CN106817896A - 树脂成型品和树脂成型品的制造方法以及树脂成型品的制造装置 - Google Patents

树脂成型品和树脂成型品的制造方法以及树脂成型品的制造装置 Download PDF

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Publication number
CN106817896A
CN106817896A CN201680002253.XA CN201680002253A CN106817896A CN 106817896 A CN106817896 A CN 106817896A CN 201680002253 A CN201680002253 A CN 201680002253A CN 106817896 A CN106817896 A CN 106817896A
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Prior art keywords
resin
skin material
synthetic resin
formed body
adhesive linkage
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铃木正人
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Tian Sheng Electrical Appliance Industry Co Ltd
Tensho Electric Industries Co Ltd
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Tian Sheng Electrical Appliance Industry Co Ltd
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/40—Applying molten plastics, e.g. hot melt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明提供一种树脂成型品，其确保由纤维混炼带来的强度、刚性、轻量化之类的特点，并且表面的平滑化、外观的美丽程度等表面性状优异，同时耐候性、耐紫外线性、耐光性也优异。该树脂成型品(10)为在由碳纤维、玻璃纤维或它们的复合纤维形成的纤维基材的成型体(1)粘贴有具有粘接层(2)的树脂表皮材料(3)的构成，为了制造该树脂成型品，在将纤维与树脂混合而成的成型体放置于托盘夹具(23)之后，在该成型体的上方配置具有粘接层的树脂表皮材料并使该表皮材料的粘接层向下，使成型体和树脂表皮材料的周围为负压状态，并且对树脂表皮材料进行加热，使托盘夹具上升从而使成型体与软化后的树脂表皮材料密合，使托盘夹具的上方区域为加压状态，然后打开托盘夹具的周围，取出树脂表皮材料被覆成型体。

Description

树脂成型品和树脂成型品的制造方法以及树脂成型品的制造 装置
技术领域
本发明涉及树脂成型品和树脂成型品的制造方法以及树脂成型品的制造装置。
背景技术
一直以来已知有将混炼纤维材料和树脂材料而成的原材料成型为所期望形状的成型品，例如使用了碳纤维作为纤维材料的纤维增强塑料就是其的一个例子，该成型品与金属制成型品相比强度、刚性优异，并且轻量、腐蚀也少，从这点考虑被用作各种量产结构部件。另外，着眼于其量产性，除了汽车的内饰件、外饰件以外，还有家电制品、体育用品等多种多样的用途。
另外，作为对这种纤维增强塑料部件施以涂布来制成制品的技术，公开了专利文献1所示的涂膜形成方法和涂布制品，其是形成了下述构成：该构成对光反射性颜料的膜厚和平行光线透射率进行了规定，以使在镜面反射光方向(又称为正反射光方向)呈金属光泽、在除此以外的方向呈碳纤维增强塑料的消光的原材料感。
专利文献2的汽车用外饰件使用通过添加炭黑和塑料制染料作为着色剂、除了混炼PC和PBT以外还以几～几十重量％的比例混炼丙烯腈-苯乙烯树脂来进行聚合物合金化而得到的树脂材料，由此就算不进行涂布也可得到深邃感、表面硬度。另外，还公开了使汽车的内装部件能够简易地得到发光功能的汽车用功能部件(专利文献3)、在不使用黑色涂料的情况下具备与以往同等的美观性、耐化学药品性等的涂布低亮度颜色的汽车车身和汽车部件(专利文献4)。此外，如专利文献5～7所示，还公开了使装饰膜、片材粘附于粘附体的真空成型方法和真空成型机。
现有技术文献
专利文献
专利文献1：日本特开2012-200681号公报
专利文献2：日本特开平11-106518号公报
专利文献3：国际公开WO2013/022027号公报
专利文献4：日本特开平5-293434号公报
专利文献5：日本特开2015-44285号公报
专利文献6：日本特开2012-116094公报
专利文献7：日本特开2012-96416公报
发明内容
发明要解决的问题
混炼纤维而成的成型品虽然如上所述具有强度、刚性优异而且轻量的优点，但纤维质的部分暴露在表面，因此成型品的表面无论如何都是粗糙面，会有形成存在凹凸的表面的不良情况。因此，根据成型品的用途，需要在后续工序中进行涂布，或者由熟练工人反复进行涂布和表面研磨来使之平滑化。这样，现有的纤维增强成型品就存在下述问题：后续工序的表面处理麻烦，价格高，而且由于进行涂布和研磨操作的熟练工人的个人差异而会使表面平滑化的品质产生偏差。另外，尤其是在户外使用碳纤维的成型品的情况下，要求耐候性、耐紫外线性。
本发明的目的在于提供一种树脂成型品，其确保由纤维混炼带来的强度、刚性、轻量化之类的特点，并且表面的平滑化、外观的美丽程度等表面性状优异，同时耐候性、耐紫外线性、耐光性也优异。
本发明的目的还在于提供树脂成型品的制造方法和制造装置，它们可实现以纤维原材料为基体的成型体的表面处理的容易化、工序数的削减、表面平滑化等表面性状的均匀化。
用于解决问题的手段
本发明涉及一种树脂成型品，其是将具有粘接层的树脂表皮材料粘贴于由碳纤维、玻璃纤维或它们的复合纤维形成的纤维基材的成型体而成的。
根据本发明的一个方案，其特征在于，所述成型体是将ABS、聚碳酸酯、聚丙烯酸酯类(又称为亚克力；acryl)、尼龙中的至少任一种作为结合剂成型于所述纤维基材而成的。
另外，根据本发明的另一方案，其特征在于，所述树脂表皮材料是在树脂膜的下侧附着有粘接层、在所述成型体的表面形成有装饰层。
根据本发明的又一方案，其特征在于，所述树脂表皮材料是在树脂膜的下侧附着有粘接层、在所述树脂膜与所述粘接层之间夹有装饰层。
根据本发明的又一方案，其特征在于，所述树脂表皮材料是在对所述树脂膜的下表面进行了蚀刻之后附着粘接层而成的。
根据本发明的又一方案，其特征在于，所述树脂表皮材料为聚丙烯酸酯类材料、聚碳酸酯材料、ABS材料、PET材料、氯乙烯材料、聚氨酯材料、聚丙烯材料中的至少任一种。
根据本发明的又一方案，其特征在于，所述树脂表皮材料的厚度为0.1mm～0.5mm。
本发明涉及一种树脂成型品的制造方法，其特征在于，在将由碳纤维、玻璃纤维或它们的复合纤维形成的纤维基材的成型体放置于托盘夹具(tray)之后，在所述成型体的上方配置具有粘接层的树脂表皮材料并使该表皮材料的所述粘接层向下，使所述成型体和所述树脂表皮材料的周围为负压状态，并且对所述树脂表皮材料进行加热，使所述托盘夹具上升从而使所述成型体与软化后的所述树脂表皮材料密合，进而使所述托盘夹具的上方区域为加压状态，然后打开所述托盘夹具的周围，取出树脂表皮材料被覆成型体。
根据本发明的树脂成型品的制造方法的一个方案，其特征在于，所述树脂表皮材料是在树脂膜的下侧附着有粘接层、在所述成型体的表面形成有装饰层。
根据本发明的树脂成型品的制造方法的另一方案，其特征在于，所述树脂表皮材料是在树脂膜的下侧附着有粘接层、在所述树脂膜与所述粘接层之间夹有装饰层。
根据本发明的树脂成型品的制造方法的又一方案，其特征在于，所述树脂表皮材料是在对所述树脂膜的下表面进行了蚀刻之后附着粘接层而成的。
根据本发明的树脂成型品的制造方法的又一方案，其特征在于，所述树脂表皮材料为聚丙烯酸酯类材料、聚碳酸酯材料、ABS材料、PET材料、氯乙烯材料、聚氨酯材料、聚丙烯材料中的至少任一种。
根据本发明的树脂成型品的制造方法的又一方案，其特征在于，所述树脂表皮材料的厚度为0.1mm～0.5mm。
根据本发明的树脂成型品的制造方法的又一方案，其特征在于，所述成型体是将ABS、聚碳酸酯、聚丙烯酸酯类、尼龙作为结合剂成型于所述纤维基材而成的。
本发明涉及一种树脂成型品的制造装置，其具有：下腔室箱，该下腔室箱以上下可动的方式收纳有纤维成型体的托盘夹具；上腔室箱，该上腔室箱内置加热器，并且相对于所述下腔室箱上下可动；树脂表皮材料，该树脂表皮材料拉设在所述上下腔室箱之间；负压加载机构，该负压加载机构与所述上下腔室箱内连通；气动加载机构，该气动加载机构与所述上腔室箱内连通；所述托盘夹具的上下动驱动装置；以及所述上腔室箱的上下动驱动装置，其中，所述制造装置被构成为通过由所述下腔室箱的上升引起的所述托盘夹具上的所述成型体对所述树脂表皮材料的按压、所述负压加载机构和所述气动加载机构的施加、释放以及所述加热器的加热而使所述树脂表皮材料粘附于所述成型体。
发明效果
根据本发明，可得到一种树脂成型品，其确保由纤维混炼带来的强度、刚性、轻量化之类的特点，并且表面的平滑化、外观的美丽程度等表面性状优异，同时耐候性、耐紫外线性、耐光性也优异。另外，可得到树脂成型品的制造方法和制造装置，它们可实现以纤维原材料为基体的成型体的表面处理的容易化、工序数的削减、表面平滑化等表面性状的均匀化。
附图说明
图1是本发明的实施例的树脂成型品的放大剖视图。
图2是本发明的另一实施例的树脂成型品的放大剖视图。
图3是本发明的又一实施例的树脂成型品的放大剖视图。
图4是本发明的又一实施例的树脂成型品的放大剖视图。
图5是本发明的实施例的树脂成型品的制造装置的纵剖视图。
图6是本发明的实施例的树脂成型品的制造工序的前段部分的示意图。
图7是表示图6所示的树脂成型品的制造工序的后段部分的示意图。
图8是表示本发明的树脂成型品的使用例的立体图。
图9是表示本发明的树脂成型品的另一使用例的立体图。
符号说明
1 成型体
2 粘接层
3、29 树脂表皮膜(透明树脂膜)
4 装饰层
5 蚀刻
10 树脂成型品
20 树脂成型品的制造装置
21 下腔室箱
22 上腔室箱
23 托盘夹具
24、31 上下动驱动装置
26 真空罐
27 切换阀
28 保持框
30 加热器
32 气压罐(pneumatic tank)
33 切割器
41 乘用车的保险杠
42 侧视镜
50 高尔夫球杆
具体实施方式
接着，参照附图对本发明的各种实施例进行说明。
图1～图4示出了本发明的各种实施例的树脂成型品10，图1的实施例为下述例子：将由碳纤维、玻璃纤维或它们的复合纤维形成的纤维基材与结合剂混合成型，由此得到成型体1，在成型体1的上表面隔着粘接层2粘贴树脂表皮膜例如透明树脂膜3来制成树脂成型品10。对于混合了纤维材料的成型体1来说，其表面由于纤维成分而成为凹凸面，但通过在其凹凸表面粘贴树脂膜3可得到平滑的表面，作为汽车的内饰件、保险杠等外饰件在不进行涂布、表面研磨的情况下即可制成美丽的内外饰件。并且，将纤维原材料和树脂原材料混合成型而得到的成型体的强度、刚性优异，而且轻量，并且量产性也优异。
作为纤维基材的成型体的成型方法，除了如上所述将纤维基材和被用作粘结剂的结合剂混合成型的方法以外，还可以列举出下述等各种成型方法：对纤维原材料进行纺织或针织等来成型；使纺织纤维原材料而形成的纤维基材缠绕结合剂来成型；使针织纤维原材料而形成的纤维基材缠绕结合剂来成型；在以上述那样的各种方法将纤维基材成型之后进一步对表面实施底涂；在以上述那样的各种方法将纤维基材成型之后进一步对表面实施底涂并进一步对表面进行砂磨，但是纤维基材的成型体的成型方法不被限定。另外，作为树脂表皮膜，可以列举出能够粘贴于纤维基材的成型体的各种合成树脂片。一个例子是使用聚丙烯酸酯类材料作为透明树脂膜3，由此耐候性、耐紫外线性良好；另外，当制成PC材料、ABS材料的薄膜时，成型性良好而能够量产，它们可根据用途来适当选择。对于粘接层来说，聚丙烯酸酯系粘接剂是合适的。另外，包含粘接层的树脂表皮膜(透明树脂膜3)的厚度t优选为0.1mm～0.5mm，其也是根据成型品的使用部位等用途而任意确定的。成型体1、粘接层2、树脂表皮膜3的各构成在以下实施例中也相同。此外，这里是除了聚丙烯酸酯类材料、PC材料、ABS材料以外还可采用PET材料、氯乙烯材料、聚氨酯材料、聚丙烯材料作为所述树脂表皮膜的一个例子。并且，其是可采用ABS、聚碳酸酯、聚丙烯酸酯类、尼龙作为结合剂的材料的例子。但是，树脂表皮膜的材质不限于这些，只要是在后述的粘贴工序中可粘贴于成型体的树脂片就行；结合剂不限于此，只要是足以将纤维基材成型的材料就行。
图2所示的实施例的树脂成型品10通过印刷机构等在由纤维基材与树脂材料混合成型而得到的成型体1的表面形成有文字、图形等装饰层4，在包含该装饰层4的成型体1的表面附着有粘接层2，进而在粘接层2的上表面粘贴有透明膜3。通过以聚丙烯酸酯系粘接剂构成粘接层2，从透明膜3的外表面看到成型体的装饰层4。
图3的实施例的树脂成型品10在成型体1的上表面附着有粘接层2，以装饰层4被夹在该粘接层2与透明膜3之间的形态在下侧的粘接层2粘贴有透明膜3。成型体1的表面的凹凸被透明膜3平滑化，并且从透明膜3的外表面看到装饰层4，这与图2的实施例是相同的。
图4所例示的树脂成型品10对树脂膜的下表面实施了蚀刻5，实施了该蚀刻的面隔着粘接层2粘贴于成型体1的上表面。使树脂膜为透明膜，并且以所期望的图案形成蚀刻，由此从透明膜3的外表面以经装饰的面的形式看到蚀刻。另外，通过蚀刻使与粘接层2的结合变得更可靠，形成为表面性状坚固的树脂成型品10。
接着，参照图5～图7对本发明的树脂成型品的制造装置和制造方法进行说明。参照图5，本实施例的树脂成型品的制造装置20具有可上下分离的下腔室箱21和上腔室箱22。在下腔室箱21内以上下可动的方式配置有托盘夹具23，该托盘夹具23用于放置上述由碳纤维、玻璃纤维或它们的复合纤维形成的纤维基材的成型体1(由虚拟线表示)。具体来说，在下腔室箱21的下侧设置上下动驱动装置24，该驱动装置24的致动杆24a被插入下腔室箱21内，托盘夹具23的支撑台25与致动杆24a连结。下腔室箱21与进行真空抽吸的装置例如真空罐26连结。真空罐26还经由切换阀27与上腔室箱22连通。另外，在下腔室箱21的上端设置膜保持框28，在该保持框28以可更换的方式安装有用图1～图4进行了说明的由树脂膜(透明膜)、粘接层、装饰层等形成的树脂表皮膜29，以将树脂表皮膜29安装于下腔室箱21的上端开口部的状态将该箱内保持为密闭状态。
在相对于下腔室箱21上升、下降的上腔室箱22内，在其上部部位配置有加热器30。在上腔室箱22的上方位置设置有上下动驱动装置31，其致动杆31a与上腔室箱22的上表面连结。另外，上腔室箱22经由切换阀27与用于使该腔室箱内为加压状态的加压装置例如气压罐32连结。以使上腔室箱22下降而与安装有树脂表皮膜29的下腔室箱21接合的状态将上下腔室箱22、21内保持为密闭状态。
参照图6、图7，对以上述构成的树脂成型品的制造装置来制造本发明的树脂成型品的方法进行说明。首先，如图6(a)所示，通过驱动装置31使上腔室箱22上升，并在下腔室箱21内的托盘夹具23上放置将对象制品的纤维基材混合成型而得到的成型体1，同时将所期望的树脂表皮膜29设置于下腔室箱上端的树脂表皮膜的保持框28。以该状态将下腔室箱21内形成为密闭状态。对于树脂表皮膜29，根据对象制品的种类、用途等来选择如用图1～图4进行了说明那样的由透明膜和粘接层构成的表皮膜、由透明膜、装饰层和粘接层构成的表皮膜或者由对下表面实施了蚀刻的透明膜和粘接层构成的表皮膜。此外，树脂表皮膜29以其粘接层向下即与托盘夹具23上的成型体1相对置的方向设置于保持框28。
接着，如图6(b)所示，通过驱动装置31使上腔室箱22下降而与下腔室箱21接合，并且如图6(c)所示对切换阀27进行操作而使得以真空抽吸装置(真空罐26)对上下腔室箱22、21内进行真空抽吸，由此设置为负压状态。另外，同时加载加热器30来对箱内的树脂表皮膜29进行加热，使表皮膜软化。树脂表皮膜29在图6(c)中略微向托盘夹具23侧下垂是表示通过该加热器30的加热使表皮膜发生了软化。
接着，如图6(d)所示，通过驱动装置24使托盘夹具23上升来将托盘夹具23上的成型体1按压到软化后的树脂表皮膜29，将树脂表皮膜29粘贴于成型体1。
之后，以开动了上腔室箱22内的加热器30的状态使上腔室箱22内由负压状态变为大气开放或气动状态，由此进一步促进树脂表皮膜29粘贴至成型体表面。图6(e)是使上腔室箱22内为大气开放的情况，图6(f)是通过气动装置和气压罐32使上腔室箱22内为气动状态的情况，作为制造工序可以采用其中的某一个，但在根据对象制品而需要更强的薄膜粘贴的情况下采用图6(f)的气动附加方式。之后，如图7(a)所示解除气动和真空抽吸，同时使上腔室箱22上升，由此从托盘夹具23取出粘贴有表皮膜29的树脂成型品。在该状态下树脂表皮膜29的周边部略微从成型体1突出，因此如图7(b)所示进行用切割器33将从成型体1突出的树脂表皮膜29的部分裁切的修剪加工，由此制成树脂成型品10。此外，在不存在树脂成型品的树脂表皮膜突出的情况下，当然可以省略图7(b)的修剪加工。
本发明的实施例涉及施加了表面处理的树脂成型品，其强度、刚性优异，而且轻量并具有耐候性、耐紫外线性、表面凹凸的平滑化和美丽的外观性，因此被用于各种地方。图8是适用于乘用车的保险杠41和侧视镜42的背部保持构件42a的例子。对现有的汽车进行简单的施工就可以更换为本实施例的树脂成型品，而且从强度等方面考虑可充分地满足功能，进而可作为呈现出充分的美观的汽车部件来提供。除此以外，还可以适用于车辆的内饰件例如驾驶座前面的仪表板、方向盘部分等各种汽车部件。另外，还可以适用于例如钓竿、高尔夫用具、打球用球拍、登山用具或者作为护理用具的杖、动力服、步行训练器材等。图9是在高尔夫球杆50的部分使用了本发明的树脂成型品10的例子，其能够实现在可满足现有的高尔夫球杆所要求的性能的同时外观也优异的高尔夫球杆。本发明的树脂成型品不限于上述两个使用例，可以适用于各种日常部件、结构部件，其应用范围广泛。
产业上的可利用性
根据本发明，可得到一种树脂成型品，其确保由纤维混炼带来的强度、刚性、轻量化之类的特点，并且表面的平滑化、外观的美丽程度等表面性状优异，同时耐候性、耐紫外线性、耐光性也优异。另外，可得到树脂成型品的制造方法和制造装置，它们可实现以纤维原材料为基体的成型体的表面处理的容易化、工序数的削减、表面平滑化等表面性状的均匀化。

Claims (15)

1.一种树脂成型品，其是将具有粘接层的树脂表皮材料粘贴于由碳纤维、玻璃纤维或它们的复合纤维形成的纤维基材的成型体而成的。
2.根据权利要求1所述的树脂成型品，其特征在于，所述成型体是将ABS、聚碳酸酯、聚丙烯酸酯类、尼龙中的至少任一种作为结合剂成型于所述纤维基材而成的。
3.根据权利要求1或2所述的树脂成型品，其特征在于，所述树脂表皮材料是在树脂膜的下侧附着有粘接层、在所述成型体的表面形成有装饰层。
4.根据权利要求1～3中任一项所述的树脂成型品，其特征在于，所述树脂表皮材料是在树脂膜的下侧附着有粘接层、在所述树脂膜与所述粘接层之间夹有装饰层。
5.根据权利要求1～4中任一项所述的树脂成型品，其特征在于，所述树脂表皮材料是在对所述树脂膜的下表面进行蚀刻之后附着粘接层而成的。
6.根据权利要求1～5中任一项所述的树脂成型品，其特征在于，所述树脂表皮材料为聚丙烯酸酯类材料、聚碳酸酯材料、ABS材料、PET材料、氯乙烯材料、聚氨酯材料、聚丙烯材料中的至少任一种。
7.根据权利要求1～6中任一项所述的树脂成型品，其特征在于，所述树脂表皮材料的厚度为0.1mm～0.5mm。
8.一种树脂成型品的制造方法，其特征在于，在将由碳纤维、玻璃纤维或它们的复合纤维形成的纤维基材的成型体放置于托盘夹具之后，在所述成型体的上方配置具有粘接层的树脂表皮材料并使该表皮材料的所述粘接层向下，使所述成型体和所述树脂表皮材料的周围为负压状态，并且对所述树脂表皮材料进行加热，使所述托盘夹具上升从而使所述成型体与软化后的所述树脂表皮材料密合，进而使所述托盘夹具的上方区域为加压状态，然后打开所述托盘夹具的周围，取出树脂表皮材料被覆成型体。
9.根据权利要求8所述的树脂成型品的制造方法，其特征在于，所述树脂表皮材料是在树脂膜的下侧附着有粘接层、在所述成型体的表面形成有装饰层。
10.根据权利要求8或9所述的树脂成型品的制造方法，其特征在于，所述树脂表皮材料是在树脂膜的下侧附着有粘接层、在所述树脂膜与所述粘接层之间夹有装饰层。
11.根据权利要求8～10中任一项所述的树脂成型品的制造方法，其特征在于，所述树脂表皮材料是在对所述树脂膜的下表面进行了蚀刻之后附着粘接层而成的。
12.根据权利要求8～11中任一项所述的树脂成型品的制造方法，其特征在于，所述树脂表皮材料为聚丙烯酸酯类材料、聚碳酸酯材料、ABS材料、PET材料、氯乙烯材料、聚氨酯材料、聚丙烯材料中的至少任一种。
13.根据权利要求8～12中任一项所述的树脂成型品的制造方法，其特征在于，所述树脂表皮材料的厚度为0.1mm～0.5mm。
14.根据权利要求8～13中任一项所述的树脂成型品的制造方法，其特征在于，所述成型体是将ABS、聚碳酸酯、聚丙烯酸酯类、尼龙中的至少任一种作为结合剂成型于所述纤维基材而成的。
15.一种树脂成型品的制造装置，其特征在于，其具有：
下腔室箱，该下腔室箱以上下可动的方式收纳有纤维成型体的托盘夹具；
上腔室箱，该上腔室箱内置加热器，并且相对于所述下腔室箱上下可动；
树脂表皮材料，该树脂表皮材料拉设在所述上下腔室箱之间；
负压加载机构，该负压加载机构与所述上下腔室箱内连通；
气动加载机构，该气动加载机构与所述上腔室箱内连通；
所述托盘夹具的上下动驱动装置；以及
所述上腔室箱的上下动驱动装置，
其中，所述制造装置被构成为通过由所述下腔室箱的上升引起的所述托盘夹具上的所述成型体对所述树脂表皮材料的按压、所述负压加载机构和所述气动加载机构的施加、释放以及所述加热器的加热而使所述树脂表皮材料粘附于所述成型体。
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