JP2002103492A - Resin laminate and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide both a resin laminate, in which a sink and a warpage are absent, an outward appearance and quality are excellent, lightweight and rigidity are held and furthermore sound absorbing qualities and sound insulating properties are kept, and a method for producing the same. SOLUTION: The resin laminate is obtained by integrally molding an overcoat layer and a matrix layer having a plurality of blind cavities which are extended from an opening part and are mutually independent. The overcoat layer is allowed to abut and thereafter during filling of a resin for a raw material of the matrix layer or after filling the same, a pressure medium is injected and the resin laminated is produced. After the matrix layer is formed, a void is secured between the matrix layer and the inner wall of a cavity and the raw material of the overcoat layer is filled to produce the resin laminate.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a resin laminate and a method for producing the same, and more particularly, to a resin laminate obtained by integrally molding an overcoat layer and a matrix layer, and a method for producing the same. Since the resin laminate of the present invention is excellent in appearance quality, lightweight and rigid, it can be used for exterior parts such as automobile hoods, trunk lids, fenders and door panels, and interior parts such as instrument panels, clusters and pillar garnishes. Can be used. Also,
Because of its excellent sound absorbing and insulating properties, it can be used as a building structural material.

[0002]

2. Description of the Related Art Conventionally, when a resin material is used as a material to manufacture a highly rigid and lightweight resin molded product having a plurality of independent blind cavities having openings on the front surface or the rear surface, a honeycomb-shaped molded product is used. A method of laminating flat plates to form a molded body, a method of erecting a reinforcing rib, and the like have been adopted. However, in the case of a honeycomb-shaped molded body, the lamination process requires a lot of time, the layers are easily separated from each other because of the lamination, the reliability is low, and it is difficult to increase the rigidity of a part of the molded body. was there. Further, in the blow molded article, there is a problem that the rigidity is low at the center of the molded article where the reinforcing ribs cannot be provided.
Further, in the case of the reinforcing rib stand, there is a problem that a surface sink due to the rib structure occurs, the mold structure becomes complicated, and the mold temperature control becomes complicated. For this reason, it is possible to easily form a resin molded body having a blind cavity having high rigidity and light weight, no sink marks and warpage, and good appearance quality without requiring a post-process such as lamination in a short process time. There was a need for method development.

[0003]

As a method for solving the above-mentioned problems, a pressurized gas is injected while the resin has fluidity at the time of heat molding to produce a resin molded body having blind cavities at a time. A way to do that has been proposed. However, since the purpose is to prevent sink marks on the surface of the molded body and increase the strength of the molded body caused by controlling the shape or volume of the blind cavity, the position of the blind cavity is controlled by the shape of the mold, and it It was difficult to form each independent blind cavity. In addition, even if the formed blind cavities communicate with each other or form independent blind cavities, the rib thickness, shape, volume, and the like cannot be controlled for each blind cavity.

For example, in Japanese Patent Publication No. 57-14968, after a cavity of an injection mold is filled with insufficient molten resin, a pressurized gas is injected from the same port to fill the cavity and fill the cavity (blind cavity). Have been proposed. However, since the gas injection port is the same as the resin injection port, there is a problem that the size, volume, and existing density of the formed hollow body cannot be easily controlled. Also, JP-A-6-134
According to Japanese Patent Publication No. 828, the structure is such that a hollow body (blind cavity) is created simply by injecting gas with a nozzle, so that each is independent of a thin portion,
There is also a problem that a large number of independent hollow bodies whose positions are controlled cannot be formed. In addition, due to the structure in which the check valve is provided at the tip of each nozzle, there has been a problem that the nozzle tip becomes large and a large number of hollow bodies cannot be set per unit area. Further, Japanese Patent Application Laid-Open No. 7-308940 proposes a method of simultaneously molding a composite molded article having a skin layer with one mold, but there is a problem that increasing rigidity and strength increases weight. .

The present invention has been made in view of the above-mentioned problems of the prior art, and has as its object to be free of sink marks and warpage, have excellent appearance quality, have light weight and rigidity, An object of the present invention is to provide a resin laminate having sound absorbing and insulating properties and a method for producing the same.

[0006]

Means for Solving the Problems The inventors of the present invention have made intensive studies to solve the above-mentioned problems, and as a result, a method of forming an overcoat layer in a cavity in advance and then integrally molding the overcoat layer with a matrix layer, Alternatively, the present inventors have found that the above problem can be solved by adopting a method in which a matrix layer is formed in a cavity and then an overcoat layer is integrally formed, and the present invention has been completed.

That is, the resin laminate of the present invention is a resin laminate obtained by integrally molding an overcoat layer and a matrix layer, wherein the matrix layer has an opening on the front surface and / or the back surface, It is characterized in that it has a plurality of mutually independent blind cavities extending in the direction of the opposite back and / or front from this opening.

Further, a preferred embodiment of the resin laminate of the present invention is:
The opening of the blind cavity is provided in a lattice shape or a staggered shape.

Further, another preferred embodiment of the resin laminate of the present invention is a resin laminate having a thickness of 1 to 50 mm, wherein the thickness of the overcoat layer is 1 / th of the thickness of the resin laminate. 2
It is characterized by the following.

Further, in the method for producing a resin laminate according to the present invention, in producing the resin laminate, the volume of a cavity defining the resin laminate can be expanded in the extending direction of the blind cavity, and Using a resin molding die having a material resin injection port and a plurality of pressure medium injection nozzles on the inner wall of the cavity, disposing the overcoat layer in contact with the inner wall of the cavity, and then removing the material resin of the matrix layer. The cavity is filled through the raw material resin inlet, and a pressure medium is injected into / from the raw material resin in the extending direction of the blind cavity through the pressure medium injection nozzle during / after the filling of the raw material resin, and substantially in the same direction. The method is characterized in that the cavity is enlarged, and the overcoat layer and the matrix layer are brought into close contact with each other and integrally molded.

According to another method of manufacturing a resin laminate of the present invention, in manufacturing the resin laminate, the volume of a cavity defining the resin laminate can be increased in the extending direction of the blind cavity. And, using a resin molding die having a raw resin injection port and a plurality of pressure medium injection nozzles on the inner wall of the cavity, the raw resin of the matrix layer is filled into the cavity through the raw resin injection port, During / after the filling of the raw material resin, a pressure medium is injected through the pressure medium injection nozzle in the extending direction of the blind cavity, and the cavity is expanded in substantially the same direction to form a matrix layer. The cavity is enlarged to secure a space between the front and / or back surface of the matrix layer and the inner wall of the cavity. Filled with, molded integrally in close contact and the overcoat layer and the matrix layer, characterized in that.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the resin laminate of the present invention will be described in detail. As described above, the resin laminate of the present invention is obtained by integrally molding the overcoat layer and the matrix layer.

Here, the matrix layer (base material layer)
Has an opening in the front and / or back surface and has a plurality of mutually independent blind cavities extending from this opening in the direction of the opposite back and / or front surface. By having such a blind cavity, the resin laminate becomes a structure having high weight, high strength, and high rigidity. Also, as a material of the matrix layer,
It can be applied as long as it is a resin that has fluidity during heat molding, and it does not matter whether it is a thermoplastic resin or a thermosetting resin. For thermosetting resin, it can be easily used by adjusting the curing reaction by the type of catalyst, amount or heating temperature, etc., but thermoplastic resin is preferred from the viewpoint of ease of setting the formation time of blind cavities having openings. It is.

As the thermoplastic resin, thermoplastic resins generally used in general injection molding, injection compression molding, compression molding, extrusion molding, stamping molding and the like can be applied as they are, for example, polyolefin resins such as polyethylene and polypropylene. , Polystyrene, polycarbonate, acrylonitrile-styrene-butadiene block copolymer, and nylon and the like, ethylene-propylene block copolymer, and thermoplastic elastomers such as styrene-butadiene block copolymer, and also, A polymer alloy or the like as one component can also be used. In addition, talc, glass beads, silicon oxide, coloring pigment, metal powder,
Various commonly used additives such as fillers such as calcium carbonate, glass fibers, polyamide fibers, carbon fibers, light stabilizers and antioxidants, pigments, lubricants, antistatic agents and antioxidants can be blended.

On the other hand, the overcoat layer may have a single-layer or multilayer structure. Examples of such a multilayer structure include a laminate and an injection molded body. Also,
As a material of the overcoat layer, an inorganic substance or an organic substance can be used. These materials can be used in shapes such as thin sheets, bulk and foam. Examples of the inorganic substance include glass, carbon, and titanium, and can be used in the form of a fiber, a sheet woven of fibers, or a sheet woven of fibers. In addition, as the organic substance, a resin, a cloth, a nonwoven fabric or a leather, and any combination thereof can be suitably used. By using these materials, a resin laminate excellent in appearance quality, design properties, strength, durability and the like can be obtained.

As the resin used as the material for the overcoat layer, the same resin as the raw material resin for the matrix layer can be used. However, in consideration of the order of laminating the overcoat layer and the matrix layer, it is desirable to use a resin having a lower melting point than the layer formed and arranged first.

Further, the above resin can be used in the form of a resin sheet, a foamed resin, an uneven resin, a transparent resin or a colored resin, and any combination thereof. For example,
As the colored resin, a resin decorated by kneading the resin, surface coating, vacuum evaporation, plating, printing, or the like can be used. Further, a resin having a smooth surface of the overcoat layer, a resin having irregularities formed by drawing, or the like can be used. In addition,
Needless to say, the transparent resin includes a colored transparent resin.

Furthermore, it is preferable that the main component forming the overcoat layer and the main component forming the matrix layer are made of the same material. At this time, the adhesiveness of the boundary surface is improved, and the peel strength is increased, which is effective.

Further, in the resin laminate of the present invention, the openings of the blind cavities can be provided in a lattice shape or a staggered shape (adjacent columns or rows are shifted at regular intervals). For example, a resin laminate having openings 20 as shown in FIG. 11 (lattice shape) or FIG. 12 (staggered shape) can be given. Furthermore,
The cross-sectional shape of the enlarged portion of the blind cavity can be rectangular when the openings are provided in a lattice shape, and polygonal when the staggered openings are provided. Thus, by appropriately selecting the arrangement of the openings of the blind cavities and the cross-sectional shape of the widened portions of the blind cavities, it is possible to obtain a resin laminate in accordance with desired rigidity, lightness, appearance quality, design, and the like. It is valid. In particular, a polygonal shape is preferable, and the stress is evenly dispersed and the rigidity is easily improved.

Further, the resin laminate has a thickness of 1 to 1.
It is preferably 50 mm. This is because it is possible to form a resin laminate having a size of more than 50 mm in multiple stages, but it is difficult to reduce the weight and rigidity due to an increase in component weight. Further, when the overcoat layer is thick, there is a problem that the cooling time in the manufacturing process becomes longer, the manufacturing cycle is delayed, and the productivity is easily deteriorated. Further, when the thickness is less than 1 mm, the shading of the decoration appears on the surface, the surface property is deteriorated, a uniform resin layer cannot be formed, or the resin may be short-circuited. Further, the thickness of the overcoat layer is preferably equal to or less than １ ／ of the thickness of the resin laminate. If it exceeds ２, the weight of the parts increases, and the effect of reducing the weight tends to decrease. Further, since the blind cavity volume is reduced, the control range of the sound absorption peak frequency is reduced, and the sound absorption effect is easily reduced.

Next, the method for producing a resin laminate of the present invention will be described in detail. This manufacturing method is a method of manufacturing the above-described resin laminate by bringing the overcoat layer into contact with the matrix layer and bringing the matrix layer into close contact with the overcoat layer to integrally mold the overcoat layer. Further, in the resin molding die used for manufacturing, the volume of the cavity defining the resin laminate can be expanded in the extending direction of the blind cavity, and the raw material resin inlet and the plurality of pressure media are provided on the inner wall of the cavity. Has an injection nozzle.

FIGS. 1 to 5 show an example of a resin molding die which can be suitably used in the production method of the present invention. 1 and 2 show a resin laminate having an overcoat layer on the surface,
In other words, a manufacturing process of the resin laminate in the case where the overcoat layer is brought into contact with the surface of the matrix layer where the openings of the blind cavities are present is shown. FIG. 1 shows a state before the raw material resin of the matrix layer is filled, and FIG. 2 shows a state when the raw material is filled to increase the cavity volume and the pressure medium is injected. On the other hand, FIGS. 3 to 5 show a manufacturing process of the resin laminate having the overcoat layer on the back surface, in other words, the resin laminate in the case where the overcoat layer is brought into contact with the surface facing the opening existing surface. ing. 3 shows the state when the overcoat layer is in contact, FIG. 4 shows the state when the matrix layer material is filled, and FIG. 5 shows the state when the blind cavity is formed.

In FIG. 1 and FIG. 2, this resin molding die comprises a movable die 1, a fixed die 2, and a gas / resin injection member 14 mounted on the fixed die 2 on the movable die 1 side. , A cavity 4 defined by the movable mold 1 and the injection member 14.

The injection member 14 is provided with a plurality of pressure medium injection nozzles 5 for injecting the pressure medium into the cavity 4 and a resin injection port 6 for injecting the matrix resin into the cavity 4. I have. The pressure medium injection nozzle 5 has a pressure medium cylinder 7, a pressure adjustment valve 8, a control valve 9, and a heating device 10 via a pressure medium chamber 3 provided between the injection member 14 and the fixed mold 2. It is in communication with the media supply system. On the other hand, the resin injection port 6 penetrates substantially the center of the injection member 14 and the fixed mold 2 and is connected to a raw resin supply system (not shown).

The pressure medium supply system can supply a predetermined amount of pressure medium to each injection nozzle at a predetermined pressure. That is, the control valve 9
After the injection timing and the pressure are controlled in the pressure medium chamber 3, the pressure medium is supplied to the pressure medium chamber 3, and the pressure medium is supplied from the pressure medium chamber 3 to each nozzle. Further, the pressure medium is preferably in a gaseous state at normal temperature and atmospheric pressure, and is used without particular limitation as long as it maintains a gaseous state at room temperature and is nonflammable, such as air, carbon dioxide, nitrogen, and argon. it can. In particular, it is desirable to use air, carbon dioxide, or nitrogen which is easy to supply and inexpensive. Further, the pressure medium is desirably a low-pressure gas of less than 1 MPa.
In some cases, a high-pressure gas of MPa or more can be used.

The pressure medium injection nozzle (injection portion) of the resin molding die has an outer diameter, a tip shape, an arrangement position, and the like.
By arbitrarily adjusting the temperature of the raw resin, the temperature of the mold, the pressure of the pressure medium, and the like, the arrangement position, shape, volume, opening diameter, and the like of the blind cavities of the obtained resin laminate are set between the blind cavities. Can be controlled uniformly. For example, a heat insulating layer can be provided at a mold portion corresponding to the position where the blind cavity is formed, or a thermal conductivity gradient can be provided in the heat insulating layer according to the distance from the resin injection gate (resin injection port). If the intervals between adjacent openings are equal, the thickness of the resin existing between the blind cavities, in other words, the thickness of the resin corresponding to the reinforcing ribs is also substantially uniform,
Rigidity with little variation can be imparted to the resin laminate. On the other hand, the arrangement interval of the pressure medium injection nozzles and the existence ratio of the pressure medium injection nozzles can be partially biased, and the resulting resin laminate can be partially biased in weight reduction, rigidity, sound absorption and sound insulation properties, and the like.

Further, it is desirable that a means capable of heating the inside of the cavity be provided in the resin molding die to control the fluidity of the raw material resin of the matrix layer and the raw material of the overcoat layer injected into the cavity. In other words, it is desirable to control the adhesion between the two layers and the adhesion between the cavity inner wall and the raw material. Examples of such heating means include heating by oil temperature, heating by heating wire, and the like. For the production of the resin laminate, a gas assist injection molding method, an injection compression molding method, a heat compression molding method, or the like can be used.

In the method for producing a resin laminate according to the present invention, the overcoat layer is disposed in contact with the inner wall of the cavity. At this time, the overcoat layer can be in contact with the injection member 14 as shown in FIG. 1, or can be in contact with the bottom of the movable mold 1 facing the injection member 14 as shown in FIG. Also, after contact of the overcoat layer,
The cavity is filled with the raw material resin of the matrix layer through the raw material resin inlet. Further, during / after the filling of the raw material resin, a pressure medium is injected through the pressure medium injection nozzle in a direction in which the blind cavity extends, and the cavity is expanded in substantially the same direction, so that the overcoat layer and the The matrix layer is brought into close contact with the matrix layer and integrally molded.

If the raw material resin is dissociated from the inner wall of the cavity near the pressure medium injection nozzle during the formation of the blind cavity, the pressure medium leaks between the inner wall of the cavity and the raw material resin and is injected into the raw resin. It is difficult to form a blind cavity. Therefore, it is desirable that the raw material resin of the matrix layer is in close contact with the vicinity of the nozzle. When the overcoat layer is brought into contact with the surface of the blind cavity where the opening exists (FIGS. 1 and 2), for example, the raw material resin of the matrix layer is brought into close contact with the overcoat layer, or the pressure medium injection nozzle is raised. And it may be inserted or brought into close contact with the raw material resin.

Preferably, the temperature of the inner wall of the cavity in contact with the overcoat layer is lower than the temperature of the inner wall of the cavity in contact with the matrix layer. In this case, the adhesion between the overcoat layer and the matrix layer can be improved. Further, the solidification of the raw material resin of the matrix layer is suppressed, the adhesion between the matrix layer and the inner wall of the cavity is maintained, and the dissociation of the matrix layer when the cavity is enlarged can be prevented. Further, remelting of the overcoat layer due to heat of the raw material resin of the matrix layer can be suppressed. For example,
In the manufacturing method shown in FIGS. 1 and 2, the temperature of the movable mold 1 to which the raw material resin of the matrix layer contacts can be higher than the temperature of the injection member 14 to which the overcoat layer contacts. Examples of such temperature control means include providing a difference in thermal conductivity on the inner wall of the cavity, using a heat insulating material, and providing a cooling pipe. It is desirable that the temperature control be performed by appropriately considering the pressure medium to be injected, the temperature of the raw material resin, and the like.

Next, another method for producing the resin laminate of the present invention will be described in detail. This manufacturing method is a method of forming a matrix layer, adhering an overcoat layer to the matrix layer and integrally forming the matrix layer to manufacture the above-described resin laminate.

FIGS. 6 to 9 show an example of a resin molding die suitably used in the production method of the present invention. This resin molding die has substantially the same configuration as the molding die shown in FIGS. 1 to 5 described above, but differs in the following points. That is, since this resin molding die is used in a method of manufacturing a resin laminate by forming a matrix layer and then securing a desired gap in the cavity and forming an overcoat layer in this gap, for example, FIG.
And a displacement means 21 (hydraulic cylinder, valve, gate cut mechanism, etc.) for securing the above-mentioned voids, as in the resin molding die shown in FIG. When a switching valve or the like is used, the resin (overcoat layer) inlet 6 ′ and the raw material resin inlet 6 can be integrated.

As the resin molding die, FIGS.
As shown in FIG. 9, a cavity defined by the fixed mold 2 and the movable mold 1 is provided, and the movable mold 1 can be displaced in substantially the same direction as the extending direction of the blind cavity to increase the cavity volume. Those having a structure can be used. Such a resin molding die is effective because it facilitates the production of a resin laminate having a desired shape.

Further, in the present production method, the raw material resin of the matrix layer is filled into the cavity through the raw material resin injection port, and the pressure medium is supplied to the cavity during / after the raw material resin is charged. In addition, the matrix layer is formed by injecting in the extending direction of the blind cavity and expanding the cavity in substantially the same direction. Then
Further, the cavity is enlarged to secure a space between the surface and / or back surface of the matrix layer and the inner wall of the cavity, and the space is filled with a raw material (eg, a resin) for the overcoat layer. And the above-mentioned matrix layer are brought into close contact with each other and are integrally molded.

In the above manufacturing method, it is preferable to cool the matrix layer when securing a gap between the front and / or back surface of the matrix layer and the inner wall of the cavity. As a result, the cavity volume can be quickly increased to secure a gap.

Further, it is preferable that the temperature of the inner wall of the cavity in contact with the raw material resin of the matrix layer is lower than the temperature of the inner wall of the cavity in contact with the overcoat layer. In this case, the resin of the matrix layer is not melted again, Fill the overcoat layer into the mold while maintaining high fluidity,
Can be molded.

In the above-described manufacturing method of the present invention, the surface of the cavity is made rough by providing irregularities on the inner wall of the cavity of the resin molding die.
It is desirable to increase the contact area. Than this,
Using the anchor effect to prevent dissociation of the resin laminate material,
Adhesion between the resin laminate raw material (matrix layer and overcoat layer) and the mold surface (cavity inner wall) constituting the cavity is improved, and a predetermined blind cavity is easily formed. For example, when the resin molding die shown in FIGS. 1 to 9 is used, the surface roughness of the cavity surface of the fixed die can be made larger than the surface roughness of the cavity surface of the movable die. In particular, the surface roughness R of the cavity surface of the fixed mold is
a (Center line average roughness defined in JIS-B0601)
Is preferably 0.25 to 200 μm. Ra
If it is less than 0.25 μm, the anchor effect cannot be used, and the resin may be dissociated from the mold surface when the cavity is enlarged, and the pressure medium may not be injected. When Ra exceeds 200 μm, the anchor effect is strong, and it becomes difficult to release the resin laminate, or even after release, a part of the resin laminate material remains on the mold surface and the surface appearance of the laminate May be significantly impaired.

The irregularities provided on the inner wall of the cavity need not necessarily be provided on the entire inner wall of the cavity.
What is necessary is just to roughen at least the periphery of the pressure medium injection nozzle. Further, the irregularities can be formed of ridges and grooves that are continuous, intermittent, or a combination of both. Such grooves and protrusions can be formed by turning, grinding, polishing, etching, or the like to roughen the inner wall of the cavity.

[0039]

EXAMPLES The present invention will be described in more detail with reference to the following Examples, but it should not be construed that the invention is limited thereto. In the following Examples and Comparative Examples, a resin laminate was manufactured, and the obtained resin laminate was evaluated.

Example 1 A resin laminate of this example was manufactured using a resin molding die having the structure shown in FIG. A pressure medium injection nozzle having a heating mechanism was provided in a fixed mold of the resin molding mold. The pressure medium injection nozzle used was φ6 mm, and the internal volume of the pressure medium chamber was 3 cm ³ . A mold having a variable volume in the cavity was used. The pressure medium injection nozzle of the pressure medium injection nozzle was φ50 mm without a check valve, and twelve pieces were arranged at equal intervals of 5 mm in the center of the mold. Nozzle tips were flat.

For the molding, an injection molding machine with a mold drawing pressure of 110 t was used. A 2 mm thick resin sheet whose surface layer is made of a colored polypropylene resin having a thickness of 1 mm (Chisso Corporation, XK4157V) and whose back surface is made of an uncolored polypropylene resin having a thickness of 1 mm is disposed in a mold as a surface treatment layer. And polypropylene resin (Chisso Corporation, XK)
4157 V) at a resin temperature of 190 ° C., and then the volume inside the cavity is reduced from 100 × 100 × 3 mm ³ to 100 × 1
It was enlarged to 00 × 10 mm ³ to form a blind cavity inside. The mold temperature was 40 ° C. for both the fixed side and the movable side. As the pressure medium, heated compressed air is used.
0 ° C. In the mold, a groove having a center line average roughness of 0.4 μm was provided on a surface in contact with the surface treatment layer, and a 1 μm groove was provided on a surface in contact with the resin laminate having an opening. Table 1 shows the evaluation results of the obtained resin laminate.

(Example 2) A molding machine and a resin molding die were used.
The same configuration as in Example 1 was adopted, and a polypropylene resin (Chip Co., Ltd.)
Injection molding of XK4157V) at a resin temperature of 190 ° C
After that, the volume in the cavity is 100 × 100 × 3 mm³From
100 × 100 × 10mm³Enlarged to form a blind cavity inside
Done. Then, the volume in the cavity is further increased to 100 × 10
0 × 10mm ³From 100 × 100 × 15mm³Expanded to
And melted polypropylene resin (Chisso Corporation, XK
4157V) was injection molded at a resin temperature of 190 ° C. Mold
The temperature was 40 ° C. for both the fixed side and the movable side. The pressure medium is
Using heated compressed air, 200 at the inlet of the pressure medium supply system
° C. For molds, center on the surface in contact with the overcoat layer
A groove having a line average roughness of 0.4 μm
A 1 μm groove was provided on the surface in contact with the trix layer. Profit
Table 1 shows the evaluation results of the obtained resin laminates.

(Examples 3 to 5) The same operation as in Example 1 was repeated except that the thickness of the resin laminate was changed by changing the thickness of the overcoat layer and the amount of change in the volume in the cavity. Body manufactured. Table 1 shows the evaluation results of the obtained resin laminate.

(Examples 6 to 10) The same operation as in Example 1 was repeated except that the surface roughness and surface shape of the mold were changed.
A resin laminate was manufactured. Table 1 shows the evaluation results of the obtained resin laminate.

Example 11 A resin laminate was manufactured by repeating the same operation as in Example 1 except for changing the mold temperature. Table 1 shows the evaluation results of the obtained resin laminate.

Example 12 A resin laminate was manufactured by repeating the same operation as in Example 1 except that the pressure medium injection nozzles provided in the mold were arranged in a staggered arrangement. Table 1 shows the evaluation results of the obtained resin laminate.

Example 13 The pressure medium injection nozzles were arranged in a staggered arrangement, the thickness of the overcoat layer was set to 0.5 mm,
The same operation as in Example 1 was repeated, except that the thickness of the resin laminate was set to 3 mm, to produce a resin laminate. Table 1 shows the evaluation results of the obtained resin laminate.

(Example 14) The pressure medium injection nozzles were arranged in a staggered arrangement, and the thickness of the resin laminate was set to 40 mm.
The same operation as in Example 1 was repeated to produce a resin laminate. Table 1 shows the evaluation results of the obtained resin laminate.

(Comparative Examples 1 to 3) The same operation as in Example 1 was repeated except that the thickness of the overcoat layer was changed and the thickness of the resin laminate was changed by changing the volume change amount in the cavity.
A resin laminate was manufactured. Table 2 shows the evaluation results of the obtained resin laminate.

(Comparative Examples 4 to 6) A resin laminate was manufactured by repeating the same operation as in Example 1 except for changing the surface roughness and surface shape of the mold. Table 2 shows the evaluation results of the obtained resin laminate.

Comparative Example 7 The same operation as in Example 1 was repeated, except that the mold temperature was changed, to produce a resin laminate.
Table 2 shows the evaluation results of the obtained resin laminate.

(Evaluation method) The following four items were evaluated for the obtained resin laminate, and as a comprehensive judgment, the number of blind cavities formed was 12, no sink marks and warpage, no lack of surface appearance, and rigidity per unit weight were obtained. Is very good, and the number of blind cavities formed is 12, no sink marks and warpage, no surface appearance is missing, and the rigidity per unit weight is high.

<Number of blind cavities formed> The average number of blind cavities of a resin laminate obtained from a resin molding die with n = 12 nozzles was observed and evaluated. <Presence or absence of sink marks and warpage> The surface appearance of the obtained resin laminate was visually observed to determine the presence or absence of sink marks and warpage. <Surface Appearance> The surface of the obtained resin laminate was visually evaluated. <Rigidity>-The obtained resin laminate was subjected to a three-point bending test using an indenter 15 and a support 16 as shown in Fig. 13 to evaluate a reaction force value against displacement. In addition, bending speed 10mm
/ Min, and the support point R25 mm.

[0054]

[Table 1]

[0055]

[Table 2]

Table 1 shows that although the resin laminates obtained in Examples 1 to 14 slightly differ in rigidity depending on the thickness, good resin laminates can be obtained as a whole. At the present time, it can be said that the first embodiment is particularly the best. on the other hand,
From Table 2, since the thickness of the resin laminate is 50 mm or more in Comparative Example 1, the thickness of the overcoat layer in Comparative Examples 2 and 3 exceeds half the thickness of the resin laminate. Since the rigidity of the laminate is poor and the surface roughness Ra of the cavity surface is out of the preferred range of the present invention in Comparative Examples 4 to 6,
In Comparative Example 7, since the temperature difference between the fixed mold and the movable mold was outside the preferred range of the present invention, it was found that sink marks were generated and the surface appearance was poor.

Although the preferred embodiments and examples of the present invention have been described in detail above, the present invention is not limited to these, and various modifications can be made within the gist of the present invention. For example, in the present specification, “front surface” and “rear surface” are equivalent to each other, and those in which both are replaced also belong to the scope of the present invention. In addition, the opening of the blind cavity 11 and the overcoat layer can be provided on both the front surface and the back surface of the matrix layer.

[0058]

As described above, according to the present invention, according to the present invention, a method of forming an overcoat layer in a cavity in advance and then integrally molding it with a matrix layer, or a method of forming a matrix layer in a cavity, Since the method and the method of integrally forming the overcoat layer are adopted, a resin laminate having no appearance marks, warpage, excellent appearance quality, light weight and rigidity, and sound absorbing and insulating properties, and a method for producing the same are provided. can do. In addition, productivity can be significantly improved by integrally molding the overcoat layer and the matrix layer.

[Brief description of the drawings]

FIG. 1 is a schematic view showing an example of a resin molding die (before blind cavity molding).

FIG. 2 is a schematic view showing the resin molding die of FIG. 1 (after blind cavity molding).

FIG. 3 is a schematic view showing another example of a resin molding die (arrangement of a surface treatment layer).

FIG. 4 is a schematic view showing the resin molding die (filled with a molten resin) of FIG. 3;

FIG. 5 is a schematic view showing the resin molding die (formation of a blind cavity) of FIG. 3;

FIG. 6 is a schematic view showing still another example of the resin molding die (before filling the blind cavity forming resin).

FIG. 7 is a schematic view showing the resin molding die of FIG. 6 (after filling the blind cavity resin).

FIG. 8 is a schematic view showing the resin molding die (forming a blind cavity) of FIG. 6;

FIG. 9 is a schematic view showing the resin molding die (formation of a surface treatment layer) of FIG.

FIG. 10 is a schematic diagram showing a test method (three-point bending test).

FIG. 11 is a view showing the arrangement of openings (lattice shape) of blind cavities of the resin laminate and the cross-sectional shape (rectangular shape) of the expanded portion.

FIG. 12 is a view showing the arrangement of openings (staggered) of blind cavities of the resin laminate and the cross-sectional shape (polygonal shape) of the expanded portion.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 movable mold (backside forming mold) 2 fixed mold (surface forming mold) 3 pressure medium chamber 4 cavity 5 pressure medium injection nozzle 6 resin injection port 6 ′ resin (overcoat layer) injection port 7 pressure medium cylinder 8 Pressure adjusting valve 9 Control valve 10 Heating device 11 Blind cavity 12 Matrix layer 13 Overcoat layer 14 Gas / resin injecting member 15 Indenter 16 Support 17 Plastic laminate 20 Blind cavity opening 21 Displacement means (cylinder)

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B29L 22:00 B29L 22:00 31:30 31:30 (72) Inventor Koichi Handa Kanagawa-ku, Yokohama-shi, Kanagawa Nissan Motor Co., Ltd. (72) Inventor Kenji Uesugi 2 Takaracho, Kanagawa-ku, Yokohama, Kanagawa Prefecture Nissan Motor Co., Ltd. (72) Masaaki Suzuki 2 Takaracho, Kanagawa-ku, Yokohama, Kanagawa Nissan Motor Co., Ltd. F-term (reference) 4F100 AJ10A AJ10B AK01A AK01B BA02 DC11B DD01A DG11A DG11B DG15A DG15B DJ00A EH362 HB00A JA20 JL10A JN01A YY00 4F202 AA11 AD05 AD08 AG03 AG07 AH17 CA11 CB22A13 CA13 CB01A13 CA11 CB01B13 AE JN22 JN27 JQ81

Claims (15)

[Claims] 1. A resin laminate obtained by integrally molding an overcoat layer and a matrix layer, wherein the matrix layer has an opening on a front surface and / or a back surface, and a back surface facing the opening. And / or a plurality of mutually independent blind cavities extending in the direction of the surface. 2. The resin laminate according to claim 1, wherein the overcoat layer has a one-layer structure or a multilayer structure. 3. The material of the overcoat layer is a resin,
The resin laminate according to claim 1, wherein the resin laminate is at least one selected from the group consisting of a fabric, a nonwoven fabric, and a leather. 4. The resin laminate according to claim 3, wherein the resin is at least one selected from the group consisting of a resin sheet, a foamed resin, an uneven resin, a transparent resin, and a colored resin. body. 5. The resin according to claim 1, wherein a main component forming the overcoat layer and a main component forming the matrix layer are made of the same material. Laminate. 6. The resin laminate according to claim 1, wherein the openings of the blind cavities are provided in a lattice shape or a staggered shape. 7. The resin laminate according to claim 1, wherein a cross-sectional shape of the expanded portion of the blind cavity is rectangular or polygonal. 8. A resin laminate having a thickness of 1 to 50 mm, wherein the thickness of the overcoat layer is １ ／ or less of the thickness of the resin laminate. 7. The resin laminate according to any one of items 7 to 7. 9. In manufacturing the resin laminate according to any one of claims 1 to 8, a volume of a cavity defining the resin laminate is expandable in an extending direction of the blind cavity, And using a resin molding die having a material resin injection port and a plurality of pressure medium injection nozzles on the inner wall of the cavity, disposing the overcoat layer in contact with the inner wall of the cavity, and then forming a raw material resin for the matrix layer. Into the cavity via the material resin inlet, and during / after filling the material resin, a pressure medium is injected through the pressure medium injection nozzle in the extending direction of the blind cavity, and in substantially the same direction. To expand the above cavity,
A method for producing a resin laminate, wherein the overcoat layer and the matrix layer are brought into close contact with each other and integrally molded. 10. The method for producing a resin laminate according to claim 9, wherein the temperature of the inner wall of the cavity in contact with the overcoat layer is lower than the temperature of the inner wall of the cavity in contact with the matrix layer. 11. In manufacturing the resin laminate according to any one of claims 1 to 8, a volume of a cavity defining the resin laminate is expandable in a direction in which the blind cavity extends, And using a resin molding die having a raw resin injection port and a plurality of pressure medium injection nozzles on the inner wall of the cavity, filling the raw material of the matrix layer into the cavity through the raw resin injection port, During / after the filling of the raw material resin, a pressure medium is injected through the pressure medium injection nozzle in the extending direction of the blind cavity, and the cavity is expanded in substantially the same direction to form a matrix layer. The cavity is enlarged to secure a space between the front and / or back surface of the matrix layer and the inner wall of the cavity, and the material of the overcoat layer is filled in the space. A method for producing a resin laminate, comprising: filling the overcoat layer and the matrix layer so as to be in close contact with each other and integrally forming the matrix layer. 12. The production of the resin laminate according to claim 11, wherein the matrix layer is cooled when a gap is secured between the front surface and / or the back surface of the matrix layer and the inner wall of the cavity. Method. 13. The temperature of the inner wall of the cavity in contact with the matrix layer is lower than the temperature of the inner wall of the cavity in contact with the overcoat layer.
Or a method for producing a resin laminate according to item 12. 14. The resin molding die has a cavity defined by a fixed die and a movable die, and the movable die is displaced in substantially the same direction as the direction in which the blind cavity extends, so that the cavity volume is increased. The surface roughness of the cavity surface of the fixed mold is larger than the surface roughness of the cavity surface of the movable mold. The method according to any one of claims 9 to 13, wherein: A method for producing a resin laminate. 15. The method for producing a resin laminate according to claim 13, wherein the surface roughness Ra of the cavity surface of the fixed mold is 0.25 to 200 μm.