JP2003071958A - Composite molding and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a composite molding in which a base material is rigidly adhesively connected to a reinforcing sheet, which has excellent face rigidity and strength and further excellent surface design properties and to provide a method for manufacturing the same. SOLUTION: The composite molding comprises a porous plate-like base material having open cell pores, the reinforcing sheet having a thickness of 1 mm or less and disposed on and fusion-bonded to the surface and/or the interior of the base material in such a manner that the sheet is fixed with an L- FRTP wire and has an opening part. The method for manufacturing the same is provided.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite molded article and a method for producing the same, and more specifically, a porous material having continuous pores such as mats, nonwoven fabrics, felts, and resin foams made of inorganic fibers and thermoplastic resins. TECHNICAL FIELD The present invention relates to a composite molded body having a reinforcing sheet on the surface and / or inside of a flexible plate-shaped base material and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, for the purpose of reinforcing the surface of a porous plate-shaped base material having continuous holes as described above and improving the design of the base material, glass fiber, carbon fiber,
A woven or non-woven fabric made of organic fibers or the like has been used as a skin material and adhered thereto. However, the woven or non-woven fabric needs to be integrated with the base material by using an adhesive or the like, and the workability is poor.

In order to increase the surface rigidity of the base material, F has been conventionally used.
Many RP face materials are used. However, since the resin used in the conventional FRP is a thermosetting resin, in order to integrate the base material and the FRP, an FRP sheet is attached to the base material via an adhesive, or the woven material such as the glass fiber is used. After aligning the cloth or non-woven fabric with the surface shape of the base material,
Since the thermosetting resin monomer is impregnated and cured and molded, there is a problem that workability is poor.

Further, there is a method in which a woven cloth or a non-woven cloth such as the above-mentioned glass fiber is made to conform to the surface shape of the base material, and then a thermoplastic resin film is laminated and heated and pressure-bonded. In addition to this, there is a problem that the impregnating property of the thermoplastic resin is poor and the product obtained cannot have sufficient strength.

Furthermore, in a stampable sheet in which continuous or discontinuous reinforcing fibers are matted and impregnated with a thermoplastic resin as an L-FRTP sheet, the glass content is reduced to improve the resin impregnation property. Because
In order to use it as a face material and develop rigidity, it is necessary to increase the thickness, and there is a problem that the weight is large and the cost is high.

In Japanese Patent Publication No. 42168/1992, a plurality of continuous fibers are aligned in one direction, impregnated with a thermoplastic resin to form a sheet, and one or more of the sheets are used as a face material for a base material. It is described that they are laminated to reinforce the base material. The weight per unit area of this fiber reinforced sheet is 150 to 1
Was 200 g / m ^2, when used in laminating two to 0 and 90 degrees, basis weight 300~2400g / m ^2, and the there is lightweight, its light weight is insufficient. Further, since this sheet is a non-porous sheet, wrinkles are generated, air is taken in, and adhesion failure occurs when laminating sheets and laminating on a base material, particularly in the case of a large area base material. However, problems such as swelling after lamination occur.

Further, in the invention described in Japanese Patent Laid-Open No. 6-238659, the wire material constituting the face material to be used is not formed by impregnating a matrix resin, and therefore the wire materials (fiber bundles) are bonded to each other. Since it is inferior, a molded product having sufficient strength cannot be obtained. Further, since the wire rod is not impregnated with a thermoplastic resin, the fibers easily fluff from the wire rod, and furthermore, it is difficult to firmly bond the sheet made of the wire rod to the base material. There is a problem that sufficient pressing and high temperature are required.

[0008]

SUMMARY OF THE INVENTION In view of the above problems of the conventional composite molded body, an object of the present invention is to strongly bond and bond the base material and the reinforcing sheet, and to have excellent surface rigidity and strength. ,
Another object of the present invention is to provide a composite molded article having excellent surface design and a method for producing the same.

[0009]

In order to achieve the above object, the present invention provides a reinforcing sheet on the surface and / or inside of a porous plate-shaped base material (hereinafter simply referred to as "base material") having continuous pores. Are arranged and fused, and the reinforcing sheet is
Provided is a composite molded article, which is a sheet having an RTP wire (hereinafter, simply referred to as “wire”) fixed thereto and having an opening, and a method for producing the same.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in more detail with reference to the following preferred embodiments. 1 to 3 are diagrams schematically illustrating a cross section of the composite molded body of the present invention. In one example of the composite molded body of the present invention, a reinforcing sheet 2 having a specific structure to be described later is arranged and fused on both sides of a base material 1 as shown in FIG. 1 without using an adhesive. The example shown in FIG.
A reinforcing sheet 2 similar to the case of FIG. 1 is arranged and fused on one surface of the base material 1. In the example shown in FIG. 3, the reinforcing sheet 2 is further arranged in the base material 1 in the example shown in FIG. And fused. This example is suitable when the base material 1 is relatively thick.

The base material in the above-mentioned composite molded body is
Porous plate-like body having continuous pores, for example, a mat made of inorganic fibers and a thermoplastic resin, a non-woven fabric, a felt,
And resin foams (for example, open-cell expanded polyethylene, open-cell expanded polypropylene, and open-cell expanded polyurethane having low surface strength), honeycomb materials, inorganic fiber mats, porous FRPs, porous FRTPs, and composites thereof. Conventionally, it has been used for interior materials, heat insulating materials, sound absorbing materials, etc. in buildings, vehicles, and other applications, and is characterized by its lightness and breathability. Although these base materials are excellent in lightness and air permeability, they have a problem that they are inferior in surface and overall strength, bending rigidity, etc. These problems are due to the surface material having high rigidity on the surface. However, in the conventional techniques, the characteristics of these base materials such as lightness, air permeability, and low cost have not been fully utilized.

The base material used in the present invention is not particularly limited as long as it is a porous plate-like material having continuous pores, but considering its suitability for use, handleability, productivity of composite molded product, etc., The basis weight is 200 to 1500 g /
It is preferably m ² . When the basis weight is less than 200 g / m ^2, it depends on the thickness, but if the thickness of the base material is increased, the base material becomes fluffy, and the strength of the base material itself is too low to be a satisfactory product even if a reinforcing sheet is laminated. On the other hand, the basis weight is 1
If it exceeds 500 g / m ² , it is not preferable because it is unsatisfactory in terms of lightness and air permeability, and air permeability is insufficient in the production of the composite molded article of the present invention described later. In addition, in the same meaning, it is preferable that the air permeability of the base material defined by JIS L 1096 is 10 to 400 cm ³ / cm ² · S in the production of the composite molded article of the present invention described later.

In the present invention, the reinforcing sheet for reinforcing the base material is a sheet to which a large number of wire rods are fixed and which has openings. A preferable example of such a reinforcing sheet is a reinforcing sheet composed of wire rods arranged substantially parallel to each other and a thermoplastic resin member arranged and fused at an angle to the wire rods. In the present invention, as the thermoplastic resin member, it is preferable to use a wire rod that is the same as or different from the plurality of wire rods that are arranged in parallel. Therefore, a reinforcing sheet formed by intersecting the wire rods is a typical example. As described below. Of course, the present invention is not limited to the above-mentioned thermoplastic resin member being a wire rod described below. For example, the reinforcing sheet may be formed by simply laminating the wire rods or may be woven.

A preferred example of the reinforcing sheet used in the present invention is, as shown in plan views of FIGS. 4 to 6, wire rods arranged substantially in parallel, and wire rods arranged and fused at an angle to the wire rods. It is a reinforcing sheet consisting of. Figure 4
Is a plurality of wire rods 3 each having a length substantially the same as the length of the reinforcing sheet 10 arranged at an appropriate interval substantially parallel to the longitudinal direction of the reinforcing sheet 10, and the other wire rods 3 are arranged so as to intersect the wire rods 3. This is an example in which the wire 4 is arranged and melt-bonded at its intersection by heating, and the reinforcing sheet 10 can give the base material excellent rigidity in both the longitudinal direction and the width direction. Especially in the direction where excellent bending rigidity is required,
It is preferable to use a larger number of wires, and in this example,
Excellent bending rigidity in the longitudinal direction. In the illustrated example, the wire 4 has a length that is substantially the same as the width of the reinforcing sheet 10, but the wire 4 is not limited to the illustrated example, and as long as it has a length that intersects the wire 3, A short wire may be used, and the short wire may be randomly arranged.

The example shown in FIG. 5 is an example in which both the wire 3 and the wire 4 have a constant angle with respect to the length or width direction of the reinforcing sheet 10. As in the example of FIG. 4, either one of the wire rod 3 and the wire rod 4 may be arranged substantially parallel to each other and arranged in any direction of the reinforcing sheet with a length substantially equal to the length or width of the reinforcing sheet 10. The example shown in FIG. 6 is an example in which a plurality of wire rods 5 are further arranged horizontally in the longitudinal direction of the reinforcing sheet 10 in the example shown in FIG. 5, and have further excellent bending rigidity in the longitudinal direction. The example shown in FIG. 7 is a reinforcing sheet obtained by arranging wire rods 6 cut into a predetermined length in a substantially horizontal and random manner and fusing them at their contact points.

In order to achieve both lightness and excellent strength, the reinforcing sheet as described above preferably has a basis weight of 10 to 200 g / m ² , more preferably 30 to 100 g / m ^2. The unit weight is m ² . If the basis weight is less than the above range, sufficient strength cannot be obtained, and if it exceeds the above range, the lightweight property cannot be satisfied. Further, since the reinforcing sheet has a large number of openings 7 between the wire rods and is permeable to air, it does not take in air when the reinforcing sheets are attached to each other or to the base material. Therefore, wrinkles and swelling do not occur and it is easy to handle.

The aperture ratio of the reinforcing sheet as described above is
It is preferably 50 to 98% of the total area of the reinforcing sheet. If the opening ratio is too low, the lightweight of the reinforcing sheet cannot be obtained, while if the opening ratio is too large, the desired rigidity cannot be obtained. In addition, the basis weight and the aperture ratio can be easily changed by changing the pitch of the wire rod.
It is possible to make a desired reinforcing sheet with one sheet. Although not shown, two or more reinforcing sheets as described above may be laminated if necessary. When laminating, the reinforcing sheet having high rigidity in all directions can be obtained by laminating the wires in the longitudinal direction and the width direction at an angle orthogonal to each other. For example, the weight per unit area when two reinforcing sheets are laminated is 20
~ 400 g / m ² . Of course, the angle of the reinforcing sheets to be laminated may be an angle at which the wire rods intersect, and the laminating angle is not particularly limited.

The thermoplastic resin for the above wire is not particularly limited, and various commercially available resins can be used. However, from the viewpoint of impregnating property, cost and physical properties, polyolefin resin, polyamide resin, Polyester resin, polycarbonate resin, polyphenylene sulfide resin, polystyrene resin, and thermoplastic polyurethane are preferable, and polyolefin resin, polyamide resin, and polyester resin are particularly preferable.

As the polyolefin resin, for example,
Polypropylene, polyethylene and the like are preferable. As the polyamide resin, for example, nylon 6.6, nylon 6, nylon 12, MXD nylon and the like are preferable.
As the polyester resin, for example, polyethylene terephthalate, polybutylene terephthalate, etc. are preferable. You may mix and use additives, such as a coloring agent, a modifier, an antioxidant, and a weather resistance, to these resins.

As the reinforcing fiber used in the wire, glass fiber, carbon fiber, aramid fiber, ceramic fiber or the like can be used alone or in combination. Among them, glass fiber is preferable because it has excellent cost performance. The average diameter of the monofilaments of these reinforcing fibers is preferably 6 to 23 μm, more preferably 10 to 17 μm. When the average diameter of the monofilament is less than 6 μm, the cost of the wire becomes high,
If it exceeds μm, the above-mentioned wire is inferior in mechanical properties, which is not preferable.

The reinforcing fiber strand for obtaining the wire is 100 to 2,000, more preferably 200 to 2,000.
It is a bundle of 1,600 monofilaments. If the number of monofilaments to be bundled is less than 100, the work becomes complicated because a large number of wire rods are required in the post-process, while if it exceeds 2,000, the reinforcing fiber strands become thick, and thus the thermoplastic resin It becomes difficult to uniformly impregnate the monofilaments into the monofilaments, and the obtained wire rod becomes thick, and if the wire rods are crossed to form a sheet, the basis weight becomes large, which is not preferable.

The wire rod is manufactured by impregnating the above-mentioned reinforcing fiber strand with the above-mentioned thermoplastic resin, and has the following characteristics. The wire rod here means one having a circular or elliptical cross section or a flat tape. Among them, the wire having a circular cross section or an elliptical cross section firmly fixes the intersections of the wire rods in the reinforcing sheet finally obtained by thermocompression bonding and makes it difficult for the wire rods to be separated from each other. Also, when the wires are arranged, it is easy to obtain a reinforcing sheet having a small basis weight and a large opening. Here, the circular cross section or the elliptical cross section means
It means a form in which the major axis / minor axis of the cross section is at least 3 or less.

The average diameter or width of the wire is not particularly limited as long as the width of the wire in the obtained reinforcing sheet is 0.2 to 8 mm, but it is 0.3 to 4.0 mm. In particular, in the case of a raw material wire rod having a circular cross section or an elliptical cross section, it is more preferably 0.5 to 1.5 mm. Thereby, the wires can be uniformly arranged in the step of arranging the wires. The average diameter of the raw material wire rod is 8 mm
If it exceeds, the weight per unit area of the reinforcing sheet becomes large, which is not preferable. Further, if the average diameter is less than 0.2 mm, the step of producing the wire becomes complicated, which is not preferable.

The reinforcing fiber content of the wire is 15-80.
vol% is preferable, and more preferably 30 to 70 vol%. When the content of the reinforcing fibers is less than 15 vol%, the reinforcing effect is low, and the reinforcing material is used as a face material, and it is necessary to increase the thickness in order to improve the rigidity, resulting in an increase in weight and an increase in cost. If it exceeds 80 vol%, the amount of the matrix (thermoplastic resin) that wraps the fiber is too small, the adhesion between the wire rods is poor, and the strength is reduced, and it is difficult to secure the impregnation rate described below at 95% or more. Become.

The impregnation rate of the thermoplastic resin of the wire is 95%.
The above is preferable. In this case, since the wire rod is impregnated with the thermoplastic resin up to the monofilament level, the mechanical strength of the obtained reinforcing sheet is improved, and it becomes possible to prevent the reinforcing fibers from being raised and fluffing due to the impregnation. When the impregnation rate of the thermoplastic resin is less than 95%, the voids are apt to become defective along with the above problems,
It becomes impossible to obtain uniform mechanical properties.

The term "impregnation rate" in the present invention means that when a cross section of a wire is observed with an electron microscope at a magnification of 200 and a 20 μm mesh is placed and a void (air bubble) is recognized in the mesh, this A mesh is added as a void area, and it is obtained by the following mathematical formula from the observed total cross-sectional area and the void area. {(Total cross-sectional area-void area) / total cross-sectional area} x 100 (%)

The method for producing the wire is not particularly limited, but a method is available in which the reinforcing fibers are aligned in one direction and impregnated with the thermoplastic resin to form a sheet, and then slits are formed to produce a tape material. One or more reinforced fibers are melt-impregnated with a thermoplastic resin and passed through a die, and then a nozzle with a desired shape is drawn out in a circular or elliptical cross section, or a flat tape shape is drawn out and reinforced as is. It can be used to make a sheet or can be wound on a reel and then used to make a reinforcing sheet. When a short wire is used for joining, a method of cutting the wire into a desired length may be used.

Considering the workability in producing the above wire, the ease of forming into a sheet, the characteristics of the reinforcing sheet to be obtained, etc., a wire having a circular or elliptical cross section is preferable. A preferable method for producing the wire having a circular cross section or an elliptical cross section is to feed the reinforcing fiber strand into a resin impregnation tank, impregnate the resin by a melt impregnation method, and then
It is preferable that one or a plurality of reinforcing fiber strands be drawn out from one nozzle and used as it is for producing a reinforcing sheet, or it is once wound on a reel and then used for producing a reinforcing sheet. Furthermore, if a method is adopted in which one reinforced fiber strand that has been bundled without splitting is pulled out from one nozzle, it becomes easier to pull out from the nozzle, the content rate of the reinforced fiber can be increased, and fluff is not generated. Can be reduced. With this method, a wire having a small diameter can be obtained relatively easily.

Details of the method for producing a reinforcing sheet using the above wire material are described in Japanese Patent Application No. 2001-210584. For example, a plurality of wire rods are pulled out from an impregnating die having a large number of nozzles at a certain tension (about 3 kg / piece) in a direction substantially parallel to the longitudinal direction of the reinforcing sheet,
On the drawn wire X, the wire Y wound on the reel is arranged with an arbitrary width on the wire X so as to intersect with the wire X. The wire X may be wound on a reel in advance and then used. Wire rods X arranged at predetermined intervals
The wire rod and the wire rod Y are heated by a heat source such as a double belt, a flat plate press, or a roll press while keeping the sheet shape to melt and soften the thermoplastic resin in the wire rod so that they are fused at their intersections, After being formed into a sheet, the edges are cut as necessary to align the edges to obtain a reinforcing sheet.
The heat fusion method at this time may be a method of heating the reinforcing sheet with a hot plate, far-infrared ray irradiation, hot air oven or the like without pressure, or by applying pressure with a double belt, a flat plate press, a roll press or the like as described above. A method of fusing may be used, and the method of fusing the wire is not particularly limited.

When the reinforcing sheet is produced by the above method, the size of the reinforcing sheet is not particularly limited, but in the case of a rectangular reinforcing sheet, the width (length) is usually the length and width.
Is usually 1000 mm or more and varies depending on the use of the base material to be reinforced. Further, the density of the wire material also varies depending on the strength and rigidity required for the reinforcing sheet and cannot be specified in a general manner, but in terms of the lightweight property and strength and rigidity of the reinforcing sheet, the direction in which bending rigidity is particularly required, for example, In the longitudinal direction of the reinforcing sheet shown in FIG. 4, when the wire 3 has a circular cross section and the diameter thereof is 0.5 mm, it is about 2.0-6.
A spacing of 0 mm is preferred. When the wire rod 4 intersecting the wire rod 3 is the same wire rod as described above, the distance between the wire rods 4 is preferably 3.0 to 120 mm, and the aspect ratio can be appropriately selected. When such a wire is fused under pressure, it has a flat elliptical cross section with a major axis of about 0.7 mm, and the reinforcing sheet has a thickness of about 0.5 mm. Of course,
The thickness of the obtained reinforcing sheet can be arbitrarily adjusted by the thickness of the wire rod, but the thickness of the reinforcing sheet is 0.3 to 1.0 mm depending on the lightness, handleability, and required performance.
The degree is suitable. By adjusting the thickness and density of these wire rods, the weight per unit area of the reinforcing sheet obtained is 10 to 10.
It can be freely adjusted within the range of 200 g / m ² .

Further, when the reinforcing sheet is obtained by heating, melting and pressing under the above-mentioned pressure, the raw material wire does not need a step for impregnating the resin because the reinforcing fiber is sufficiently impregnated with the thermoplastic resin. It is also possible to perform hot melt fusion pressing with a pressure (for example, 0.1 to 1.0 kg / cm ² ) that slightly presses the upper and lower surfaces, and it is possible to quickly manufacture a reinforcing sheet. In adhering to the base material, it becomes possible to fully adhere and integrate with a light pressure.

Since the reinforcing sheet has a low basis weight as described above, the shape of the wire material constituting the reinforcing sheet is usually visually recognizable. The wire material in the reinforcing sheet has a width of 0.2 to 8 mm. , 0.3 to 4 mm is more preferable. If the width exceeds 8 mm, the weight of the reinforcing sheet is increased, the opening is reduced, the weight is reduced, and the cost is increased, which is not preferable. Further, if the width of the wire in the reinforcing sheet is less than 0.2 mm, it is necessary to reduce the diameter or width of the raw wire used.
This is not preferable because it complicates the process of producing the raw material wire and increases the cost. Incidentally, the raw material wire rod is a wire rod before being made into a reinforcing sheet, and a wire material obtained by fusing these wire rods together into a sheet is a wire rod in the reinforcing sheet. Then the width becomes larger.

In the above description, the same wire is used as the binder for the wires arranged in parallel, but the binder may be a wire different from the above wire. Further, a thermoplastic resin member which is not reinforced with glass fiber, for example, a thermoplastic resin member of any shape, such as a thermoplastic resin strand, thread, string, tape, net, woven fabric, non-woven fabric, A reinforcing sheet can be obtained in the same manner as described above, and a non-woven fabric is particularly preferable because it is possible to easily bond the wire rods arranged in parallel to each other, and it is inexpensive and excellent in lightness.

The composite molded article of the present invention comprising the base material and the reinforcing sheet as described above may be formed by any method and is not particularly limited, but as a preferred method, the present invention is the surface of the base material. A method for producing the above composite, in which the reinforcing sheet is laminated inside and / or inside, hot air is passed through the laminated body, and the reinforcing sheet is fused to the surface and / or inside of the base material. The method of the present invention will be described with reference to FIG. 8 using the method for producing the composite molded body shown in FIG. 1 as a representative example.

In the method of the present invention, as shown in FIG. 8, the reinforcing sheet 12 wound in a roll shape on both sides of the base material 11 is unwound and a pair of rolls 13 and 13 are provided on both sides of the base material 11. With a uniform thickness and laminated to form a heating furnace 14
Send to. The heating furnace 14 includes a hot air generator 15 for softening and melting the thermoplastic resin (about 16
Hot air (air, nitrogen gas, etc.) heated to 0 to 200 ° C. is blown, and preferably blown onto the entire surface of the laminate A in the furnace. A hot air suction device 14 ′ is arranged on the opposite side of the laminate A in the heating furnace 14, and most of the hot air passes through the breathable laminate A and is returned to the hot air generator 15. And reheated to a predetermined temperature. During this time, the thermoplastic resin forming the reinforcing sheet 12 is softened and melted to form the base material 1
Fused to the surface of 1. When the base material 11 itself contains a thermoplastic resin, the thermoplastic resin in the base material 11 is also softened and melted, and the reinforcing sheet 12 is more firmly fused to the base material 11.

The laminate A sent from the heating furnace 14 may be sent to the cooling device 16 as it is, but the thickness of the laminate A is further compressed and the reinforcing sheet 12 is completely fused to the base material 11. For this reason, the laminated body A can be pressed through the pair of rolls 17 having a certain clearance (see the enlarged view) and then fed to the cooling device 16. In the cooling device 16, the cold air generated by the cold air generator 18 is applied to the entire surface of the laminated body A, and sucked from the back surface of the laminated body A to pass the cool air through the laminated body A to forcibly cool the laminated body A. The cold air in this cooling does not have to be the air cooled by the cooling device in particular, and may be cooled by the air having a normal temperature. Further, it may be left alone for cooling. By this cooling, the reinforcing sheet 12 for the base material 11
Is firmly fused and the thickness of the laminate A is determined. Note that, in FIG. 8, the base material 11, the reinforcing sheet 12, and a conveyor such as a belt conveyor that conveys the laminate A are omitted. The above method is a preferred method for producing the composite molded article of the present invention, and it goes without saying that the composite molded article of the present invention is not limited to the product produced by the above preferred method.

In the thus obtained composite molded body, since the base material has air permeability and the reinforcing sheet has the opening, the obtained composite molded body also has air permeability. The air-permeable composite molded body can be molded into an arbitrary shape by, for example, low pressure molding or spring back molding. Therefore, the composite molded article of the present invention configured as described above is useful in various applications because of its high strength, excellent sound absorption and excellent heat insulation, and is particularly useful as a base material for interior materials for vehicle ceilings. , It is useful for the purpose of laminating a surface material on the surface. Further, as the vehicle ceiling material, it is preferable to align the wire rods in the longitudinal direction of the composite molded body in order to suppress the bending of the vehicle ceiling material in the front-rear direction, that is, the longitudinal direction. As a result, the ceiling material has a desired strength and a weight reduction can be realized.

[0038]

EXAMPLES The present invention will be described in more detail with reference to Examples and Comparative Examples. Example 1 Using a monofilament having an average diameter of 13 μm, one glass fiber strand having a number of bundles of 600 without splitting was introduced into acid-modified molten polypropylene (melting temperature 260 ° C.), and melt impregnation was performed. After that, the wire rod having a substantially circular cross section was wound up on a reel by pulling it out from a nozzle having an inner diameter of 0.49 mm at a speed of 50 m / min. The obtained wire has an average diameter of 0.49 mm and a glass content of 52.
The vol% and the impregnation rate were 100% as an average value of n = 5.
n represents the number of measurements (hereinafter the same).

The glass content is measured by first heating the obtained wire rod in an electric furnace at 600 ° C. to burn off the resin, and then measuring the weight of the remaining glass to obtain a glass content of 75. A weight% measurement was obtained. From this value, the specific gravity of the resin was 0.91 and the specific gravity of the glass fiber was 2.54, which was converted to vol%.

Then, the reel wound with this wire is
Fifty pieces of the wire rods were arranged side by side to draw out the wire rods, and the interval between the wire rods was set to 6 mm to form a warp yarn. The width orthogonal to the length direction of the wire is 1500 m
m, and the length in the same direction as the wire rod was 3500 mm.
With respect to this warp yarn, the same wire rod from another reel was arranged at a wire rod interval of 6 mm so as to be orthogonal to the above-mentioned wire rod, to obtain a weft yarn. The basis weight in this state is 100 g / m ² . This sheet was pressed at a pressure of 0.5 kg / cm ² for 10 seconds using a flat plate press heated to 200 ° C. Then, it was cooled to obtain a reinforcing sheet of 1500 × 3500 × 0.3 mm (aperture ratio 80%).

Next, a mat-like material having an air permeability of 40 cm ³ / cm ² · S made of inorganic fiber was prepared as a base material. This mat-like material is prepared by mixing glass fibers and polypropylene fibers in a weight ratio of 3: 2 and supplying them to a card machine.
It is a product manufactured by defibrating and providing 30 needle punches per 1 cm ² . The mat-like material has a thickness of 8 mm and a basis weight of 800 g / m ² .

Next, using the apparatus shown schematically in FIG. 8, 800 g / m ² of the above mat-like material was placed on the above-mentioned 100 g / m ² reinforcing sheet, and further 100 g / m ² of it was placed thereon. The reinforcing sheet was placed to form a three-layered laminate. After that, the air heated from the top to the bottom of the laminate (temperature: about 200
C.) was passed through a hot air oven for 20 seconds, and then air was forcibly sent to cool it. The rolls (13, 13, 17, 1) were both heated and cooled.
The clearance of 7) was 2.5 mm, and at this time, the reinforcing sheet was not wrinkled or swollen. The obtained flat plate has a thickness of 2.5 mm, and a weight of 1000 mm with a length of 150 mm and a width of 50 mm from this flat plate.
A test piece of g / m ² was cut out, and the maximum bending failure load, elastic gradient and air permeability were measured at n = 3. The longitudinal direction is shown as TD and the width direction is shown as MD.
The average value is shown in Table 1.

Example 2 First, a wire rod was obtained in the same manner as in Example 1. 250 reels wound with this wire rod were arranged to draw out the wire rod, and the wire rod interval was set to 6 mm to obtain a warp yarn. The width orthogonal to the length direction of the wire rod was 1500 mm, and the length in the same direction as the wire rod was 3500 mm. With respect to this warp, the same wire was cut into a length of 30 mm by a pelletizer to prepare a short wire, and the obtained short wire was uniformly dispersed on the warp. The basis weight in this state is 100 g / m ² .
The weight of the reinforcing sheet is 50 g / m ^{2 for the} warp.
And the short wire is 50 g / m ² . This reinforcing sheet was heated to 200 ° C. using a flat plate press to 0.5 kg /
Pressed with a pressure of cm ² for 10 seconds. Then cool down 1
Reinforcement sheet of 500 x 3500 x 0.3 mm (Opening ratio 8
2%) was obtained.

Example 1 except that the above reinforcing sheet was used
A composite molded body (flat plate) was obtained in the same manner as in (1). At this time, the reinforcing sheet was not wrinkled or swollen. The obtained flat plate had a thickness of 2.5 mm, and a weight per unit area of 150 mm and a width of 50 mm was 100 mm.
A 0 g / m ² test piece was cut out and the maximum bending failure load, elastic gradient and air permeability were measured at n = 3. The longitudinal direction is shown as TD and the width direction is shown as MD. The average value is shown in Table 1.

Comparative Example 1 In the same manner as in Example 1, the thickness is 10 mm and the basis weight is 100.
A base material (mat) having an air permeability of 0 g / m ² of 35 cm ³ / cm ² · S was obtained. Using this mat only, heating was performed in a hot air oven and then cooling was performed to obtain a flat plate. The obtained flat plate has a thickness of 2.5 mm and a length of 150 mm.
mm and width 50 mm, a test piece having a basis weight of 1000 g / m ² was cut out, and the maximum bending failure load, elastic gradient and air permeability were measured at n = 3. The longitudinal direction is TD,
The width direction is shown as MD. The average value is shown in Table 1.

Example 4 By the same method as in Example 1, the thickness is 10 mm and the basis weight is 100.
A base material (mat) having an air permeability of 0 g / m ² of 5 cm ³ / cm ² · S was obtained. The procedure of Example 1 was repeated except that this mat was replaced with the mat of Example 1. At this time, it took 60 seconds to heat the surface exposed to hot air during the heating, that is, the plasticizing degree of the reinforcing sheet on the upper portion was large and that on the lower side was low. The obtained flat plate had a thickness of 2.5 mm, and a test piece was cut out in the same manner as in Example 1,
The maximum bending failure load, elastic gradient and air permeability were measured at n = 3. The longitudinal direction is shown as TD and the width direction is shown as MD. The average value is shown in Table 1.

Example 3 First, a wire rod was obtained in the same manner as in Example 1. This wire rod was cut with a pelletizer to a length of 30 mm to prepare a short wire rod, and the obtained short wire rod was uniformly dispersed. The basis weight in this state is 100 g / m ² . This sheet is heated to 200 ° C. with a flat plate press to 0.5 kg / cm ²
Was pressed for 30 seconds. Then cool to 1500
Reinforcement sheet of × 3500 × 0.3mm (Opening ratio 84%)
Got

Example 1 except that the above reinforcing sheet was used
A composite molded body (flat plate) was obtained in the same manner as in (1). At this time, the reinforcing sheet was not wrinkled or swollen. The obtained flat plate had a thickness of 2.5 mm, and a weight per unit area of 150 mm and a width of 50 mm was 100 mm.
A 0 g / m ² test piece was cut out and the maximum bending failure load, elastic gradient and air permeability were measured at n = 3. The longitudinal direction is shown as TD and the width direction is shown as MD. The average value is shown in Table 1.

Comparative Example 2 Thickness 0.1 mm, glass content 52 vol%, basis weight 1
A reinforcing sheet of 75 g / cm ² was prepared. This reinforcing sheet contains glass fibers continuously in the length direction and is impregnated with polypropylene resin. This sheet was cut into a size of 1500 × 3500. This reinforcing sheet has no openings and the aperture ratio is 0%.

A flat plate was obtained in the same manner as in Example 1 except that the above sheet was used. At the time of heating, the sheet partially contracted, and the fibers were unevenly distributed in some places. In addition, wrinkles were generated due to uneven distribution of fibers. On the other hand, the initial sheet does not have an aperture ratio, it takes time to plasticize, and the surface exposed to hot air during heating, that is, the upper part of the reinforcing sheet has large plasticization, and the lower part has poor plasticization and contraction. As a result, only the periphery where the opening was formed was bonded to the base material. For this complex is incomplete, so
Maximum bending failure load, elastic gradient and air permeability were not measured.

[0051]

・ Bending breaking load measurement conditions Span: 100 mm Crosshead speed: 50 mm / min. ・ Number of sheets: Number of reinforcing sheets fixed to the base material ・ Directivity TD: Line length direction MD: Line width direction ・ Air permeability measurement conditions Conforms to JIS L 1096 (General textile test method)

[0053]

According to the present invention as described above, the problems of the conventional surface reinforcing sheet can be solved, and the surface reinforcing sheet can be easily prepared, and the reinforcing sheet and the base material can be integrated without using an adhesive or the like. The surface rigidity of the base material can be dramatically improved in spite of its good workability and handleability, excellent workability, and low weight and lightweight.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a composite molded body as an example of the present invention.

FIG. 2 is a cross-sectional view of a composite molded body of another example of the present invention.

FIG. 3 is a cross-sectional view of a composite molded body according to still another example of the present invention.

FIG. 4 is a plan view of an example of a reinforcing sheet used in the present invention.

FIG. 5 is a plan view of another example of a reinforcing sheet used in the present invention.

FIG. 6 is a plan view of a reinforcing sheet of still another example used in the present invention.

FIG. 7 is a plan view of a reinforcing sheet of still another example used in the present invention.

FIG. 8 is a diagram schematically illustrating a method for producing a composite molded body of the present invention.

[Explanation of symbols]

1,11: Base material 2, 10, 12: Reinforcing sheet 3, 4, 5, 6: Wire rod 7: opening 13: Roll 14,14 ': heating furnace 15: Hot air generator 16: Cooling device 17: Roll 18: Cold air generator A: laminated body

Continued front page    F-term (reference) 4F100 AA00A AG00B AG00C AK01A                       AK01B AK01C AK03 AL07                       AS00A BA02 BA03 BA06                       BA10B BA10C DC16B DC16C                       DG01A DG04B DG04C DG15A                       DJ00A DJ01A EJ82B EJ82C                       GB07 HB00 JB16A JB16B                       JB16C JD02A JK01 YY00A                       YY00B YY00C

Claims (12)

[Claims] 1. A reinforcing sheet is arranged and fused on the surface and / or inside of a porous plate-shaped base material having continuous pores,
A composite molded article, wherein the reinforcing sheet is a sheet to which a unidirectional long fiber reinforced thermoplastic resin (hereinafter referred to as L-FRTP) wire is fixed and which has an opening. 2. The composite molded article according to claim 1, wherein the porous plate-shaped base material is at least one selected from a mat made of inorganic fibers and a thermoplastic resin, a non-woven fabric, a felt, and a resin foam. . 3. The basis weight of the porous plate-shaped base material is 200 to 1
It is 500 g / m < ² >, The composite molded object of Claim 1 or 2. 4. A porous plate-shaped base material according to JIS L 1096.
Has an air permeability of 10 to 400 cm ³ / cm ² · S
The composite molded body according to any one of claims 1 to 3. 5. A reinforcing sheet made of L-FRTP wire,
The composite molded article according to claim 1, comprising an L-FRTP wire arranged substantially in parallel and a thermoplastic resin member arranged and fused at an angle to the wire. 6. The composite molded article according to claim 5, wherein the thermoplastic resin member is an L-FRTP wire. 7. A reinforcing sheet made of L-FRTP wire,
The composite molded article according to claim 1, which is a sheet obtained by arranging L-FRTP wire rods cut into a predetermined length substantially horizontally and randomly and fusing at their contact points. 8. The composite molded body according to claim 1, wherein the reinforcing sheet arranged on one surface of the L-FRTP wire has a basis weight of 10 to 200 g / m ² . 9. The L-FRTP wire has a reinforcing fiber content of 1.
5 to 80 vol% and the thermoplastic resin impregnation rate is 95
% Or more, The composite molded body according to any one of claims 5 to 8. 10. The L-FRTP wire is a wire formed by producing a glass fiber strand that is bundled without splitting and impregnating one glass fiber strand with a thermoplastic resin. 9. The composite molded article according to any one of 9 above. 11. The air permeability defined by JIS L 1096 is 10 to 400 cm ³ / cm ² · S.
10. The composite molded article according to any one of 10. 12. A reinforcing sheet is laminated on the surface and / or inside of a porous plate-shaped base material having continuous pores, and hot air is passed through the laminate to form the porous sheet-shaped base material. Consisting of fusing to the surface and / or the interior of the material,
The method for producing a composite molded body, wherein the reinforcing sheet is a sheet to which an L-FRTP wire is fixed and which has an opening.