WO2012036170A1 - 面材強化発泡体 - Google Patents
面材強化発泡体 Download PDFInfo
- Publication number
- WO2012036170A1 WO2012036170A1 PCT/JP2011/070897 JP2011070897W WO2012036170A1 WO 2012036170 A1 WO2012036170 A1 WO 2012036170A1 JP 2011070897 W JP2011070897 W JP 2011070897W WO 2012036170 A1 WO2012036170 A1 WO 2012036170A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- face material
- glass fiber
- resin
- reinforced foam
- nonwoven fabric
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/021—Fibrous or filamentary layer
- B32B2260/023—Two or more layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/08—Cars
Definitions
- the present invention is a lightweight, laminated face material made of glass fiber and thermoplastic resin on both surfaces of the foam, is excellent in moldability, particularly deep drawability, and from the face material reinforced foam.
- the obtained molded body relates to a face material reinforced foam excellent in dimensional stability, and a molded body obtained from the face material reinforced foam.
- Patent Document 1 uses a reinforced face material having a tensile elastic modulus of 4 to 10 kgf / mm 2 at 180 ° C. to enhance the face material, thereby improving deep drawability and rigidity of the face material reinforced foam, It has been proposed to increase thermal dimensional stability.
- a foam As a lightweight foam, a foam is known in which a thermoplastic resin is passed through a die having a plurality of discharge holes to form a foamed strand, and these are integrated.
- U.S. Patent No. 6,057,033 discloses a die having a plurality of rows of orifices or slits (discharge holes) arranged such that a foamable molten thermoplastic composition contacts and coalesces adjacent strands or profiles to be extruded.
- a process for the production of a foam having a structure in which the strands or profiles are arranged substantially parallel to the longitudinal axis of the foam is disclosed.
- the foam has anisotropy in structure as compared with a general foam and has an extremely high extensibility in a direction perpendicular to the strand direction (extrusion direction).
- the face material reinforced foam described in Patent Document 1 in which reinforcing face materials are laminated on both surfaces of the foam is used.
- the corner portion R is 10 mm
- the height is 200 mm
- the corner angle is 60 degrees
- the expansion rate is 200. %
- an anisotropic foamed material such as a so-called strand converging foam described in Patent Document 2, for example, a reinforcing surface material having a high tensile elastic modulus at 180 ° C., as described in Patent Document 1.
- a face material reinforced foam is produced by laminating layers, the deep drawn molded body as described above exhibits significant elongation in the vertical direction of the foam strand, but the reinforced face material is also deformed. There has been a problem that the dimensions and shape of the face material reinforced foam change.
- An object of the present invention is to provide a face material reinforced foam from which a molded article having excellent dimensional stability can be obtained even in light weight, moldability, particularly deep drawing, and a molded article obtained therefrom.
- the present inventor has made extensive studies to achieve the above object, and as a result, the tensile elastic modulus is 0.7 to 1.2 kgf / mm 2 which is considerably smaller than that used in Patent Document 1 and the like, and Using a reinforcing face material having a tensile elastic modulus of 0.8 to 2.0 kgf / mm 2 containing a glass fiber nonwoven fabric having an average fiber length of 15 to 100 mm in a specific range, and having an expansion ratio of 0.8 to 2.0 kgf / mm 2
- a face-reinforced foam laminated on both surfaces of a strand-bundled foam with a non-crosslinked thermoplastic resin of 10 to 40 times can provide a molded article with excellent lightness and moldability and excellent dimensional stability. It has been found that it can be done, and has reached the present invention.
- a face-reinforced foam obtained by laminating a reinforcing face material made of a glass fiber nonwoven fabric and a thermoplastic resin on both surfaces of a strand bundling foam made of a non-crosslinked thermoplastic resin with an expansion ratio of 10 to 40 times by a continuous strand extrusion method.
- the glass fiber nonwoven fabric has a tensile modulus of 0.7 to 1.2 kgf / mm 2 and the glass fiber constituting the glass fiber nonwoven fabric has an average fiber length of 15 to 100 mm.
- a face material-reinforced foam having a glass fiber content of 25 to 40% by mass and a tensile modulus of the reinforcing face material of 0.8 to 2.0 kgf / mm 2 .
- the thermoplastic resin is a linear low density polyethylene having a density of 900 to 930 kg / m 3 . 8).
- the binder is at least one resin selected from the group consisting of urethane resin, acrylic resin and vinyl acetate resin.
- the crosslinked resin is polyvinyl alcohol or a polyfunctional acrylic polyol. 10. 10.
- strengthening foam which can obtain the molded object excellent in lightweight property, moldability, especially deep drawing molding, and the dimensional stability is provided, and a molded object obtained therefrom.
- a molded product from a face material reinforced foam is used as an automobile interior part, it is repeatedly exposed to a high humidity environment with a temperature of 90 ° C. to ⁇ 40 ° C. and a relative humidity (RH) of 95%.
- RH relative humidity
- it is required to have a dimensional change of less than 1 mm (dimensional change of less than 1/1000) with respect to an initial dimension of 1000 mm, but the present invention provides a face material-reinforced foam that can satisfy these requirements.
- the average fiber length of the glass fibers constituting the glass fiber nonwoven fabric is 15 to 100 mm, preferably 20 to 85 mm.
- the glass fiber length is shorter than 15 mm, it is not preferable because it easily tears during molding.
- the glass fiber length exceeds 100 mm, the variation in the fabric weight of the nonwoven fabric increases, the glass fiber tends to drop off when handling the nonwoven fabric, the workability decreases, and the nonwoven fabric is impregnated with a thermoplastic resin. This is not preferable because the resin oozes out from the nonwoven fabric.
- the glass fiber nonwoven fabric used in the present invention needs to have a tensile modulus of 0.7 to 1.2 kgf / mm 2 .
- the tensile elastic modulus at 180 ° C. of the glass fiber material is less than 0.7 kgf / mm 2 , the processability of the nonwoven fabric and the dimensional stability of the face material reinforced foam are excellent, but the stretchability of the drawn part is insufficient during molding. It is not preferable because it breaks.
- the tensile elastic modulus is larger than 1.2 kgf / mm 2 , the moldability is very good, but the glass fiber of the nonwoven fabric is likely to drop off, and the handleability and workability are deteriorated. Residual strain increases as the material is stretched. In some cases, when handling molded products in high-temperature (low-temperature) and high-humidity environments, the strain at the time of molding is alleviated to reduce the dimensional stability of the face-reinforced foam. Is not preferable because the surface smoothness of the molded product may be impaired. Among them, more preferably 0.9 ⁇ 1.15kgf / mm 2 tensile modulus, particularly preferably 0.9 ⁇ 1.1kgf / mm 2.
- the glass fiber nonwoven fabric used for this invention contains the binder.
- the binder gloss (loss on ignition) is contained in the glass fiber nonwoven fabric in a solid content of 5 to 20% by mass, more preferably 7 to 16% by mass. If the content of the binder resin is less than 5% by mass, the binding force of the glass fibers will be weakened, resulting in an increase in fiber dropping during processing, impairing workability, and weakening the desired reinforcing effect, resulting in tearing during molding.
- the binder resin used is not particularly limited, and various binder resins such as a urethane resin, an acrylic resin, a vinyl acetate resin, and a starch (starch) can be used. Especially, as a binder resin, a vinyl acetate resin or a starch (starch) type
- the binder resin may contain a cross-linked resin so as to have the tensile elastic modulus.
- the content of the crosslinked resin is preferably 0.1 to 3% by mass, particularly preferably 0.2 to 2% by mass, based on the solid content of the binder.
- the cross-linked resin in the binder resin is not particularly limited, but polyvinyl alcohol (PVA) or polyfunctional acrylic polyol is preferably used, and polyvinyl alcohol is particularly preferable in terms of cost and processability.
- the clearance gap between glass fibers is impregnated with the thermoplastic resin.
- the thermoplastic resin combined with the glass fiber nonwoven fabric is preferably a resin that is easily impregnated into the nonwoven fabric and has high adhesion to the foamed resin. If the adhesiveness between the foam and the reinforced face material is insufficient, the strength of the face material reinforced foam will decrease, it will peel off during molding, and the resulting molded product will have sufficient dimensional stability. This is not preferable.
- the adhesive strength between the foam and the reinforcing face material is preferably 0.05 kgf / mm 2 or more, more preferably 0.1 to 5 kgf / mm 2 at 180 ° peeling.
- the thermoplastic resin is not particularly limited.
- the melt flow rate (MFR, 230 ° C.) is preferably 5 to 50 g / 10 min, and more preferably 8 to 45 g / 10 min.
- the thermoplastic resin is not particularly limited, but from the viewpoint of cost, heat resistance, and ease of processing, an olefin resin, a copolymer with an ethylene resin such as EVA (ethylene-vinyl acetate copolymer), or those It is preferred to use a mixture.
- EVA ethylene-vinyl acetate copolymer
- low density polyethylene having a density of 900 to 930 kg / m 3 is preferable
- linear polyethylene is preferable in terms of permeability into the nonwoven fabric, processability, and cost.
- the reinforcing face material made of the glass fiber nonwoven fabric and the thermoplastic resin preferably contains 25 to 40% by mass, particularly 30 to 35% by mass of the glass fiber in the reinforcing face material. If the glass fiber content in the reinforcing face material exceeds 40% by mass, the tensile elastic modulus of the reinforcing face material is lowered, the elongation at the time of molding is insufficient, and the molded body is torn, which is not preferable. On the other hand, as the resin content is increased by decreasing the glass fiber content, the tensile modulus of the reinforcing face material increases and the extensibility increases. However, if the glass fiber content is less than 25% by mass, the product weight increases. Or increase in price.
- the glass fiber nonwoven fabric is impregnated with the thermoplastic resin
- the glass fiber nonwoven fabric is not particularly limited, but when the glass fiber nonwoven fabric is in a sheet form, it is preferably impregnated on both surfaces of the sheet.
- the thermoplastic resin having a temperature suitable for processing and appropriate viscosity characteristics and the thermoplastic resin impregnated in the thickness direction of the glass fiber nonwoven fabric, You may just impregnate from the surface.
- thermoplastic resin When a reinforcing surface material having excellent extensibility by deep drawing or the like is desired, it is preferable to impregnate the glass fiber nonwoven fabric so that the thermoplastic resin is present uniformly. Furthermore, as a method for impregnating the thermoplastic resin into the glass fiber nonwoven fabric, any apparatus that can directly impregnate the molten thermoplastic resin can be used. For example, a method in which a thermoplastic resin is combined with a glass fiber nonwoven fabric, which is an adherend, by a continuous lamination process such as a spray-type hot-melt laminating method or an extrusion laminating method of a hot-melt resin is more preferable.
- the viscosity of the molten thermoplastic resin impregnated into the glass fiber nonwoven fabric is too high, the resin does not sufficiently penetrate into the fiber material, and it is not preferable because sufficient stretchability cannot be imparted to the reinforcing face material.
- the viscosity of the molten thermoplastic resin is too low, the glass fiber nonwoven fabric is impregnated with the molten thermoplastic resin, and the resin oozes out from the glass fiber nonwoven fabric, which makes it difficult to process.
- the reinforced face material needs to have a tensile elastic modulus of 0.8 to 2.0 kgf / mm 2 in a high temperature tensile test set at an atmospheric temperature of 180 ° C., particularly 0.9 to 1.5 kgf / mm 2 . Preferably there is.
- the rigidity and dimensional stability of the moldability are good, but the extensibility of the reinforced face material at the time of molding is reduced and at the time of molding. It is not preferable because tearing tends to occur.
- the tensile elastic modulus of the reinforcing face material exceeds 2.0 kgf / mm 2 , the moldability is good, but it is preferable because the dimensional change and shape deformation of the molded body increase in the process in which the molding strain relaxes with time. Absent.
- the resin for forming the foam in the present invention is not particularly limited, and a thermoplastic resin material is used. From the viewpoint of cost and deep drawing, it is preferable to use a non-crosslinkable polyolefin resin. Among polyolefin-based resins, it is particularly preferable to use a polypropylene-based resin that has high heat resistance and rigidity and is inexpensive.
- the melt flow rate (MFR, 230 ° C.) is preferably 5 to 30 g / 10 min, more preferably 5 to 20 g / 10 min.
- the strand-focused foam in the present invention is not particularly limited, but can be obtained by a continuous strand extrusion foaming method discharged from a plurality of die nozzles.
- the foam uses an extruder having a multi-hole die having an opening diameter of 0.5 to 3 mm and a numerical aperture of 50 to 5000, and at a melt extrusion temperature of 160 to 250 ° C.
- the discharge amount V per opening is 0.03 to 0.5 kg / h, and it is obtained by a method in which extrusion foaming is performed by releasing the nearest resin pressure of the die opening portion into the atmosphere at 3 to 20 MPa.
- the material when a strand converging foam is used for the foam, the material has anisotropy having a higher tensile elongation in the vertical direction than the tensile elongation in the extrusion direction of the foam.
- the expansion ratio of the foam is 10 to 40 times, preferably 13 to 30 times.
- the expansion ratio is less than 10 times, the rigidity of the face material-reinforced foam is good, but it is not preferable because the lightness is impaired.
- the expansion ratio exceeds 40 times, it is favorable in terms of lightness and cost of the face material-reinforced foam, but it is not preferable because rigidity cannot be imparted and dimensional stability is impaired.
- the face material reinforced foam in the present invention is produced by laminating a reinforced face material on both surfaces of the foam, and the shape of the face material reinforced foam may be a board shape or a sheet shape.
- the method of laminating the foam and the reinforced face material is not particularly limited, but the thermoplastic resin is appropriately exuded to the back surface of the glass fiber nonwoven fabric while impregnating the glass fiber nonwoven fabric with the thermoplastic resin.
- a method of laminating a reinforcing face material and a foam using the adhesive property of the above, a reinforcing face material obtained by impregnating a glass fiber nonwoven fabric with a thermoplastic resin, and a foam to be laminated thereon are prepared in advance.
- extrusion laminating method and a spray-type hot melt laminating method as a method of laminating with a foam while combining a thermoplastic resin with a nonwoven fabric.
- the extrusion laminating method has a disadvantage that the apparatus is large and requires a wide space, and the apparatus cost is very high, but there is an advantage that a high basis weight thermoplastic resin can be easily applied with a relatively uniform basis weight.
- the spray-type hot melt laminating method can be processed at a relatively low cost, but has a demerit that the basis weight of the thermoplastic resin is not uniform or is not suitable for application of a high basis weight resin.
- the reinforcing face material when the reinforcing face material is prepared in advance, it can be suitably processed by the above extrusion laminating method or spray hot melt laminating method.
- the method of bonding the reinforcement surface material prepared beforehand by a hot roll is the method of bonding by pressing with the heated roll in the state which accumulated the reinforcement surface material on both surfaces of the foam.
- the method of pasting together the prepared reinforcing face material by hot air laminating is to blow hot air simultaneously on the foam and the reinforcing face material to soften and melt the resin on each surface, and then to cool the respective interfaces with a cooling roll It is the method of pasting together while pushing and cooling.
- a hot-air laminate the apparatus is complicated in design, and there is a demerit that high-temperature hot air must be blown to sufficiently soften and melt the material.
- the equipment is inexpensive and does not take up space, and it is desired to homogenize the heating temperature in the product width direction, it is relatively easy to control and the thermoplastic resin impregnated in the foam and reinforced face material is heated and melted simultaneously. Therefore, even when the processing speed is high, there is an advantage that the bonding can be sufficiently performed.
- the face material reinforced foam obtained as described above can be further subjected to stamping molding or vacuum molding in a subsequent step.
- stamping molding the base material is softened and melted by preheating and formed into a specific shape by a cooling press, but an adhesive layer is previously laminated on the surface of the molded body, and simultaneously with the press, on the surface of the base material.
- Cosmetic materials such as felt, ethylene-propylene-diene rubber (EPDM), ethylene-propylene rubber (EPR), olefin elastomer (TPO) sheet represented by butyl rubber graft polyethylene and the like can be bonded together.
- a highly transferable resin such as olefin resin such as polypropylene or polyethylene or the above-mentioned olefin elastomer is melted and cast on the surface of the glass fiber non-woven fabric. It is also possible to produce a face material reinforced foam by using this, and to transfer the uneven shape of the mold onto the surface of the molded product during press molding to give a design.
- the mold shape is transferred by pasting the decorative material on the molded product at the same time as molding, or by combining a resin with high transferability in the process of processing the reinforcing face material in advance.
- the glass fiber content is preferably 10 to 20% by mass, more preferably 12 to 18% by mass, based on the total mass of the face material reinforced foam.
- the thermal dimensional stability of the molded product is impaired.
- the face material reinforced foam This is not preferable because it causes problems such as shrinkage of dimensions and collapse of the shape.
- the residual stress becomes large, so that the dimensional shape stability and shape stability are significantly impaired.
- the glass fiber content exceeds 20% by mass, the dimensional stability of the face material-reinforced foam can be improved, but the lightness is impaired, or the tensile elastic modulus of the reinforced face material becomes too high. This is not preferable because tearing occurs during molding.
- various physical property values are obtained as follows. 1.
- the basis weight of the glass fiber nonwoven fabric was cut into a plate shape having dimensions of 200 mm in length and 200 mm in width, the mass (g) was measured with an electronic balance to the last two digits, and the basis weight of the glass fiber nonwoven fabric was calculated by the following formula.
- Glass fiber nonwoven fabric basis weight (g / m 2 ) Mass (g) / (200 (m) / 1000 (m) ⁇ 200 (m) / 1000 (m))
- Reinforced face material weight (g / m 2 ) Mass (g) / (200 (m) / 1000 (m) ⁇ 200 (m) / 1000 (m))
- the tensile elongation in 180 degreeC was computed using the following formula
- 180 ° C tensile elongation (%) (Displacement amount until the nonwoven fabric breaks (mm) ⁇ Chuck interval (mm)) ⁇ 100
- the average value (n 5) of the obtained tensile elongation was defined as the tensile elongation at 180 ° C.
- the tensile modulus and tensile elongation of the reinforced face material at 180 ° C. are the same as those in 5. above.
- the tensile elastic modulus and tensile elongation at 180 ° C. of the reinforcing face material were calculated by the same method as the 180 ° C. tensile test of the glass fiber nonwoven fabric described in 1. above.
- the reinforced face material was cut into a plate shape having dimensions of 30 mm in length and 30 mm in width, and a material from which moisture was sufficiently removed was used as a test piece. This test piece is put in a magnetic dish (mass: W 0 ), and the total mass (w 1 ) of the test piece and the magnetic dish is measured to the last 4 digits with an electronic balance, and it is placed in an electric furnace set at 450 ° C. for 5 hours.
- Deep-drawing formability A plate-shaped face material reinforced foam having dimensions of 2400 mm in length and 1500 mm in width, in which reinforced face materials are laminated on both surfaces of the foam, was used. Four sides were clamped and fixed at a position of 50 mm at the end, and after sufficiently softening and melting by pre-heating in a far-infrared heating furnace, the face material-reinforced foam was quickly conveyed into the mold.
- the mold has a square pyramid shape with a central part of 1200mm in length, 1000mm in width, and a hypotenuse of 200mm. The upper surface of the mold is concave and the lower surface is convex. A mold that is 60 degrees was used.
- the molded product is produced by pressing the above-mentioned softened and melted face material reinforced foam while clamping the clearance between the molds to 5.5 mm, and strengthens the face material at all deep drawing (corner, standing wall) sites.
- the foam was evaluated for tearing.
- the method of tearing the face material reinforced foam when the length is 100 mm or more, “large tear”, when the length is 100 to 10 mm, “medium tear”, When the foam or both were torn about 10-5 mm in length and had holes, it was evaluated as “small tear”.
- the plane part of the face material reinforced foam molded by the method described in the above deep drawing moldability is marked with a straight line of 1000 mm at three vertical positions and 750 mm at three horizontal positions, On the inclined part, straight lines of 750 mm and 150 mm were written in both the vertical and horizontal directions, and the initial length (L 0 ) of the straight line was measured by a scale with a minimum step of 0.5 mm.
- L 0 initial length of the straight line was measured by a scale with a minimum step of 0.5 mm.
- four cycles of the humidity-cooling heat cycle test were performed under the following temperature and humidity conditions.
- the cycle of the wet and cold heat cycle test is as follows.
- initial conditions a temperature of 23 ° C. and a humidity of 50% for 0.5 hours (hereinafter referred to as initial conditions), and then at a temperature of 90 ° C. for 11.5 hours. Thereafter, the temperature is maintained at ⁇ 40 ° C. for 7.5 hours through the initial conditions, and is again maintained at the temperature of 70 ° C. and 50% humidity for 7.5 hours through the initial conditions. After that, the initial condition is maintained at ⁇ 40 ° C. for 7.5 hours to return to the initial condition, which is one cycle.
- the longitudinal change (extrusion foaming line direction: 2400 mm) of the face material reinforced foam is MD direction
- the transverse direction (width direction with respect to the extrusion foaming line: 1500 mm) is TD direction
- the dimensional change calculated in both MD direction and TD direction was calculated, and this was taken as the dimensional change after the thermal cycle test of the face material reinforced foam.
- a unit of dimensional change x 1/1000 it means a deformation amount (mm) in which a molded body having an initial dimension of 1000 mm is deformed after a thermal cycle test, and the same meaning as dimensional change rate x 0.1 (%). is there.
- a dimensional change of less than (1.0) ⁇ 1/1000 is “ ⁇ ”, and (1.0 to 1.5) ⁇ 1/1000 is “ ⁇ ”. ”, (1.5 to 2.0) ⁇ 1/1000 was evaluated as“ ⁇ ”, and when the dimensional change exceeded (2.0 ⁇ 1) / 1000, it was evaluated as“ ⁇ ”.
- the dimensional change is less than 2 ⁇ 1/1000, particularly passenger cars, as sufficient dimensional stability against severe changes in temperature and humidity in the vehicle environment. When used for interior use, the dimensional change needs to be less than 1 ⁇ 1/1000.
- Example 1 A glass fiber nonwoven fabric having an average fiber diameter of 13 ⁇ m and an average fiber length of 25 mm is used.
- a binder made of a mixture of urethane resin and acrylic resin (mass ratio 80:20) is 10% by mass with respect to the mass of the glass fiber. attached is such that, further, the PVA as a crosslinking component to 0.5 wt% externally added relative to the weight of the binder, 200 ° C. at obtained by performing 90 seconds heat treatment, ignition at a basis weight 50 g / m 2
- a glass fiber nonwoven fabric with 10% weight loss (igros) was used. This glass fiber nonwoven fabric had a tensile elastic modulus at 180 ° C. of 1.0 kgf / mm 2 and a tensile elongation at 180 ° C. of 0.83%.
- a linear low density polyethylene resin (LLDPE, density 919 kg / m 3 MFR: 8.0 g / 10 min) as a thermoplastic resin is 50 g / m 2 in a molten state of 280 to 290 ° C. as a thermoplastic resin. It applied directly so that it might become.
- the LLDPE resin is directly applied so that the basis weight of the resin is 100 g / m 2 in total with a basis weight of 50 g / m 2 from the back side of the glass fiber nonwoven fabric, and impregnated by an extrusion laminating method to obtain a glass content.
- a 33% by mass reinforcing face material was produced.
- the basis weight of this reinforcing face material was 150 g / m 2 and the LLDPE resin content was 67% by mass. Moreover, the tensile elasticity modulus in 180 degreeC was 1.1 kgf / mm ⁇ 2 >, and the tensile elongation in 180 degreeC was 5.7%.
- homopolypropylene resin having an MFR at 230 ° C. of 3.3 g / 10 min and a melt tension at 230 ° C. of 7.9 g was discharged at 230 ° C. at a discharge rate of 75 kg / hour (h). And melted at a temperature setting of 6.5% by mass with respect to 100% by mass of the homopolypropylene resin.
- the temperature is set so that the resin temperature immediately before foaming is 185 ° C., the hole diameter is 1332 (4 holes in the thickness direction of the foam, 333 holes in the width direction), the hole diameter is 0.59 mm, and the hole interval is 4.5 mm.
- the product is extruded through a multi-strand die nozzle so that the resin pressure becomes 8.3 MPa, and the pressure is released to atmospheric pressure at a stretch.
- a foam having a size of 12 mm, a thickness of 12 mm, and a basis weight of 380 g / m 2 was produced.
- hot air of 280 ° C. is blown between the reinforcing face material prepared in advance as described above and the foam to melt the LLDPE resin of the reinforcing face material and the PP (polypropylene) resin on the surface of the foam.
- a PTFE polytetrafluoroethylene
- the weight of the obtained face material reinforced foam was 680 g / m 2 , the thickness was 11 mm, and the glass content in the face material reinforced foam was 15% by mass.
- the face material reinforced foam obtained as described above is retained in a far-infrared heating furnace having a set temperature of 280 ° C. for 120 seconds and heated so that the surface temperature of the molded product becomes 170 to 180 ° C.
- the die was set at 30 ° C., and deep drawing was performed under the conditions of a die clearance setting of 5.5 mm.
- the molded product of the obtained face material reinforced foam had no cracks at the deep drawing corner (standing wall inclined surface), and the surface appearance was beautiful. Furthermore, when this molded body was used and the dimensional change of the molded body before and after the test was examined by the above-described cooling / heating cycle test, the dimensional change was 0.98 ⁇ 1/1000 (dimensional change rate 0.098%). It was confirmed that the stability was excellent.
- Example 2 A face material reinforced foam having the same production conditions as Example 1 was obtained except that the amount of PVA added as a crosslinking component of the binder of the glass fiber nonwoven fabric was 3%.
- Example 3 A face material-reinforced foam having the same production conditions as in Example 1 was obtained except that a nonwoven fabric with a basis weight of 40 g / m 2 was used, although the basis weight of the glass fiber nonwoven fabric was appropriate.
- Example 4 A reinforced face material having the same production conditions as in Example 1 was obtained except that a nonwoven fabric with a basis weight of 65 g / m 2 was used, although the basis weight of the glass fiber nonwoven fabric was appropriate but extremely high.
- Examples 5 and 6 A face material-reinforced foam having the same production conditions as in Example 1 was obtained except that the amount of the binder for binding the glass fibers was 15% by mass and 20% by mass.
- Example 7 The same production conditions as in Example 1 except that the basis weight (mass per unit area) of the thermoplastic resin impregnated into the glass fiber nonwoven fabric was 38 g / m 2 and the glass fiber content in the reinforcing face material was 40% by mass. A face material reinforced foam was obtained.
- Comparative Example 1 A face material reinforced foam having the same production conditions as in Example 1 was obtained except that the addition amount of PVA as a crosslinking component of the binder of the glass fiber nonwoven fabric was 5%.
- Comparative Example 2 A face material reinforced foam having the same production conditions as in Example 1 was obtained except that PVA which is a crosslinking component of the binder of the glass fiber nonwoven fabric was not added.
- Comparative Example 3 The surface is the same production conditions as in Example 1 except that a nonwoven fabric with a basis weight of 30 g / m 2 is used, and the glass fiber content contained in the reinforcing face material is 23 mass%. A material reinforced foam was obtained.
- Comparative Example 4 A face material reinforced foam having the same production conditions as in Example 1 was obtained except that a glass fiber nonwoven fabric having an average fiber length of 10 mm was used.
- Comparative Example 5 A face material reinforced foam having the same production conditions as in Example 1 was obtained except that a glass fiber nonwoven fabric having an average fiber length of 120 mm was used.
- Comparative Example 6 A face material-reinforced foam that was the same as in Example 1 was obtained except that the amount of the binder for binding glass fibers was changed to 4% by mass.
- Comparative Example 7 The same as Example 1 except that the basis weight (mass per unit area) of the thermoplastic resin impregnated into the glass fiber nonwoven fabric was 25 g / m 2 and the glass fiber content in the reinforcing face material was 50% by mass. A face material reinforced foam was obtained.
- Comparative Example 8 The same as Example 1 except that the basis weight (mass per unit area) of the thermoplastic resin impregnated into the glass fiber nonwoven fabric was 110 g / m 2 and the glass fiber content in the reinforcing face material was 19% by mass. A face material reinforced foam was obtained.
- the face material reinforced foam provided by the present invention is lightweight, excellent in moldability, particularly deep drawability, and a molded body obtained from the face material reinforced foam is excellent in dimensional stability. It is widely used as a member for vehicles such as a ceiling material for automobiles.
- the entire contents of the specification, claims, and abstract of Japanese Patent Application No. 2010-206018 filed on September 14, 2010 are incorporated herein as the disclosure of the specification of the present invention. Is.
Landscapes
- Laminated Bodies (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
Abstract
Description
1.ガラス繊維不織布と熱可塑性樹脂からなる強化面材を、ストランド連続押出法による発泡倍率10~40倍の非架橋の熱可塑性樹脂によるストランド集束発泡体の両表面に積層した面材強化発泡体であって、前記ガラス繊維不織布の引張弾性率が0.7~1.2kgf/mm2であり、該ガラス繊維不織布を構成するガラス繊維の平均繊維長が15~100mmであり、前記強化面材中のガラス繊維の含有量が25~40質量%であり、かつ、強化面材の引張弾性率が0.8~2.0kgf/mm2であることを特徴とする面材強化発泡体。
3.前記バインダーの固形分中に0.1~3.0質量%の架橋樹脂を含有する上記1又は2に記載の面材強化発泡体。
4.面材強化発泡体におけるガラス繊維の含有量が、10~20質量%である上記1~3のいずれかに記載の面材強化発泡体。
5.前記熱可塑性樹脂が、非架橋のポリオレフィン樹脂である上記1~4のいずれかに記載の面材強化発泡体。
7.前記熱可塑性樹脂が、密度が900~930kg/m3の、直鎖状の低密度ポリエチレンである上記1~6のいずれかに記載の面材強化発泡体。
8.前記バインダーが、ウレタン樹脂、アクリル樹脂及び酢酸ビニル樹脂からなる群から選ばれる少なくとも1種の樹脂である請求項2~7のいずれかに記載の面材強化発泡体。
9.前記架橋樹脂が、ポリビニルアルコール又は多官能型アクリルポリオールである上記3~8のいずれかに記載の面材強化発泡体。
10.上記1~9のいずれかに記載の面材強化発泡体から得られる成形体。
例えば、面材強化発泡体からの成形体を自動車内装部品として使用する場合は、温度が90℃から-40℃、95%の相対湿度(RH)の多湿度の環境に繰り返し曝されるが、この場合でも、成形体の寸法変化は初期の寸法1000mmに対して2mm未満(寸法変化=2/1000未満)であることが要求され、また、自動車の内装天井部品のような条件の厳しい環境で使用される場合は、初期寸法1000mmに対して寸変化1mm未満(寸法変化1/1000未満)であることが要求されるが、本発明により、これらを満足しうる面材強化発泡体が提供される。
ガラス繊維不織布を構成するガラス繊維の平均繊維長が15~100mm、好ましくは20~85mmであることを必須とする。ガラス繊維長が15mmより短い場合は、成形時に裂けやすくなり好ましくない。一方、ガラス繊維長が100mmを超える場合、不織布の目付けのバラツキが大きくなったり、不織布を取り扱うときにガラス繊維が脱落しやすいため加工性が低下したり、不織布に熱可塑性樹脂を含浸させる際に不織布からの樹脂の染み出しが多くなるため好ましくない。
なかでも、引張弾性率が0.9~1.15kgf/mm2がより好ましく、特に、0.9~1.1kgf/mm2が好ましい。
使用されるバインダー樹脂は、特に限定されるものではなく、ウレタン樹脂、アクリル樹脂、酢酸ビニル樹脂、でんぷん(スターチ)系などの種々のバインダー樹脂を用いることができる。なかでも、バインダー樹脂としては、酢酸ビニル樹脂又はでんぷん(スターチ)系が好ましい。
バインダー樹脂中の架橋樹脂としては、特に限定されないが、コストや加工性の面で、ポリビニルアルコール(PVA)、又は多官能型アクリルポリオールを用いることが好ましく、ポリビニルアルコールが特に好ましい。
上記ガラス繊維不織布は、ガラス繊維の隙間が熱可塑性樹脂により含浸されている。本発明において、ガラス繊維不織布と複合する熱可塑性樹脂としては、不織布への含浸がし易く発泡樹脂との接着性の高い樹脂であることが好ましい。
発泡体と強化面材の接着性が不足していると、面材強化発泡体の強度が低下したり、成形時に剥離して裂けたり、また、得られる成形体が十分な寸法安定性を有しなくなり好ましくない。発泡体と強化面材の接着強度は、180度剥離において、好ましくは0.05kgf/mm2以上、より好ましくは0.1~5kgf/mm2である。
熱可塑性樹脂に特に制限はないが、コスト、耐熱性、及び加工のし易さの点から、オレフィン樹脂、EVA(エチレンー酢酸ビニル共重合体)のようなエチレン樹脂との共重合体、又はそれら混合物を使用することが好ましい。なかでも、密度が900~930kg/m3の低密度ポリエチレンが好ましく、直鎖状のポリエチレンを用いることが、不織布内部への浸透性、加工性、コストの点で好ましい。
前記ガラス繊維不織布と前記熱可塑性樹脂からなる強化面材は、強化面材中のガラス繊維の含有量が25~40質量%、特には30~35質量%含まれることが好ましい。強化面材中のガラス繊維の含有量が40質量%を超えると、強化面材の引張弾性率が低下して成形時の伸び性が不足し、成形体に裂けが生じたりするため好ましくない。一方、ガラス繊維含有量を減らして樹脂含有量を増やすほど強化面材の引張弾性率が上がり、伸び性が高くなるが、ガラス繊維の含有量が25質量%未満の場合は、製品重量が増えたり価格が上がったりするため好ましくない。
さらに、ガラス繊維不織布への熱可塑性樹脂の含浸方法として、溶融した熱可塑性樹脂を直接含浸させることができる装置であればいずれも使用できる。例えば、ホットメルト樹脂のスプレー式ホットメルトラミネート法や押出ラミネート法などの連続積層加工により、被接着体であるガラス繊維不織布に熱可塑性樹脂を複合させる方法がより好ましい。
一方、強化面材の引張弾性率が2.0kgf/mm2を超える場合、成形性は良好になるが、成形歪みが時間とともに緩和する過程における成形体の寸法変化や形状崩れが大きくなるため好ましくない。
本発明で発泡体を形成する樹脂としては、特に限定されず、熱可塑性樹脂材料が使用される。コストや深絞り成形をするという点から、非架橋性のポリオレフィン系の樹脂を使用することが好ましい。ポリオレフィン系の樹脂のなかでも、耐熱性や剛性が高く、安価であるポリプロピレン系の樹脂を使用することが特に好ましい。ポリプロピレン系樹脂としては、メルトフローレート(MFR、230℃)は好ましくは5~30g/10min、より好ましくは5~20g/10minである。
本発明における面材強化発泡体は、発泡体の両表面に強化面材を積層することにより製造され、その形状は、ボード状、又はシート状のものを採用することもできる。
発泡体と強化面材との積層方法は、特に限定されないが、ガラス繊維不織布に熱可塑性樹脂を含浸させながら、ガラス繊維不織布の裏面まで熱可塑性樹脂を適度に染み出させることで、熱可塑性樹脂の接着性を使用して強化面材と発泡体とを積層する方法や、ガラス繊維不織布に熱可塑性樹脂を含浸させた強化面材と、これに積層する発泡体とを予めを用意しておき、次工程において熱ロールによる両者を積層する方法や、両者を熱風式ラミネートによる貼り合せる方法などがある。
また、予め用意された強化面材を、熱ロールにより貼り合せる方法とは、発泡体の両表面に強化面材を重ねた状態で、加熱したロールで押さえつけることで貼り合せる方法である。
熱風式ラミネートの場合、設計上装置が複雑で、材料を十分軟化溶融させるためには高温の熱風を吹きつけなければならないデメリットがある。しかし、装置が安価で場所をとらず、製品幅方向の加熱温度を均質化したい場合は、比較的こまやかに制御しやすく、発泡体と強化面材に含浸されている熱可塑性樹脂を同時に加熱溶融させて貼り合わせることができるため、加工速度が速い場合でも十分に貼り合せ加工できるといったメリットがある。
スタンピング成形の場合、予備加熱により基材を軟化溶融させ、冷却プレスによりある特定形状に成形するが、予め成形体の表面に接着層を積層させておき、プレスと同時に、基材の表面に、フェルトやエチレン-プロピレン-ジエンゴム(EPDM)、エチレン-プロピレンゴム(EPR)、ブチルゴムグラフトポリエチレン等に代表されるオレフィン系エラストマー(TPO)シートなどの化粧材を貼り合せることができる。また、予め、強化面材の加工工程において、ポリプロピレンやポリエチレンなどのオレフィン系樹脂や、前述のオレフィン系エラストマーなど、転写性の高い樹脂を溶融させ、ガラス繊維不織布表面に、キャストし強化面材を作製し、これを用いて面材強化発泡体とし、プレス成形時に成形品表面に金型の凹凸形状を転写させ、意匠をつけることもできる。
面材強化発泡体は、ガラス繊維の含有量が、面材強化発泡体の全質量中に10~20質量%であることが好ましく、更には12~18質量%であることが好ましい。ガラス繊維の含有量が10質量%未満になると、成形品の熱寸法安定性が損なわれ、例えば自動車の内装材などの温湿度環境が苛酷な状況でそれを使用した場合、面材強化発泡体の寸法が縮んだり、形状が崩れてしまうといった不具合を生じるため好ましくない。特に成形歪みの大きな深絞り成形品の場合、残留応力が大きくなるため、寸法形状安定性や形状安定性が著しく損なわれてしまう。
1.ガラス繊維不織布の目付
不織布を縦200mm、横200mmの寸法の板状に裁断し、その質量(g)を電子天秤により下2桁まで測定し、以下の式によりガラス繊維不織布の目付を算出した。それぞれ算出した目付けの平均値(n=5)をガラス繊維不織布の目付とした。
ガラス繊維不織布目付(g/m2)
=質量(g)/(200(m)/1000(m)×200(m)/1000(m))
強化面材を縦200mm、横200mmの寸法の板状に裁断し、その質量(g)を電子天秤で下2桁まで測定し、以下の式により強化面材の目付を算出した。それぞれ算出した目付けの平均値(n=5)を強化面材目付とした。
強化面材の目付(g/m2)
=質量(g)/(200(m)/1000(m)×200(m)/1000(m))
面材強化発泡体を縦200mm、横200mmの寸法の板状に裁断し、その質量(g)を電子天秤で下2桁まで測定し、以下の式により面材強化発泡体の目付を算出した。それぞれ算出した目付けの平均値(n=5)を面材強化発泡体目付とした。
面材強化発泡体目付(g/m2)
=質量(g)/(200/1000(m)×200/1000(m))
面材強化発泡体の平板部より、試験片を縦200mm、横200mmの板状に裁断し、その厚みをデジタルノギスにより下2桁まで測定し、厚みの平均値(n=5)を面材強化発泡体厚みとした。
ガラス繊維不織布を縦200mm、横25mmの寸法の板状に裁断し、予め180℃に加熱した不織布を高温引張試験装置に、チャック間隔150mmで固定し、引張速度50mm/minにて試験片を引っ張ったときの最大荷重(kgf)と試験片面積(mm)を用い、以下の式により引張弾性率を算出した。得られた引張弾性率の平均値(n=5)を不織布の180℃における引張弾性率とした。
180℃引張弾性率(kgf/mm2)=
((最大荷重(kgf)÷(試験片幅25(mm))×チャック間隔150(mm)×引張伸度(%))
180℃引張伸度(%)
=(不織布が破断するまでの変位量(mm)÷チャック間隔(mm))×100
得られた引張伸度の平均値(n=5)を180℃における引張伸度とした。
強化面材の引張弾性率及び引張伸度も、上記5.に記載したガラス繊維不織布の180℃引張試験と同じ方法により、強化面材の180℃における引張弾性率と引張伸度を算出した。
強化面材を縦30mm、横30mmの寸法の板状に裁断し、十分水分を除いたものを試験片として使用した。かかる試験片を磁性皿(質量:W0)に入れ、試験片と磁性皿との合計質量(w1)を電子天秤にて下4桁まで測り、450℃に設定した電気炉中に5時間放置し、シリカゲルを入れたデシケータ中で室温まで温度を下げ、有機成分燃焼後の強化面材の残った磁性皿の質量(w2)を電子天秤にて下4桁まで測定し、以下の式から強化面材のガラス繊維含有量を算出した。
強化面材の異なる場所から試験片を採取し、上記測定を5回行い、それぞれ得られたガラス繊維含有量を平均した値を、強化面材中のガラス繊維含有量とした。
強化面材中のガラス繊維含有量(質量%)
=((W2-W0)/(W1-W0))×100
強化面材を、発泡体の両表面に積層した、縦2400mm、横1500mmの寸法の板状の面材強化発泡体を使用した。その端部50mmの位置で4辺をクランプ固定し、遠赤外線加熱炉において十分予備加熱することで軟化、溶融させた後、速やかに面材強化発泡体を金型内部に搬送した。
金型としては、中央部が縦1200mm、横1000mm、斜辺200mmの四角錐台形状にくぼんでいる、金型上面が凹型で下面が凸型であり、全てのコーナー部分のRが10mmで傾斜角60度である金型を使用した。金型間のクリアランスを5.5mmとして、軟化溶融した上記面材強化発泡体をクランプしたままプレスすることで、成形体を作製し、すべての深絞り(コーナー、立て壁)部位において面材強化発泡体に破れがないか評価を行った。
評価においては、面材強化発泡体の破れ方として、長さ100mm以上裂けている場合は、「裂け大」、長さ100~10mm裂けている場合は、「裂け中程度」、強化面材及び発泡体、又は、その両方が長さ10~5mm程度破れて穴があいている場合は「裂け小」と評価した。
まず、上記8の深絞り成形性に記載されている方法で成形した面材強化発泡体の平面部には縦3箇所に1000mm、横3箇所に750mmの直線を罫書き、立面傾斜部には縦横ともに750mm及び150mmの直線を罫書き、スケールにより直線の初期長さ(L0)を、0.5mmを最小刻みとして測定した。
次に、設定温度の精度が±1℃、設定湿度の精度が±2%RHである高湿恒温槽を使用し、以下の温度湿度の条件において、湿冷熱サイクル試験を4サイクル実施した。
当該湿冷熱サイクル試験のサイクルは以下のとおりである。
まず、温度23℃湿度50%で0.5時間(以下、初期条件という。)、次いで温度90℃で11.5時間保持する。その後、初期条件を経て-40℃で7.5時間保持し、再度初期条件を経て、温度70℃湿度50%で7.5時間保持する。その後、初期条件を経て-40℃で7.5時間保持して初期条件に戻し、これを1サイクルとする
全ての直線を評価後、以下の式により、冷熱サイクル試験後の寸法変化を算出した。
冷熱サイクル試験後の寸法変化(×1/1000)
=((L0-l1)÷L0)×1000
なお、寸法変化の単位である×1/1000として、初期寸法1000mmの成形体が冷熱サイクル試験後に変形した変形量(mm)を意味し、寸法変化率×0.1(%)と同じ意味である。
なお、成形体として、例えば、自動車用の内装部品などに使用しようとする場合、車内環境の苛酷な温湿度変化に対して十分な寸法安定性として、寸法変化2×1/1000未満、特に乗用車用の内装用に使用する場合は、寸法変化1×1/1000未満とする必要がある。
実施例1~7、及び比較例1~8の面材強化発泡体の作製条件、その評価結果等については、表1、表2にまとめて示した。
平均繊維径13μm、平均繊維長25mmのガラス繊維不織布を用い、これに対しウレタン樹脂とアクリル樹脂との混合物(質量比率80:20)からなるバインダーを、ガラス繊維の質量に対して10質量%になるように付着させ、さらに、架橋成分としてPVAをバインダーの質量に対して0.5質量%外添して、200℃にて90秒間熱処理を行って得られる、目付け50g/m2で強熱減量(イグロス)10%のガラス繊維不織布を使用した。このガラス繊維不織布の180℃における引張弾性率は1.0kgf/mm2、180℃における引張伸度は0.83%であった。
この強化面材の目付は150g/m2であり、LLDPE樹脂含有量が67質量%であった。また、180℃における引張弾性率は1.1kgf/mm2、180℃における引張伸度は5.7%であった。
次いで、連続ラインにおいて、前記のようにして予め用意した強化面材と発泡体の間に、280℃の熱風を吹きつけ、強化面材のLLDPE樹脂と発泡体表面のPP(ポリプロピレン)樹脂を溶かした後、速やかにPTFE(ポリテトラフルオロエチレン)被覆ロールで押さえることで、発泡体の両表面に強化面材を貼り合せ、面材強化発泡体を作製した。
前記のようにして得られた面材強化発泡体を、設定温度280℃の遠赤外線加熱炉内に120秒間滞留させ、成形体の表面温度170~180℃となるように加熱し、即座に前述の金型を30℃に設定し、金型クリアランス設定5.5mmの条件で深絞り成形を行った。
さらに、この成形体を使用し、前述の冷熱サイクル試験により試験前後の成形体の寸法変化を調べたところ、寸法変化0.98×1/1000(寸法変化率0.098%)であり、寸法安定性に優れることが確認できた。
ガラス繊維不織布のバインダーの架橋成分であるPVAの添加量を3%にしたこと以外はすべて実施例1と同じ製造条件である、面材強化発泡体を得た。
ガラス繊維不織布の目付けが適正ではあるが低い、目付40g/m2の不織布を使用した以外は、実施例1と同じ製造条件である、面材強化発泡体を得た。
ガラス繊維不織布の目付けが適正ではあるが極端に高い、目付65g/m2の不織布を使用した以外は実施例1と同じ製造条件である、強化面材を得た。
ガラス繊維を結束するバインダー量を15質量%及び20質量%にした以外は、実施例1と同じ製造条件である面材強化発泡体を得た。
ガラス繊維不織布に含浸させる熱可塑性樹脂の目付(単位面積あたりの質量)を38g/m2とし、強化面材中のガラス繊維含有量を40質量%にした以外は、実施例1と同じ製造条件である面材強化発泡体を得た。
ガラス繊維不織布のバインダーの架橋成分であるPVAの添加量を5%にしたこと以外はすべて実施例1と同じ製造条件である、面材強化発泡体を得た。
ガラス繊維不織布のバインダーの架橋成分であるPVAを添加しなかったこと以外はすべて実施例1と同じ製造条件である、面材強化発泡体を得た。
ガラス繊維不織布の目付が極端に低い、目付30g/m2の不織布を使用し、強化面材に含まれるガラス繊維含有量を23質量%にした以外は実施例1と同じ製造条件である、面材強化発泡体を得た。
平均繊維長が10mmであるガラス繊維不織布を使用したこと以外は、実施例1と同じ製造条件である面材強化発泡体を得た。
平均繊維長が120mmであるガラス繊維不織布を使用したこと以外は、実施例1と同じ製造条件である面材強化発泡体を得た。
ガラス繊維を結束するバインダー量を4質量%にした以外は、実施例1と同じである面材強化発泡体を得た。
ガラス繊維不織布に含浸させる熱可塑性樹脂の目付(単位面積あたりの質量)を25g/m2とし、強化面材中のガラス繊維含有量を50質量%にした以外は、実施例1と同じである面材強化発泡体を得た。
ガラス繊維不織布に含浸させる熱可塑性樹脂の目付(単位面積あたりの質量)を110g/m2とし、強化面材中のガラス繊維含有量を19質量%にした以外は、実施例1と同じである面材強化発泡体を得た。
なお、2010年9月14日に出願された日本特許出願2010-206018号の明細書、特許請求の範囲、及び要約書の全内容をここに引用し、本発明の明細書の開示として、取り入れるものである。
Claims (10)
- ガラス繊維不織布と熱可塑性樹脂からなる強化面材を、ストランド連続押出法による発泡倍率10~40倍の非架橋の熱可塑性樹脂によるストランド集束発泡体の両表面に積層した面材強化発泡体であって、前記ガラス繊維不織布の引張弾性率が0.7~1.2kgf/mm2であり、該ガラス繊維不織布を構成するガラス繊維の平均繊維長が15~100mmであり、前記強化面材中のガラス繊維の含有量が25~40質量%であり、かつ、強化面材の引張弾性率が0.8~2.0kgf/mm2であることを特徴とする面材強化発泡体。
- 前記ガラス繊維不織布は、ガラス繊維不織布中のバインダーが固形分として5~20質量%である請求項1に記載の面材強化発泡体。
- 前記バインダーの固形分中に0.1~3.0質量%の架橋樹脂を含有する請求項1又は2に記載の面材強化発泡体。
- 面材強化発泡体におけるガラス繊維の含有量が、10~20質量%である請求項1~3のいずれかに記載の面材強化発泡体。
- 前記熱可塑性樹脂が、非架橋のポリオレフィン樹脂である請求項1~4のいずれかに記載の面材強化発泡体。
- 前記ポリオレフィン樹脂が、メルトフローレート(230℃)が5~30g/10minのポリプロピレン系樹脂である請求項5に記載の面材強化発泡体。
- 前記熱可塑性樹脂が、密度が900~930kg/m3の、直鎖状の低密度ポリエチレンである請求項1~6のいずれかに記載の面材強化発泡体。
- 前記バインダーが、ウレタン樹脂、アクリル樹脂及び酢酸ビニル樹脂からなる群から選ばれる少なくとも1種の樹脂である請求項2~7のいずれかに記載の面材強化発泡体。
- 前記架橋樹脂が、ポリビニルアルコール又は多官能型アクリルポリオールである請求項3~8のいずれかに記載の面材強化発泡体。
- 請求項1~9のいずれかに記載の面材強化発泡体を成形して得られる成形体。
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2012534019A JP5840616B2 (ja) | 2010-09-14 | 2011-09-13 | 面材強化発泡体 |
CN2011800372600A CN103038059A (zh) | 2010-09-14 | 2011-09-13 | 面材强化发泡体 |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2010-206018 | 2010-09-14 | ||
JP2010206018 | 2010-09-14 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2012036170A1 true WO2012036170A1 (ja) | 2012-03-22 |
Family
ID=45831628
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/JP2011/070897 WO2012036170A1 (ja) | 2010-09-14 | 2011-09-13 | 面材強化発泡体 |
Country Status (3)
Country | Link |
---|---|
JP (1) | JP5840616B2 (ja) |
CN (1) | CN103038059A (ja) |
WO (1) | WO2012036170A1 (ja) |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH0344570B2 (ja) * | 1985-07-03 | 1991-07-08 | Ube Industries | |
JPH0732397A (ja) * | 1993-07-15 | 1995-02-03 | Mitsui Toatsu Chem Inc | 積層成形品の連続製造方法及びその装置 |
JPH10510494A (ja) * | 1995-10-04 | 1998-10-13 | イソスポルト・フエアブントバウタイレ・ゲゼルシヤフト・ミツト・ベシユレンクテル・ハフツング | 合成パネル及びその製造方法 |
JP2008174073A (ja) * | 2007-01-18 | 2008-07-31 | Sanwa Kogyo Kk | 車両用成形内装材 |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP3044570B2 (ja) * | 1990-11-24 | 2000-05-22 | アルスイス エアーレックス エージー | 熱可塑性サンドイッチ材製品の製造法 |
JPH06198794A (ja) * | 1992-12-28 | 1994-07-19 | Mitsui Toatsu Chem Inc | 複合構造体 |
JPH06293097A (ja) * | 1993-04-09 | 1994-10-21 | Toray Ind Inc | 強化発泡体 |
JPH0826148A (ja) * | 1994-07-12 | 1996-01-30 | Bitsugu:Kk | 自動車の外装材 |
US6030907A (en) * | 1996-07-29 | 2000-02-29 | Sowa Chemical Co., Ltd. | Composite substrate for plastic reinforcement, and fiber-reinforced plastic using such composite substrate |
CN101570987A (zh) * | 2009-05-27 | 2009-11-04 | 董升顺 | 一种聚氨酯复合保温板及其制作方法 |
CN101736476A (zh) * | 2010-01-10 | 2010-06-16 | 常州同维佳业新材料科技有限公司 | 一种泡沫填充的立体增强材料 |
-
2011
- 2011-09-13 WO PCT/JP2011/070897 patent/WO2012036170A1/ja active Application Filing
- 2011-09-13 CN CN2011800372600A patent/CN103038059A/zh active Pending
- 2011-09-13 JP JP2012534019A patent/JP5840616B2/ja not_active Expired - Fee Related
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH0344570B2 (ja) * | 1985-07-03 | 1991-07-08 | Ube Industries | |
JPH0732397A (ja) * | 1993-07-15 | 1995-02-03 | Mitsui Toatsu Chem Inc | 積層成形品の連続製造方法及びその装置 |
JPH10510494A (ja) * | 1995-10-04 | 1998-10-13 | イソスポルト・フエアブントバウタイレ・ゲゼルシヤフト・ミツト・ベシユレンクテル・ハフツング | 合成パネル及びその製造方法 |
JP2008174073A (ja) * | 2007-01-18 | 2008-07-31 | Sanwa Kogyo Kk | 車両用成形内装材 |
Also Published As
Publication number | Publication date |
---|---|
CN103038059A (zh) | 2013-04-10 |
JPWO2012036170A1 (ja) | 2014-02-03 |
JP5840616B2 (ja) | 2016-01-06 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US5300360A (en) | Thermoplastic composite adhesive film | |
US20060246797A1 (en) | Sound absorbing laminates | |
JPH06344431A (ja) | 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 | |
JP5830470B2 (ja) | 発泡体、面材強化発泡体及び成形体 | |
EP2751197B1 (de) | Thermoplastische elastomerzusammensetzung, folie und verwendung | |
JP5840616B2 (ja) | 面材強化発泡体 | |
JP4580066B2 (ja) | フッ素系樹脂積層体及びそれからなる成形体 | |
JP2004276442A (ja) | 成形体 | |
KR100755102B1 (ko) | 자동차내장 천정성형용 부재 및 이를 사용한 자동차내장천정부재 | |
JP3070960B2 (ja) | 積層体及びこのものからの成形品 | |
JP2006315213A (ja) | 自動車内装材用基材 | |
JP3884670B2 (ja) | 積層複合体の製造方法 | |
JP2018024247A (ja) | 加飾フィルムおよびそれを用いた加飾成形体の製造方法 | |
JP2018009159A (ja) | 加飾フィルムおよびそれを用いた加飾成形体の製造方法 | |
JP2018016071A (ja) | 加飾フィルムおよびそれを用いた加飾成形体の製造方法 | |
US20140065351A1 (en) | Forming cellular material by melt-stretching melt-stretchable material | |
JP6859894B2 (ja) | 加飾フィルムおよびそれを用いた加飾成形体の製造方法 | |
JP2000264991A (ja) | ポリオレフィン系樹脂発泡体の製造方法 | |
CN114311898A (zh) | 一种冷裱复合膜用聚丙烯薄膜及其制备方法和冷裱复合膜 | |
JP2010247387A (ja) | 粘着部材 | |
JP2000218750A (ja) | 強化樹脂シート | |
JP2000015729A (ja) | 分散法スタンパブルシートの膨張成形品および分散法スタンパブルシート | |
JP3912155B2 (ja) | 樹脂フィルムの熱成形方法及び加飾樹脂成形体の製造方法 | |
CN116554624A (zh) | 聚乙烯醇缩丁醛改性材料及其制备方法与应用 | |
CN118288649A (en) | Buffer packaging material and application thereof |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
WWE | Wipo information: entry into national phase |
Ref document number: 201180037260.0 Country of ref document: CN |
|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 11825170 Country of ref document: EP Kind code of ref document: A1 |
|
ENP | Entry into the national phase |
Ref document number: 2012534019 Country of ref document: JP Kind code of ref document: A |
|
NENP | Non-entry into the national phase |
Ref country code: DE |
|
122 | Ep: pct application non-entry in european phase |
Ref document number: 11825170 Country of ref document: EP Kind code of ref document: A1 |