JP2001150467A - Method for manufacturing laminated panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a laminated panel by which the yield of the laminated panel using a porous rigid sheet can be enhanced by clamping a mold in such a manner that the rigid sheet does not break, when the laminated panel consisting of the porous rigid sheet and a thermoplastic resin is manufactured. SOLUTION: One piece of a porous rigid sheet 6 is arranged opposite to a mold face between the parts of a mold 21 and a molten thermoplastic resin 4' is supplied to a space between the parts of the mold 21. Further, the thermoplastic resin 4' is pressed so that the resin 4' and the rigid sheet 6 are laminated in one piece. In this case, the relationship between the bending strength A (MPa) of the rigid sheet 6 as measured by a bending test method set forth by JIS A1408 and the max. pressurized face pressure B (MPa) of the molten thermoplastic resin 4' in a shaping process from the start of its supply to the completion of its shaping, is set to meet 0<B/A<=0.5.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a laminated panel in which a thermoplastic resin layer and a porous hard layer are laminated.

[0002]

2. Description of the Related Art Conventionally, as a method of manufacturing a laminated panel in which a thermoplastic resin layer and a porous hard layer are stacked, for example, a manufacturing method as disclosed in Japanese Patent Application Laid-Open No. 1-235613, that is, male and female A skin material serving as a porous hard layer is arranged between a pair of unclosed molds, and then a molten thermoplastic resin is supplied between the skin material and a molding surface of one of the molds, and mold clamping is performed. In general, a method of laminating and integrating a skin material and a thermoplastic resin is used.

[0003]

However, in the method of manufacturing a laminated panel as described above, a high pressure is required by mold clamping in order to shape the thermoplastic resin supplied between the unclosed molds. Become. For this reason, when a porous hard plate that is easily cracked is used as the skin material, there is a possibility that the surface is cracked depending on the magnitude of the pressure contact pressure at the time of mold clamping.

For this reason, there arises a problem that the yield of the laminated panel using the porous hard plate is greatly reduced.

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and an object of the present invention is to provide a method for manufacturing a porous panel in which a porous hard plate and a thermoplastic resin are laminated. It is an object of the present invention to provide a method of manufacturing a laminated panel that can improve the yield of a laminated panel using a porous hard plate by clamping a plate so as not to break.

[0006]

Means for Solving the Problems The inventors of the present invention have conducted intensive studies to solve the above-mentioned problems, and as a result, the maximum pressing surface pressure at the time of forming a thermoplastic resin has been set to the value of the porous hard plate used. By setting the specific range based on the bending strength, a production method capable of obtaining an intended laminated panel without breaking the porous hard plate has been found.

That is, in the method of manufacturing a laminated panel according to the first invention of the present application, at least one porous hard plate is arranged between a pair of male and female molds so as to face the mold surface, and then the above-described metal mold is formed. A method of manufacturing a laminated panel by supplying a molten thermoplastic resin between molds, pressing the laminate, and laminating and integrating the porous hard plate and the thermoplastic resin.
The bending strength A (MPa) of the porous hard plate according to the bending test method specified in IS A1408, and the maximum pressing surface pressure B (MPa) during the shaping process from the start of the supply of the thermoplastic resin to the completion of shaping. ) Satisfies the following equation (1).

0 <B / A ≦ 0.5 (1) According to the above configuration, according to the bending strength of the material of the porous hard plate. Since the maximum pressurized surface during the shaping step is determined, the desired laminated panel can be obtained without breaking the porous hard plate, and as a result, the yield of the laminated panel can be improved.

Further, the product C of the pressing surface pressure C (MPa) and the pressing time H (s) during the cooling step from the completion of the shaping of the thermoplastic resin to the start of the mold opening for taking out the formed laminated panel. H may satisfy the following equation (2).

0 <C · H ≦ 50 (MPa · s) (2) In this case, the product of the pressurizing surface pressure and the pressurizing time during the cooling step is expressed by the above equation (2). Is satisfied, the possibility that the porous hard plate is cracked during the cooling process is eliminated, so that the rate at which the porous hard plate is cracked during the manufacturing process can be greatly reduced, and as a result, the yield of the laminated panel can be reduced. It can be greatly improved.

Further, during the cooling step, the pressure contact pressure may be changed as required.

In this case, it is possible to prevent the deformation by increasing the pressing surface pressure. Further, by reducing the pressing surface pressure, it is possible to more reliably prevent the porous hard plate from cracking.

Further, the method for manufacturing a laminated panel according to the present invention comprises:
The present invention can also be applied to a laminated panel in which a porous hard layer is laminated on both surfaces of a thermoplastic resin layer.

In this case, before the molten thermoplastic resin is supplied between the pair of male and female molds, two porous hard plates are arranged on the mold surface, and between the porous hard plates. What is necessary is just to supply the said thermoplastic resin.

Further, the method for producing a laminated panel of the present invention can be applied to a laminated panel having a hollow portion in a thermoplastic resin.

In this case, in the cooling step, a compressed fluid is supplied to at least a part of the unsolidified portion of the thermoplastic resin in the mold, and the space between the molds is increased to form a hollow portion in the thermoplastic resin. May be formed.

[0017]

DESCRIPTION OF THE PREFERRED EMBODIMENTS [Embodiment 1] An embodiment of the present invention will be described with reference to FIGS.
It is as follows.

Before describing the method for manufacturing a laminated panel according to the present embodiment, the laminated panel will be described.

As shown in FIG. 3, the laminated panel 11 of the present embodiment has a structure in which a porous hard layer 3 is laminated on one surface of a thermoplastic resin layer 2. In other words, the structure is such that the porous hard plate 6 serving as the porous hard layer 3 is integrally laminated on one surface of the thermoplastic resin plate 4 serving as the thermoplastic resin layer 2.

The thermoplastic resin layer 2 can be used as it is as a thermoplastic resin which is generally used in general injection molding, injection compression molding, extrusion molding, vacuum pressure molding, blow molding or stamping molding. .

That is, as the material of the thermoplastic resin layer 2,
For example, polyolefin resins such as polyethylene and polypropylene, polystyrene, polycarbonate, acrylonitrile-styrene-butadiene block copolymer, general thermoplastic resins such as nylon, ethylene-propylene block copolymer, styrene-butadiene block copolymer, etc. Examples thereof include thermoplastic elastomers and polymer alloys thereof. Therefore, the thermoplastic resin plate 4 referred to in the present invention includes all of them.

The thermoplastic resin plate 4 contains fillers such as talc and glass fiber, pigments, lubricants, antistatic agents, antioxidants, and other commonly used additives. Is also good.

Further, the thermoplastic resin plate 4 may contain an adhesive resin in order to enhance the adhesiveness with the porous hard plate 6 which is integrally laminated.

As the adhesive resin, unsaturated carboxylic acid,
Copolymers of one or more monomers selected from the group consisting of unsaturated carboxylic anhydrides, epoxy group-containing vinyl monomers, unsaturated carboxylic esters and vinyl esters with olefin monomers, unsaturated carboxylic acids or unsaturated carboxylic acids An acid-modified olefin polymer grafted with an anhydride is exemplified.

The unsaturated carboxylic acids include acrylic acid and methacrylic acid, etc., the unsaturated carboxylic anhydrides include maleic anhydride, the epoxy group-containing vinyl monomers include glycidyl methacrylate, and the unsaturated carboxylic esters. Is methyl acrylate, ethyl acrylate, methyl methacrylate, ethyl methacrylate and the like, and the vinyl ester is vinyl acetate and the like.

The copolymer of one or more monomers selected from the group consisting of unsaturated carboxylic acids, unsaturated carboxylic anhydrides, epoxy group-containing vinyl monomers, unsaturated carboxylic esters and vinyl esters, and olefin monomers includes: Ethylene / (meth) acrylic acid copolymer, ethylene / (meth) acrylic acid copolymer metal crosslinked product, ethylene / glycidyl methacrylate copolymer, ethylene /
Glycidyl methacrylate / vinyl acetate copolymer, ethylene / glycidyl methacrylate / (meth) acrylate copolymer, ethylene / (meth) acrylate copolymer, ethylene / (meth) acrylate / maleic anhydride copolymer And an ethylene / vinyl acetate copolymer.

Examples of the acid-modified olefin polymer grafted with an unsaturated carboxylic acid or an unsaturated carboxylic acid anhydride include a maleic anhydride-grafted ethylene copolymer, a maleic anhydride-grafted propylene polymer and the like. Can be

The adhesive resin is appropriately selected depending on the thermoplastic resin constituting the thermoplastic resin plate 4 and the material of the porous hard plate 6.

The mixing ratio of the above-mentioned adhesive resin is not particularly limited as long as the thermoplastic resin plate 4 and the porous hard plate 6 can be bonded to each other.
And the adhesive strength of the porous hard plate 6 and the product performance are appropriately selected, and preferably 0.1 to
20 parts by weight are used.

Such an adhesive resin is applied to the thermoplastic resin plate 4
, Good adhesive strength with the porous hard plate 6 can be obtained.

The porous hard plate 6 has fine voids in its material, and the voids may be open cells or closed cells. In addition, from the viewpoint of the adhesive strength with the thermoplastic resin plate 4, the porous hard plate 6 may have a rough surface such as a fine hole or unevenness on the surface of the porous hard plate 6 to be bonded to the thermoplastic resin plate 4. Is better.

The hardness of the porous hard plate 6 is as follows.
For example, in the bending test method for architectural boards specified in JIS A1408, those having a bending fracture load of 1 kgf (9.8 N) or more in a test using a No. 5 specimen are preferably used.

As a material of the porous hard plate 6, a material suitable for an exterior material and an interior material of a building is preferably used. In general, calcium silicate-based, cement-based, gypsum-based, or pottery and porcelain obtained by firing can be used, and inorganic materials made from minerals are preferably used. Further, a material obtained by adding a reinforcing fiber such as pulp or glass fiber to a calcium silicate-based, cement-based, or gypsum-based material can also be used.

The porous hard plate 6 has a heat insulating property, a non-combustible property, a sound insulation property, a sound absorbing property,
Various functions can be added to the laminated panel 11 by giving the performance against electromagnetic interference.

Further, the surface of the porous hard plate 6 is subjected to decoration such as printing, pasting of decorative paper, painting, spraying, pasting of a synthetic resin film sheet, and transfer of an uneven pattern. May be appropriately selected depending on the intended use and purpose.

By subjecting the surface of the porous hard plate 6 to decorative processing as described above, it is possible to enhance the design, and it is possible to reduce post-processing when a wall or the like is constructed. In addition, the decorative panel not only enhances the design of the laminated panel 11 but also provides waterproofing, mold-proofing, insect-proofing, and non-flammability.
Various performances can be added to (1).

The laminated panel 11 shown in FIG. 3 shows an example in which the thermoplastic resin layer 2 has a solid structure. However, the present invention is not limited to this, and an air layer is formed on the thermoplastic resin layer 2. May be included. This air layer may be foamed or hollow. By forming the air layer in this way, it becomes possible to add heat insulating performance to the panel or to increase rigidity.

As a laminated panel having an air layer inside the thermoplastic resin layer 2, for example, as shown in FIG. 4, a laminated panel 13 having a thermoplastic resin layer 2 in which a hollow portion 2 a is formed as an air layer is exemplified.

The laminated panel 11 is formed of a thermoplastic resin plate at the portion where the porous hard plate 6 is not bonded, at the outer periphery of the laminated panel 11 or at the notch or opening of the porous hard plate 6. 4, a hook or a joint for connecting to a rib or a boss, or another member. Further, a fitting portion for fitting adjacent laminated panels 11 when a plurality of laminated panels 11 are combined may be provided on the outer surface of the panel.

For example, by providing ribs in the portion of the thermoplastic resin plate 4, the rigidity of the laminated panel 11 can be increased. In addition, a large number of man-hours were required for assembling with only the porous hard plate 6, but by providing hooks, joints, and fitting portions on the thermoplastic resin plate 4, misalignment at the time of installation can be prevented. The efficiency of construction can be improved.

Next, a method of manufacturing the above-described laminated panel will be described below with reference to FIGS.

The manufacturing method of the laminated panel 11 in which the thermoplastic resin plate 4 shown in FIG. 3 has a solid structure will be described with reference to the manufacturing process diagram shown in FIG. 1 and air inside the thermoplastic resin plate 4 shown in FIG. A method of manufacturing the laminated panel 12 in which the hollow portion 2a is formed as a layer will be described with reference to a manufacturing process diagram shown in FIG. 2 in addition to FIG.

First, a manufacturing process of the laminated panel 11 shown in FIG. 3 will be described below with reference to FIGS. 1 (a) to 1 (d).

First, as shown in FIG. 1A, the upper die 22 of the mold (molding die) 21 is arranged so as to be opened with respect to the lower die 23, and as shown in FIG. Lower mold 2 in cavity
A single porous hard plate 6 serving as the porous hard layer 3 is arranged on 3. The lower mold 23 has a resin passage 24 for supplying the molten thermoplastic resin 4 ′ into the cavity of the mold 21 and a fluid passage for supplying a compressed fluid, for example, compressed air, into the cavity. 25 are formed.

Next, as shown in FIG.
And lower mold 2 through resin passage 24 in mold 21.
3 between the porous hard plate 6 and the cavity surface of the lower mold 23 from the discharge port 24a near the surface of the molten resin 4 '.
Supply.

Next, as shown in FIG. 1D, the mold is clamped and pressurized at a predetermined pressure to shape the molten thermoplastic resin 4 '. In this way, the molten thermoplastic resin 4 'spreads in the cavity of the mold 21, and the porous hard plate 6 and the thermoplastic resin plate 4 are integrally formed.

During the shaping process from the start of the supply of the molten thermoplastic resin 4 'to the completion of the shaping, that is, during the process from FIG. 1C to FIG. By controlling the maximum value of (the force divided by the projected area of the laminate), the porous hard plate 6 is prevented from cracking. However, the completion of the shaping means a state in which the molten thermoplastic resin 4 ′ has spread to every corner of the cavity of the mold 21, that is, a state in which the cavity is filled with the molten thermoplastic resin.

Here, the control of the maximum value of the pressing surface pressure during the shaping process will be described below.

In general, during the shaping step, when the molten thermoplastic resin 4 ′ is supplied between the porous hard plate 6 and the cavity surface of the lower mold 23, the molten thermoplastic resin 4 ′ is brought into contact with the cavity surface of the lower mold 23 by the resin. The molten thermoplastic resin 4 'is caused to flow in a space formed between the porous hard plate and the molten thermoplastic resin 4', and the molten thermoplastic resin 4 'is spread out by mold clamping for shaping.

At this time, the porous hard plate 6 is
Is also pressed from the mold surface. In this case, in the porous hard plate 6, the molten thermoplastic resin 4 'receives a reaction force in the porous portion in contact with the molten thermoplastic resin 4', while the molten thermoplastic resin 4 ' The bending force will be applied to the part not in contact with '. When the bending force is increased, the porous hard plate is cracked or cracked.

That is, when the maximum pressing surface pressure during the shaping step of the molten thermoplastic resin 4 ′ increases, the porous hard plate 6
In the same manner, when the bending strength of the porous hard plate 6 that indicates the difficulty of cracking of the porous hard plate 6 is reduced, the porous hard plate 6 is easily cracked or cracked.

Therefore, in order to prevent a crack from being generated in a porous hard plate having a certain bending strength, the maximum pressing surface pressure during the shaping step is determined to be less than the bending strength of the porous hard plate.
It is important to mold so as not to exceed a certain ratio.

Here, the relationship between the maximum pressing surface pressure applied to the porous hard plate during the shaping step and the yield is shown in Table 1.

[0054]

[Table 1]

Table 1 shows the results obtained by using a porous hard plate having a bending strength A of 10 MPa as measured by a bending test method specified in JIS A1408.

The yields shown in Table 1 indicate the percentage of molded products that were formed without cracking or cracking in the calcium silicate plate when molded 50 times under each molding condition.

From Table 1, it can be seen that the yield of 75% or more is obtained when the maximum pressing surface pressure B is 5 MPa or less. At that time, B / A is 0.5. Also,
A yield of 85% or more is obtained when B / A is 0.3, and a yield of 95% or more is obtained when B / A is 0.3% or more.
/ A is 0.2.

That is, the porous hard plate 6 obtained by the bending test method specified in JIS A1408.
Bending strength A (MPa), and the maximum pressing surface pressure during the shaping process from the start of the supply of the thermoplastic resin 4 'to the completion of shaping (the mold clamping force divided by the projected area of the laminate) B ( MP
What is necessary is just to set so that the relationship with a) satisfies the following expression (1).

0 <B / A ≦ 0.5 (1) The flexural strength of the porous hard plate 6 is set so as to satisfy the above equation (1). A and the maximum pressing surface pressure B during the shaping process from the start of supply of the thermoplastic resin 4 ′ in the mold 21 to the completion of shaping.
Setting the maximum pressing surface B during the shaping process in accordance with the bending strength A of the material of the porous hard plate 6, so that the porous hard plate 6 is not cracked. The desired laminated panel 11 can be obtained, and as a result, the yield of the laminated panel 11 can be improved.

That is, in order to improve the yield of the laminated panel, if at least B / A is within the range of the above formula (1), the bending hardness A and the maximum pressing surface pressure B of the porous hard plate to be used are determined. It can be understood that the relationship may be appropriately set. Further, the above B / A is preferably 0.3 or less, more preferably 0.2 or less.

Further, Table 1 shows the product of the pressing surface pressure C (MPa) and the pressing time H (s) during the cooling step and the relationship between the product and the yield (%).

The pressing surface pressure C during the cooling step is 0MPa.
It is set to a value larger than a.

The product of the pressurizing time H and the pressurizing surface pressure C, CH (M
It can be seen that a higher yield is achieved when Pa · s) is 50 or less.

Here, if the product (integral value) of the pressurized surface pressure and the pressurization time after completion of the shaping is smaller than 0.1, the resin and the mold surface do not adhere firmly, and the cooling is slowed down. Problems such as cracking and deformation occur.

If the above integral value is larger than 50, the porous hard plate is cracked or cracked.

From the above, the molten thermoplastic resin 4 ′
Pressurizing surface pressure C (MP) during the cooling process from the completion of shaping to the start of mold opening for taking out the formed laminated panel 11
The product C · H of a) and the pressurization time H (s) should satisfy the following equation (2).

0 <C · H ≦ 50 (MPa · s) (2) As described above, the product of the pressurizing surface pressure and the pressurizing time during the cooling step is expressed by the above equation (2). Is satisfied, the possibility that the porous hard plate is cracked during the cooling process is eliminated, so that the rate at which the porous hard plate is cracked during the manufacturing process can be greatly reduced, and as a result, the yield of the laminated panel can be reduced. It can be greatly improved.

In the above-mentioned cooling step, the thermoplastic resin 4 'is cooled while being pressurized at a predetermined pressing surface pressure to obtain the laminated panel 11 as a molded body. The mold may be clamped with the same pressing surface pressure from the beginning to the end, or the pressing surface pressure may be increased in the middle,
It may be lowered or arbitrarily changed. However, in order to prevent a problem such as cracking or cracking of the porous hard plate 6 during the cooling step, the pressing surface pressure C (MPa) during the cooling step is set to satisfy 0 <C <2.9. It is preferable to keep in the range. At this time, the pressurization time H (s) is 5 <H
It is preferred to keep in the range of <60.

Regarding the above-mentioned change in the pressing force, the shaping may be performed with the mold clamping force as it is after the shaping is completed, or the shaping may be performed immediately after the shaping is completed, immediately after a predetermined time elapses, or stepwise or The pressing force may be changed by continuously increasing, decreasing, or increasing or decreasing the mold clamping force.

When the pressing surface pressure B at the time of completion of shaping is a value close to 0.5 A, it is necessary to lower the pressing surface pressure within 5 seconds after completion of shaping in order to further prevent cracking of the porous hard plate. Is preferred.

When the pressing surface pressure B at the time of completing the shaping is a value close to 0, the pressing surface pressure is set to 2MP within 5 seconds after the completion of the shaping.
It is preferable to raise the temperature within the range of a or less in order to prevent deformation of the molded product.

As the timing for changing the mold clamping force during the cooling step, an arbitrary time from completion of shaping by mold clamping to removal of the molded product is appropriately selected.
Preferably, it is between 1 second and 20 seconds after the completion of shaping by mold clamping.

Next, the manufacturing process of the laminated panel 13 shown in FIG. 4 will be described. As described above, in the manufacturing process of the laminated panel 13 having the hollow portion 2a, the following process is added to the manufacturing process of the laminated panel 11 having no hollow portion.

That is, as shown in FIG. 2 (a), the discharge port 25 is formed through the fluid passage 25 into the molten thermoplastic resin 4 ′ formed in the cavity of the mold 21.
For example, air is sent as a compressed fluid from a. And
After a lapse of a predetermined time, the upper mold 22 is raised by a predetermined height,
In this state, cooling is performed for a predetermined time. As a result, FIG.
As shown in (b), the hollow portion 2a is formed in the thermoplastic resin plate 4.
Is formed.

Thereafter, the mold 21 is opened, and the laminated panel 12 having the structure in which the porous hard layer 3 is laminated on both surfaces of the thermoplastic resin layer 2 having the hollow portion 2a is taken out from the mold 21.

In this case, as a method of supplying the molten thermoplastic resin into the mold, in order to prevent the supplied molten thermoplastic resin from being unnecessarily cooled, the molten thermoplastic resin is supplied through a resin passage provided in the mold. Then, it is preferable to inject and supply the molten thermoplastic resin directly into the cavity. When the mold clamping is performed after the completion of the supply of the molten thermoplastic resin, a method of supplying the thermoplastic resin between the molds by an external supply unit having a resin supply nozzle or the like may be used. Is appropriately adopted.

The following method may be employed to prevent the porous hard plate from being damaged by preventing excessive pressure from being applied to the porous hard plate in the mold. That is, the molten thermoplastic resin is supplied between the unclosed molds, and after the supply of the resin is completed, the mold is closed by moving the female mold and / or the male mold in the mold clamping direction, thereby closing the mold. A method may be used in which the molten thermoplastic resin is pressed and spread into the cavity by clamping with a pressing force.

Further, the mold clamping is started during the supply of the molten thermoplastic resin, or the supply of the molten thermoplastic resin is started during the continuous mold clamping operation, so that the mold closing operation and the melting The supply operation of the thermoplastic resin may be performed in parallel, and the supply of the molten thermoplastic resin may be completed simultaneously with or before the completion of the mold clamping.

In the case where the porous hard layer 3 is laminated on both surfaces of the thermoplastic resin layer 2 as in the laminated panel 11 or 12, the cavity surface of the porous hard plate 6 and the lower mold 23 is formed. By supplying the molten thermoplastic resin 4 ′ between the first and second steps, it is possible to prevent problems such as running of the resin onto the porous hard plate 6.

More preferably, the molten thermoplastic resin is supplied to substantially the center of the back side of the porous hard plate 6 to shift the position of the porous hard plate 6 and to prevent the porous hard plate 6 from being displaced.
Can be prevented from being damaged. In order to supply the molten thermoplastic resin to substantially the center of the back surface of the porous hard plate 6,
In addition to being supplied to one point substantially at the center of the porous hard plate 6, the molten thermoplastic resin supplied to two or more points on the back side of the porous hard plate 6 is integrated and supplied near the center. You may do so.

When the position where the porous hard plate 6 is laminated on the thermoplastic resin layer 2 is, for example, a position that is deviated in the entire laminated panel 1, the supply of the molten thermoplastic resin is not performed. It is preferable to perform the process not only at the approximate center of the back surface of the hardened hard plate but also at a position where the flow of the molten thermoplastic resin can be balanced. When the molten thermoplastic resin is supplied to two or more positions on the back surface of the porous hard plate, make sure that the resin does not penetrate between the surface of the porous hard plate and the mold surface. In order to do so, it is necessary to adjust the amount of each supplied resin according to the size and shape of the porous hard plate, the interval between the supply positions, and the like.

Prior to the supply of the molten thermoplastic resin, the porous hard plate may be suctioned to the mold surface or held by an adhesive, an adhesive tape, or the like. The porous hard plate alone may be used, or both porous hard plates may be used. Thus, the porous hard plate is
By holding the porous hard layer in advance, it is possible to prevent problems such as cracking of the porous hard layer.

As one of the methods for forming an air layer in the thermoplastic resin, a general thermoplastic resin hollow molding method can be applied. After the thermoplastic resin is completely shaped, the thermoplastic resin is not solidified. By supplying a compressed fluid to at least a part of the part to form a hollow part, a part of the mold may be moved to form a hollow part, or a thermoplastic resin may be formed by increasing a distance between the mold parts. A hollow portion may be formed in the resin.

Further, a foamed layer may be formed in a thermoplastic resin as an air layer. In this case, the foamed layer may be formed by using a thermoplastic resin containing a foaming agent. After such a hollow portion is once formed, a foamed layer may be formed by injecting a thermoplastic resin containing a foaming agent into the hollow portion after the mold or the molded product is taken out. At this time, the thermoplastic resin may be the same material as the thermoplastic resin of the molded body, or may be a different material. Alternatively, urethane foaming may be performed by injecting a mixture of diisocyanate and diol into the hollow portion.

By forming the air layer on the laminated panel as described above, it is possible to easily increase the rigidity of the panel and enhance the heat insulating property of the laminated body.

The compressed fluid used to form the hollow portion as the air layer is generally injection of a compressed gas into a molten thermoplastic resin, but may be a liquid.
The fluid used is generally a compressed gas such as air, nitrogen or carbon dioxide, but a liquid such as liquefied carbon dioxide gas or water which is easily vaporized by the heat of the molten thermoplastic resin can also be used.

The compressed gas of the above compressed fluid is 1MP
The gas may be a high-pressure gas of a or more, or a low-pressure gas of less than 1 MPa. However, preferably, low-pressure air of less than 1 MPa is used, so that the molding can be performed at low cost. The injection pressure of the compressed gas to be injected may be constant from the start to the end of the injection, or may be arbitrarily changed during the injection.

The timing of supplying the compressed fluid is not particularly limited as long as the hollow can be formed, for example, after the supply of the thermoplastic resin is started, or after the molten thermoplastic resin reaches the medium inlet. Can be performed at any timing, but from 1 second to 2 seconds after the completion of the shaping of the thermoplastic resin.
It is preferable to perform the operation during 0 seconds from the viewpoint of easy supply of the compressed fluid.

After the supply of the medium is started, the supply of the compressed fluid may be performed continuously or intermittently until the resin is cooled and solidified in the mold. After that, the supply of the fluid may be stopped during the cooling and solidification of the resin to maintain the pressure.

The supply of such a fluid is not necessarily required to be at one location, but may be supplied from a plurality of locations as needed, such as the shape and size of the molded product. Further, the compressed fluid may be supplied from any part of the thermoplastic resin, and the supply of the compressed fluid to the thermoplastic resin may be performed from the part where the porous hard layer is not laminated to the thermoplastic resin. Alternatively, an opening for supplying a compressed fluid may be provided in the porous hard layer, and the compressed fluid may be supplied to the thermoplastic resin from the opening.

In supplying the fluid, at the same time as or after the supply of the fluid is started, the fluid is discharged from a part of the molded product in the mold while supplying the fluid, and the fluid is discharged into the hollow portion where the fluid is formed. It may be circulated, which promotes cooling of the resin and shortens the molding cycle.

As a method of discharging the supplied fluid, the supply operation of the fluid may be performed from multiple points, and the supply pressure of the fluid may be made different to release the fluid from the lower pressure side, or a medium exclusively used for release. A discharge port may be provided, or the fluid may be discharged from a supply port to which the fluid is supplied. In this case, the supply and discharge of the fluid may be repeatedly performed. It is not something to be done.

The timing of starting the discharge of the fluid may be the same as the start of the supply of the fluid, or may be after a lapse of a predetermined time after the start of the supply of the fluid. Of course, the supply operation and the discharge operation of the fluid may be performed in parallel or alternately, and the discharge operation of the fluid may be continued after the supply of the fluid is completed.

As the member for supplying the fluid, a supply member used for ordinary molding of a thermoplastic resin is used, and is not particularly limited, and a fixed or movable compressed fluid supply pin or a porous member is used. .

In addition, when the cavity space is expanded to form a hollow portion by moving a part of the mold or increasing the space between the molds in parallel with the supply of the compressed fluid, the cavity space is increased. The timing is not particularly limited as long as the hollow can be formed by the increase of the cavity, but it can be performed at an arbitrary timing after the supply of the compressed fluid is started, and performed at a timing of 1 second to 20 seconds after the start of the supply of the compressed fluid. Is preferable from the viewpoint of easy formation of the hollow. This timing is appropriately selected according to the size of the product, the molding conditions, the fluid pressure, the amount of increase in the cavity space, and the like.

Various molding conditions not specified in the present invention, such as the temperature of the supplied molten resin, the supply pressure, the supply speed, the distance between the dies at the time of supply of the molten resin, the compression speed (the clamping speed), and the mold temperature, are as follows. It is appropriately selected according to the type of resin used, the shape of the mold, the size of the laminate, and the like, and is not particularly limited in the method of the present invention.

According to the present invention, the thermoplastic resin layer and the porous hard layer can be firmly adhered to each other without increasing the number of steps. It is possible to provide a laminated panel which adds functions and performances that were not obtained, has good workability, and is hard to crack. Thereby, it is suitably used as a building panel, board, or concrete driving formwork requiring rigidity.

In the present embodiment, a method of manufacturing a laminated panel in which a porous hard layer is laminated on one surface of a thermoplastic resin layer has been described. A method for manufacturing a laminated panel in which a porous hard layer is laminated on both sides will be described.

Embodiment 2 Another embodiment of the present invention will be described below with reference to FIGS. For convenience of explanation, members having the same functions as those in the first embodiment are denoted by the same reference numerals, and description thereof is omitted.

In the present embodiment, as shown in FIG. 5, a porous hard layer 3 is provided on both surfaces of a thermoplastic resin layer 2 having a solid structure.
A method for manufacturing a laminated panel 13 having a structure in which the laminated layers 3 are laminated will be described. As shown in FIG. 6, a method for manufacturing a laminated panel 14 having a hollow structure in which a hollow portion 2a is formed in the thermoplastic resin layer 2 will also be described. explain.

First, the manufacturing method of the laminated panel 13 in which the thermoplastic resin layer 2 shown in FIG. 5 has a solid structure will be described with reference to the manufacturing process diagram shown in FIG. 7 and air inside the thermoplastic resin layer 2 shown in FIG. A method of manufacturing the laminated panel 14 in which the hollow portion 2a is formed as a layer will be described with reference to a manufacturing process diagram shown in FIG. 8 in addition to FIG.

First, the manufacturing process of the laminated panel 13 shown in FIG. 5 will be described below with reference to FIGS. 7 (a) to 7 (d).

First, as shown in FIG.
The upper mold 22 is arranged in an open state with respect to the lower mold 23, and FIG.
As shown in (b), two porous hard plates 5 and 6 that become porous hard layers 3 and 3 are formed on the lower mold 23 in the cavity.
Distribute.

In the lower porous hard plate 5, a notch 5a for connecting the resin passage 24 between the porous hard plates 5 and 6 and a notch 5b for connecting the fluid passage 25 are provided.
Are formed. The resin passage 24 is a passage for supplying the molten thermoplastic resin 4 ′ into the cavity of the mold 21, and the fluid passage 25 is a passage for supplying a compressed fluid, for example, compressed air, into the cavity. is there.

Therefore, the porous hard plate 5 is formed such that the cutout portion 5b corresponds to the discharge port 25a of the fluid passage 25 formed near the surface of the lower die 23, and
The notch 5a is disposed so as to correspond to the discharge port 24a of the resin passage 24 formed near the surface of the lower mold 23.

Next, as shown in FIG.
And lower mold 2 through resin passage 24 in mold 21.
3 through a discharge port 24a in the vicinity of the surface.
The molten thermoplastic resin 4 'is supplied in between.

Next, as shown in FIG. 7D, mold clamping is performed to shape the molten thermoplastic resin 4 '.

Thus, the molten thermoplastic resin 4 ′ spreads in the cavity of the mold 21, and the porous hard plate 5.
6 and the thermoplastic resin plate 4 are integrated and shaped.

During the shaping process from the start of the supply of the molten thermoplastic resin 4 'to the completion of the shaping, that is, during the process from FIG. 7C to FIG. By controlling the maximum value of the force divided by the projected area of the laminate, the porous hard plate 6 is prevented from cracking. However, the completion of the shaping means that the molten thermoplastic resin 4 ′
Shows a state in which the mold has spread to every corner of the cavity of the mold 21, that is, a state in which the cavity is filled with a molten thermoplastic resin.

Also in this case, similarly to the first embodiment, cracking and cracking of the two porous hard plates 5 and 6 are prevented by controlling the maximum value of the pressing surface pressure during the shaping process. can do. The porous hard plates 5 and 6
Shall be made of the same material.

That is, the porous hard plate 5 obtained by the bending test method specified in JIS A1408
A bending strength A (MPa) of 6 and the thermoplastic resin 4 ′
Pressurizing surface pressure during the shaping process from the start of the supply to the completion of shaping (the mold clamping force divided by the projected area of the laminate) B (MP
What is necessary is just to set so that the relationship with a) satisfies the following expression (1).

0 <B / A ≦ 0.5 (1) The porous hard plates 5 and 6 satisfy the above-mentioned expression (1).
Flexural strength A of the thermoplastic resin 4 ′ in the mold 21
The maximum pressing surface pressure B during the shaping process from the start of the supply of the material to the completion of the shaping is determined according to the bending strength A of the material of the porous hard plate 6 during the shaping process. Since B is determined, the desired laminated panel 13 can be obtained without cracking the porous hard plate 6, and as a result, the yield of the laminated panel 13 can be improved.

Further, the pressing surface pressure C (MPa) and the pressing time H during the cooling step from the completion of the shaping of the thermoplastic resin 4 ′ to the start of the mold opening for taking out the formed laminated panel 13.
What is necessary is just to make the product C · H of (s) satisfy the following expression (2).

0 <C · H ≦ 50 (MPa · s) (2) As described above, the product of the pressurizing surface pressure and the pressurizing time during the cooling step is expressed by the above equation (2). Is satisfied, the possibility that the porous hard plate is cracked during the cooling process is eliminated, so that the rate at which the porous hard plate is cracked during the manufacturing process can be greatly reduced, and as a result, the yield of the laminated panel can be reduced. It can be greatly improved.

When the materials of the porous hard plates 5 and 6 are different, the one having the weaker bending strength is determined by the above equation (1).
And it is sufficient.

Next, the steps of manufacturing the laminated panel 14 shown in FIG. 6 will be described. As described above, in the manufacturing process of the laminated panel 14 having the hollow portion 2a, the following process is added to the manufacturing process of the laminated panel 13 having no hollow portion.

That is, as shown in FIG. 8A, the discharge port 25 is inserted through the fluid passage 25 into the molten thermoplastic resin 4 ′ shaped in the cavity of the mold 21.
For example, air is sent as a compressed fluid from a. And
After a lapse of a predetermined time, the upper mold 22 is raised by a predetermined height,
In this state, cooling is performed for a predetermined time. As a result, FIG.
As shown in (b), the hollow portion 2a is formed in the thermoplastic resin plate 4.
Is formed.

Then, the mold 21 is opened, and the laminated panel 14 having the structure in which the porous hard layers 3 and 3 are laminated on both surfaces of the thermoplastic resin layer 2 having the hollow portion 2a is taken out from the mold 21.

As described above, a frequently used laminating method is as follows.
A porous hard plate is placed between a pair of male and female molds, and then a molten thermoplastic resin is supplied, shaped and laminated. In this case, as a method of supplying the molten thermoplastic resin into the mold, in order to prevent unnecessary cooling of the supplied molten thermoplastic resin, directly through a resin passage provided in the mold. A method of injecting and supplying a molten thermoplastic resin into the cavity is preferable. When the mold clamping is performed after the completion of the supply of the molten thermoplastic resin, a method of supplying the thermoplastic resin between the molds by an external supply unit having a resin supply nozzle or the like may be used. Is appropriately adopted.

In order to prevent the porous hard plate in the mold from being subjected to excessive pressure and to prevent the porous hard plate from being damaged, the following method may be employed. That is, the molten thermoplastic resin is supplied between the unclosed molds, and after the supply of the resin is completed, the mold is closed by moving the female mold and / or the male mold in the mold clamping direction, thereby closing the mold. A method may be used in which the molten thermoplastic resin is pressed and spread into the cavity by clamping with a pressing force.

The mold closing is started during the supply of the molten thermoplastic resin, or the supply of the molten thermoplastic resin is started during the continuous mold clamping operation, and the operation of closing the mold and the molten state are started. The supply operation of the thermoplastic resin may be performed in parallel, and the supply of the molten thermoplastic resin may be completed simultaneously with or before the completion of the mold clamping.

In the case where the porous hard layers 3 and 3 are laminated on both surfaces of the thermoplastic resin layer 2 as in the laminated panel 13 or 14 described above, at least two porous hard plates 5. By supplying the molten thermoplastic resin 4 ′ between the gaps 6, problems such as running of the resin onto the porous hard plate 6 can be prevented. At this time, when the molten thermoplastic resin is supplied directly between the two porous hard plates 5 and 6 via the resin passage 24 provided in the mold 21, the porous It is necessary to provide an opening (notch portion 5a) in the rigid hard plate 5 which is equal to or larger than the resin supply port.

More preferably, the molten thermoplastic resin is supplied to substantially the center of the back surface side of the porous hard plate 6 so that the displacement of the porous hard plate 6 and the displacement of the porous hard plate 6 are prevented.
Can be prevented from being damaged. In addition, in order to supply the molten thermoplastic resin 4 ′ to substantially the center of the back surface of the porous hard plate 6, besides supplying the molten thermoplastic resin 4 ′ to a substantially central point of the porous hard plate 6,
The molten thermoplastic resin supplied to two or more points on the back surface side of the porous hard plate 6 may be integrated and supplied near the center.

When the position where the porous hard plate is laminated on the thermoplastic resin layer is, for example, at a position which is deviated in the entire laminated panel, the supply of the molten thermoplastic resin is performed by the porous hard plate. It is preferable to perform the process not only at the approximate center of the back surface of the plate but also at a position where the flow of the molten thermoplastic resin can be balanced. When the molten thermoplastic resin is supplied to two or more positions on the back surface of the porous hard plate,
In order to prevent the resin from penetrating between the surface of the porous hard plate and the mold surface, the amount of each supplied resin is determined according to the size, shape, interval of the supply position, etc. of the porous hard plate. It needs to be adjusted.

Prior to the supply of the molten thermoplastic resin, the porous hard layer may be suctioned to the mold surface or held by an adhesive, an adhesive tape, or the like. Only the porous hard layer may be used, or both porous hard layers may be used. Thus, the porous hard plate is
By holding the porous hard layer in advance, it is possible to prevent problems such as cracking of the porous hard layer.

As one method of forming an air layer in the thermoplastic resin, a general thermoplastic resin hollow molding method can be applied. After the thermoplastic resin is completely shaped, the thermoplastic resin is not solidified. A compressed fluid is supplied to at least a part of the part to form a hollow part, and at this time, a part of the mold may be moved to form a hollow part. A hollow portion may be formed in the plastic resin.

Further, a foamed layer may be formed in a thermoplastic resin as an air layer. In this case, the foamed layer may be formed by using a thermoplastic resin containing a foaming agent. After such a hollow portion is once formed, a foamed layer may be formed by injecting a thermoplastic resin containing a foaming agent into the hollow portion after the mold or the molded product is taken out. At this time, the thermoplastic resin may be the same material as the thermoplastic resin of the molded body, or may be a different material. Further, urethane may be injected into the hollow portion to perform urethane foaming.

By forming the air layer on the laminated panel in this manner, it is easy to increase the rigidity of the panel and to enhance the heat insulation of the laminated body.

The compressed fluid used for forming the hollow portion as the air layer is generally injection of a compressed gas into a molten thermoplastic resin, but may be liquid.
The fluid used is generally a compressed gas such as air, nitrogen or carbon dioxide, but a liquid such as liquefied carbon dioxide gas or water which is easily vaporized by the heat of the molten thermoplastic resin can also be used.

The compressed gas of the above compressed fluid is 1MP
The gas may be a high-pressure gas of a or more, or a low-pressure gas of less than 1 MPa. However, preferably, low-pressure air of less than 1 MPa is used, so that the molding can be performed at low cost. The injection pressure of the compressed gas to be injected may be constant from the start to the end of the injection, or may be arbitrarily changed during the injection.

The timing of supplying the compressed fluid is not particularly limited as long as the hollow can be formed, for example, after the start of the supply of the thermoplastic resin or after the molten thermoplastic resin reaches the medium inlet. Can be performed at an arbitrary timing, but from 1 second to 2 seconds after the completion of the shaping of the thermoplastic resin.
It is preferable to perform the operation during 0 seconds from the viewpoint of easy supply of the compressed fluid.

The supply of the compressed fluid may be performed continuously or intermittently until the resin is cooled and solidified in the mold after the supply of the medium is started, or the hollow portion may be formed. After that, the supply of the fluid may be stopped during the cooling and solidification of the resin to maintain the pressure.

The supply of the fluid does not need to be at a single location, but may be supplied from a plurality of locations as needed, such as the shape and size of the molded product. Further, the compressed fluid may be supplied from any part of the thermoplastic resin, and the supply of the compressed fluid to the thermoplastic resin may be performed from the part where the porous hard layer is not laminated to the thermoplastic resin. Alternatively, an opening for supplying a compressed fluid may be provided in the porous hard layer, and the compressed fluid may be supplied to the thermoplastic resin from the opening.

In supplying the fluid, simultaneously with or after the start of the supply of the fluid, the fluid is discharged from a part of the molded article in the mold while supplying the fluid, and the fluid is supplied into the hollow part where the fluid is formed. It may be circulated, which promotes cooling of the resin and shortens the molding cycle.

As a method of discharging the supplied fluid, the operation of supplying the fluid may be performed from multiple points, and a difference may be provided in the supply pressure of the fluid to discharge the fluid from the lower pressure, or a medium dedicated to discharge may be used. A discharge port may be provided, or the fluid may be discharged from a supply port to which the fluid is supplied. In this case, the supply and discharge of the fluid may be repeatedly performed. It is not something to be done.

The timing of starting the discharge of the fluid may be the same as the start of the supply of the fluid, or may be after a certain time has elapsed after the start of the supply of the fluid. Of course, the supply operation and the discharge operation of the fluid may be performed in parallel or alternately, and the discharge operation of the fluid may be continued after the supply of the fluid is completed.

As the member for supplying the fluid, a supply member used for ordinary hollow molding of a thermoplastic resin is used, and it is not particularly limited, and a fixed or movable compressed fluid supply pin or a porous member is used. .

When the cavity space is expanded to form a hollow portion by moving a part of the mold or increasing the space between the molds in parallel with the supply of the compressed fluid, the cavity space is increased. The timing is not particularly limited as long as the hollow can be formed by the increase of the cavity, but it can be performed at an arbitrary timing after the supply of the compressed fluid is started, and performed at a timing of 1 second to 20 seconds after the start of the supply of the compressed fluid. Is preferable from the viewpoint of easy formation of the hollow. This timing is appropriately selected according to the size of the product, the molding conditions, the fluid pressure, the amount of increase in the cavity space, and the like.

Various molding conditions not specified in the present invention, such as the temperature of the supplied molten resin, the supply pressure, the supply speed, the distance between the dies during the supply of the molten resin, the compression speed (the clamping speed), and the temperature of the dies, are as follows. The method is appropriately selected according to the type of resin used, the shape of the mold, the size of the laminate, and the like, and is not particularly limited in the method of the present invention.

As described above, according to the method for manufacturing a laminated panel of the present invention, a porous hard plate is laminated on both sides of the thermoplastic resin plate at the same time as the formation of the thermoplastic resin plate. Therefore, the porous hard plates can be laminated on both surfaces of the thermoplastic resin plate without increasing the step of laminating the porous hard plates.

[0141]

Hereinafter, the present invention will be described with reference to Examples.
The present invention is not limited to these.

(Example 1) The size of a product (laminated panel) manufactured by this example is 50 cm long and 100 cm wide.
And the projected area of the product is 5000 cm ² . The pressing surface pressure is obtained by dividing a mold clamping force by a projected area of a product to be pressurized. In this case, the mold clamping force is 2000 kN.
In the case of (200t), the pressing surface pressure is 4 MPa.

A calcium silicate plate cut into a predetermined shape (Hilac N # 80, manufactured by Asano Slate Co., Ltd., thickness: 5 mm, JI) between a pair of male and female unclosed upper and lower molds
Flexural strength according to SA1408: 10 MPa (Asano Slate '98 comprehensive catalog value) was placed on the lower mold.

The upper mold is lowered at a speed of 20 mm / sec.
The mold was closed. Upper and lower mold clearance is 20
The mold clamping was temporarily stopped at the position of mm. At this position, 84.5 parts by weight of polypropylene (Sumitomo Noblen AX568 manufactured by Sumitomo Chemical Co., Ltd., melt flow index 6)
5 g / 10 min) and 15 parts by weight of glass fiber (RES03X-TP69A manufactured by Nippon Sheet Glass Co., Ltd., fiber length 3 m)
m, fiber diameter 13 μm) and a modifier 0.5 parts by weight (Umex 1001 manufactured by Sanyo Kasei Kogyo Co., Ltd.). And between the cavity surface of the lower mold.

After the supply of the resin was completed, the upper mold was lowered again, the mold clamping operation was restarted, and press molding was performed at a molding pressure of 4 MPa.
Thereafter, by lowering the pressure to 0.6 MPa and cooling under pressure for 60 seconds, a laminated panel having good adhesion between the thermoplastic resin layer and the porous hard layer, less deformation, and high rigidity was obtained. .

In the above-described method for manufacturing a laminated panel, the maximum pressing surface pressure B during the shaping step is 4 MPa, and the bending strength A of the porous hard plate is 10 MPa. It can be seen that (1) is satisfied. Therefore, in this example, since the porous hard plate was not cracked or cracked during the manufacturing process, the yield of the laminated panel could be significantly improved.

(Example 2) The method of manufacturing a laminated panel in this example is the same as that of Example 1 except that two calcium silicate plates are stacked and placed between molds as a porous hard plate. The molding is performed in the same manner except that the molten thermoplastic resin is supplied between the two calcium silicate plates from the resin supply port provided in the mold through the opening provided in the calcium silicate plate on the side facing the mold. Was.

As a result, the resulting laminated panel had a thermoplastic resin layer and a porous hard layer adhered well, and had a porous hard layer without cracks or cracks on both sides of the thermoplastic resin layer. It became.

(Example 3) In Example 2, a calcium silicate plate provided with an air supply opening (hereinafter, referred to as an air supply port) was placed on the lower mold, and the shaping of the molten thermoplastic resin was completed. Then, 2 seconds later, low-pressure air of 0.6 MPa was supplied from eight air supply ports provided in the lower die, and 10 seconds after the start of air supply, the upper die was raised by 8 mm, cooled for 60 seconds, and taken out of the molded product. The operation was performed in the same manner except that the air supply was stopped 5 seconds before the start of the mold opening.

As a result, the obtained laminated panel had a hollow portion, and the thermoplastic resin layer and the porous hard layer were well bonded.

Here, the maximum pressing surface pressure B during the shaping step is 4 MPa as in the first embodiment, and the pressing surface pressure and the pressing time in the cooling step are 0.6 × 12 = 7.
2 (MPa · s).

[0152]

According to the method for manufacturing a laminated panel of the present invention, at least one porous hard plate is arranged between a pair of male and female molds so as to face the mold surface, and then the molten metal is melted between the molds. A method of manufacturing a laminated panel by supplying and pressing a thermoplastic resin in a state, and laminating and integrating the porous hard plate and the thermoplastic resin. A bending test method specified in JIS A1408 The bending strength A (MPa) of the porous hard plate and the maximum pressing surface pressure B (MPa) during the shaping process from the start of the supply of the thermoplastic resin to the completion of shaping.
The relationship with a) satisfies the following expression (1).

0 <B / A ≦ 0.5 (1) Accordingly, the shaping step is performed according to the bending strength of the material of the porous hard plate. Since the maximum pressurized surface is determined, the target laminated panel can be obtained without cracking the porous hard plate, and as a result, the yield of the laminated panel can be improved.

Further, the product C of the pressing surface pressure C (MPa) and the pressing time H (s) during the cooling process from the completion of the shaping of the thermoplastic resin to the start of the mold opening for taking out the formed laminated panel. H may satisfy the following equation (2).

0 <C · H ≦ 50 (MPa · s) (2) In this case, the product of the pressurizing surface pressure and the pressurizing time during the cooling step is calculated by the above equation (2). Is satisfied, the possibility that the porous hard plate is cracked during the cooling process is eliminated, so that the rate at which the porous hard plate is cracked during the manufacturing process can be greatly reduced, and as a result, the yield of the laminated panel can be reduced. There is an effect that it can be greatly improved.

Further, during the cooling step, the pressure contact pressure may be changed as required.

In this case, the deformation can be prevented from occurring by increasing the pressing surface pressure. Further, by reducing the pressing surface pressure, it is possible to more reliably prevent the porous hard plate from cracking.

The method of manufacturing a laminated panel according to the present invention comprises:
The present invention can also be applied to a laminated panel in which a porous hard layer is laminated on both surfaces of a thermoplastic resin layer.

In this case, before supplying the molten thermoplastic resin between the pair of male and female dies, two porous hard plates are arranged on the surface of the die, and between the porous hard plates. What is necessary is just to supply the said thermoplastic resin.

Further, the method for producing a laminated panel of the present invention can be applied to a laminated panel having a hollow portion in a thermoplastic resin.

In this case, in the cooling step, a compressed fluid is supplied to at least a part of the non-solidified portion of the thermoplastic resin in the mold, and the space between the molds is increased to form a hollow portion in the thermoplastic resin. May be formed.

[Brief description of the drawings]

FIG. 1 shows a method for manufacturing a laminated panel of the present invention, wherein (a)
Is a sectional view showing a state in which an upper mold of a mold is opened with respect to a lower mold, (b) is a sectional view showing a step of setting a porous hard plate in the mold, and (c) is a mold. Sectional drawing which shows the process of supplying a molten thermoplastic resin into the cavity of (a), (d)
It is sectional drawing which shows a mold clamping and shaping process.

FIG. 2A is a cross-sectional view showing a manufacturing process following FIG. 1D and showing a process of injecting air into a thermoplastic resin layer;
(B) is sectional drawing which shows the upper die raising process after completion of shaping | molding.

FIG. 3 is a schematic cross-sectional view of a solid-structured laminated panel manufactured by the method for manufacturing a laminated panel of the present invention.

FIG. 4 is a schematic sectional view of a laminated panel having a hollow structure manufactured by the method for manufacturing a laminated panel of the present invention.

FIG. 5 is a schematic cross-sectional view of another solid-structured laminated panel manufactured by the method for manufacturing a laminated panel of the present invention.

FIG. 6 is a schematic sectional view of another laminated panel having a hollow structure produced by the method for producing a laminated panel of the present invention.

FIG. 7 shows another method of manufacturing a laminated panel of the present invention,
(A) is a sectional view showing a state in which an upper mold of a mold is opened with respect to a lower mold, (b) is a sectional view showing a step of setting two porous hard plates in the mold, (c) is a cross-sectional view showing a step of supplying a molten thermoplastic resin between two porous hard plates in a mold, and (d) is a cross-sectional view showing a mold clamping and shaping step.

FIG. 8A is a cross-sectional view showing a manufacturing process following FIG. 7D, which shows a process of injecting air into a thermoplastic resin layer;
(B) is sectional drawing which shows the upper die raising process after completion of shaping | molding.

[Explanation of symbols]

 Reference Signs List 4 thermoplastic resin plate 4 'molten thermoplastic resin 6 porous hard plate 11 laminated panel 12 laminated panel 13 laminated panel 14 laminated panel 21 mold 22 upper mold 23 lower mold

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Takeo Kitayama 2-1-1 Tsukahara, Takatsuki-shi, Osaka Sumitomo Kagaku Kogyo Co., Ltd. (72) Inventor Shigeyoshi Matsubara 2-1-1 Tsukahara, Takatsuki-shi, Osaka Sumitomo Chemical Industries Co., Ltd. F-term (reference) 4F202 AD08 AD17 AD35 AG03 AG07 AG20 AH46 AR02 AR11 CA09 CB01 CB12 CB20 CK19 CK41 4F204 AA11 AD02 AG03 AG07 AM32 AR03 FA01 FB01 FB12 FF01 FN11

Claims (6)

[Claims] At least one porous hard plate is arranged between a pair of male and female dies so as to face a die surface, and then a molten thermoplastic resin is supplied between the dies and pressed. And manufacturing a laminated panel by laminating and integrating the porous hard plate and the thermoplastic resin. The bending strength of the porous hard plate according to a bending test method specified in JIS A1408. A relationship wherein A (MPa) and the maximum pressing surface pressure B (MPa) during the shaping process from the start of the supply of the thermoplastic resin to the completion of shaping satisfy the following formula (1): Panel manufacturing method. 0 <B / A ≦ 0.5 (1) 2. A product of a pressurizing surface pressure C (MPa) and a pressurizing time H (s) during a cooling step from the completion of the shaping of the thermoplastic resin to the start of mold opening for taking out a formed laminated panel. The method for manufacturing a laminated panel according to claim 1, wherein C · H satisfies the following expression (2). 0 <C · H ≦ 50 (MPa · s) (2) 3. The method for manufacturing a laminated panel according to claim 1, wherein the pressure contact pressure is changed during the cooling step. 4. Before the supply of molten thermoplastic resin between a pair of male and female molds, two porous hard plates are arranged on the mold surface, and the porous hard plate is placed between the porous hard plates. The method for manufacturing a laminated panel according to any one of claims 1 to 3, wherein a thermoplastic resin is supplied. 5. In the cooling step, a compressed fluid is supplied to at least a part of an unsolidified portion of the thermoplastic resin in the mold, and a space between the molds is increased to form a hollow portion in the thermoplastic resin. The method for producing a laminated panel according to claim 1, wherein the laminated panel is formed. 6. At least one porous hard plate is arranged between a pair of male and female molds so as to face the mold surface, and then a molten thermoplastic resin is supplied between the molds and pressed. Then, a method for manufacturing a laminated panel by laminating and integrating the porous hard plate and the thermoplastic resin, wherein a mold for removing the laminated panel formed from the completion of the shaping of the thermoplastic resin A method for manufacturing a laminated panel, wherein a product C · H of a pressurized surface pressure C (MPa) and a pressurization time H (s) during a cooling step until the start of opening satisfies the following expression (3). 0 <CH ≦ 50 (MPa · s) (3)