JPH08276446A - Manufacture of molding composite material - Google Patents
Manufacture of molding composite materialInfo
- Publication number
- JPH08276446A JPH08276446A JP8235595A JP8235595A JPH08276446A JP H08276446 A JPH08276446 A JP H08276446A JP 8235595 A JP8235595 A JP 8235595A JP 8235595 A JP8235595 A JP 8235595A JP H08276446 A JPH08276446 A JP H08276446A
- Authority
- JP
- Japan
- Prior art keywords
- thermoplastic resin
- resin layer
- core material
- skin material
- film
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
Landscapes
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Nonwoven Fabrics (AREA)
- Finishing Walls (AREA)
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は芯材と表皮材との接着強
度が高く、軽量で賦形性に優れ、建築物、船舶、車両等
の内装材等として好適に使用される成形複合体の製造方
法に関する。FIELD OF THE INVENTION The present invention has a high adhesive strength between a core material and a skin material, is lightweight and has excellent shapeability, and is preferably used as an interior material for buildings, ships, vehicles and the like. Manufacturing method.
【０００２】[0002]
【従来の技術】内装材としては、例えば特開平２−５７
３３３号公報に記載のような、無機繊維が熱可塑性樹脂
で相互に接着されて板状に形成されたマット状物に、ホ
ットメルト接着剤層が全面に接着され、更に表皮材が接
着されてなる吸音材が知られている。ここで用いられる
ホットメルト接着剤層は、ポリオレフィン系、ポリアミ
ド系、ポリエステル系、ポリウレタン系等であり、０．
２〜３ｍｍの孔径を有し、開口率が０．５〜２０％の通
気性のものである。マット状物表面に該ホットメルト接
着剤層及び表皮材を接着するには、マット状物の表面温
度が熱可塑性樹脂の融点以上となるように加熱し、次に
この加熱した表面にホットメルト接着剤層と表皮材とを
接着する。或いは、ホットメルト接着剤と表皮材とを予
め加熱して接着するものである。このようにしてなる吸
音材を賦形するには、マット状物の熱可塑性樹脂及びホ
ットメルト接着剤層の融点以上の温度に加熱し、比較的
低温のプレス機でプレスすることが行われる。2. Description of the Related Art As an interior material, for example, Japanese Patent Application Laid-Open No. 2-57.
As described in Japanese Patent No. 333 gazette, a hot-melt adhesive layer is adhered over the entire surface to a mat-like material in which inorganic fibers are adhered to each other with a thermoplastic resin and formed into a plate shape, and further a skin material is adhered. The sound absorbing material is known. The hot melt adhesive layer used here is a polyolefin-based, polyamide-based, polyester-based, polyurethane-based, etc.
It has a hole diameter of 2 to 3 mm and an air permeability of 0.5 to 20%. To bond the hot-melt adhesive layer and the skin material to the surface of the mat-like material, the mat-like material is heated so that the surface temperature is equal to or higher than the melting point of the thermoplastic resin, and then the hot-melt adhesion is applied to the heated surface. The agent layer and the skin material are bonded together. Alternatively, the hot melt adhesive and the skin material are preheated to bond them. To shape the sound-absorbing material thus formed, heating is performed at a temperature higher than the melting points of the thermoplastic resin and the hot-melt adhesive layer of the mat-like material, and pressing is performed with a relatively low temperature press machine.
【０００３】[0003]
【発明が解決しようとする課題】上記公報に記載の吸音
材は、通気性を得るために多くの貫通孔を有するので、
マット状物と表皮材に対しては完全な全面接着ではな
く、ホットメルト接着剤層の開口部分は非接着状態であ
る。そして所定の形状に賦形された成形複合体の曲面部
分では、該接着剤層及びその貫通孔が引き伸ばされ、非
接着部分が拡大する。その結果、この部分の接着強度が
著しく低下して、マット状物と表皮材とが剥離し易くな
り、深いプレス成形や使用中の高温等、過酷な条件には
対応できなくなることがある。Since the sound absorbing material described in the above publication has many through holes in order to obtain air permeability,
The mat-like material and the skin material are not completely adhered to each other, and the opening portion of the hot melt adhesive layer is in a non-adhesive state. Then, in the curved surface portion of the molded composite shaped into a predetermined shape, the adhesive layer and the through hole thereof are stretched, and the non-bonded portion is expanded. As a result, the adhesive strength of this portion is remarkably reduced, the mat-like material and the skin material are easily separated, and it may not be possible to cope with severe conditions such as deep press molding and high temperature during use.
【０００４】又、上記吸音材を製造するには、マット状
物の表面温度が熱可塑性樹脂の融点以上となるように加
熱し、該表面にホットメルト接着剤層と表皮材とを接着
する工程と、これをプレス機に移してプレス成形する工
程とが必要である。ところが、加熱温度がホットメルト
接着剤層の融点以上であっても、その流動性が小さい場
合には表皮材との接着強度が十分確保できないことがあ
る。又、プレス機に移す間に熱可塑性樹脂の温度が融点
以下に下がるので、プレス成形する前に、マット状物と
表皮材とが貼り合わされたものを再び熱可塑性樹脂の融
点以上に加熱しなければならないという問題がある。In order to manufacture the above-mentioned sound absorbing material, a step of heating the mat-like material so that the surface temperature of the mat-like material is equal to or higher than the melting point of the thermoplastic resin, and bonding the hot-melt adhesive layer and the skin material to the surface. And a step of transferring this to a press machine and press-molding it. However, even if the heating temperature is equal to or higher than the melting point of the hot melt adhesive layer, if the fluidity is small, the adhesive strength with the skin material may not be sufficiently secured. Also, since the temperature of the thermoplastic resin falls below the melting point during transfer to the press machine, it is necessary to heat again the mat-like material and the skin material pasted together above the melting point of the thermoplastic resin before press molding. There is a problem that it must be.
【０００５】本発明は、上記従来の問題点を解消し、深
いプレス成形や過酷な条件にも耐え得るように芯材と表
皮材とが強固、且つ均一に接着され、接着と賦形とを一
工程で行うことができる成形複合体の製造方法を提供す
ることを目的とする。The present invention solves the above-mentioned problems of the prior art and firmly and evenly adheres the core material and the skin material so as to withstand deep press molding and harsh conditions. It is an object of the present invention to provide a method for producing a molded composite that can be performed in one step.
【０００６】[0006]
【課題を解決するための手段】請求項１記載の本発明成
形複合体の製造方法は、加熱加圧により賦形可能なシー
ト状の芯材に、メルトインデックスが８〜２０である熱
可塑性樹脂フィルムを重ね合わせ、該熱可塑性樹脂フィ
ルムをその樹脂の流れ度が３ｇ／１０分以上となる温度
に加熱、溶融し、該溶融樹脂面に表皮材を重ねて加圧す
ることにより、芯材と表皮材とを接着すると同時に賦形
するものである。According to the method for producing a molded composite of the present invention as set forth in claim 1, a thermoplastic resin having a melt index of 8 to 20 in a sheet-shaped core material which can be shaped by heating and pressing. The films are stacked, the thermoplastic resin film is heated and melted at a temperature at which the flow rate of the resin becomes 3 g / 10 minutes or more, and the skin material is overlaid on the surface of the molten resin to pressurize the core material and the skin. The material is bonded and shaped at the same time.
【０００７】請求項２記載の本発明成形複合体の製造方
法は、加熱加圧により賦形可能なシート状の芯材に、メ
ルトインデックスが８〜２０である熱可塑性樹脂層（ａ
１）と、該熱可塑性樹脂層（ａ１）よりも溶融温度の高
い耐熱樹脂層（ｂ）と、熱可塑性樹脂層（ｃ）とがこの
順に積層されてなる複合フィルムの層を重ね合わせ、層
（ａ１）を表皮材に重ね合わせるとともに、耐熱樹脂層
（ｂ）の融点以下であって、層（ａ１）の樹脂の流れ度
が３ｇ／１０分以上となる温度に加熱、溶融し、加圧す
ることにより、芯材と表皮材とを接着すると同時に賦形
するものである。According to a second aspect of the present invention, there is provided a thermoplastic resin layer (a) having a melt index of 8 to 20 on a sheet-shaped core material which can be shaped by heating and pressing.
1), a heat-resistant resin layer (b) having a melting temperature higher than that of the thermoplastic resin layer (a1), and a thermoplastic resin layer (c) are laminated in this order on top of each other to form a composite film layer, (A1) is superposed on the skin material, and is heated, melted, and pressed at a temperature not higher than the melting point of the heat-resistant resin layer (b) and the resin flow rate of the layer (a1) is 3 g / 10 minutes or more. As a result, the core material and the skin material are bonded and shaped at the same time.
【０００８】本発明で使用される芯材は加熱加圧により
賦形可能なもので、無機質繊維又は有機質繊維もしくは
これらの混合繊維が熱可塑性樹脂により相互に接着され
た不織布、又はこれら繊維による編布、織布が挙げられ
る。また、パルプからなる例えば厚紙、段ボール紙、チ
ップボード、更には、これらの２種以上が積層されたも
のも用いることができる。The core material used in the present invention can be shaped by heating and pressing, and is a non-woven fabric in which inorganic fibers, organic fibers or mixed fibers thereof are adhered to each other by a thermoplastic resin, or knitted with these fibers. Examples include cloth and woven cloth. In addition, for example, cardboard, corrugated paper, chipboard made of pulp, and a laminate of two or more of these can also be used.
【０００９】上記不織布、編布、織布（以下「布製品」
という）に用いられる無機質繊維としてはガラス繊維、
岩綿、石綿、炭素繊維等が挙げられ、有機質繊維として
は植物繊維、動物繊維などの天然繊維、セルロース系、
ポリアミド系、ポリエステル系、ポリアクリル系、ポリ
プロピレン系等の合成樹脂繊維が挙げられる。The above non-woven fabrics, knitted fabrics and woven fabrics (hereinafter referred to as "fabric products")
As the inorganic fiber used for the glass fiber,
Examples include rock fiber, asbestos, carbon fiber, and the like. Organic fibers include natural fibers such as plant fibers and animal fibers, cellulosic fibers,
Examples thereof include polyamide, polyester, polyacrylic, polypropylene, and other synthetic resin fibers.
【００１０】上記無機質繊維と有機質繊維とは適宜混抄
されたものでもよい。成形複合体の耐熱変形性、寸法安
定性等の点では無機質繊維を主体とするものが好まし
い。これら布製品の繊維密度は低すぎると強度が不足し
て破れ易く、高すぎると賦形し難くなるので、３００〜
７００ｇ／ｍ2 であることが好ましい。また、不織布の
場合には強度を高めるため、所望によりニードルパンチ
が施されてもよい。The inorganic fibers and the organic fibers may be appropriately mixed and made. From the viewpoint of heat distortion resistance and dimensional stability of the molded composite, it is preferable to mainly use inorganic fibers. If the fiber density of these cloth products is too low, the strength is insufficient and they are easily torn, and if too high, it becomes difficult to shape.
It is preferably 700 g / m 2 . Further, in the case of a non-woven fabric, needle punching may be performed if desired in order to increase the strength.
【００１１】不織布の繊維同士を相互に接着する熱可塑
性樹脂は、例えばポリエチレン、ポリプロピレン、飽和
ポリエステル、ポリアミド、ポリスチレン、ポリビニル
ブチラール等が挙げられ、粉末、繊維、エマルジョン等
の状態で用いることができる。不織布に嵩高さを付与し
たり、賦形性をよくするために合成樹脂繊維が用いられ
る場合には、該熱可塑性樹脂は合成樹脂繊維よりも融点
の低いものを用いるのが好ましい。Examples of the thermoplastic resin for adhering the fibers of the non-woven fabric to each other include polyethylene, polypropylene, saturated polyester, polyamide, polystyrene, polyvinyl butyral and the like, and they can be used in the form of powder, fiber, emulsion or the like. When synthetic resin fibers are used to impart bulkiness to the nonwoven fabric or to improve shapeability, it is preferable to use a thermoplastic resin having a melting point lower than that of the synthetic resin fibers.
【００１２】芯材側に重ねられる熱可塑性樹脂フィルム
もしくは複合フィルムの熱可塑性樹脂層が溶融しても、
芯材の種類、即ち材質や表面状態によっては、溶融樹脂
の芯材内部への含浸が不充分であったり、又は芯材との
接着性が悪い場合があるので、例えば芯材として段ボー
ル紙やチップボードを用いる場合には予めその表面を接
着可能な状態にする必要がある。そのため本発明では芯
材として上記の他に、上記芯材の片面もしくは両面に熱
可塑性樹脂層が設けられたものも芯材として用いられ
る。この熱可塑性樹脂層としては、ポリプロピレン、ポ
リエチレン、エチレン−酢酸ビニル共重合体、エチレン
−アクリル酸アミド共重合体、エチレン−アクリル酸エ
チル共重合体等のポリオレフィン系樹脂、ポリ塩化ビニ
ル、ポリアミド、ポリスチレン、ポリビニルブチラール
等が挙げられる。[0012] Even if the thermoplastic resin film of the core material side or the thermoplastic resin layer of the composite film is melted,
Depending on the type of core material, that is, the material and surface condition, the impregnation of the molten resin into the core material may be insufficient, or the adhesiveness with the core material may be poor. When using a chip board, it is necessary to make its surface ready to be bonded. Therefore, in the present invention, in addition to the above core material, a core material in which a thermoplastic resin layer is provided on one or both surfaces is also used as the core material. Examples of the thermoplastic resin layer include polyolefin resins such as polypropylene, polyethylene, ethylene-vinyl acetate copolymer, ethylene-acrylic acid amide copolymer, ethylene-ethyl acrylate copolymer, polyvinyl chloride, polyamide, polystyrene. , Polyvinyl butyral and the like.
【００１３】芯材と表皮材とを貼り合わせる熱可塑性樹
脂フィルム又は複合フィルムの熱可塑性樹脂層は、ホッ
トメルト型接着剤として用いられるものが選択でき、こ
のようなものとしては、メルトインデックスが８〜２０
である高密度ポリエチレン、中低密度ポリエチレン、線
状低密度ポリエチレン、ポリプロピレン、エチレン−酢
酸ビニル共重合体等のポリオレフィン系樹脂の１種又は
２種以上の混合物、ポリアミド、ポリ塩化ビニル、及び
これら熱可塑性樹脂の酸変性物等が挙げられる。The thermoplastic resin layer of the thermoplastic resin film or the composite film for laminating the core material and the skin material can be selected from those used as hot melt type adhesives, and such a material has a melt index of 8 ~ 20
High density polyethylene, medium low density polyethylene, linear low density polyethylene, polypropylene, one or a mixture of two or more polyolefin resins such as ethylene-vinyl acetate copolymer, polyamide, polyvinyl chloride, and these heats. Examples thereof include acid-modified plastic resins.
【００１４】上記熱可塑性樹脂フィルム又は複合フィル
ムの熱可塑性樹脂層に使用される熱可塑性樹脂のメルト
インデックスは８〜２０であり、メルトインデックスが
８未満では、成形後の表皮材と芯材との接着強度が充分
に得られず、メルトインデックスが２０を超えると、表
皮材や芯材との界面における気泡の巻き込み等によって
表面の平滑性が充分に得られない。The thermoplastic resin used in the thermoplastic resin layer of the above-mentioned thermoplastic resin film or composite film has a melt index of 8 to 20, and when the melt index is less than 8, the skin material and the core material after molding are formed. If the adhesive strength cannot be sufficiently obtained and the melt index exceeds 20, the surface smoothness cannot be sufficiently obtained due to the inclusion of bubbles at the interface with the skin material or the core material.
【００１５】上記複合フィルムにおいて、メルトインデ
ックスが８〜２０である熱可塑性樹脂層（ａ１）と耐熱
樹脂層（ｂ）との間に、更に接着層（ａ２）が設けられ
てもよいが、これらの接着層（ａ２）に使用される樹脂
としては、例えば、酸変性ポリエチレン、酸変性エチレ
ン−酢酸ビニル共重合体等が挙げられ、酸変性ポリエチ
レンのベースになるポリエチレンとしては直鎖状低密度
ポリエチレン又は高密度ポリエチレンが好ましい。上記
接着層（ａ２）は耐熱樹脂層（ｂ）と熱可塑性樹脂層
（ｃ）との間にも設けることが好ましい。In the above composite film, an adhesive layer (a2) may be further provided between the thermoplastic resin layer (a1) having a melt index of 8 to 20 and the heat resistant resin layer (b). Examples of the resin used for the adhesive layer (a2) include acid-modified polyethylene, acid-modified ethylene-vinyl acetate copolymer, and the like. As a base of acid-modified polyethylene, linear low-density polyethylene is used. Alternatively, high density polyethylene is preferred. The adhesive layer (a2) is preferably provided also between the heat resistant resin layer (b) and the thermoplastic resin layer (c).
【００１６】複合フィルムの耐熱樹脂層（ｂ）は前記熱
可塑性樹脂層（ａ１）、接着層（ａ２）及び熱可塑性樹
脂層（ｃ）よりも溶融温度が３０℃以上、好ましくは５
０℃以上高いものが好ましい。これにより芯材、複合フ
ィルム、表皮材との積層物全体を加熱して耐熱樹脂層
（ｂ）以外の樹脂層を溶融させることができる。The heat-resistant resin layer (b) of the composite film has a melting temperature of 30 ° C. or higher, preferably 5 or more than that of the thermoplastic resin layer (a1), adhesive layer (a2) and thermoplastic resin layer (c).
It is preferably higher than 0 ° C. This makes it possible to heat the entire laminate of the core material, the composite film, and the skin material to melt the resin layers other than the heat-resistant resin layer (b).
【００１７】このような耐熱樹脂層（ｂ）の樹脂として
は、例えばポリブチレンテレフタレート、ポリエチレン
テレフタレート、ポリカーボネート、ポリアミド等、及
びこれらの変性物等の耐熱樹脂が挙げられる。このう
ち、接着層（ａ２）に使用される酸変性ポリオレフィン
との接着強度を大きくできる点で、最も好ましいのは極
性の大きいポリアミドである。Examples of the resin of the heat resistant resin layer (b) include heat resistant resins such as polybutylene terephthalate, polyethylene terephthalate, polycarbonate, polyamide, and modified products thereof. Of these, polyamide having the highest polarity is most preferable because it can increase the adhesive strength with the acid-modified polyolefin used for the adhesive layer (a2).
【００１８】熱可塑性樹脂層（ｃ）に関しては、芯材表
面の熱可塑性樹脂と熱融着するものであればよく、この
ような樹脂としては、高密度ポリエチレン、中低密度ポ
リエチレン、線状低密度ポリエチレン、ポリプロピレ
ン、エチレン−酢酸ビニル共重合体等のポリオレフィン
系樹脂の１種又は２種以上の混合物、ポリアミド、ポリ
塩化ビニル、及びこれら熱可塑性樹脂の酸変性物等が挙
げられる。With respect to the thermoplastic resin layer (c), any material may be used as long as it can be heat-sealed with the thermoplastic resin on the surface of the core material. Examples of such resin include high density polyethylene, medium and low density polyethylene, and linear low Examples thereof include one or a mixture of two or more polyolefin resins such as density polyethylene, polypropylene, and ethylene-vinyl acetate copolymer, polyamide, polyvinyl chloride, and acid-modified products of these thermoplastic resins.
【００１９】複合フィルムの製造方法は特に限定される
ものではなく、共押出法、押出ラミネート法、ドライラ
ミネート法等が適用される。好ましくは，インフレーシ
ョン法やＴダイ法等の共押出法が採用される。The method for producing the composite film is not particularly limited, and a coextrusion method, an extrusion laminating method, a dry laminating method and the like are applied. Preferably, a coextrusion method such as an inflation method or a T-die method is adopted.
【００２０】本発明で使用される表皮材は植物繊維、動
物繊維などの天然繊維、セルロース系、ポリアミド系、
ポリエステル系、ポリアクリル系、ポリプロピレン系等
の合成樹脂繊維等からなる織布もしくは不織布が好適に
用いられる。このような織布もしくは不織布等の繊維系
の表皮材を用いると、熱可塑性樹脂フィルム或いは複合
フィルムの熱可塑性樹脂層（ａ１）が溶融して繊維間に
食い込むアンカー効果により芯材との接着強度が大とな
る。また、例えばポリウレタン発泡体のように連続気泡
を有する発泡シートを織布もしくは不織布の芯材と貼り
合わせる面に設けておけば、芯材の凹凸を吸収し、表皮
材表面の意匠性を高め、且つクッション性を付与するこ
ともできる。表皮材の厚みは１〜２ｍｍのものが適当で
ある。Skin materials used in the present invention include natural fibers such as plant fibers and animal fibers, cellulosics, polyamides,
Woven or non-woven fabrics made of synthetic resin fibers such as polyester, polyacrylic and polypropylene are preferably used. When such a fiber-based skin material such as woven cloth or non-woven cloth is used, the thermoplastic resin layer (a1) of the thermoplastic resin film or the composite film is melted and the adhesive effect with the core material is caused by the anchoring effect which penetrates between the fibers. Is large. Further, if a foamed sheet having open cells such as polyurethane foam is provided on the surface to be bonded to the core material of the woven or non-woven fabric, the unevenness of the core material is absorbed, and the design of the surface of the skin material is improved, Moreover, cushioning properties can be imparted. A skin material having a thickness of 1 to 2 mm is suitable.
【００２１】本発明でいう流れ度とは、ＪＩＳ Ｋ ７
２１０に規定される測定条件のうち温度を除くすべての
条件を採用したときの、所定温度における１０分間に押
出される樹脂の質量として定義する。従って、本発明で
は熱可塑性樹脂フィルム或いは複合フィルムの熱可塑性
樹脂層（ａ１）のこの数値が３ｇ／１０分以上となる接
着温度を採用することが必要である。これにより溶融状
態において流動性がよく充分な接着力が確保されるとと
もに、深い賦形がなされる場合でも全面を均一な接着状
態に保ちながら充分対応し得るという効果が顕著であ
る。The flow rate in the present invention means JIS K 7
It is defined as the mass of the resin extruded in 10 minutes at a predetermined temperature when all the measurement conditions defined in 210 except temperature are adopted. Therefore, in the present invention, it is necessary to adopt an adhesive temperature at which this value of the thermoplastic resin layer (a1) of the thermoplastic resin film or the composite film is 3 g / 10 minutes or more. As a result, the effect that the fluidity is good in the molten state and a sufficient adhesive force is secured, and that even when deep shaping is performed, it is possible to sufficiently deal with it while maintaining a uniform adhesive state on the entire surface.
【００２２】本発明成形複合体の製造方法では、熱可塑
性樹脂フィルム又は複合フィルムの熱可塑性樹脂層
（ｃ）を芯材に重ね、熱可塑性樹脂フィルム又は複合フ
ィルムの熱可塑性樹脂層（ａ１）、（ｃ）が溶融状態の
ままで表皮材を重ねて賦形することが必要である。即
ち、加熱による熱可塑性樹脂フィルム又は熱可塑性樹脂
層（ｃ）と熱可塑性樹脂（ａ１）の溶融による芯材と表
皮材との接着と、所望の形状に賦形することを同時に行
うので一工程だけで成形複合体を得ることができる。ま
た、接着のために加熱し、賦形時にも加熱するという無
駄をなくすこともできる。In the method for producing the molded composite of the present invention, the thermoplastic resin layer (c) of the thermoplastic resin film or the composite film is laminated on the core material, and the thermoplastic resin layer (a1) of the thermoplastic resin film or the composite film, It is necessary to stack and shape the skin material while (c) remains in the molten state. That is, since the thermoplastic resin film or the thermoplastic resin layer (c) and the thermoplastic resin (a1) are melted by heating, the core material and the skin material are adhered to each other, and a desired shape is formed at the same time. A molded composite can be obtained by itself. Further, it is possible to eliminate the waste of heating for bonding and heating during shaping.
【００２３】加熱の手段は赤外線ヒーター、遠赤外線ヒ
ーター、熱風、電熱等種々のものが使用できるが、遠赤
外線ヒーターを用いるのが好ましい。Various means such as an infrared heater, a far infrared heater, hot air, and electric heating can be used as the heating means, but the far infrared heater is preferably used.
【００２４】[0024]
【作用】本発明成形複合体の製造方法は、熱可塑性樹脂
フィルム或いは複合フィルムの熱可塑性樹脂層（ａ１）
の流れ度が３ｇ／１０分以上となる加熱接着温度を採用
するとともに、同時に加圧しながら賦形するものである
から、該熱可塑性樹脂フィルム或いは複合フィルムの熱
可塑性樹脂層（ａ１）は溶融状態において流動性がよい
ので賦形され易く、曲部における芯材または表皮材の変
形に伴う伸縮に追随し、接着面において該フィルムが破
断したりせず、芯材の繊維組織に食い込み、完全且つ均
一な面接着状態が保たれる。このため芯材と表皮材との
接着強度が強い成形複合体が得られる。The method for producing a molded composite according to the present invention comprises a thermoplastic resin film or a thermoplastic resin layer (a1) of a composite film.
The thermoplastic resin layer (a1) of the thermoplastic resin film or the composite film is in a molten state because it is formed by applying a heating and adhesion temperature at which the flow rate of 3 g / 10 min or more and simultaneously applying pressure. Since it has good fluidity in, it is easily shaped, follows the expansion and contraction due to the deformation of the core material or the skin material in the curved portion, does not break the film at the adhesive surface, bites into the fiber structure of the core material, and A uniform surface adhesion state is maintained. Therefore, a molded composite body having a strong adhesive strength between the core material and the skin material can be obtained.
【００２５】又、上記複合フィルムの熱可塑性樹脂層
（ａ１）と熱可塑性樹脂層（ｃ）との間に上記熱可塑性
樹脂層（ａ１）よりも溶融温度の高い耐熱樹脂層（ｂ）
を介在することにより、該耐熱樹脂層（ｂ）は上記熱可
塑性樹脂層（ａ１）及び熱可塑性樹脂層（ｃ）と強固に
積層されながらも熱溶融することがないので、上記成形
複合体の通気の遮断性は確実なものとなる。Further, between the thermoplastic resin layer (a1) and the thermoplastic resin layer (c) of the composite film, a heat-resistant resin layer (b) having a higher melting temperature than that of the thermoplastic resin layer (a1).
Since the heat-resistant resin layer (b) is firmly laminated with the thermoplastic resin layer (a1) and the thermoplastic resin layer (c) by interposing, the heat-resistant resin layer (b) is not melted by heat. Ventilation is surely blocked.
【００２６】[0026]
【実施例】次に本発明の実施例を図面を参照しながら説
明する。 （実施例１）Embodiments of the present invention will now be described with reference to the drawings. (Example 1)
【００２７】芯材１１としては、ガラス繊維（直径２０
〜４０μｍ、長さ２０〜１００ｍｍ）７０重量部とポリ
エステル繊維（６デニール、長さ２０〜８０ｍｍ）３０
重量部を混抄してウェブ状にしたものに、ニードルパン
チ（密度３０点／ｍ2 ）を施した厚さ約９ｍｍ、重さ５
００ｇ／ｍ2 のフェルト状物を用い、これを熱可塑性樹
脂エマルジョン貯槽中に通してエマルジョンを含浸させ
た後、挟着ロールに通して上記エマルジョン量を固形分
で３０ｇ／ｍ2 に調整し、これを熱風乾燥装置内で約１
００℃で加熱してエマルジョン中の水分を乾燥するとと
もに、フェルト状物中に含浸、分散された熱可塑性樹脂
で繊維同士を部分的に結着せしめた不織布からなるもの
である。As the core material 11, glass fiber (diameter 20
˜40 μm, length 20-100 mm) 70 parts by weight and polyester fiber (6 denier, length 20-80 mm) 30
Needle punching (density of 30 points / m 2 ) was applied to a web made by mixing parts by weight. Thickness of about 9 mm, weight of 5
A felt-like material of 00 g / m 2 was used, which was passed through a thermoplastic resin emulsion storage tank to be impregnated with the emulsion, and then passed through a sandwich roll to adjust the amount of the emulsion to 30 g / m 2 in terms of solid content, Approximately 1 of this in a hot air dryer
It is composed of a non-woven fabric in which fibers are partially bound by a thermoplastic resin impregnated and dispersed in a felt-like material while heating the emulsion to dry water in the emulsion.
【００２８】図１は請求項１記載の本発明成形複合体の
製造方法の実施例を示す断面図であり、ガラス繊維を主
体としポリエステル繊維が混抄された不織布よりなる芯
材１１及び溶融温度１２５℃、メルトインデックス（Ｍ
Ｉ）が２０の線状低密度ポリエチレン（ＬＬＤＰＥ）フ
ィルム１２を、５０℃に加熱した下金型４１（賦形深さ
１５ｍｍ）内に入れ、遠赤外線ヒーター（１ｋＷ）３、
３、・・・により厚さ７０μｍのＬＬＤＰＥフィルム１
２面を表１に示す各温度に加熱し、この上にポリエステ
ル繊維を用いた不織布（繊維密度１８０ｇ／ｍ2 ）から
なる表皮材１３を重ね、直ちに図１Ｂに示すように上金
型４を閉じて４ｋｇ／cm2 の圧力で加熱加圧して賦形し
た。このときの加圧時間は２０秒、金型のクリアランス
は５ｍｍとした。FIG. 1 is a cross-sectional view showing an embodiment of the method for producing a molded composite of the present invention according to claim 1, which is a core material 11 made of a non-woven fabric mainly composed of glass fibers and mixed with polyester fibers, and a melting temperature 125. ℃, melt index (M
The linear low density polyethylene (LLDPE) film 12 having I) of 20 was placed in the lower mold 41 (forming depth 15 mm) heated to 50 ° C., and the far infrared heater (1 kW) 3,
3, ... by 70 μm thick LLDPE film 1
The two surfaces were heated to the respective temperatures shown in Table 1, and a skin material 13 made of a non-woven fabric using polyester fibers (fiber density 180 g / m 2 ) was laid on this, and immediately the upper mold 4 was placed as shown in FIG. 1B. It was closed and heated and pressed at a pressure of 4 kg / cm 2 to shape. The pressing time at this time was 20 seconds, and the mold clearance was 5 mm.
【００２９】上記成形によって、芯材１１及び表皮材１
３が該ＬＬＤＰＥフィルム１２により全面接着され、Ｌ
ＬＤＰＥフィルム１２は溶融された状態で加圧により賦
形されたので、芯材１１及び表皮材１３にその一部が含
浸されて一体化し、図１Ｃに示すように成形複合体１が
作製された。脱型して得られた成形複合体１について以
下のような評価試験を行った。その結果を併せて表１に
示す。By the above molding, the core material 11 and the skin material 1
3 is adhered to the entire surface by the LLDPE film 12,
Since the LDPE film 12 was shaped by pressing in a molten state, the core material 11 and the skin material 13 were partially impregnated and integrated, and the molded composite body 1 was produced as shown in FIG. 1C. . The following evaluation test was performed on the molded composite body 1 obtained by demolding. The results are also shown in Table 1.
【００３０】接着性試験：芯材と表皮材との端部を剥離
し、８５℃雰囲気下において一方を固定、他方に１０ｇ
／ｍｍの静荷重を架けた状態で１８０度剥離試験を行
い、破壊する場合を×、破壊しない場合は○とする。Adhesion test: The core material and the skin material were peeled off at the ends, and one was fixed in an atmosphere of 85 ° C. and the other 10 g.
A 180-degree peel test is performed with a static load of / mm applied, and x indicates failure, and o indicates not.
【００３１】（実施例２）ＭＩ＝２０のＬＬＤＰＥに代
えて、溶融温度１３０℃、ＭＩ＝１５の高密度ポリエチ
レン（ＨＤＰＥ）を用いたこと以外は実施例１同様に成
形複合体を得、評価試験を行った。その結果を併せて表
１に示す。Example 2 A molded composite was obtained and evaluated in the same manner as in Example 1 except that high density polyethylene (HDPE) having a melting temperature of 130 ° C. and MI = 15 was used in place of LLDPE having MI = 20. The test was conducted. The results are also shown in Table 1.
【００３２】（比較例１）ＭＩ＝２０のＬＬＤＰＥに代
えて、溶融温度１２５℃、ＭＩ＝５のＬＬＤＰＥを用い
たこと以外は実施例１同様に成形複合体を得、評価試験
を行った。その結果を併せて表１に示す。Comparative Example 1 A molded composite was obtained in the same manner as in Example 1 except that LLDPE having a melting temperature of 125 ° C. and MI = 5 was used instead of LLDPE having MI = 20, and an evaluation test was conducted. The results are also shown in Table 1.
【００３３】（実施例３）図２は請求項２記載の本発明
成形複合体の実施例を示す断面図であり、この成形複合
体２は実施例１で用いられたＬＬＤＰＥフィルム１２の
代わりに、図２に示す複合フィルム２０が用いられた以
外は実施例１と同じ構成のものであり、ＬＬＤＰＥ樹脂
層２１が表皮材１３に、溶融温度２２５℃（耐熱性）の
ポリアミド樹脂層２３が酸変性線状低密度ポリエチレン
樹脂層２２及びＨＤＰＥ樹脂層２４でサンドイッチ状に
積層されて芯材１１にそれぞれ全面接着され、ＬＬＤＰ
Ｅ樹脂層２１及びＨＤＰＥ樹脂層２４は溶融された状態
で芯材１１及び表皮材１３に加圧賦形されるので、芯材
１１及び表皮材１３にその一部が含浸されて成形複合体
２が作製された。(Example 3) FIG. 2 is a cross-sectional view showing an example of the molded composite of the present invention according to claim 2, and this molded composite 2 is replaced by the LLDPE film 12 used in Example 1. 2 has the same configuration as that of Example 1 except that the composite film 20 shown in FIG. 2 is used. The LLDPE resin layer 21 is the skin material 13, and the polyamide resin layer 23 having a melting temperature of 225 ° C. (heat resistance) is an acid. The modified linear low-density polyethylene resin layer 22 and the HDPE resin layer 24 are laminated in a sandwich shape and are entirely adhered to the core material 11, respectively, and LLDP is used.
Since the E resin layer 21 and the HDPE resin layer 24 are pressure-molded to the core material 11 and the skin material 13 in a molten state, the core material 11 and the skin material 13 are partially impregnated to form the molded composite 2 Was created.
【００３４】上記複合フィルム２０は、溶融温度１２５
℃、ＭＩ＝２０のＬＬＤＰＥ樹脂層（厚さ７０μｍ）２
１、ＭＩ＝３の酸変性ＬＬＤＰＥ樹脂層（厚さ１０μ
ｍ）２２、溶融温度２２５℃のポリアミド樹脂層（厚さ
１０μｍ）２３、ＭＩ＝１のＨＤＰＥ樹脂層（厚さ１０
０μｍ）５２が共押出成形によりこの順に積層されてな
るものである。得られた成形複合体２について評価試験
を行った。その結果を併せて表１に示す。The composite film 20 has a melting temperature of 125.
LLDPE resin layer (thickness 70 μm) at ℃ and MI = 20 2
1, MI = 3 acid-modified LLDPE resin layer (thickness 10μ
m) 22, a polyamide resin layer with a melting temperature of 225 ° C. (thickness 10 μm) 23, an HDPE resin layer with MI = 1 (thickness 10).
0 μm) 52 are laminated in this order by coextrusion molding. An evaluation test was performed on the obtained molded composite body 2. The results are also shown in Table 1.
【００３５】又、表１に示す各接着温度に加熱して得ら
れた成形複合体の芯材と表皮材との接着強度について、
常温で引張速度２００ｍｍ／分の１８０度剥離強度を測
定し、併せて表１に示した。Regarding the adhesive strength between the core material and the skin material of the molded composite obtained by heating at the respective adhesive temperatures shown in Table 1,
The 180-degree peel strength at a tensile speed of 200 mm / min was measured at room temperature and is also shown in Table 1.
【００３６】（実施例４）ＭＩ＝２０のＬＬＤＰＥに代
えて、溶融温度１３０℃、ＭＩ＝１５の高密度ポリエチ
レン（ＨＤＰＥ）を用いたこと以外は実施例３同様に成
形複合体を得、評価試験を行った。その結果を併せて表
１に示す。Example 4 A molded composite was obtained and evaluated in the same manner as in Example 3 except that high density polyethylene (HDPE) having a melting temperature of 130 ° C. and MI = 15 was used in place of LLDPE having MI = 20. The test was conducted. The results are also shown in Table 1.
【００３７】（比較例２）ＭＩ＝２０のＬＬＤＰＥに代
えて、溶融温度１２５℃、ＭＩ＝５のＬＬＤＰＥを用い
たこと以外は実施例３同様に成形複合体を得、評価試験
を行った。その結果を併せて表１に示す。(Comparative Example 2) A molded composite was obtained and evaluated in the same manner as in Example 3 except that LLDPE having a melting temperature of 125 ° C and MI = 5 was used in place of LLDPE having MI = 20. The results are also shown in Table 1.
【００３８】[0038]
【表１】 [Table 1]
【００３９】[0039]
【発明の効果】本発明複合成形体の製造方法は叙上の通
りであり、芯材と表皮材とが完全且つ均一に全面接着さ
れ、凹部や凸部においても接着強度が非常に優れたもの
となる。また、溶融樹脂面に表皮材を重ねると同時に加
圧して、芯材と表皮材との接着と賦形とを同時に行うの
で、一工程だけで成形複合体を得ることができる。その
ため、接着工程の後で賦形時にもう一度加熱するという
無駄をなくすこともできる。The method for producing the composite molded article of the present invention is as described above, and the core material and the skin material are completely and uniformly adhered to each other, and the adhesive strength is very excellent even in the concave and convex portions. Becomes In addition, since the skin material is superposed on the surface of the molten resin and pressed at the same time, the core material and the skin material are bonded and shaped at the same time, so that the molded composite body can be obtained in only one step. Therefore, it is possible to eliminate the waste of heating again during shaping after the bonding step.
【００４０】又、上記複合フィルムの熱可塑性樹脂層
（ａ１）と熱可塑性樹脂層（ｃ）との間に上記熱可塑性
樹脂層（ａ１）よりも溶融温度の高い耐熱樹脂層（ｂ）
を介在することにより、該耐熱樹脂層（ｂ）は上記熱可
塑性樹脂層（ａ１）及び熱可塑性樹脂層（ｃ）と強固に
積層されながらも熱溶融することがないので、上記成形
複合体の通気の遮断性は確実なものとなる。Further, between the thermoplastic resin layer (a1) and the thermoplastic resin layer (c) of the composite film, a heat-resistant resin layer (b) having a higher melting temperature than the thermoplastic resin layer (a1).
Since the heat-resistant resin layer (b) is firmly laminated with the thermoplastic resin layer (a1) and the thermoplastic resin layer (c) by interposing, the heat-resistant resin layer (b) is not melted by heat. Ventilation is surely blocked.
【００４１】[0041]
【図１】請求項１記載の本発明の成形複合体の製造方法
の実施例を示す断面図である。FIG. 1 is a cross-sectional view showing an example of a method for producing a molded composite body according to the first aspect of the present invention.
【図２】請求項２記載の本発明の成形複合体の製造方法
の実施例を示す断面図である。FIG. 2 is a cross-sectional view showing an embodiment of the method for producing the molded composite body of the present invention according to claim 2.
１，２，：成形複合体 ３ ：遠赤外線ヒーター １１ ：芯材 １２ ：線状低密度ポリエチレンフィルム １３ ：表皮材 ４ ：上金型 ４１ ：下金型 ２０ ：複合フィルム ２１ ：線状低密度ポリエチレン樹脂層 ２２ ：酸変性線状低密度ポリエチレン樹脂層 ２３ ：ポリアミド樹脂層 ２４ ：高密度ポリエチレン樹脂層 1,2 ,: Molded composite 3: Far infrared heater 11: Core material 12: Linear low-density polyethylene film 13: Skin material 4: Upper mold 41: Lower mold 20: Composite film 21: Linear low-density polyethylene Resin layer 22: Acid-modified linear low-density polyethylene resin layer 23: Polyamide resin layer 24: High-density polyethylene resin layer
───────────────────────────────────────────────────── 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 Ｂ２９Ｃ 65/70 7639−4Ｆ Ｂ２９Ｃ 65/70 Ｂ３２Ｂ 5/26 Ｂ３２Ｂ 5/26 27/10 27/10 27/12 27/12 31/20 7148−4Ｆ 31/20 Ｂ６０Ｒ 13/02 Ｂ６０Ｒ 13/02 Ｚ Ｂ６３Ｂ 3/68 Ｂ６３Ｂ 3/68 Ｄ０４Ｈ 1/58 Ｄ０４Ｈ 1/58 Ｚ Ｅ０４Ｆ 13/00 8913−2Ｅ Ｅ０４Ｆ 13/00 Ｂ 13/08 8913−2Ｅ 13/08 Ａ 13/16 8913−2Ｅ 13/16 // Ｂ２９Ｋ 101:12 Ｂ２９Ｌ 9:00 31:10 31:58 ─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. 6 Identification number Office reference number FI technical display location B29C 65/70 7639-4F B29C 65/70 B32B 5/26 B32B 5/26 27/10 27/10 27/12 27/12 31/20 7148-4F 31/20 B60R 13/02 B60R 13/02 Z B63B 3/68 B63B 3/68 D04H 1/58 D04H 1/58 Z E04F 13/00 8913-2E E04F 13 / 00 B 13/08 8913-2E 13/08 A 13/16 8913-2E 13/16 // B29K 101: 12 B29L 9:00 31:10 31:58
Claims (2)
材に、メルトインデックスが８〜２０である熱可塑性樹
脂フィルムを重ね合わせ、該熱可塑性樹脂フィルムをそ
の樹脂の流れ度が３ｇ／１０分以上となる温度に加熱、
溶融し、該溶融樹脂面に表皮材を重ねて加圧することに
より、芯材と表皮材とを接着すると同時に賦形する成形
複合体の製造方法。1. A thermoplastic resin film having a melt index of 8 to 20 is superposed on a sheet-shaped core material which can be shaped by heating and pressing, and the thermoplastic resin film has a resin flow rate of 3 g / Heating to a temperature of 10 minutes or more,
1. A method for producing a molded composite, which comprises melting and forming a skin material on the surface of the molten resin and pressing the same to bond the core material and the skin material and at the same time shape.
材に、メルトインデックスが８〜２０である熱可塑性樹
脂層（ａ１）と、該熱可塑性樹脂層（ａ１）よりも溶融
温度の高い耐熱樹脂層（ｂ）と、熱可塑性樹脂層（ｃ）
とがこの順に積層されてなる複合フィルムの層を重ね合
わせ、層（ａ１）を表皮材に重ね合わせるとともに、耐
熱樹脂層（ｂ）の融点以下であって、層（ａ１）の樹脂
の流れ度が３ｇ／１０分以上となる温度に加熱、溶融
し、加圧することにより、芯材と表皮材とを接着すると
同時に賦形する成形複合体の製造方法。2. A thermoplastic resin layer (a1) having a melt index of 8 to 20 on a sheet-shaped core material that can be shaped by heating and pressing, and a thermoplastic resin layer (a1) having a melting temperature higher than that of the thermoplastic resin layer (a1). High heat resistant resin layer (b) and thermoplastic resin layer (c)
Are laminated in this order, the layers of the composite film are laminated, the layer (a1) is laminated on the skin material, and the flow rate of the resin of the layer (a1) is equal to or lower than the melting point of the heat-resistant resin layer (b). Is a temperature of 3 g / 10 minutes or more, is melted, and is pressed to bond the core material and the skin material and at the same time shape the molded composite body.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP8235595A JPH08276446A (en) | 1995-04-07 | 1995-04-07 | Manufacture of molding composite material |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP8235595A JPH08276446A (en) | 1995-04-07 | 1995-04-07 | Manufacture of molding composite material |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH08276446A true JPH08276446A (en) | 1996-10-22 |
Family
ID=13772277
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP8235595A Pending JPH08276446A (en) | 1995-04-07 | 1995-04-07 | Manufacture of molding composite material |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH08276446A (en) |
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-
1995
- 1995-04-07 JP JP8235595A patent/JPH08276446A/en active Pending
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| CN100368174C (en) * | 2004-06-03 | 2008-02-13 | 刘坤钟 | Manufacturing method of composite material label slice |
| KR20140033334A (en) * | 2011-01-25 | 2014-03-18 | 쿼드란트 플라스틱 컴포지츠 일본 리미티드 | Flexurally rigid laminated sheets, parts molded therefrom and method of fabrication and method of fabrication |
| JP2014508055A (en) * | 2011-01-25 | 2014-04-03 | クオドラント・プラスチック・コンポジット・ジャパン 株式会社 | Laminated plate having bending rigidity, molded product from the laminated plate, manufacturing method thereof and manufacturing method thereof |
| JP2013047030A (en) * | 2011-08-29 | 2013-03-07 | Kasai Kogyo Co Ltd | Interior part for automobile and method for manufacturing the same |
| JP2016501745A (en) * | 2012-11-13 | 2016-01-21 | ハンファ アズデル インコーポレイテッド | Articles containing flims and methods of using them |
| CN103600809A (en) * | 2013-10-30 | 2014-02-26 | 江苏科技大学 | Vibration damping and noise reducing flexible sandwich plate for ship structure |
| JP2016087935A (en) * | 2014-11-05 | 2016-05-23 | 本田技研工業株式会社 | Method and apparatus for producing resin molded article |
| CN104401085A (en) * | 2014-12-04 | 2015-03-11 | 苏州贝多环保技术有限公司 | Color-changeable adsorbent cotton and preparation method of color-changeable polymeric oil-absorbing material |
| CN113966270A (en) * | 2019-03-29 | 2022-01-21 | 弗劳恩霍夫应用研究促进协会 | Method for producing a sandwich composite component having a pressed two-dimensional or three-dimensional shape, and such a sandwich composite component |
| CN113966270B (en) * | 2019-03-29 | 2023-09-08 | 弗劳恩霍夫应用研究促进协会 | Method for producing a sandwich composite member having a pressed two-dimensional or three-dimensional shape and such a sandwich composite member |
| CN109958691A (en) * | 2019-04-28 | 2019-07-02 | 上海交通大学 | A kind of underlying component assembling manufacturing method of LNG ship large scale polyurethane insulating case |
| CN110127367A (en) * | 2019-04-28 | 2019-08-16 | 上海交通大学 | The shunting of LNG ship polyurethane insulating case, afflux interactive mode assembling manufacturing method |
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