recyclability by a simple procedure with high productivity.
【０００７】[0007]
【課題を解決するための手段】上記目的を達成し得た本
発明方法とは、繊維強化樹脂積層成形品を製造するに当
たり、熱可塑性樹脂（ａ）と強化繊維を含む第１材料層
（Ａ）と、該熱可塑性樹脂よりも融点の高い熱可塑性樹
脂（ｂ）または該樹脂（ｂ）と強化繊維を含む第２材料
層（Ｂ）が積層された状態で、前記第２材料層（Ｂ）を
構成する熱可塑性樹脂（Ａ）の融点よりも高い温度で加
熱して可塑化した状態で加圧成形した後、前記第１材料
層（Ｂ）側の表層部が冷却・固化した状態或は溶融・半
溶融の状態で、前記熱可塑性樹脂（ｂ）の融点よりも低
く且つ熱可塑性樹脂（ａ）の融点よりも高い温度に加熱
することによって、前記第１材料層（Ａ）側の表面が、
強化繊維の弾性的復帰力によって、該繊維が起毛乃至膨
出した状態、および／または前記第１材料層（Ａ）側の
表面より深部側が、強化繊維の弾性的復帰力によって、
該強化繊維間に空隙が形成された状態とする点に要旨を
有するものである。Means for Solving the Problems The method of the present invention capable of achieving the above-mentioned object means that a first material layer (A) containing a thermoplastic resin (a) and a reinforcing fiber is used for producing a fiber-reinforced resin laminated molded article. ) And a thermoplastic resin (b) having a melting point higher than that of the thermoplastic resin or a second material layer (B) containing the resin (b) and a reinforcing fiber in a laminated state, the second material layer (B ) Is heated at a temperature higher than the melting point of the thermoplastic resin (A) and is pressure-molded in a plasticized state, and then the surface layer portion on the first material layer (B) side is cooled or solidified or Is in a molten / semi-molten state, and is heated to a temperature lower than the melting point of the thermoplastic resin (b) and higher than the melting point of the thermoplastic resin (a), whereby the first material layer (A) side The surface is
Due to the elastic restoring force of the reinforcing fibers, the fibers are fluffed or swollen, and / or the deeper side than the surface on the first material layer (A) side is due to the elastic restoring force of the reinforcing fibers.
The gist is that the voids are formed between the reinforcing fibers.
【０００８】また上記目的は、熱可塑性樹脂（ａ）と強
化繊維を含む材料層（Ｃ）と、該熱可塑性樹脂（ａ）よ
りも融点の高い熱可塑性樹脂（ｂ）または該樹脂（ｂ）
と強化繊維によって予め成形された基板層（Ｄ）が積層
された状態で、該基板層（Ｄ）を構成する熱可塑性樹脂
（ｂ）の軟化温度よりも低く且つ前記材料層（Ｃ）を構
成する熱可塑性樹脂（ａ）よりも高い温度で加熱して前
記材料層（Ｃ）を可塑化した状態で加圧成形した後、前
記材料層（Ｃ）側の表層部が冷却・固化した状態或は溶
融・半溶融の状態で、前記熱可塑性樹脂（ｂ）の融点よ
りも低く且つ熱可塑性樹脂（ａ）の融点よりも高い温度
に加熱することによって、前記材料層（Ｃ）側の表面
が、強化繊維の弾性的復帰力によって、該繊維が起毛乃
至膨出した状態、および／または前記材料層（Ｃ）側の
前記表面より深部側が、強化繊維の弾性的復帰力によっ
て、該強化繊維間に空隙が形成された状態とすることに
よっても達成される。[0008] Further, the above object is to provide a material layer (C) containing a thermoplastic resin (a) and reinforcing fibers, and a thermoplastic resin (b) or a resin (b) having a melting point higher than that of the thermoplastic resin (a).
And a substrate layer (D) formed in advance by reinforcing fibers are laminated, the temperature is lower than the softening temperature of the thermoplastic resin (b) constituting the substrate layer (D) and the material layer (C) is constituted. After the material layer (C) is pressure-molded while being heated at a temperature higher than that of the thermoplastic resin (a), the surface layer portion on the material layer (C) side is cooled or solidified or Is in a molten / semi-molten state and is heated to a temperature lower than the melting point of the thermoplastic resin (b) and higher than the melting point of the thermoplastic resin (a), so that the surface on the material layer (C) side is , The state in which the fibers are raised or bulged by the elastic restoring force of the reinforcing fibers, and / or the deeper side than the surface on the material layer (C) side, due to the elastic restoring force of the reinforcing fibers, It can also be achieved by forming voids in the
【０００９】[0009]
【作用】本発明者らは、繊維強化樹脂成形品において、
吸音機能を付与する為の具体的な形態について検討し
た。そして、強化繊維として主に利用されているガラス
繊維が有している弾性的復帰力に着目し、この弾性的復
帰力にを巧みに利用すれば一方側表面が前記強化繊維を
起毛乃至膨出した状態にする、および／または該表面の
深部側が該強化繊維間に空隙が形成された状態とするこ
とができ、この様な形態の繊維強化樹脂成形品は、吸音
機能が付与できることを見出した。In the fiber-reinforced resin molded product, the present inventors have
A specific form for imparting a sound absorbing function was examined. Then, paying attention to the elastic restoring force of the glass fiber which is mainly used as the reinforcing fiber, if one skillfully utilizes this elastic returning force, one surface bulges or swells the reinforcing fiber. It has been found that the fiber-reinforced resin molded article of such a form can be imparted with a sound absorbing function, by making it into a state of being formed and / or having a void formed between the reinforcing fibers on the deep side of the surface. .
【００１０】まずこの原理について説明する。繊維強化
樹脂成形品を製造するには、まず強化繊維と熱可塑性樹
脂を含む混合物を、加熱して可塑化した状態で低圧で加
圧成形して中間成形体とした後、冷却・固化されるが、
この冷却・固化の過程において、加圧成形に供された前
記可塑化混合物は、表面近傍から順次冷却・固化してい
くことになる。そもそも、前記可塑化混合物は、ガラス
繊維等の高剛性繊維が樹脂中にランダムに散らばったも
のを、暫定的にシート状またはブロック状にして可塑化
し、加圧成形に供するものである。従って、この中間成
形体の状態においては、高剛性繊維は既に加圧されて該
成形体の中に閉じ込められている状態になっており、可
塑化すれば強化繊維の弾性的復帰力で自ら体積膨張しよ
うとする。ところが、成形によって所定の形状を得るた
めには、当然のことながら、圧力をかけつつ冷却して形
状を保持する必要がある。従来の成形方法においては、
可塑化混合物を単に加圧して冷却し、形状を保持しよう
とするものであるから、中間成形体内に閉じ込められた
高剛性繊維は、その弾性的復帰力を発揮することなく、
中間成形体内に閉じ込められたままである。First, this principle will be described. In order to manufacture a fiber-reinforced resin molded product, first, a mixture containing a reinforcing fiber and a thermoplastic resin is heated and plasticized to form an intermediate molded product under low pressure, which is then cooled and solidified. But,
In the process of cooling and solidifying, the plasticized mixture subjected to pressure molding is sequentially cooled and solidified from near the surface. In the first place, the plasticized mixture is one in which high-rigidity fibers such as glass fibers are randomly dispersed in the resin, provisionally plasticized into a sheet or block, and subjected to pressure molding. Therefore, in the state of this intermediate molded body, the high-rigidity fiber is already in a state of being compressed and confined in the molded body, and if it is plasticized, it will self-volume due to the elastic return force of the reinforcing fiber. Trying to expand. However, in order to obtain a predetermined shape by molding, it is needless to say that it is necessary to cool while applying pressure to maintain the shape. In the conventional molding method,
Since the plasticized mixture is simply pressed and cooled to retain its shape, the high-rigidity fiber trapped in the intermediate molded body does not exert its elastic return force,
It remains trapped in the intermediate compact.
【００１１】成形前の可塑化状態をできるだけ損なわな
い様に、形状を整えるの必要な最低限の成形を行ない、
その後一方側表面の表層部が冷却・固化した状態 或は
溶融・半溶融の状態、即ち内部が未だ高温状態にあるう
ちに、（１）加圧力を解除または軽減して一方側表面に
高温ガスの吹きつけ等を行なって、溶融状態にすれば前
記強化繊維の弾性的復帰力が存分に発揮され、一方表面
で強化繊維が起毛乃至膨出した状態、および／または内
部が体積膨張しようとする現象（以下、この現象を「ス
プリングバック」と呼ぶ）が生じることによって、強化
繊維間に空隙が形成された状態（以下、この状態の層を
「スプリングバック層」と呼ぶ）とすることができる。
そして、これらの状態によって、吸音性が良好なものと
なる。The minimum molding necessary for adjusting the shape is carried out so as not to damage the plasticized state before molding as much as possible.
After that, while the surface layer of one side surface is cooled / solidified or in a molten / semi-melted state, that is, while the inside is still in a high temperature state, When the molten fiber is blown or the like to bring it into a molten state, the elastic restoring force of the reinforcing fiber is fully exerted, while the surface of the reinforcing fiber is raised or swelled, and / or the volume of the inside tends to expand. A phenomenon (hereinafter, this phenomenon is referred to as “springback”) occurs, and thus a state in which voids are formed between the reinforcing fibers (hereinafter, the layer in this state is referred to as a “springback layer”) can be obtained. it can.
Then, due to these states, the sound absorbing property becomes good.
【００１２】尚この様な状態を達成する為の加熱の具体
的手段については、特に限定されるものではなく、例え
ば赤外線加熱、高温金型や高温金属板等による直接加
熱、高温ガスの吹き付けによる加熱、更にはバーナによ
る加熱等が挙げられる。このうち、上記の様な状態が効
率良く達成されること、および加熱効率や加熱温度の調
整等を考慮すると、高温ガスの吹き付けによる加熱が最
も好ましい。またこのとき用いる高温ガスの種類につい
ても、特に限定されるものでなく、窒素ガスやＡｒガス
等の不活性ガスや空気等が挙げられる。The specific means of heating for achieving such a state is not particularly limited, and for example, infrared heating, direct heating by a high temperature mold or a high temperature metal plate, or blowing of a high temperature gas may be used. Heating, and further heating with a burner and the like can be mentioned. Of these, the heating by blowing a high-temperature gas is the most preferable in consideration of efficiently achieving the above-mentioned state, and adjusting the heating efficiency and the heating temperature. The type of high temperature gas used at this time is not particularly limited, and examples thereof include inert gas such as nitrogen gas and Ar gas, air, and the like.
【００１３】本発明者らは、上記の様な状態を有効に利
用し、良好な吸音特性と高剛性を兼ね備えた繊維強化樹
脂成形品を簡単な手順で製造すべく、様々な角度から検
討した。その結果、前述した方法に従って製造すれば、
希望する繊維強化樹脂成形品が１回の成形で得られるこ
とを見出し、本発明を完成した。The inventors of the present invention have studied from various angles in order to effectively utilize the above-mentioned state and to manufacture a fiber-reinforced resin molded product having good sound absorption characteristics and high rigidity by a simple procedure. . As a result, if manufactured according to the method described above,
The present invention has been completed by finding that the desired fiber-reinforced resin molded product can be obtained by molding once.
【００１４】本発明方法の基本的な手順およびその作用
について説明する。本発明方法においては、まず熱可塑
性性樹脂（ａ）と強化繊維を含む第１材料層（Ａ）と、
該熱可塑性樹脂よりも融点の高い熱可塑性樹脂（ｂ）と
強化繊維を含む第２材料層（Ｂ）が積層された状態で、
前記第２材料層（Ｂ）を構成する熱可塑性樹脂（ｂ）の
融点よりも高い温度で加熱して可塑化した状態で加圧成
形する。このとき、前記熱可塑性樹脂（ａ），（ｂ）は
いずれも可塑化しているので、容易に成形できることに
なる。The basic procedure of the method of the present invention and its operation will be described. In the method of the present invention, first, a first material layer (A) containing a thermoplastic resin (a) and reinforcing fibers,
In a state where a thermoplastic resin (b) having a higher melting point than the thermoplastic resin and a second material layer (B) containing reinforcing fibers are laminated,
It is heated and molded at a temperature higher than the melting point of the thermoplastic resin (b) constituting the second material layer (B) to be pressure-molded in a plasticized state. At this time, since the thermoplastic resins (a) and (b) are both plasticized, they can be easily molded.
【００１５】その後、前記第１材料層（Ａ）側の表層部
が冷却・固化した状態或は溶融・半溶融の状態で、前記
熱可塑性樹脂（ｂ）の融点より低く且つ熱可塑性樹脂
（ａ）よりも高い温度に加熱する。これによって、
（イ）前記第１材料層（Ａ）側の表面が、強化繊維の弾
性的復帰力によって、該繊維が起毛乃至膨出した状態、
および／または（ロ）前記第１材料層（Ａ）側の表面よ
り深部側が、強化繊維の弾性的復帰力によって、該強化
繊維に空隙が形成された状態、とすることができる。こ
れらの状態によって、最終的に製造された成形品は吸音
特性を有するものとなる。After that, in a state where the surface layer portion on the side of the first material layer (A) is cooled and solidified or in a state of being melted and semi-molten, the temperature is lower than the melting point of the thermoplastic resin (b) and the thermoplastic resin (a A) to a higher temperature. by this,
(A) The surface on the side of the first material layer (A) is in a state where the fibers are raised or swollen by the elastic restoring force of the reinforcing fibers,
And / or (b) The deeper side than the surface on the side of the first material layer (A) can be in a state where voids are formed in the reinforcing fibers due to the elastic restoring force of the reinforcing fibers. Due to these conditions, the finally manufactured molded product has a sound absorbing property.
【００１６】一方、第２材料層（Ｂ）は、可塑化した状
態で加圧成形した後は、熱可塑性樹脂（ｂ）は溶融され
ることなく、起毛乃至膨出やスプリングバックが発生す
ることなく、冷却・固化が進行するだけであり、この部
分については、高剛性を発揮することになる。尚第２材
料層（Ｂ）については、強化繊維を含まなくても希望す
る剛性が達成されるならば、熱可塑性樹脂（ｂ）だけで
構成されても良い。On the other hand, after the second material layer (B) is pressure-molded in a plasticized state, the thermoplastic resin (b) is not melted, and naps or swelling or springback occurs. However, only cooling and solidification proceed, and this part exhibits high rigidity. The second material layer (B) may be composed of only the thermoplastic resin (b) as long as the desired rigidity can be achieved without including reinforcing fibers.
【００１７】尚前記第２材料層（Ｂ）は、熱可塑性樹脂
（ｂ）、または該樹脂（ｂ）と強化繊維によって予め成
形された基板からなる層［前記基板層（Ｄ）］としても
良く、このときは、可塑化温度は前記熱可塑性樹脂
（ｂ）の軟化温度よりも低く且つ前記熱可塑性樹脂
（ａ）よりも高い温度とすれば良い。これによって予め
成形された基板層（Ｄ）を溶融させることなく、前記材
料層［材料層（Ｃ）］中の熱可塑性樹脂（ａ）を可塑化
することによって、成形が可能となる。The second material layer (B) may be a layer [the substrate layer (D)] composed of a thermoplastic resin (b) or a substrate preformed with the resin (b) and reinforcing fibers. At this time, the plasticizing temperature may be lower than the softening temperature of the thermoplastic resin (b) and higher than that of the thermoplastic resin (a). As a result, molding is possible by plasticizing the thermoplastic resin (a) in the material layer [material layer (C)] without melting the substrate layer (D) that has been molded in advance.
【００１８】本発明の上記工程において、加圧成形する
ときの具体的手段については、圧縮成形が代表的に挙げ
られるが、これに限らず、基板層を用いない場合は、例
えば射出成形や射出圧縮成形、更には他の成形方法を採
用することもでき、要するに加圧した状態で成形できる
方法であれば良い。また加圧成形するときの圧力は、材
料の流動性を確保するという観点から、例えば圧縮成形
の場合は、５０〜２００ｋｇｆ／ｃｍ2 程度が好まし
い。In the above-mentioned steps of the present invention, compression molding is representatively mentioned as a concrete means for pressure molding, but the present invention is not limited to this, and when the substrate layer is not used, for example, injection molding or injection molding. It is possible to employ compression molding and other molding methods as long as they can be molded in a pressurized state. The pressure at the time of pressure molding is preferably about 50 to 200 kgf / cm 2 in the case of compression molding, for example, from the viewpoint of ensuring the fluidity of the material.
【００１９】前記第１材料層（Ａ）や材料層（Ｃ）で
は、特に、強化繊維と熱可塑性樹脂（ａ）ができるだけ
均一に混合された材料を用いるのが好ましいが、この材
料は、エアーミキシング（圧縮空気による混合）によっ
て作成されたものの方が、強化繊維が３次元にランダム
に配向しているので、スプリングバック等が発生し易く
なり、好ましい材料である。これに対し、抄紙法によっ
て作成されたものや、２次元配向の連続繊維マットを原
料組成物として用いた場合には、強化繊維は２次元のラ
ンダム配向であるので、本発明方法を適用しても吸音特
性を発揮できるほど十分な起毛乃至膨出層および／また
はスプリングバック層が形成されにくく、あまり推奨さ
れる材料ではない。In the first material layer (A) and the material layer (C), it is particularly preferable to use a material in which the reinforcing fibers and the thermoplastic resin (a) are mixed as uniformly as possible, but this material is air. The material produced by mixing (mixing with compressed air) is a preferable material because the reinforcing fibers are three-dimensionally randomly oriented and springback and the like are more likely to occur. On the other hand, when a continuous fiber mat made by a papermaking method or a continuous fiber mat having a two-dimensional orientation is used as a raw material composition, the reinforcing fibers have a two-dimensional random orientation. In addition, it is difficult to form a raised or swelled layer and / or a springback layer sufficient to exhibit sound absorbing properties, and it is not a highly recommended material.
【００２０】本発明で用いる強化繊維の代表的なものと
してガラス繊維、炭素繊維、金属繊維、セラミックス繊
維、アラミド繊維、ポリアミド繊維、ポリエステル繊
維、ポリエステル繊維、アクリル繊維等の人工繊維が挙
げられ、これらを単独または複数組合せて用いることが
できるが、強化繊維の全てを人工繊維とする必要はな
く、例えば麻や綿の他、古紙を解繊したセルロース系繊
維等の天然繊維を一部に含んでいても良い。特に、古紙
を解繊したセルロース系繊維を利用することは、リサイ
クルおよび環境保護の両面からして有利であり、しかも
安価であり良好な吸音特性が発揮される。但し、第１材
料層（Ａ）や材料層（Ｃ）で用いる強化繊維としては、
弾性的復帰力が比較的小さい人工繊維や天然繊維の含有
量は強化繊維の弾性的復帰力を余り低下させない程度に
抑える必要がある。また強化繊維の径については、同じ
重量の場合には、径が細い方が本数が多くなり、嵩高く
なって起毛乃至膨出および／またはスプリングバックが
発生し易いので、３〜２０μｍ程度が最適である。更
に、強化繊維の長さについては、起毛乃至膨出および／
またはスプリングバック層による吸音特性を考慮する
と、５〜５０ｍｍであることが好ましい。Typical examples of the reinforcing fiber used in the present invention include artificial fibers such as glass fiber, carbon fiber, metal fiber, ceramic fiber, aramid fiber, polyamide fiber, polyester fiber, polyester fiber and acrylic fiber. Can be used alone or in combination, but it is not necessary to use all the reinforcing fibers as artificial fibers. For example, in addition to hemp and cotton, some natural fibers such as cellulose-based fibers obtained by disintegrating waste paper can be included. You may stay. In particular, the use of cellulosic fibers obtained by defibrating used paper is advantageous from the viewpoint of both recycling and environmental protection, is inexpensive, and exhibits good sound absorbing properties. However, as the reinforcing fibers used in the first material layer (A) and the material layer (C),
The content of artificial fibers or natural fibers having a relatively small elastic restoring force needs to be suppressed to the extent that the elastic restoring force of the reinforcing fibers is not significantly reduced. Regarding the diameter of the reinforcing fiber, when the weight is the same, the smaller the number is, the larger the number is and the more easily the fibers are raised and bulge and / or the spring back is generated. Is. Furthermore, regarding the length of the reinforcing fiber, raising or swelling and / or
Alternatively, considering the sound absorption characteristics of the springback layer, the thickness is preferably 5 to 50 mm.
【００２１】一方、本発明で用いられる熱可塑性樹脂
（ａ），（ｂ）としては、前記したポリプロピレンが代
表的なものとして挙げられるが、その他ポリエチレン、
ＡＢＳ、ポリエチレンテレフタレート、ポリカーボネー
ト、ポリスチレン、ポリアセタール、ポリアクリレー
ト、ポリアミド等の汎用樹脂、更にはポリスルホン、ポ
リフェニレンスルフィド、ポリエーテルエーテルケト
ン、ポリイミド、ポリアミドイミド等の耐熱性に優れた
熱可塑性樹脂等も用いることができる。このうち特に好
ましいのは、ポリプロピレンである。またこのポリプロ
ピレンは、ホモポリマーは勿論のこと、ポリプロピレン
−エチレンブロック共重合体、ポリプロピレン−エチレ
ンランダム共重合体、更には無水マレイン酸で変性した
ポリプロピレン等のいずれも使用でき、これらを単独ま
たは複合して用いれば良い。またこれらの熱可塑性樹脂
の原料形態は、粉末状または繊維状のいずれでも良い
が、特に熱可塑性樹脂（ａ）として用いる場合は、繊維
状であることが好ましい。また本発明で規定する融点の
関係を有していれば、熱可塑性樹脂（ａ），（ｂ）とし
て同種のものも用いることもできる。On the other hand, as the thermoplastic resins (a) and (b) used in the present invention, the above-mentioned polypropylene can be mentioned as a typical one.
General-purpose resins such as ABS, polyethylene terephthalate, polycarbonate, polystyrene, polyacetal, polyacrylate, polyamide, etc., as well as thermoplastic resins with excellent heat resistance such as polysulfone, polyphenylene sulfide, polyether ether ketone, polyimide, polyamide-imide, etc. You can Of these, polypropylene is particularly preferable. Further, as the polypropylene, not only a homopolymer but also a polypropylene-ethylene block copolymer, a polypropylene-ethylene random copolymer, and a polypropylene modified with maleic anhydride can be used, and these can be used alone or in combination. You can use it. The raw material form of these thermoplastic resins may be either powdery or fibrous, but when used as the thermoplastic resin (a), it is preferably fibrous. Further, if the thermoplastic resins (a) and (b) have the melting point relationship defined in the present invention, the same kind of thermoplastic resins can be used.
【００２２】本発明方法によって得られる繊維強化樹脂
成形品は、吸音性と剛性のいずれも良好なものとなり、
ノイズシールドやアンダーシールドとして有効に利用で
きるものとなる。また、本発明の成形品は、樹脂と強化
繊維のみを使用するものであるので、リサイクル性にお
いても良好である。The fiber-reinforced resin molded product obtained by the method of the present invention has good sound absorption and rigidity,
It can be effectively used as a noise shield or under shield. Further, since the molded product of the present invention uses only the resin and the reinforcing fiber, it has good recyclability.
【００２３】以下本発明を実施例によって更に詳細に説
明するが、下記実施例は本発明を限定する性質のもので
はなく、前・後記の趣旨に特徴して設計変更することは
いずれも本発明の技術的範囲に含まれるものである。The present invention will be described in more detail with reference to the following examples. The following examples are not intended to limit the present invention, and any modification of the design of the present invention is possible in view of the spirit of the preceding and following items. Are included in the technical scope of.
【００２４】[0024]
実施例１ 長さ１３ｍｍのチョップドガラス繊維（商品名「ＦＴ５
９９」，繊維径１３μｍ，旭ファイバーグラス株式会社
製）、ポリプロピレン樹脂パウダー（商品名「ＭＡ８１
０Ｂ」，昭和電工株式会社製）、およびマレイン酸変性
ポリプロピレンパウダー（商品名「ＥＲ３２０Ｐ」，昭
和電工株式会社製）を４０／５４／６（重量比）の割合
でガラス繊維束を開繊させながら圧縮空気を用いて混合
した綿状の材料を、２００℃にてホットプレスして３ｍ
ｍ厚みのシートにした。Example 1 Chopped glass fiber having a length of 13 mm (trade name "FT5"
99 ", fiber diameter 13 μm, manufactured by Asahi Fiber Glass Co., Ltd., polypropylene resin powder (trade name" MA81 "
0B ", manufactured by Showa Denko KK, and maleic acid-modified polypropylene powder (trade name" ER320P ", manufactured by Showa Denko KK) at a ratio of 40/54/6 (weight ratio) while opening the glass fiber bundle. The cotton-like material mixed with compressed air is hot pressed at 200 ° C for 3 m.
A m-thick sheet was prepared.
【００２５】一方、長さ１３ｍｍのチョップドガラス繊
維（商品名「ＦＴ５９９」，繊維径１３μｍ，旭ファイ
バーグラス株式会社製）とエチレン−酢酸ビニルコポリ
マー樹脂パウダー（商品名「ＦＭ２２−１」，昭和電工
株式会社製）を１／１（重量比）の割合で、上記場合と
同様に混合し、これを前記ポリプロピレン／ガラス繊維
シートの上にのせて１００℃にてホットプレスし、全体
で５ｍｍの厚みの成形体にした。On the other hand, a chopped glass fiber having a length of 13 mm (trade name "FT599", fiber diameter 13 μm, manufactured by Asahi Fiber Glass Co., Ltd.) and ethylene-vinyl acetate copolymer resin powder (trade name "FM22-1", Showa Denko KK (Manufactured by the company) in a ratio of 1/1 (weight ratio) in the same manner as in the above case, and this is placed on the polypropylene / glass fiber sheet and hot pressed at 100 ° C. to give a total thickness of 5 mm. It was made into a molded body.
【００２６】得られた成形体を２２０℃にて溶融し、１
００℃に設定した金型に投入して面圧１００ｋｇｆ／ｃ
ｍ2 で３０秒間圧縮した後、１１０℃の窒素ガスをエチ
レン−酢酸ビニルコポリマー樹脂／ガラス繊維層に３０
秒間吹きつけ、続けて室温の空気を吹きつけて冷却し
て、３ｍｍのポリプロピレン／ガラス繊維の固化層と、
６ｍｍ厚のエチレン−酢酸コポリマー樹脂／ガラス繊維
の起毛乃至膨出および／またはスプリング層からなる成
形品を得た。The obtained molded body was melted at 220 ° C. and
100kgf / c of surface pressure when put into the mold set at 00 ℃
After compressing at m 2 for 30 seconds, nitrogen gas at 110 ° C. is applied to the ethylene-vinyl acetate copolymer resin / glass fiber layer for 30 seconds.
For 3 seconds, followed by room temperature air for cooling and 3 mm polypropylene / glass fiber solidified layer,
A 6 mm thick molded product of ethylene-acetic acid copolymer resin / glass fiber nap or swelling and / or spring layer was obtained.
【００２７】得られた成形品について、ポリプロピレン
／ガラス繊維の固化層の曲げ弾性率を測定したところ、
約５．４ＧＰａであった。これは上記実施例で、３ｍｍ
厚みにしたポリプロピレン／ガラス繊維のシートのみを
２２０℃に溶融し、１００℃に設定した金型に投入して
面圧１００ｋｇｆ／ｃｍ2 で６０秒圧縮成形して得られ
た成形品の曲げ弾性率５．６ＧＰａとほぼ等しかった。
また１５００Ｈｚでの吸音率を測定したところ、吸音率
は０．５であった。The flexural modulus of the polypropylene / glass fiber solidified layer of the molded article thus obtained was measured.
It was about 5.4 GPa. This is the above embodiment, 3 mm
Bending elastic modulus of a molded product obtained by melting only a thick polypropylene / glass fiber sheet at 220 ° C., placing it in a mold set at 100 ° C. and compression-molding for 60 seconds at a surface pressure of 100 kgf / cm 2. It was almost equal to 5.6 GPa.
When the sound absorption coefficient at 1500 Hz was measured, the sound absorption coefficient was 0.5.
【００２８】[0028]
【発明の効果】本発明は以上の様に構成されており、良
好な吸音性と高剛性を兼ね備え、エンジンルームや車体
下部のノイズシールドやアンダーシールドとして有効に
利用することができ、しかもリサイクル性に優れた繊維
強化樹脂成形品を簡単な手順で生産性良く製造すること
ができた。EFFECT OF THE INVENTION The present invention is constituted as described above, and has good sound absorption and high rigidity, and can be effectively used as a noise shield or an under shield in the engine room and the lower part of the vehicle body, and is recyclable. It was possible to manufacture excellent fiber-reinforced resin molded products with high productivity by a simple procedure.
───────────────────────────────────────────────────── 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 Ｂ２９Ｋ 105:08 (72)発明者 奥村 俊明 兵庫県神戸市西区高塚台１丁目５番５号 株式会社神戸製鋼所神戸総合技術研究所内─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. 6 Identification number Internal reference number FI Technical indication B29K 105: 08 (72) Inventor Toshiaki Okumura 1-5-5 Takatsukadai, Nishi-ku, Kobe-shi, Hyogo Stock Kobe Steel Co., Ltd.Kobe Research Institute
Claims (2)
たり、熱可塑性樹脂（ａ）と強化繊維を含む第１材料層
（Ａ）と、該熱可塑性樹脂よりも融点の高い熱可塑性樹
脂（ｂ）または該樹脂（ｂ）と強化繊維を含む第２材料
層（Ｂ）が積層された状態で、前記第２材料層（Ｂ）を
構成する熱可塑性樹脂（ｂ）の融点よりも高い温度で加
熱して可塑化した状態で加圧成形した後、前記第１材料
層（Ａ）側の表層部が冷却・固化した状態或は溶融・半
溶融の状態で、前記熱可塑性樹脂（ｂ）の融点よりも低
く且つ熱可塑性樹脂（ａ）の融点よりも高い温度に加熱
することによって、前記第１材料層（Ａ）側の表面が、
強化繊維の弾性的復帰力によって、該繊維が起毛乃至膨
出した状態および／または前記第１材料層（Ａ）側の表
面より深部側が、強化繊維の弾性的復帰力によって、該
強化繊維間に空隙が形成された状態とすることを特徴と
する繊維強化樹脂成形品の製造方法。1. When manufacturing a fiber-reinforced resin laminated molded article, a first material layer (A) containing a thermoplastic resin (a) and reinforcing fibers, and a thermoplastic resin (b) having a melting point higher than that of the thermoplastic resin (b). Or a temperature higher than the melting point of the thermoplastic resin (b) constituting the second material layer (B) in a state where the second material layer (B) containing the resin (b) and the reinforcing fiber is laminated. After pressure molding in a heated and plasticized state, the thermoplastic resin (b) is melted in a state where the surface layer portion on the side of the first material layer (A) is cooled and solidified or in a molten and semi-molten state. By heating to a temperature lower than the melting point and higher than the melting point of the thermoplastic resin (a), the surface on the side of the first material layer (A) becomes
Due to the elastic restoring force of the reinforcing fibers, the fibers are fluffed or swollen and / or deeper than the surface on the first material layer (A) side is affected by the elastic restoring force of the reinforcing fibers between the reinforcing fibers. A method for producing a fiber-reinforced resin molded article, characterized in that a void is formed.
り、熱可塑性樹脂（ａ）と強化繊維を含む材料層（Ｃ）
と、該熱可塑性樹脂（ａ）よりも融点の高い熱可塑性樹
脂（ｂ）または該樹脂（ｂ）と強化繊維によって予め成
形された基板層（Ｄ）が積層された状態で、該基板層
（Ｄ）を構成する熱可塑性樹脂（ｂ）の軟化温度よりも
低く且つ前記材料層（Ｃ）を構成する熱可塑性樹脂
（ａ）よりも高い温度で加熱して前記材料層（Ｃ）を可
塑化した状態で加圧成形した後、前記材料層（Ｃ）側の
表層部が冷却・固化した状態或は溶融・半溶融の状態
で、前記熱可塑性樹脂（ｂ）の融点よりも低く且つ熱可
塑性樹脂（ａ）の融点よりも高い温度に加熱することに
よって、前記材料層（Ｃ）側の表面が、強化繊維の弾性
的復帰力によって、該繊維が起毛乃至膨出した状態、お
よび／または前記材料層（Ｃ）側の前記表面より深部側
が、強化繊維の弾性的復帰力によって、該強化繊維間に
空隙が形成された状態とすることを特徴とする繊維強化
樹脂成形品の製造方法。2. A material layer (C) containing a thermoplastic resin (a) and a reinforcing fiber in producing a fiber-reinforced resin molded article.
And a thermoplastic resin (b) having a melting point higher than that of the thermoplastic resin (a) or the resin (b) and a substrate layer (D) preformed by a reinforcing fiber are laminated, and the substrate layer ( The thermoplastic resin (b) constituting D) is heated at a temperature lower than the softening temperature of the thermoplastic resin (b) and higher than the thermoplastic resin (a) constituting the material layer (C) to plasticize the material layer (C). After pressure molding under the above condition, the surface layer portion on the side of the material layer (C) is in a state of being cooled / solidified or in a state of being molten / semi-molten, which is lower than the melting point of the thermoplastic resin (b) and is thermoplastic. By heating to a temperature higher than the melting point of the resin (a), the surface of the material layer (C) side is raised or swollen by the elastic restoring force of the reinforcing fibers, and / or The deeper side than the surface on the material layer (C) side elastically restores the reinforcing fibers. The method for producing a fiber-reinforced resin molded article, characterized by a state of voids between the reinforcing fibers are formed.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP7056653A JPH08224793A (en) | 1995-02-20 | 1995-02-20 | Manufacture of fiber reinforced resin molding |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP7056653A JPH08224793A (en) | 1995-02-20 | 1995-02-20 | Manufacture of fiber reinforced resin molding |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH08224793A true JPH08224793A (en) | 1996-09-03 |
Family
ID=13033337
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP7056653A Withdrawn JPH08224793A (en) | 1995-02-20 | 1995-02-20 | Manufacture of fiber reinforced resin molding |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH08224793A (en) |
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| JP2014070426A (en) * | 2012-09-28 | 2014-04-21 | Toyobo Co Ltd | Board for water cut-off door, and water gate, sluiceway, and sluice pipe having the same |
| JP2014125532A (en) * | 2012-12-26 | 2014-07-07 | Toray Ind Inc | Fiber reinforced resin sheet, molding, integrated molding, methods of producing the sheet and moldings, and packaging member |
| JP2014172201A (en) * | 2013-03-06 | 2014-09-22 | Toray Ind Inc | Fiber-reinforced resin sheet, integrated molding, method of producing the same and mounting member |
| WO2014162873A1 (en) * | 2013-04-02 | 2014-10-09 | 東レ株式会社 | Sandwich laminate, sandwich structure and unified molded product using same and processes for producing both |
| JP2015039842A (en) * | 2013-08-22 | 2015-03-02 | 東レ株式会社 | Fiber-reinforced resin sheet, integrated molding, and method for producing them |
| WO2015029634A1 (en) * | 2013-08-30 | 2015-03-05 | 東レ株式会社 | Sandwich structure and integrated molded article using same, as well as production methods therefor |
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-
1995
- 1995-02-20 JP JP7056653A patent/JPH08224793A/en not_active Withdrawn
Cited By (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2014070426A (en) * | 2012-09-28 | 2014-04-21 | Toyobo Co Ltd | Board for water cut-off door, and water gate, sluiceway, and sluice pipe having the same |
| JP2014125532A (en) * | 2012-12-26 | 2014-07-07 | Toray Ind Inc | Fiber reinforced resin sheet, molding, integrated molding, methods of producing the sheet and moldings, and packaging member |
| US10093777B2 (en) | 2012-12-26 | 2018-10-09 | Toray Industries, Inc. | Fiber-reinforced resin sheet, integrated molded product and process for producing same |
| JP2014172201A (en) * | 2013-03-06 | 2014-09-22 | Toray Ind Inc | Fiber-reinforced resin sheet, integrated molding, method of producing the same and mounting member |
| CN105073403A (en) * | 2013-04-02 | 2015-11-18 | 东丽株式会社 | Sandwich laminate, sandwich structure and unified molded product using same and processes for producing both |
| KR20150138202A (en) * | 2013-04-02 | 2015-12-09 | 도레이 카부시키가이샤 | Sandwich laminate, sandwich structure and unified molded product using same and processes for producing both |
| US20160303824A1 (en) * | 2013-04-02 | 2016-10-20 | Toray Industries ,Inc. | Sandwich laminate, sandwich structure and unified molded product using same and processes for producing both |
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| WO2014162873A1 (en) * | 2013-04-02 | 2014-10-09 | 東レ株式会社 | Sandwich laminate, sandwich structure and unified molded product using same and processes for producing both |
| US11059261B2 (en) | 2013-04-02 | 2021-07-13 | Toray Industries, Inc. | Sandwich laminate, sandwich structure and unified molded product using same and processes for producing both |
| US11969984B2 (en) | 2013-04-02 | 2024-04-30 | Toray Industries, Inc. | Sandwich laminate, sandwich structure and unified molded product using same and processes for producing both |
| JP2015039842A (en) * | 2013-08-22 | 2015-03-02 | 東レ株式会社 | Fiber-reinforced resin sheet, integrated molding, and method for producing them |
| WO2015029634A1 (en) * | 2013-08-30 | 2015-03-05 | 東レ株式会社 | Sandwich structure and integrated molded article using same, as well as production methods therefor |
| JPWO2015029634A1 (en) * | 2013-08-30 | 2017-03-02 | 東レ株式会社 | Sandwich structure, integrated molded product using the same, and manufacturing method thereof |
| US9962904B2 (en) | 2013-08-30 | 2018-05-08 | Toray Industries, Inc. | Sandwich structure and integrally formed article using the same, and methods for production thereof |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| A300 | Withdrawal of application because of no request for examination |
Free format text: JAPANESE INTERMEDIATE CODE: A300 Effective date: 20020507 |