JP2001341670A - Front end panel, and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a front end panel manufactured using a resin, and improved in impact strength and weld part strength, and provide a manufacturing method therefor. SOLUTION: This panel is a front end panel layered with moldings. A comprising a glass fiber-reinforced resin of a thermoplastic resin containing a glass fiber, and metal sheets B. The metal sheets B are set inside a die cavity, the hot molten glass fiber-reinforced resin is poured into the cavity to be followed by cooling and solidifying, and both are integrated to manufacture the front end panel, in this manufacturing method.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a front end panel obtained by using a resin and a metal plate, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, parts have been individually assembled in an engine room when an automobile is manufactured. However, since the number of parts is large and the assembling work is complicated, in recent years, a plurality of parts have been integrated and integrated. The method of incorporating it into the engine room is adopted. For example, components incorporated in the front part of the vehicle body, specifically, a radiator and a cooling fan thereof are held by a front end panel that constitutes the front part of the vehicle body, and are integrated into the engine room. (JP-A-7-165116).

[0003] Such a front end panel is required to have particularly high rigidity, heat resistance, and impact resistance among many automobile parts, and a metal panel is conventionally used. Recently, a resin-made front end panel has also been proposed from the viewpoint of problems of weight and problems of manufacturing efficiency of a complicated shape (Japanese Patent Laid-Open No. 11-152062).

[0004]

However, such a conventional resin front end panel has insufficient impact strength, and the strength (bending strength, tensile strength) of a weld portion usually formed because it is made of resin. Impact strength along with static strength such as strength) was not sufficient. Under such circumstances, an object to be solved by the present invention is to provide a front end panel with improved impact strength and weld strength obtained by using a resin, and a method of manufacturing the same.

[0005]

SUMMARY OF THE INVENTION The present invention provides a front end panel formed by laminating a molded article (A) made of glass fiber reinforced resin, which is a thermoplastic resin containing glass fiber, and a metal plate (B). Such is the case. Further, the present invention relates to a method of manufacturing a front end panel in which a metal plate (B) is set in a mold cavity, a glass fiber reinforced resin melted by heating and melted is injected into the cavity, solidified by cooling, and integrated. Such is the case. Hereinafter, the present invention will be described in detail.

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The glass fiber reinforced resin used in the present invention is a thermoplastic resin containing glass fibers. As such a thermoplastic resin, a polyolefin-based thermoplastic resin, a polyamide-based thermoplastic resin, a polyester-based thermoplastic resin, or a mixture of two or more of these resins is preferable.

As the polyolefin-based thermoplastic resin, for example, polypropylene, propylene-ethylene block copolymer, propylene-ethylene random copolymer, high-density polyethylene, or a mixture thereof can be used. As the polyamide-based thermoplastic resin,
Polyamide-6, polyamide-11, polyamide-1
2, polyamide 4-6, polyamide-6,6, polyamide-6,10, polyamide-6,12, or an alloy resin thereof, or the like. Examples of the polyester-based thermoplastic resin include polyethylene terephthalate, polybutylene terephthalate, polycarbonate, polyester carbonate, and alloy resins thereof. The above thermoplastic resins can be used alone or in combination of two or more. Among such thermoplastic resins, a polyolefin-based thermoplastic resin is preferable for obtaining a suitable molded product.

As the polyolefin-based thermoplastic resin, an amorphous or crystalline polyolefin-based thermoplastic resin can be used, but a crystalline polyolefin-based thermoplastic resin is preferable. Among these, polyethylene, polypropylene, poly (1-butene), ethylene-
Propylene copolymer, poly (3-methylbutene-1),
Poly (4-methylpentene-1) or a copolymer of propylene and a non-conjugated diene is preferred. Further preferred are polypropylene resins such as homopolypropylene, block copolymers or random copolymers of propylene and other olefins, or mixtures thereof, especially unsaturated carboxylic acids modified with unsaturated carboxylic acids or derivatives thereof. It is preferably a polypropylene resin containing a modified polyolefin. As described above, by adding an unsaturated carboxylic acid-modified polyolefin such as an unsaturated carboxylic acid-modified polypropylene-based resin to a polypropylene-based resin and using the same, adhesion to glass fibers can be improved, and further excellent strength can be secured. The content of the unsaturated carboxylic acid-modified polyolefin is preferably from 0.01 to 50% by weight.

Further, the thermoplastic resin used in the present invention includes:
Various additives and fillers as necessary, such as antioxidants,
An antifogging agent, an antistatic agent, a nucleating agent, an ultraviolet absorber, a pigment and the like can be included. In addition, for example, a recycled resin may be blended within a range that does not hinder the present invention.

The glass fiber reinforced resin used in the present invention is a thermoplastic resin containing glass fibers. The glass fiber content is preferably 5 to 60% by weight. If the glass fiber content is less than 5%, the strength, rigidity or durability at high temperatures may not be sufficient, and if the glass fiber content exceeds 60% by weight, the moldability deteriorates and the appearance becomes poor. In some cases, the weight may increase due to the glass fiber, and the weight may not be sufficiently reduced. The glass fiber content is more preferably 1
It is 5 to 50% by weight, more preferably 20 to 45% by weight.

[0011] The type of glass fiber contained in the glass fiber reinforced resin is not limited. E-glass (El
ectrical glass), C glass (Chemical glass), A glass (Alkali glass), S glass (High strength glas)
s), and filamentous fibers obtained by melt spinning glass such as alkali-resistant glass. The fiber diameter of the glass fiber is not particularly limited either, but is preferably 3 to 25 μm, and more preferably 8 to 20 μm.

The thickness of the metal plate (B) used in the present invention is preferably 0.05 to 2 mm, more preferably 0.1 to 1 mm.
mm, most preferably 0.1-0.5 mm. If the thickness is too small, the strength, rigidity and impact strength at high temperatures are often insufficient. On the other hand, if the thickness is too large, the weight of the molded body becomes heavy, and it is difficult to follow the curved surface shape of the molded body, and the structure of the molded body may be limited.

The type of the metal plate is not limited. Examples of the metal plate (B) include a steel plate, an aluminum plate, a copper plate, and a zinc plate. When the layer made of the metal plate (B) has a curved surface, a steel plate is preferable as the metal plate (B) from the viewpoint of the bending workability and drawability of the layer.

As the type of the steel sheet, a cold-rolled steel sheet (SP
C), hot-rolled steel sheet (SPN), strip steel strip (SP
M), tin plate (SPTE, SPTH), zinc iron plate (S
PG), lightweight section steel (SSC), and the like. Preferably, a cold rolled steel plate (SPC) or a hot rolled thin steel plate (SP
N). In particular, it is preferable to use a cold-rolled steel plate (SPC) to obtain a good compact.

The front end panel of the present invention includes:
A front end panel formed by laminating a molded article (A) made of glass fiber reinforced resin which is a thermoplastic resin containing glass fiber and a metal plate (B), wherein the molded article (A) and a metal plate ( A front end panel in which B) is integrated with a polar group-containing thermoplastic resin (C) is preferable.

The polar group-containing thermoplastic resin (C) referred to herein.
Examples of the polar group include acyl group, amino group, amide group, alkoxy group, isocyanate group, imide group, urethane group, alkoxycarbonyl group, acyloxy group (including acryloxy group and methacryloxy group), epoxy group, oxazoline group, and carboxyl group. Groups (including a maleic acid group and a maleic anhydride group), a carbonyl group, a cyano group, a hydroxyl group, a sulfoxyl group, a sulfone group, a thiol group, a nitrile group, and a mercapto group. By using the thermoplastic resin having these polar groups, the glass fiber reinforced resin (A) and the metal plate (B) are more preferably integrated.

The polar group-containing thermoplastic resin (C) includes
Unsaturated carboxylic acids such as acrylic acid or unsaturated dicarboxylic acids such as maleic acid or derivatives of these unsaturated acids such as esters, acid anhydrides, salts, amides and imides; unsaturated alcohols such as allyl alcohol; unsaturated amines Allyl isocyanate; or a polyolefin modified with vinylalkoxysilane is preferred, more preferably an unsaturated dicarboxylic acid or anhydride thereof, or a polyolefin modified with an unsaturated alcohol, even more preferably maleic anhydride or maleic anhydride. Polyolefin modified with a mixture of acid and maleic acid.

The modification of the polyolefin with these compounds is carried out, for example, by graft-polymerizing these compounds to the polyolefin. Known methods can be used for the method of graft polymerization. Both components,
For example, a method of melt-kneading using an extruder or a method of reacting in a solution is used. In each case, an ordinary radical generator can be used as a catalyst. The polyolefin used here is preferably the above-mentioned polypropylene resin.

The graft ratio of these compounds to polyolefin is preferably 0.01 to 40% by weight, more preferably 0.05 to 20% by weight, and most preferably 0.1 to 1% by weight.
0% by weight. If the graft ratio is too low, the adhesion to the metal plate is often unsatisfactory, and if the graft ratio is too high, the workability may decrease. In the present invention, the modified polyolefin may be used after being diluted with an unmodified polyolefin, and the average graft ratio after dilution is preferably within the above range.

The front end panel of the present invention is a front end panel formed by laminating the molded body (A) made of the glass fiber reinforced resin and the metal plate (B). As the front end panel of the present invention, it is preferable that all or a part of the metal plate (B) is exposed to the surface layer of the molded article (A), and the rigidity and heat resistance of the molded article (A) are excellent. It is preferable because the impact strength can be further improved and a front end panel excellent in design and surface hardness can be obtained. In addition, the metal plate (B) is a molded product (A)
Is preferably disposed on one or both surfaces of the molded article (A) to further improve the excellent rigidity, heat resistance, and impact strength of the molded article (A), and to obtain a molded article having excellent design and surface hardness. Is preferred. By using the metal plate (B) for parts and welds where rigidity, heat resistance and impact strength are required, it is excellent in rigidity, heat resistance, impact strength and weld strength in front end panels which are usually complicated in shape. Can be obtained.

Further, in the present invention, the strength of the weld portion is greatly improved by applying to the molded product (A) having a weld portion formed by injection molding, injection compression molding, expansion injection molding, or gas injection injection molding. A front end panel can be obtained. That is, the front end panel of the present invention is a front end panel in which the molded body (A) made of the glass fiber reinforced resin and the metal plate (B) are laminated, and the molded body (A) is , A front end panel obtained by molding by injection molding, injection compression molding, expansion injection molding, or gas injection injection molding, wherein a metal plate (B) is arranged in a portion including a weld of the molded body (A). It can be mentioned as a suitable one.

In the front end panel of the present invention, the metal plate (B) is set in a mold cavity, and the glass fiber reinforced resin melted by heating is injected into the cavity, and solidified by cooling, and the two are integrated. It is manufactured by a method of manufacturing a front end panel. As a result, steps such as bonding after molding can be omitted, and a front end panel of any shape excellent in high rigidity, high heat resistance, impact strength, and strength of a weld portion can be efficiently and inexpensively provided. . Here, it is preferable that the metal plate (B) is a metal plate previously integrated with the polar group-containing thermoplastic resin (C).

The metal plate (B) and the polar group-containing thermoplastic resin (C) can be integrated by a known method, such as press molding, laminate molding, or cast molding.

Further, according to the method of manufacturing a front end panel of the present invention, the glass fiber reinforced resin contains 5 to 60% by weight of glass fibers arranged in parallel with each other.
The use of a glass fiber reinforced resin in the form of a pellet having a size of about 100 mm is preferable because a suitable front end panel can be efficiently manufactured.

The front end panel of the present invention is used as a front end panel which is required to have particularly excellent impact strength and weld strength among automobile parts. In particular, the front end panel of the present invention has further enhanced rigidity and heat resistance, which are features of the glass fiber reinforced resin, and is extremely useful as a front end panel that is excellent in balance with weight reduction.

[0026]

EXAMPLES Hereinafter, the present invention will be described in more detail with reference to examples, but the present invention is not limited to these examples. In these examples, the test methods used for various evaluations are as follows.

(1) Injection molding machine FS160S25ASEN manufactured by Nissei Plastic Industry Co., Ltd.

(2) Mold for Injection Molding The cavity has a shape of a flat plate having a width of 90 mm, a length of 150 mm and a thickness of 3 mm, and has two gates on both sides in the length direction (two-point gate). Was used. Each gate is openable and closable.When only one gate is open, a molded product without weld is obtained.When both gates are open, a weld is provided at the center in the length direction. A molded article is obtained.

(3) Injection molding conditions Each was set as follows. Cylinder temperature: 250
° C, mold temperature: 50 ° C, screw rotation speed: 30 rpm
m, back pressure: 0 MPa.

(4) Melt flow rate (MFR) In accordance with JIS K7210, the polypropylene resin was measured according to the method specified in Condition 1 in Table 1.

(5) Flexural modulus The obtained molded body is cut out in parallel with the resin flow direction.
It was measured based on the method specified in JIS-K-7203.

(6) Impact strength Evaluated according to DIN 53453 test. Specifically 9
Each molded body of 0 mm x 150 mm x 3 mm is converted to 10 mm x
When a weld part is 22 mm and a weld part is present, a test piece is prepared by cutting the weld part so as to exist at a position 12.5 mm from the lower end, and the test piece is left in a constant temperature chamber at 23 ° C. for 24 hours. (Manufactured by Tester Sangyo). The entire lower 12.5 mm range of the test piece was fixed with a chuck, and a position 7 mm above the end of the chuck was hit in the thickness direction to measure the impact strength.

Reference Example 1 180 mm × 180 mm ×
A maleic anhydride-modified polypropylene-based resin (a propylene-ethylene block copolymer modified with maleic anhydride on a 0.1 mm thick cold-rolled steel plate (SPC); propylene in a propylene-ethylene block copolymer) The content of the ethylene random copolymer part is 22% by weight, the content of the repeating unit derived from ethylene in the propylene-ethylene random copolymer part is 45% by weight,
The graft ratio of maleic anhydride was 0.2% by weight, MFR = 4
(0 g / 10 minutes) 3 g of the pellets were placed, and pressed with a press machine NF-37 manufactured by Shinto Metal Industry Co., Ltd., which was adjusted to a temperature of 200 ° C., for 2 minutes to heat and fuse to obtain a laminate. The thickness of the maleic anhydride-modified polypropylene resin layer is about 0.11
mm. Press pressure is 200 per cm ²
N. This laminate is cut into 90 mm x 90 mm,
The mold is closed by bringing the steel plate side into close contact with one side of the mold cavity wall surface of the injection molding machine, and the melted glass fiber reinforced polypropylene resin is supplied into the mold from only one side gate, and 90
A molded product of mm × 150 mm × 3 mm was obtained. The glass fiber reinforced polypropylene resin is a propylene homopolymer pellet containing glass fibers arranged in parallel with each other (Smithtran, manufactured by Sumitomo Chemical Co., Ltd., glass fiber content: 40%, pellet length: 9 mm, glass fiber length: 9 mm) ) Was used. Table 1 shows the flexural modulus, flexural strength and impact strength of the obtained molded body.

Reference Example 2 The same operation as in Reference Example 1 was carried out except that a laminate of a steel sheet and a maleic anhydride-modified polypropylene resin prepared by the same operation as in Reference Example 1 was arranged on both sides in a mold. By the method, a molded body having a steel plate having a thickness of 0.1 mm on both surfaces was obtained. Table 1 shows the flexural modulus, flexural strength and impact strength of the obtained molded body.

Reference Example 3 The same method as in Reference Example 1 except that the thickness of the steel plate was set to 0.2 mm
A compact having a thick steel plate was obtained. Table 1 shows the flexural modulus, flexural strength and impact strength of the obtained molded body.

Reference Example 4 The same method as in Reference Example 2 except that the thickness of the steel sheet was set to 0.2 mm
A compact having a thick steel plate was obtained. Table 1 shows the flexural modulus, flexural strength and impact strength of the obtained molded body.

Comparative Example 1 A molten glass fiber reinforced polypropylene resin was placed in one side of a mold in the same manner as in Reference Example 1 except that a laminate of a steel sheet and a maleic anhydride-modified polypropylene resin was not placed in the mold. A molded product was obtained by supplying only from the gate. Flexural modulus, bending strength,
Table 1 shows the impact strength.

Reference Example 5 A method similar to that of Reference Example 1 except that molten glass fiber reinforced polypropylene resin was supplied into the mold from the gates on both sides to operate so that a weld was formed at the center of the flat plate. Thus, a molded article having a weld portion and having a steel sheet having a thickness of 0.1 mm disposed on one side was obtained. Table 2 shows the flexural modulus, flexural strength, and impact strength of the obtained molded body.

REFERENCE EXAMPLE 6 A method similar to that of Reference Example 2, except that molten glass fiber reinforced polypropylene resin was supplied from the gates on both sides into a mold and an operation was performed so that a weld was formed at the center of the flat plate. Thus, a molded article having a weld portion and having a steel sheet having a thickness of 0.1 mm disposed on both sides was obtained. Table 2 shows the flexural modulus, flexural strength, and impact strength of the obtained molded body.

REFERENCE EXAMPLE 7 The same method as in Reference Example 3 except that the molten glass fiber reinforced polypropylene resin was supplied into the mold from the gates on both sides to operate to form a weld at the center of the flat plate. Thus, a molded body having a weld portion and having a steel plate having a thickness of 0.2 mm disposed on one side was obtained. Table 2 shows the flexural modulus, flexural strength, and impact strength of the obtained molded body.

Reference Example 8 The same method as in Reference Example 4 except that molten glass fiber reinforced polypropylene-based resin was supplied from the gates on both sides to form a weld at the center of the flat plate. Thus, a molded body having a weld portion and having a steel plate having a thickness of 0.2 mm disposed on both surfaces was obtained. Table 2 shows the flexural modulus, flexural strength, and impact strength of the obtained molded body.

[Comparative Example 2] A molten glass fiber reinforced polypropylene resin was supplied from the gates on both sides into the mold and welded to the center of the flat plate in the same manner as in Reference Example 5 except that the laminate was not placed in the mold. A molded body having a part was obtained. Table 2 shows the flexural modulus, flexural strength, and impact strength of the obtained molded body.

The "evaluation method" in Tables 1 and 2 refers to the surface of the test piece pressed in the bending test for the evaluation of the bending elastic modulus and the bending strength, and for the evaluation of the impact strength, for the evaluation of the impact strength. Shows the striking surface. It is not necessary to consider the evaluation direction for a test piece having a steel plate laminated on both sides (Example 2 and the like) and a test piece having no steel sheet laminated (Comparative Example 1 and the like).

As described above, the molded article of the reference example in which the metal plate (B) is laminated is excellent in impact strength and strength of a weld portion. The molded article of the reference example is also excellent in rigidity and heat resistance. By using the metal plate (B) for a portion where the impact strength of the front end panel, the strength of the weld portion, and the rigidity are required, the impact strength and the strength of the weld portion are particularly excellent, and the rigidity is further improved. An excellent front end panel can be obtained.

(Table 1) No Weld ------------------------------------------------------------------------------------------------------------------ 1 Reference Example 2 Reference Example 3 Reference Example 4 Comparative Example 1 ----------------------------------- ) 0.1 0.1 0.2 0.2-Steel sheet arrangement One side Both sides One side Both sides None Evaluation direction Resin side-Resin side--23 ° C Flexural modulus (MPa) 13300 24800 14600 36800 5870 Flexural strength (MPa) 215 249 256 341 138 Impact strength (kJ / m ² ) 25.0 41.9 − 65.2 23.1 110 ° C. Flexural modulus (MPa) − 13100 − 17900 3320 Flexural strength (MPa) − 145 − 250 61 Evaluation direction Steel sheet side − Steel sheet side − − 23 ° C. Flexural modulus (MPa) 11500 − 13300 − − Flexural strength (MPa) 165 − 176 − − Impact strength (kJ / m ² ) 39.0 − − − − −−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−

(Table 2) With Weld ------------------------------------------------------------------------------------------------------------------ 5 Reference Example 5 Reference Example 6 REFERENCE EXAMPLE 7 REFERENCE EXAMPLE 8 COMPARATIVE EXAMPLE 2 ------------------------- ) 0.1 0.1 0.2 0.2 0.2-Steel plate arrangement One side Both sides One side Both sides None Evaluation direction Resin side-Resin side--23 ° C Flexural modulus (MPa) 10600 21000 11200 32400 4420 Flexural strength (MPa) 173 220 198 291 51 Impact strength (kJ / m ² ) 4.3 17.6 6.5 43.0 3.0 110 ° C Flexural modulus (MPa)-11600-16700 2300 Flexural strength (MPa)-125-195 20 Evaluation direction Steel sheet side-Steel sheet side--23 ° C flexural modulus (MPa) 9900 - 10400 - - flexural strength (MPa) 80 - 67 - - impact strength ^{(kJ / m 2) 13.8 -} 38.9 - - -----------------------------------

[0047]

As described in detail above, according to the present invention,
A front end panel having improved impact strength and weld strength obtained by using a resin, and a method for manufacturing the same are provided. As the front end panel of the present invention,
A front-end panel that further enhances the rigidity and heat resistance that are characteristic of glass fiber reinforced resin is provided, and it is a front-end panel that has a high degree of freedom in applicable structures, and a front-end panel that is excellent in balance with weight reduction. is there. The front end panel of the present invention is extremely useful as a front end panel that requires particularly high rigidity, heat resistance, impact strength, and strength of a weld portion among a large number of automobile parts. Extremely high.

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Claims (13)

[Claims] 1. A front end panel comprising a molded body (A) made of glass fiber reinforced resin which is a thermoplastic resin containing glass fibers, and a metal plate (B) laminated. 2. A molded article (A) comprising a glass fiber reinforced resin.
The front end panel according to claim 1, wherein the metal plate (B) and the metal plate (B) are integrated by a polar group-containing thermoplastic resin (C). 3. The front end panel according to claim 1, wherein all or a part of the metal plate (B) is exposed on the surface of the molded body (A). 4. The front end panel according to claim 1, wherein the metal plate (B) is disposed on one or both surfaces of the molded body (A). 5. The molded article (A) is obtained by molding by injection molding, injection compression molding, expansion injection molding, or gas injection injection molding, and a metal plate ( The front end panel according to any one of claims 1 to 4, wherein B) is arranged. 6. The front end panel according to claim 1, wherein the thermoplastic resin is a polypropylene resin. 7. The front end panel according to claim 1, wherein the glass fiber content of the glass fiber reinforced resin is 5 to 60% by weight. 8. The front end panel according to claim 1, wherein the metal plate (B) is a metal plate having a thickness of 0.05 to 2 mm. 9. The metal plate (B) is a steel plate.
Front end panel according to any of the above 10. A method of manufacturing a front end panel in which a metal plate (B) is set in a mold cavity, a glass fiber reinforced resin melted by heating is injected into the cavity, solidified by cooling, and integrated. 11. The method for manufacturing a front end panel according to claim 10, wherein the metal plate (B) is a metal plate previously integrated with a polar group-containing thermoplastic resin (C). 12. The metal plate (B) has a thickness of 0.05 to 2 mm.
The method for manufacturing a front end panel according to claim 10, wherein the metal plate is a metal plate. 13. The metal plate (B) is a steel plate.
13. The method for manufacturing a front end panel according to any one of claims 12 to 12.