JP2000117908A - Member for molding and inner part - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a member for molding having high rigidity, excellent molding characteristics and dimensional stability, which is lightweight and can be reclaimed as a same type of plastic by forming a plastic sheet base from a plastic sheet having a mica kneaded therein. SOLUTION: A mica-containing sheet 2 is formed by kneading an inorganic pigment of a mica mineral such as a muscovite or the like in a sheet or a flake shape having clear cleavability to a plastic sheet, and it is pressed/heated and molded for manufacturing a part for molding. At this time, a skin material 4 for outer decoration and a spun bonded nonwoven fabric 1 for outer decoration are adhered on at least one surface thereof. A sheet having a polypropylene resin as a main component is preferable for the plastic sheet. In the case that a weight is concerned, a thick material of an expanded plastic sheet is adhered to the plastic sheet containing a mica or the like for using.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention mainly relates to automobiles,
It is related to a laminate that is molded and used so as to follow a flat or curved shape as an interior material used for ceilings, side surfaces, etc. of aircraft or ships, and various buildings. The present invention relates to a lightweight molding member having good moldability and an interior part using the same.

[0002]

2. Description of the Related Art Conventionally, base materials used for interiors such as ceilings, doors, and side walls of automobiles are provided with a predetermined fiber assembly by adding certain thermosetting fibers to natural fibers or synthetic fibers which have been opened. What was pressed uniformly and formed into a predetermined curved surface shape, a paper corrugated cardboard sheet was sandwiched in a hot press and forcibly formed into a curved surface, a polypropylene sheet reinforced with glass fiber, Plastic sheet members made of urethane sheets are known.

[0003] However, molding members obtained by these combinations have inherent problems in molding workability and cost, and have advantages and disadvantages in properties such as heat resistance, moisture resistance and dimensional stability of molded products. In fact, there is a need for improvement. Above all, polypropylene sheets and urethane sheets reinforced with glass fibers have excellent properties such as heat resistance, moisture resistance and dimensional stability of the molded product, and are lightweight by using plastic with foaming properties. The sheet is softened by heating in a heated heating oven, and then it can be press-formed with a cooling mold, so that only one cooling mold is required. There is an advantage that can be manufactured.

However, since glass fibers are used, it is necessary to remarkably improve the working environment in the process of manufacturing a molding member, and even if these laminates are disposed of after being used as interior materials, they must be reused. At present, even if it is incinerated, it has no choice but to landfill because glass fiber is mixed.

[0005]

Accordingly, the present invention provides
High rigidity, good workability at the time of installation, excellent moldability at the time of pressing, no defects such as wrinkles, excellent properties such as heat resistance, moisture resistance, dimensional stability, etc. of the product after molding, light weight, An object of the present invention is to provide an excellent molding member and an interior part using the same, which can simplify a hot press process and can be recycled into similar plastics after use.

[0006]

The present invention has the following configuration. 1. A molding member comprising a plastic sheet substrate, pressurized / heated, molded, and a skin material bonded to at least one surface thereof, wherein the plastic sheet substrate is a plastic sheet kneaded with mica. Molding member to do. 2. 2. The molding member according to the above item 1, wherein the plastic sheet substrate is a laminate obtained by laminating a foamed plastic sheet on a plastic sheet kneaded with mica. 3. 3. The molding member according to the above item 1 or 2, wherein the plastic sheet obtained by kneading the mica is a foamed plastic sheet. 4. 4. The molding member according to the above 1, 2 or 3, wherein the maximum bending load of the molding member is 1 to 5 kgf. 5. An interior part using the molding member according to any one of the above items 1 to 4.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION The present inventors have intensively studied a method for satisfying rigidity and stretchability required for a board-shaped laminate having thermoformability. Considering basic physical properties such as moldability and dimensional stability, a plastic sheet is most preferable. Therefore, the material was examined. When a polyethylene sheet is used as the molding substrate, the temperature during heat molding can be reduced. From this viewpoint, the polyethylene sheet is excellent in low-temperature moldability, but has a drawback that it is easily deformed and distorted under high temperature conditions during use.

In particular, when used as an interior part such as an automobile ceiling, the polyethylene sheet cannot withstand an environment exposed to a temperature of 90 ° C. or more for a long time. On the other hand, if a hard polyester sheet or the like is used to prevent deformation due to temperature, deformation due to temperature can be prevented, but it is necessary to raise the temperature during molding to 250 ° C. or more, which is the deformation temperature. However, there are problems such as the cost of the material and the cost of the material.

For these reasons, polypropylene that does not substantially deform in the temperature range used as interior parts is the most suitable material for interior parts, and it is preferable that polypropylene resin be the main component. However, the polypropylene sheet has insufficient rigidity unless it has a considerable thickness, and the weight increases to maintain the strength as an interior component having a large area. However, there has been a problem that rigidity is insufficient when the thickness is reduced and the weight is reduced.

Therefore, the inventors have studied in more detail. It is generally known that mixing a non-deformable inorganic substance into a soft polypropylene resin improves the strength of the plastic sheet. Among them, the method of mixing glass fiber into plastic is already known as a method for dramatically improving strength, but when glass fiber is used,
There is a problem that the short fibers are liable to float, and it is necessary to make a special improvement in the working environment in the manufacturing process of the laminate such as molding members, or reuse these laminates after using them as interior materials. However, even if it is discarded, it cannot be reused while maintaining its strength because the glass fiber breaks.Furthermore, even if it is incinerated for dumping, it is still filled with glass fiber. At present, there is no choice but to dispose of it.

[0011] From the above, the present inventors further studied a method of improving the strength of the plastic sheet and preventing the plastic sheet from being deformed. The polypropylene sheet kneaded with mica or the like is higher in rigidity and superior to glass fiber. thing,
It has been found that it is easy to reuse the loss generated in the manufacturing process. A material obtained by kneading plastic and mica in the same way as glass fiber is dramatically improved in rigidity because it is not a one-dimensional material like glass fiber but a two-dimensional material because mica is flat. It is considered that the kneading can maintain rigidity in both the vertical and horizontal directions.

For example, a 2.1 mm thick polypropylene sheet alone has a maximum bending load of about 0.5 kgf, but a polypropylene sheet containing 40% by weight of mica has a maximum bending load of 5 kgf or more. Therefore, sufficient rigidity can be maintained as an interior part.

As the inorganic material to be mixed with these polypropylenes, inorganic pigments having a plate-like or flaky shape and having a clear cleavage property are preferable. For example, kaolinite (kaolin mineral), mica, brittle mica, pyrophyllite There are light, talc, smectite, vermiculite, chlorite, septe chlorite, serpentine, stilp nomelane and montmorillonite.

Among these, the most preferred are mica-group minerals. Mica includes muscovite (muscovite),
Sericite (sericite), phlogopite (flokopite), biotite (biotite), fluorophlogopite (artificial mica), red mica, soda mica, vanadin mica, illite, chimica, paragonite, brittle mica and the like.

Among these mica, muscovite, sericite, phlogopite and the like have large tabularity in various physical properties such as particle size and aspect ratio (numerical value obtained by dividing the average diameter by the thickness). This is the most preferable in that many flat plates can be arranged therein.

As described above, in the present invention, flatness (flat shape) is used.
It is sufficient that mica is held, but among mica, a more preferable average particle size range is 3 μm to 100 μm.
m, and a more preferable average particle size range is 5 μm to 5 μm.
0 μm. Theoretically, when the average particle diameter is less than 3 μm, the orientation of mica in the forming member sheet is difficult to be parallel to the support, and when it exceeds 100 μm, part of the mica protrudes from the film layer. It is considered that as the thickness of the mica becomes about several μm, the number of layers of the oriented mica in the forming member sheet decreases, and the effect of improving the rigidity decreases.

The aspect ratio of mica is preferably 5 or more, and particularly preferably the aspect ratio is 10 or more. Theoretically, a material having an aspect ratio of less than 5 cannot be oriented parallel to the molding member sheet, so that the rigidity improving effect is poor. It is considered that the higher the aspect ratio is, the higher the number of layers of the mica in the forming member sheet is, and thus the higher the rigidity is.

Further, in order to increase the rigidity of the sheet, the higher the adhesiveness of the interface between the polypropylene resin and these mica, the higher the rigidity of the sheet. Since the adhesion at the interface affects the rigidity, it is preferable to form a sheet by appropriately adding a coupling agent acting on the interface.

Examples of the coupling agent used in the present invention include a silane coupling agent containing Si in a hydrophilic part, a titanate coupling agent containing Ti in a hydrophilic part, and an aluminum coupling agent containing Al in a hydrophilic part. Is mentioned. The structure of the coupling agent is roughly divided into a hydrophilic group that interacts with an inorganic compound such as mica and a hydrophobic group that interacts with an organic compound such as a resin. It is obtained by hydrolyzing an alkoxy group bonded to an element or Si.

Regarding the hydrophobic group of the coupling agent,
When the hydrophobic group portion is an organic oligomer, a polymer organic film is formed on the surface of the inorganic compound, which has the effect of completely hydrophobizing the surface and increasing the adhesion to the resin matrix.
When the hydrophobic group has a reactive organic functional group such as an epoxy group, a vinyl group, or an amino group, the functional group and the reactive functional group of the resin matrix are cross-linked to further improve the adhesiveness with the resin matrix. Increase. Therefore, the composition of the hydrophobic group portion of the coupling agent is determined by the compatibility with the resin as the affinity partner.

To treat mica with these coupling agents, there are a method of treating the surface of the mica with the coupling agent in advance, and a method of adding the mica together with the mica at the time of forming plastic pellets. The addition amount of these coupling agents is 0.1 to 5 parts by weight (solid content or active ingredient), preferably 0.5 to 2 parts by weight, based on 100 parts by weight (solid content) of mica. When the addition amount is less than 0.1 part by weight, the coating of the mica surface with the coupling agent becomes insufficient, which is not preferable. When the addition amount exceeds 5 parts by weight, the effect of the coupling agent reaches a plateau and is uneconomical. .

The mica treated with the coupling agent in this way has an increased hydrophobicity on the surface, so that the adhesion to the polypropylene resin is enhanced, and a high rigidity can be obtained.

However, when these thick plastic sheets are used singly as interior parts such as automobile ceilings, the weight of the plastic sheets may be too large to be suitable. After further study on this point, if a thick sheet of foamed plastic sheet was bonded to a plastic sheet containing mica, etc., the plastic sheet containing mica could be made thinner while maintaining rigidity, and as a whole laminated It is possible to reduce the weight of the body. further,
If a foaming agent can be mixed into a plastic containing mica without using these foamed plastic sheets and foamed as it is, a more inexpensive and useful laminate can be obtained.

The foamed plastic sheet used in the present invention includes foamed polypropylene, foamed polyethylene,
Foamed polycarbonate, foamed PET, foamed polystyrene, foamed urethane, semi-rigid urethane, and the like can be given. The foamed plastic sheet becomes a rigid sheet when the expansion ratio is several times, but exhibits a soft and flexible film-like property when the expansion ratio is several tens times.

In the present invention, in order to compensate for the lack of rigidity of the polypropylene sheet containing mica, the polypropylene sheet is laminated with a low-density foam sheet. The expansion ratio is about 20 to 40 times, and the thickness is about 0.5 mm to 5 mm. In order to reduce the weight, it is preferable to use a plastic sheet having a higher expansion ratio.

Such a foamed plastic sheet is
Pellets made by kneading various foaming agents are made and made into a non-stretched film or sheet using an extruder set to a specified temperature, or an inert gas is injected into the melted part of the extruder to create and extrude bubbles. It can be obtained by preparing pellets containing moisture and extruding them into films or sheets.

In particular, these foamed plastic sheets sometimes have insufficient melt tension when formed into a sheet, making film formation difficult. However, irradiation with an electron beam promotes crosslinking in the film to improve the melt tension. It can also be manufactured.

When the rigidity of the foamed plastic sheet produced in this manner is determined to be suitable for the purpose of the present invention, a foamed plastic sheet having a thickness of 0.5 to 2 mm and a foaming plastic sheet having a thickness of 0.5 to 2 mm with an expansion ratio of about 3 times. A 5 mm thick mica-containing plastic sheet may be used. However, when further weight reduction is required, a plastic sheet having a foaming ratio of about 30 times 1 to 5 mm and a mica-containing plastic sheet having a thickness of about 0.5 mm are combined. As described above, a two-layer structure of a mica-containing plastic sheet and a foamed plastic sheet, or a three-layer structure of a type in which a foamed plastic sheet is sandwiched between mica-containing plastic sheets according to required rigidity. Of course, this does not prevent further overlapping of the foam sheet.

The material of the foamed plastic sheet used in the present invention is preferably a high-rigidity plastic having high rigidity, such as polycarbonate or polyester, from the viewpoint of improving the rigidity, but is inferior in followability to a mold during thermoforming. For this reason, the heating mold must be heated to a high temperature, resulting in high energy cost, and it is more preferable to use a low melting point plastic such as a polypropylene sheet or a polyethylene sheet.

Further, in the laminate for molding of the present invention, various auxiliary layers such as a skin material and a backing material, which have been conventionally used, are further added to form a multilayer laminate having a moldability. Can be a body. Also,
It is common that skin material is laminated on this laminate,
In addition, various laminating layers can be formed to enhance the characteristics. For example, when dimensional stability at the time of processing is required, a laminate may be further added with a plastic sheet, a film, an aluminum foil or the like having a melting point higher than the thermoforming temperature.

The laminated structure of the laminate is determined by the generally required rigidity, elasticity and lightness. For example, when a foamed plastic sheet having a thickness of 2 mm is used, and when used as an automobile ceiling material, a mica-containing plastic sheet / foamed plastic sheet / a mica-containing plastic sheet three layers sandwiching the foamed plastic sheet. The structure is basically mentioned. Of course, depending on the required elasticity and rigidity, various layers such as a mica-containing plastic sheet / foamed plastic sheet two-layer structure, mica-containing plastic sheet / foamed plastic sheet / mica-containing plastic sheet / foamed plastic sheet / mica-containing plastic sheet, etc. Laminated molding laminates can be considered.

The thickness of these laminates is determined by the goals of rigidity and weight reduction, but is usually 1 to 5 mm.
The maximum bending load is preferably set to 1 to 5 kgf. 1mm
If it is less than the above, it is difficult to maintain the rigidity, and even if the thickness is 5 mm or more, no particular improvement in characteristics can be expected. If the maximum bending load is less than 1 kgf, one side is 1
If the size is more than 5 m, the sagging becomes large, and the workability at the time of mounting may be inferior. Even if it exceeds 5 kgf, no particular improvement in characteristics is observed.

The laminate of the present invention is easily formed by heat molding in a heating mold, so that mutual adhesion can be easily achieved. However, considering long-term use conditions and harsh environments, a new adhesive layer is provided to improve reliability. It is preferable to improve the properties. Examples of the adhesive layer used for this include a molten polyethylene layer, polypropylene, polyvinyl chloride, polystyrene, an ethylene-propylene copolymer, an ethylene-vinyl acetate copolymer or a hot melt adhesive, and an emulsion adhesive.

In particular, when a laminate obtained by laminating a base material on which molten polyethylene is laminated is used, polyethylene having a melting point of 120 ° C. is melted at the time of heat molding and shows a strong adhesive force, and follows deformation during molding. This is preferable because the molten polyethylene between the base materials is fluidized, and there is room for slight displacement, so that a molded article having good appearance can be obtained.

In the laminate of the present invention, a skin material or a backing material is formed on its exterior, or an auxiliary layer is inserted between layers of the foamed plastic sheet to improve the appearance, rigidity and stretchability. Can be. Examples of the auxiliary layer used for this purpose include an aluminum foil, a polyester film, a polyethylene terephthalate film, a polycarbonate film, a polystyrene film, and a spunbonded nonwoven fabric using these resins. The thickness of these auxiliary layers is 7 to 20 μm for aluminum foil, and 10 to 2 for polyester film.
One having a thickness of 0 μm is used. Of course, some of these may be selected and combined to form an auxiliary layer.

The purpose of these auxiliary layers is to serve as an auxiliary material for compensating for the lack of rigidity, a skin material for maintaining the aesthetic appearance of the surface, and a cushioning material for preventing rubbing noise caused by vibration. It is preferably formed on any one of the layers or on the surface of the molding laminate. In particular, as a skin material which is located on the outermost layer and becomes an exterior that can be seen by human eyes, polyester non-woven fabric skin, tricot skin, leather, synthetic leather and the like are used. As the backing material, nonwoven fabrics obtained by various manufacturing methods are mainly used.

When the molded article to be used as an interior part of the present invention is molded by heating, the molding temperature is preferably from 130 to 250 ° C., and more preferably from 160 to 2 from the viewpoint of the followability of the laminate to the heating mold.
It should be about 00 ° C. As the heat molding method, after laminating all materials other than the skin material and the back treatment material in a heating mold heated in advance at 160 ° C. to 200 ° C., the material is removed from the heating mold, and then another heating is performed. 130 ° C mold
A method using a two-stage heating type in which the skin material and the backing material are superimposed and heated and bonded at a low temperature.

Further, a method in which the second-stage mold is heated at room temperature as a non-heated mold. After preliminarily softening and holding the laminate in a hot air oven at about 200 ° C., the laminate is bonded to a heated laminate to bond the skin material and the backing material by the residual heat of the laminate, and the normal room temperature is applied. Transfer to a cooling and heating mold placed in a vacuum and pressurizing. The pressurization at this time is a pressure of about 0.5 to ¹⁰ kgf / cm ^{2 and} a pressurization time of about 30 seconds to 1 minute.

Heating at the time of the above-mentioned molding can be carried out through a heating device such as a heating tube provided in a receiving die or a pressing die through a heating steam or other heat medium, or a heat distribution for introducing hot air or another heat medium into the mold. Holes may be provided, and a heat medium may be introduced through the heat distribution holes to directly heat the laminate to a molding temperature. FIG.
1 shows a state in which a molding member is sandwiched between a receiving die having these heating means and a pressing die. After this in Figure 3,
This shows a state in which the laminate is pressed and heated, held for several tens of seconds, and hot-pressed.

[0040]

Embodiments will be described below. The numerical values such as blending and concentration are numerical values based on the weight of the solid component or the active ingredient.

Measurement of maximum bending load The laminated body was cut off by 50 mm × 150 mm, and the span width was 10 mm.
At 0 mm, the center was pressed at a speed of 50 mm / min, and a curve related to the tension and strain was obtained. Then, the load at the time when the material was broken was defined as the maximum bending load.

Example 1 40% phlogopite having a particle diameter of 40 μm and an aminosilane coupling agent were added to a polypropylene resin pellets in a Hensyl mixer so as to have a concentration of 40% and an aminosilane coupling agent in a concentration of 1%, and the resulting mixture was charged into a twin-screw extruder. The mixture was melt-kneaded to obtain phlogopite-containing pellets. The obtained pellets were extruded with a T-die extruder to obtain a polypropylene sheet (2.2 mm thick) in which phlogopite was kneaded at 40%. This was sandwiched between a pair of heat-molded blocks heated to 200 ° C. and pressure-molded at 5 kgf / m ² . Thereafter, a polyethylene sheet having a thickness of 15 μm and a 180 g / m ² tricot nonwoven fabric as a skin material are laminated on this sheet, and a 40 g / m ² polyester spun pound nonwoven fabric is laminated on the opposite surface as a back treatment material. Pressure molding was carried out at a pressure of 5 kgf between a pair of heating mold blocks heated to ℃ to obtain a desired interior part. Its maximum bending load was 3.1 kgf.

Example 2 Two polypropylene sheets (1.2 mm thick) obtained by kneading 40% of the phlogopite obtained in Example 1 were used.
Double-expanded foamed polypropylene (trade name: Pef, manufactured by Toray Industries Inc.) is sandwiched and overlapped, and
After heating in an oven at 0 ° C., the same skin material and spunbond as in Example 1 were pasted and pressed. The maximum bending load was 3.2 kgf.

Example 3 A polypropylene pellet containing 40% by weight of the phlogopite obtained in Example 1 was melt-extruded from a T-die into both sides of a foamed polypropylene having a foam thickness of 2 mm and a 25-fold expansion (trade name: Pef manufactured by Toray Industries Inc.) to a thickness of 100 μm. Lamination was performed to obtain a laminated body having a San Germanium structure using a foamed polypropylene sheet as a core material. After heating this in a 180 ° C. oven, the same skin material and spunbond as in Example 1 were pasted and cold pressed. The maximum bending load was 2.2 kgf.

Example 4 A polypropylene sheet (1.2 mm thick) obtained by kneading 40% of the phlogopite obtained in Example 1 and having the same size and a 2 mm thickness 2
5 times expanded polypropylene (PEF manufactured by Toray) is superimposed and PET is used as an auxiliary layer on the kneaded mica sheet side.
7 μm through a 15 μm thick polyethylene sheet on the side of the film 12 μm and the other expanded polypropylene sheet.
After laminating an aluminum foil having a thickness of μm and heating and pressing the same, a skin material (through a 15 μm thick polyethylene sheet on the aluminum side) and a spun bond (the PET film side) were further laminated as in Example 1. It was heated and pressed.
The maximum bending load was 2.1 kgf.

Example 5 To a resin mixture in which 70% of a polypropylene resin and 30% of a polyethylene resin were mixed, 20% of phlogopite was added, 10% of azodicarbonamide was added as a blowing agent, and 3% of divinylbenzene was added as a crosslinking aid. And mixed uniformly with a Hensyl mixer. This was formed into a sheet having a thickness of 2.5 mm by a T-die method using a vent type extruder. The obtained resin sheet was irradiated with ionizing radiation to crosslink the resin. This was heated at 230 ° C. to decompose the foaming agent to obtain a foam sheet. After softening the laminate by holding it in an oven furnace heated to 180 ° C. for 40 seconds, a polyethylene sheet having a thickness of 15 μm and a 180 g / m ² tricot nonwoven fabric as a skin material were laminated on the sheet, and 40 g / m ^{2 on} the opposite surface. the ^second polyester spunbond nonwoven fabric overlay, and pressing at a pressure 5kgf sandwiched between a pair of blocks to give a molded article of interest. Its maximum bending load was 4.1 kgf.

Comparative Example 1 An interior part was produced in the same manner as in Example 3 using a foamed polypropylene sheet containing 30 parts of glass fiber. The maximum bending load was 1.8 kgf.

[0048]

As described above, the laminate for molding and the interior part of the present invention have sufficient rigidity and good moldability.

[Brief description of the drawings]

FIG. 1 is an example of a layer configuration of a molding laminate according to the present invention. (A) Example 1, (b) Example 2, (c) Example 4 of a conceptual diagram is shown.

FIG. 2 is a conceptual diagram showing a state where a laminate is sandwiched between heating dies.

FIG. 3 is a conceptual diagram showing a state where a heating mold is pressed.

[Explanation of symbols]

 1. Spunbonded nonwoven fabric for exterior 2. 2. Mica-containing sheet Foamed plastic sheet 4. Exterior skin material 5. Adhesive layer 6. Auxiliary material layer 7. 7. Heat press type device Molding laminate

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4F055 AA21 AA24 BA10 BA23 EA04 FA05 FA06 GA31 4F100 AC05A AK01A AK01D AK04 AK07 AK41 AS00B AS00C BA02 BA03 BA04 BA05 BA06 BA10B BA10C CA23A DG15 DJ01D EJ172 EJ422 GB08

Claims (5)

[Claims] 1. A pressure-sensitive plastic sheet base material.
What is claimed is: 1. A molding member which is heated and molded, and a skin material is bonded to at least one surface thereof, wherein the plastic sheet substrate is a plastic sheet kneaded with mica. 2. The molding member according to claim 1, wherein the plastic sheet base is a laminate in which a foamed plastic sheet is bonded to a plastic sheet kneaded with mica. 3. The plastic sheet obtained by kneading the mica is a foamed plastic sheet.
Or the molding member according to claim 2. 4. A maximum bending load of the molding member is 1 to 5 kg.
The molding member according to claim 1, 2 or 3, which is f. 5. An interior part using the molding member according to any one of claims 1 to 4.