JP2005169803A - Decorative sheet and manufacturing method of decorative high rigidity molded product - Google Patents

Decorative sheet and manufacturing method of decorative high rigidity molded product Download PDF

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JP2005169803A
JP2005169803A JP2003412086A JP2003412086A JP2005169803A JP 2005169803 A JP2005169803 A JP 2005169803A JP 2003412086 A JP2003412086 A JP 2003412086A JP 2003412086 A JP2003412086 A JP 2003412086A JP 2005169803 A JP2005169803 A JP 2005169803A
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molded product
decorative
rigidity molded
sheet
rigidity
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Kazuhiro Saito
和弘 齋藤
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Marelli Corp
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Calsonic Kansei Corp
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<P>PROBLEM TO BE SOLVED: To provide a decorative sheet capable of easily uniformizing the thickness of a resin for covering a fabric for a short time while obtaining the same decorative properties as a carbon fiber reinforced resin, and a manufacturing method of a decorative high rigidity molded product. <P>SOLUTION: The decorative sheet 1 can be easily manufactured for a short time because a transparent or translucent pervious sheet 1a comprising a thermoplastic resin and a fabric sheet 1b containing carbon fibers can be bonded by a heat press. The thickness of the pervious sheet 1a for covering the fabric sheet 1b is also uniform. Since this decorative sheet 1 is constituted so that the pattern of the carbon fiber-containing fabric sheet 1b is seen through from the surface pervious sheet 1a, the same decorative properties as the carbon fiber reinforced resin can be applied to the high rigidity molded product by bonding the decorative sheet 1 to the surface of another high rigidity molded product. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

本発明は、自動車の車体構成部品として好適な加飾高剛性成形品の製造方法に関するものである。   The present invention relates to a method for manufacturing a decorative high-rigidity molded article suitable as a vehicle body component of an automobile.

軽量で高剛性な車体構成部品として、炭素繊維を含む織物に透明又は半透明な熱硬化性樹脂を含浸させて硬化させた炭素繊維強化樹脂が知られている。この種の炭素繊維強化樹脂は、物性的に優れた機能を有するだけでなく、内部の炭素繊維がその表面を覆う透明又は半透明の樹脂から透けて見えるため、加飾性にも優れている(例えば、特許文献1。)。
特開平11−107107号公報
As a lightweight and highly rigid vehicle body component, a carbon fiber reinforced resin obtained by impregnating a transparent or translucent thermosetting resin into a woven fabric containing carbon fibers and curing is known. This type of carbon fiber reinforced resin not only has excellent physical properties, but also has excellent decorating properties because the internal carbon fibers can be seen through the transparent or translucent resin covering the surface. (For example, Patent Document 1).
JP-A-11-107107

しかしながら、このような従来の炭素繊維強化樹脂にあっては、炭素繊維含有の織物に熱硬化性樹脂を含浸させた状態で硬化させながら成形する製造方法になっているため、樹脂の硬化に長い時間(約2時間程度)を要すると共に、織物を被覆する樹脂層の厚みが不均一になり易く、製造が困難であった。   However, in such a conventional carbon fiber reinforced resin, since it is a manufacturing method in which a carbon fiber-containing woven fabric is cured while being impregnated with a thermosetting resin, it is long to cure the resin. Time (about 2 hours) was required, and the thickness of the resin layer covering the fabric was likely to be non-uniform, making it difficult to manufacture.

本発明は、このような従来の技術に着目してなされたものであり、炭素繊維強化樹脂と同様の加飾性を得ることができながら、短時間で且つ容易であり、織物を覆う樹脂の厚さを均一にすることができる加飾シート及び加飾高剛性成形品の製造方法を提供するものである。   The present invention has been made by paying attention to such a conventional technique, and while being able to obtain the same decorativeness as that of the carbon fiber reinforced resin, it is easy in a short time and the resin covering the fabric. The present invention provides a decorative sheet capable of making the thickness uniform and a method for producing a decorative high-rigidity molded product.

請求項1記載の発明は、熱可塑性樹脂から成る透明又は半透明の透過シートと、炭素繊維含有の織物シートとを、少なくとも表面側に透過シートが位置するように二層又は多層構成にして重ね合わせた状態で、熱プレスを加えて接合したことを特徴とする加飾シートの製造方法である。   According to the first aspect of the present invention, a transparent or translucent transparent sheet made of a thermoplastic resin and a carbon fiber-containing woven sheet are laminated in a two-layer or multilayer structure so that the transparent sheet is positioned at least on the surface side. It is the manufacturing method of the decorating sheet | seat characterized by applying the hot press in the state put together, and joining.

請求項2記載の発明は、熱可塑性樹脂から成る透明又は半透明の透過シートと、炭素繊維含有の織物シートとを、少なくとも表面側に透過シートが位置するように二層又は多層構成にして重ね合わせた状態で、熱プレスを加えて接合することにより加飾シートを形成し、該加飾シートを、高剛性成形品を形成するための合成樹脂の成形金型内にインサートして、射出成形、スタンピングプレス成形、射出プレス成形の何れか又は組み合わせにより成形し、高剛性成形品の表面に加飾シートを接合した構造の加飾高剛性成形品を製造することを特徴とする加飾高剛性成形品の製造方法である。   According to the second aspect of the present invention, a transparent or translucent transparent sheet made of a thermoplastic resin and a carbon fiber-containing woven sheet are laminated in a two-layer or multilayer structure so that the transparent sheet is positioned at least on the surface side. In a combined state, a decorative sheet is formed by joining by applying a heat press, and the decorative sheet is inserted into a molding die of a synthetic resin for forming a high-rigidity molded product, and injection molding is performed. Decorative high-rigidity, characterized by manufacturing a decorative high-rigidity molded product with a structure in which a decorative sheet is bonded to the surface of a high-rigidity molded product, molded by any one or combination of stamping press molding and injection press molding It is a manufacturing method of a molded article.

請求項3記載の発明は、高剛性成形品が、合成樹脂に発泡アルミを接合した構造であることを特徴とする加飾高剛性成形品の製造方法である。   The invention described in claim 3 is a method for producing a decorated high-rigidity molded product, wherein the high-rigidity molded product has a structure in which foamed aluminum is bonded to a synthetic resin.

請求項4記載の発明は、合成樹脂が強化フィラーを含んでいることを特徴とする加飾高剛性成形品の製造方法である。   Invention of Claim 4 is a manufacturing method of the decorative highly rigid molded product characterized by the synthetic resin containing the reinforcement filler.

請求項5記載の発明は、高剛性成形品が、合成樹脂と発泡アルミから成る二層構造であることを特徴とする加飾高剛性成形品の製造方法である。   The invention according to claim 5 is a method for producing a decorated high-rigidity molded product, wherein the high-rigidity molded product has a two-layer structure made of synthetic resin and foamed aluminum.

請求項6記載の発明は、高剛性成形品が、合成樹脂の間に発泡アルミを挟んだ三層構造であることを特徴とする加飾高剛性成形品の製造方法である。   The invention described in claim 6 is a method for producing a decorated high-rigidity molded product, wherein the high-rigidity molded product has a three-layer structure in which foamed aluminum is sandwiched between synthetic resins.

請求項7記載の発明は、高剛性成形品が、発泡アルミの間に合成樹脂を挟んだ三層構造であることを特徴とする加飾高剛性成形品の製造方法である。   The invention according to claim 7 is a method for producing a decorated high-rigidity molded product, wherein the high-rigidity molded product has a three-layer structure in which a synthetic resin is sandwiched between foamed aluminum.

請求項8記載の発明は、高剛性成形品の合成樹脂が、成形時の樹脂圧により、発泡アルミのセルを突き破り、発泡アルミの内部へ浸透した状態になっていることを特徴とする加飾高剛性成形品の製造方法である。   The invention according to claim 8 is a decoration in which the synthetic resin of the high-rigidity molded product is in a state where the foamed aluminum cell is penetrated by the resin pressure during molding and penetrates into the foamed aluminum. It is a manufacturing method of a highly rigid molded product.

請求項9記載の発明は、高剛性成形品の合成樹脂が、成形時の樹脂圧により、発泡アルミのセルを突き破り、発泡アルミの反対側の面まで達してることを特徴とする加飾高剛性成形品の製造方法である。   The invention according to claim 9 is characterized in that the synthetic resin of the high-rigidity molded article penetrates the cell of the foamed aluminum by the resin pressure at the time of molding and reaches the surface on the opposite side of the foamed aluminum. It is a manufacturing method of a molded article.

請求項10記載の発明は、高剛性成形品の合成樹脂が、成形時の樹脂圧により、発泡アルミのセルを突き破り、セル破壊部が貫通して二層の合成樹脂同士が連通した状態になっていることを特徴とする加飾高剛性成形品の製造方法である。   In the invention according to claim 10, the synthetic resin of the high-rigidity molded article breaks through the foamed aluminum cell by the resin pressure at the time of molding, and the cell destruction part penetrates and the two layers of synthetic resin are in communication with each other. It is the manufacturing method of the decorative highly rigid molded product characterized by being characterized.

請求項11記載の発明は、加飾シートの透過シートの表面に光触媒層が形成されていることを特徴とする加飾高剛性成形品の製造方法である。   The invention according to claim 11 is a method for producing a decorated high-rigidity molded product, wherein a photocatalyst layer is formed on the surface of a transparent sheet of the decorative sheet.

請求項1記載の発明によれば、熱可塑性樹脂から成る透明又は半透明の透過シートと、炭素繊維含有の織物シートとを、熱プレスを加えるだけで接合できるため、加飾シートの製造が短時間で且つ容易に行える。織物シートを覆う透過シートの厚さも均一である。この加飾シートは、表面の透過シートから炭素繊維含有の織物シートの模様が透けて見えるため、この加飾シートを他の高剛性成形品の表面に接合することにより、その高剛性成形品に対して炭素繊維強化樹脂と同様の加飾性を付与することができる。   According to the first aspect of the present invention, since a transparent or translucent transparent sheet made of a thermoplastic resin and a carbon fiber-containing woven sheet can be joined simply by applying a hot press, the production of the decorative sheet is short. Can be done in time and easily. The thickness of the transmission sheet covering the fabric sheet is also uniform. Since this decorative sheet can be seen through the pattern of the carbon fiber-containing woven sheet from the transparent sheet on the surface, the decorative sheet is joined to the surface of another high-rigidity molded article to create a high-rigidity molded article. On the other hand, the same decorativeness as that of the carbon fiber reinforced resin can be imparted.

請求項2記載の発明によれば、加飾シートを、高剛性成形品を形成するための合成樹脂の成形金型内にセットして成形することにより、加飾シートを高剛性成形品の表面に接合することができる。炭素繊維強化樹脂と同様の加飾性を有する加飾シートを、高剛性成形品の表面に接合した加飾高剛性成形品を形成したため、加飾性と高剛性が求められる自動車の外板部品等への適用に好適である。加飾シートと高剛性成形品の接合は、高剛性成形品側の樹脂部分だけにより行われても、或いは高剛性成形品側の樹脂部分と加飾シート側の熱可塑性樹脂の両方により行われても良い。   According to the invention described in claim 2, the decorative sheet is set in a molding die of a synthetic resin for forming a high-rigidity molded product and molded, whereby the decorative sheet is formed on the surface of the high-rigidity molded product. Can be joined. A decorative high-rigidity molded product is formed by joining a decorative sheet having the same decorative properties as carbon fiber reinforced resin to the surface of a high-rigidity molded product. It is suitable for application to etc. The decorative sheet and the high-rigidity molded product can be joined only by the resin portion on the high-rigidity molded product side, or by both the resin portion on the high-rigidity molded product side and the thermoplastic resin on the decorative sheet side. May be.

請求項3記載の発明によれば、高剛性成形品が合成樹脂に発泡アルミを接合した構造のため、合成樹脂の基本的機能に、発泡アルミのもつ静電シールド性、導電性、防音性、保温性、衝撃吸収性等の機能を付加をすることができる。成形時に、発泡アルミが溶融樹脂の熱を奪うため、樹脂の固化速度が高まり、ボイドの発生を抑制することができる。   According to the invention described in claim 3, since the high-rigidity molded article has a structure in which foamed aluminum is joined to synthetic resin, the basic functions of the synthetic resin include electrostatic shielding properties, conductivity, soundproofing, Functions such as heat retention and shock absorption can be added. At the time of molding, the foamed aluminum takes the heat of the molten resin, so that the solidification speed of the resin is increased and the generation of voids can be suppressed.

請求項4記載の発明によれば、高剛性成形品の合成樹脂が強化フィラーを含んでいるため、樹脂部分の強度が高まる。   According to invention of Claim 4, since the synthetic resin of a highly rigid molded article contains the reinforcement filler, the intensity | strength of a resin part increases.

請求項5記載の発明によれば、高剛性成形品が合成樹脂と発泡アルミから成る二層構造であるため、構造が単純で、二次加工が容易である。   According to the invention described in claim 5, since the high-rigidity molded product has a two-layer structure made of synthetic resin and foamed aluminum, the structure is simple and secondary processing is easy.

請求項6記載の発明によれば、高剛性成形品が合成樹脂の間に発泡アルミを挟んだ三層構造であるため、発泡アルミの両面が合成樹脂により覆われるため、発泡アルミの酸化防止効果がある。   According to the invention described in claim 6, since the high-rigidity molded product has a three-layer structure in which the foamed aluminum is sandwiched between the synthetic resins, both surfaces of the foamed aluminum are covered with the synthetic resin. There is.

請求項7記載の発明によれば、高剛性成形品が発泡アルミの間に合成樹脂を挟んだ三層構造であるため、二層の発泡アルミが中間の合成樹脂により結合され、発泡アルミだけで全部を構成する場合に比べて強度が向上する。   According to the seventh aspect of the invention, since the high-rigidity molded product has a three-layer structure in which a synthetic resin is sandwiched between foamed aluminum, the two-layered foamed aluminum is bonded by the intermediate synthetic resin, and only the foamed aluminum is used. The strength is improved as compared with the case where all the components are configured.

請求項8記載の発明によれば、高剛性成形品の合成樹脂が、成形時の樹脂圧により、発泡アルミのセルを突き破り、発泡アルミの内部へ浸透した状態になっているため、合成樹脂と発泡アルミとの接合強度が高まる。   According to the invention described in claim 8, since the synthetic resin of the high-rigidity molded product is in a state where the foamed aluminum cell is pierced by the resin pressure at the time of molding and penetrates into the foamed aluminum, Bond strength with foamed aluminum is increased.

請求項9記載の発明によれば、高剛性成形品の合成樹脂が、成形時の樹脂圧により、発泡アルミのセルを突き破り、発泡アルミの反対側の面まで達してるため、合成樹脂と発泡アルミとの接合強度が更に高まる。   According to the invention described in claim 9, since the synthetic resin of the high-rigidity molded product penetrates the cell of the foamed aluminum by the resin pressure at the time of molding and reaches the opposite surface of the foamed aluminum, the synthetic resin and the foamed aluminum Further increase the bonding strength.

請求項10記載の発明によれば、高剛性成形品の合成樹脂の間に発泡アルミを挟んだ三層構造にした場合に、合成樹脂が、成形時の樹脂圧により、発泡アルミのセルを突き破り、セル破壊部が貫通して二層の合成樹脂同士が連通した状態になっているため、三層間の接合強度が更に高まる。   According to the invention of claim 10, when a three-layer structure in which foamed aluminum is sandwiched between synthetic resins of high-rigidity molded products, the synthetic resin breaks through the cells of the foamed aluminum due to the resin pressure at the time of molding. In addition, since the cell destruction portion penetrates and the two layers of synthetic resin are in communication with each other, the bonding strength between the three layers is further increased.

請求項11記載の発明によれば、加飾シートの透過シートの表面に光触媒層が形成されているため、高剛性成形品の表面の防汚・抗菌効果が得られる。   Since the photocatalyst layer is formed in the surface of the permeation | transmission sheet | seat of a decorating sheet according to invention of Claim 11, the antifouling and antibacterial effect of the surface of a highly rigid molded article is acquired.

炭素繊維強化樹脂と同様の加飾性を得ることができながら、短時間で且つ容易であり、織物を覆う樹脂の厚さを均一にすることができる加飾シート及び加飾高剛性成形品の製造方法を提供する、という目的を、熱可塑性樹脂から成る透明又は半透明の透過シートと、炭素繊維含有の織物シートとを、少なくとも表面側に透過シートが位置するように二層又は多層構成にして重ね合わせた状態で、熱プレスを加えて接合したことにより、実現した。以下、本発明の最良の実施形態を図面に基づいて説明する。   A decorative sheet and a decorative high-rigidity molded product that can obtain the same decorative property as a carbon fiber reinforced resin, can be made in a short time and easily, and can make the thickness of the resin covering the fabric uniform. The purpose of providing a manufacturing method is to form a transparent or translucent transparent sheet made of thermoplastic resin and a carbon fiber-containing woven sheet into a two-layer or multilayer structure so that the transparent sheet is located at least on the surface side. This was realized by applying heat press and joining them in a superposed state. DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, the best embodiment of the invention will be described with reference to the drawings.

図1〜図4は、本発明の第1実施例を示す図である。第1実施例は、基本的に合成樹脂3a、5aと発泡アルミ3b、5bとの二層構造から成る高剛性成形品3、5の表面に、加飾シート1を接合することにより、加飾高剛性成形品2、4を形成している。図3は、高剛性成形品3の成形時の樹脂圧が通常な場合の加飾高剛性成形品2を示し、図4は高剛性成形品5の成形時の樹脂圧を高めた場合の加飾高剛性成形品4を示している。   1 to 4 are views showing a first embodiment of the present invention. In the first embodiment, the decoration sheet 1 is basically joined to the surface of the high-rigidity molded products 3 and 5 having a two-layer structure of synthetic resins 3a and 5a and foamed aluminum 3b and 5b. High-rigidity molded products 2 and 4 are formed. FIG. 3 shows a decorative high-rigidity molded product 2 when the resin pressure at the time of molding the high-rigidity molded product 3 is normal, and FIG. 4 shows an increase when the resin pressure at the time of molding the high-rigidity molded product 5 is increased. The decorative high-rigidity molded product 4 is shown.

図1に示すように、加飾シート1は、熱可塑性樹脂から成る2枚の透過シート1aの間に炭素繊維含有の織物シート1bを挟んだ状態で接合した三層構造をしている。透過シート1aは熱可塑性樹脂(例えばポリカーボネート)から成り、無色透明、有色透明、乳白色等の半透明で、表面の透過シート1aから織物シート1bの模様が透けて見える。二層でも、三層以上の多層でも良いが、必ず使用状態で見られる方の表面側に透過シート1aが位置するように接合する。透過シート1aの表面には、図示せぬ光触媒層が形成されている。織物シート1bに炭素繊維ガラス、アラミド繊維を混合しても良い。   As shown in FIG. 1, the decorative sheet 1 has a three-layer structure in which a carbon fiber-containing fabric sheet 1b is sandwiched between two transmission sheets 1a made of a thermoplastic resin. The transmission sheet 1a is made of a thermoplastic resin (for example, polycarbonate) and is translucent such as colorless and transparent, colored and transparent, milky white, and the pattern of the fabric sheet 1b can be seen through the transmission sheet 1a on the surface. Two layers or three or more layers may be used, but the bonding is performed so that the transmission sheet 1a is positioned on the surface side that is always seen in use. A photocatalyst layer (not shown) is formed on the surface of the transmission sheet 1a. Carbon fiber glass and aramid fiber may be mixed in the woven fabric sheet 1b.

図2に示すように、2枚の透過シート1aと、1枚の織物シート1bは、重ね合わせた状態で、一対の熱プレス体Pの間で熱プレスすることより、透過シート1aが軟化して織物シート1bの繊維の隙間に入り込み、三層が一体接合され、あたかも織物シート1bが、二層を合わせた厚さの透過シート1aの内部に埋設された状態となる。   As shown in FIG. 2, the two permeable sheets 1 a and the one woven sheet 1 b are overlapped and hot pressed between a pair of hot press bodies P, so that the transmissive sheet 1 a is softened. Then, the fabric sheet 1b enters the gap between the fibers, and the three layers are integrally joined, and the fabric sheet 1b is embedded in the transmission sheet 1a having a thickness including the two layers.

このようにして形成した加飾シート1に対して、接合する相手方の部品の形状に応じて、予め真空成形、圧空成形、熱プレス成形等により、予備賦形を行っても良い。   Preliminary shaping may be performed on the decorative sheet 1 formed in this way by vacuum forming, pressure forming, hot press forming, or the like in advance according to the shape of the mating part to be joined.

高剛性成形品3、5を構成する発泡アルミ3b、5bは、軽量、比重0.3(0.2〜0.8の範囲で可変)であり、静電シールド性、導電性、防音性、保温性、衝撃吸収性がある。発泡アルミ3b、5bの大きさは、2500mm×650mm×450mmの物を必要に応じて切出し又はスライス加工して使用する。   The foamed aluminum 3b and 5b constituting the high-rigidity molded products 3 and 5 are lightweight and have a specific gravity of 0.3 (variable within a range of 0.2 to 0.8), and have electrostatic shielding properties, conductivity, soundproofing properties, Insulates heat and absorbs shock. For the size of the foamed aluminum 3b, 5b, a 2500 mm × 650 mm × 450 mm object is cut out or sliced as necessary.

切り出し、又はスライス加工した物の断面切口は、発泡アルミ3b、5bのセル断面が露出している。切出し又はスライス加工した発泡アルミ3b、5bをプレス圧縮又はローラープレスすることでヤング率を高めることが可能である。圧縮することで体積が減るため、比重は大きくなる。   The cell cross section of the foamed aluminum 3b and 5b is exposed at the cross section cut out of the cut or sliced product. The Young's modulus can be increased by press-compressing or roller-pressing the cut or sliced foamed aluminum 3b, 5b. Since the volume is reduced by compression, the specific gravity is increased.

そして、図2に示すように、この発泡アルミ3b、5bを、前記加飾シート1と一緒に、一対の成形金型M内にインサート又はインモールドする。キャビティ空間Cを形成する内面には、吸引通路Vの吸引口が形成され、加飾シート1及び発泡アルミ3b、5bをそれぞれ内面に吸着した状態にしている。次に、加飾シート1と、発泡アルミ3b、5bの間のキャビティ空間C内に溶融した合成樹脂3a、5aを射出して、合成樹脂3a、5aの成形を行う。   Then, as shown in FIG. 2, the foamed aluminum 3 b and 5 b are inserted or in-molded into the pair of molding dies M together with the decorative sheet 1. The suction port of the suction passage V is formed on the inner surface forming the cavity space C, and the decorative sheet 1 and the foamed aluminum 3b and 5b are respectively adsorbed to the inner surface. Next, the synthetic resins 3a and 5a are injected into the cavity space C between the decorative sheet 1 and the foamed aluminum 3b and 5b to form the synthetic resins 3a and 5a.

成形方法は、通常の射出成形、スタンピング成形、射出プレス成形の何れでも良く、それらの組み合わせでも良い。溶融樹脂の熱により、加飾シート1の裏側の透過シート1aが軟化して、合成樹脂3a、5aと確実に接合される。加飾シート1を、本実施形態のような三層構造でなく、単純な透過シート1aと織物シート1bからなる二層構造にし、加熱軟化した合成樹脂3a、5aが加飾シート1の裏側の織物シート1bに直接接するような場合でも、溶融樹脂が織物シート1bの繊維の隙間に入り込むため、確実に接合する。   The molding method may be any of ordinary injection molding, stamping molding, injection press molding, or a combination thereof. Due to the heat of the molten resin, the transparent sheet 1a on the back side of the decorative sheet 1 is softened and reliably joined to the synthetic resins 3a and 5a. The decorative sheet 1 is not a three-layer structure as in this embodiment, but a two-layer structure composed of a simple transmission sheet 1a and a woven sheet 1b, and the heat-softened synthetic resins 3a and 5a are on the back side of the decoration sheet 1. Even when the fabric sheet 1b is in direct contact with the fabric sheet 1b, the molten resin enters the gaps between the fibers of the fabric sheet 1b, so that the fabric sheet 1b is reliably joined.

発泡アルミ3b、5bをインサート又はインモールドするため、成形時に発泡アルミ3b、5bが溶融樹脂の熱を奪い、合成樹脂3a、5aの固化速度が高まることとなり、合成樹脂3a、5a側におけるボイドの発生が抑制される。   Since the foamed aluminum 3b and 5b are inserted or in-molded, the foamed aluminum 3b and 5b take away the heat of the molten resin at the time of molding, and the solidification speed of the synthetic resins 3a and 5a is increased. Occurrence is suppressed.

合成樹脂3a、5aは、前記の成形方法に使用できる材料であれば何でも良い(例えばポリプロピレン)。また、合成樹脂3a、5a中に、強度を高めるための強化フィラーを混合しても良い。   The synthetic resins 3a and 5a may be anything as long as they can be used for the molding method (for example, polypropylene). Further, a reinforcing filler for increasing the strength may be mixed in the synthetic resins 3a and 5a.

強化フィラーとしては、短繊維のガラスフィラー(GF)、長繊維のガラスフィラー(LGF)、ランダム長繊維のガラスフィラー(RGF・GMTガラスマットサーモプラスチック)、ガラス繊維織物(TGF)、短繊維の炭素繊維(CF)、長繊維の炭素繊維(LCF)、ランダム長繊維の炭素繊維(RCF)、炭素繊維織物(TCF)、ステンレスの短繊維(SF)、ステンレスの長繊維(LSF)などの強化繊維を使用することができる。他にも、タルク、マイカ(雲母)、貝殻紛、植物繊維が使用でき、上記フィラーとのランダムな組み合わせが容易で使用用途に応じた物性値(曲げ弾性率、引っ張り破断点強度、Izod衝撃値)が得られる。   Reinforcing fillers include short fiber glass filler (GF), long fiber glass filler (LGF), random long fiber glass filler (RGF / GMT glass mat thermoplastic), glass fiber fabric (TGF), and short fiber carbon. Reinforcing fibers such as fiber (CF), long-fiber carbon fiber (LCF), random long-fiber carbon fiber (RCF), carbon fiber fabric (TCF), stainless steel short fiber (SF), and stainless steel long fiber (LSF) Can be used. In addition, talc, mica (mica), shellfish powder, and vegetable fiber can be used. Random combinations with the above fillers are easy, and physical properties (flexural modulus, tensile strength at break, Izod impact value) according to the intended use. ) Is obtained.

成形時の樹脂圧が通常でも、合成樹脂3aが発泡アルミ3bのセルを突き破り、発泡アルミ3bの内部へ部分的に浸透した状態となる(図3参照)。従って、発泡アルミ3bに対する合成樹脂3aのアンカー効果により、合成樹脂3aと発泡アルミ3bとの接合強度が高まる。   Even if the resin pressure at the time of molding is normal, the synthetic resin 3a breaks through the cells of the foamed aluminum 3b and partially penetrates into the foamed aluminum 3b (see FIG. 3). Therefore, the joint strength between the synthetic resin 3a and the foamed aluminum 3b is increased by the anchor effect of the synthetic resin 3a with respect to the foamed aluminum 3b.

成形時の樹脂圧が高い場合には、合成樹脂5aが発泡アルミ5bのセルを突き破って反対側の面まで達した状態となる(図4参照)。従って、合成樹脂5aと発泡アルミ5bとの接合強度が更に高まる。   When the resin pressure at the time of molding is high, the synthetic resin 5a breaks through the cell of the foamed aluminum 5b and reaches the opposite surface (see FIG. 4). Accordingly, the bonding strength between the synthetic resin 5a and the foamed aluminum 5b is further increased.

この第1実施例によれば、熱可塑性樹脂から成る透明又は半透明の透過シート1aと、炭素繊維含有の織物シート1bとを、少なくとも表面側に透過シート1aが位置するように二層又は多層構成で接合して加飾シート1を形成したため、この加飾シート1を他の高剛性成形品3、5に表面に接合することにより、その高剛性成形品3、5の表面に、透過シート1aから透けて見える炭素繊維含有の織物シート1bの模様が表れ、従来の炭素繊維強化樹脂と同様の加飾性をその高剛性成形品3、5に対して付与することができる。透過シート1aが熱可塑性樹脂のため、熱プレスするだけで、短時間に織物シート1bとの接合が完了し、加飾シート1の製造が容易で、量産性に優れる。織物シート1bを覆う透過シート1aの厚さも均一である。   According to the first embodiment, a transparent or translucent transparent sheet 1a made of a thermoplastic resin and a carbon fiber-containing woven sheet 1b are arranged in two or more layers so that the transparent sheet 1a is positioned at least on the surface side. Since the decorative sheet 1 is formed by bonding in the configuration, the decorative sheet 1 is bonded to the surface of the other high-rigidity molded products 3 and 5 so that the transparent sheet is formed on the surface of the high-rigidity molded products 3 and 5. The pattern of the carbon fiber-containing woven fabric sheet 1b that can be seen through from 1a appears, and the decorativeness similar to that of the conventional carbon fiber reinforced resin can be imparted to the high-rigidity molded products 3 and 5. Since the permeable sheet 1a is a thermoplastic resin, the joining with the woven fabric sheet 1b is completed in a short time only by hot pressing, and the decorative sheet 1 can be easily manufactured and is excellent in mass productivity. The thickness of the transmission sheet 1a covering the fabric sheet 1b is also uniform.

また、炭素繊維強化樹脂と同様の加飾性を有する加飾シート1を、高剛性成形品3、5の表面に接合することにより、加飾高剛性成形品2、4を形成したため、加飾性と高剛性が求められる自動車の外板部品等への適用に好適である。   Moreover, since the decorative high-rigidity molded products 2 and 4 were formed by joining the decorative sheet 1 having the same decorative property as the carbon fiber reinforced resin to the surfaces of the high-rigidity molded products 3 and 5, It is suitable for application to automobile outer plate parts and the like that require high performance and high rigidity.

更に、高剛性成形品3、5が、合成樹脂3a、5aに発泡アルミ3b、5bを接合した構造のため、合成樹脂3a、5aの基本的機能に、発泡アルミ3b、5bのもつ静電シールド性、導電性、防音性、保温性、衝撃吸収性等の機能を付加をすることができる。   Furthermore, since the high-rigidity molded products 3 and 5 have a structure in which the foamed aluminum 3b and 5b are joined to the synthetic resins 3a and 5a, the electrostatic shield of the foamed aluminum 3b and 5b is included in the basic functions of the synthetic resins 3a and 5a. Functions such as conductivity, conductivity, soundproofing, heat retention and shock absorption can be added.

加えて、高剛性成形品3、5が合成樹脂3a、5aと発泡アルミ3b、5bから成る二層構造であるため、構造が単純で、二次加工が容易であると共に、加飾シート1の表面側の透過シート1aにおける表面に、光触媒層(図示せぬ)が形成されているため、加飾シート1の表面の防汚・抗菌効果が得られる。   In addition, since the high-rigidity molded products 3 and 5 have a two-layer structure made of synthetic resins 3a and 5a and foamed aluminum 3b and 5b, the structure is simple and secondary processing is easy. Since the photocatalyst layer (not shown) is formed on the surface of the transmission sheet 1a on the surface side, the antifouling / antibacterial effect on the surface of the decorative sheet 1 is obtained.

図5及び図6は、本発明の第2実施例を示す図である。以下の実施例では、第1実施例と高剛性成形品7、9の部分だけ相違するので、高剛性成形品7、9の構造のみを詳しく説明し、加飾シート1自体の説明は省略する。   5 and 6 are views showing a second embodiment of the present invention. In the following examples, only the portions of the high-rigidity molded products 7 and 9 are different from those of the first example, so only the structure of the high-rigidity molded products 7 and 9 will be described in detail, and the description of the decorative sheet 1 itself will be omitted. .

第2実施例では、基本的に合成樹脂7a、9aの間に、発泡アルミ7b、9bを挟んだ三層構造からなる高剛性成形品7、9に、加飾シート1を接合することで、加飾高剛性成形品6、8を形成している。図5は、高剛性成形品7の成形時の樹脂圧が通常な場合の加飾高剛性成形品6を示し、図6は高剛性成形品9の成形時の樹脂圧を高めた場合の加飾高剛性成形品8を示している。   In the second embodiment, the decorative sheet 1 is basically joined to the high-rigidity molded products 7 and 9 having a three-layer structure sandwiching the foamed aluminum 7b and 9b between the synthetic resins 7a and 9a. The decorative high-rigidity molded products 6 and 8 are formed. FIG. 5 shows a decorative high-rigidity molded product 6 when the resin pressure at the time of molding the high-rigidity molded product 7 is normal, and FIG. 6 shows an increase in the resin pressure when molding the high-rigidity molded product 9. The decorative high-rigidity molded product 8 is shown.

図5の樹脂圧が通常の場合は、合成樹脂7aが発泡アルミ7bのセルを突き破り、発泡アルミ7bの内部へ部分的に浸透した状態となる。図6の樹脂圧が高い場合には、合成樹脂9aが発泡アルミ9bのセルを突き破り、セル破壊部が貫通して二層の合成樹脂9a同士が連通した状態になっている。従って、合成樹脂9aと発泡アルミ9bから成る三層間の接合強度が更に高まる。   When the resin pressure in FIG. 5 is normal, the synthetic resin 7a breaks through the cells of the foamed aluminum 7b and partially penetrates into the foamed aluminum 7b. When the resin pressure in FIG. 6 is high, the synthetic resin 9a breaks through the cell of the foamed aluminum 9b, the cell destruction portion penetrates, and the two layers of the synthetic resin 9a communicate with each other. Accordingly, the bonding strength between the three layers made of the synthetic resin 9a and the foamed aluminum 9b is further increased.

また、発泡アルミ7b、9bを合成樹脂7a、9aの間に挟んだ三層構造は、発泡アルミ7b、9bの両面が合成樹脂7a、9aにより覆われるため、発泡アルミ7b、9bの酸化防止効果がある。   In addition, the three-layer structure in which the foamed aluminum 7b and 9b are sandwiched between the synthetic resins 7a and 9a has both sides of the foamed aluminum 7b and 9b covered with the synthetic resins 7a and 9a. There is.

図7及び図8は、本発明の第3実施例を示す図である。第3実施例も、先の実施例と高剛性成形品11、13の部分だけ相違するので、高剛性成形品11、13の構造のみを詳しく説明し、加飾シート1自体の説明は省略する。   7 and 8 are views showing a third embodiment of the present invention. Since the third embodiment is also different from the previous embodiment only in the high-rigidity molded products 11 and 13, only the structure of the high-rigidity molded products 11 and 13 will be described in detail, and the description of the decorative sheet 1 itself will be omitted. .

第3実施例では、基本的に発泡アルミ11b、13bの間に、合成樹脂11a、13aを挟んだ三層構造からなる高剛性成形品11、13に、加飾シート1を接合することにより、加飾高剛性成形品10、12を形成している。図7は、高剛性成形品11の成形時の樹脂圧が通常な場合の加飾高剛性成形品10を示し、図8は高剛性成形品13の成形時の樹脂圧を高めた場合の加飾高剛性成形品12を示している。   In the third embodiment, by joining the decorative sheet 1 to the high-rigidity molded products 11 and 13 having a three-layer structure basically sandwiching the synthetic resins 11a and 13a between the foamed aluminum 11b and 13b, The decorative high-rigidity molded products 10 and 12 are formed. FIG. 7 shows a decorative high-rigidity molded product 10 when the resin pressure during molding of the high-rigidity molded product 11 is normal, and FIG. 8 shows the applied pressure when the resin pressure during molding of the high-rigidity molded product 13 is increased. The decorative high-rigidity molded product 12 is shown.

図7の樹脂圧が通常の場合は、合成樹脂11aが発泡アルミ11bのセルを突き破り、発泡アルミ11bの内部へ部分的に浸透した状態となる。図8の樹脂圧が高い場合には、合成樹脂13aが発泡アルミ13bのセルを突き破って反対側の面まで達した状態となる。従って、合成樹脂13aと発泡アルミ13bとの接合強度が更に高まる。   When the resin pressure in FIG. 7 is normal, the synthetic resin 11a penetrates the cell of the foamed aluminum 11b and partially penetrates into the foamed aluminum 11b. When the resin pressure in FIG. 8 is high, the synthetic resin 13a reaches the opposite surface by breaking through the cell of the foamed aluminum 13b. Accordingly, the bonding strength between the synthetic resin 13a and the foamed aluminum 13b is further increased.

発泡アルミ11b、13bの間に合成樹脂11a、13aを挟んだ三層構造であるため、二層の発泡アルミ11b、13bが中間の合成樹脂11a、13aにより結合され、発泡アルミ11b、13bだけで全部を構成する場合に比べて強度が向上する。   Since the synthetic resin 11a, 13a is sandwiched between the foamed aluminum 11b, 13b, the two layers of foamed aluminum 11b, 13b are joined by the intermediate synthetic resin 11a, 13a, and only the foamed aluminum 11b, 13b The strength is improved as compared with the case where all the components are configured.

本発明に係る加飾高剛性成形品2、4、6、8、10、12は、自動車のドア、バックドア(リヤゲート)、クォータパネルの外板部品、フロントエンド骨格部品等に使用することができる。また、衝撃吸収性もあるため、バンパービーム(バンパーアーマチャー)や、フロントエンドモジュール、フェンダー、ボンネット、トランク、アンダーカバー、コアサポート、バックパネル、トランクフロア等にも採用可能である。   The decorative high-rigidity molded articles 2, 4, 6, 8, 10, 12 according to the present invention can be used for automobile doors, back doors (rear gates), quarter panel outer plate parts, front end frame parts, and the like. it can. In addition, since it has shock absorption, it can also be used for bumper beams (bumper armatures), front end modules, fenders, bonnets, trunks, undercovers, core supports, back panels, trunk floors, etc.

この発明の第1実施例に係る加飾シートの製造方法を示す断面図。Sectional drawing which shows the manufacturing method of the decorating sheet which concerns on 1st Example of this invention. この発明の第1実施例に係る加飾高剛性成形品の製造方法を示す断面図。Sectional drawing which shows the manufacturing method of the decorative highly rigid molded product which concerns on 1st Example of this invention. この発明の第1実施例に係る加飾高剛性成形品(通常樹脂圧成形品)を示す部分断面図。The fragmentary sectional view which shows the decoration high-rigidity molded product (normal resin pressure molded product) which concerns on 1st Example of this invention. この発明の第1実施例に係る加飾高剛性成形品(高樹脂圧成形品)を示す部分断面図。The fragmentary sectional view which shows the decoration high-rigidity molded product (high resin pressure molded product) which concerns on 1st Example of this invention. この発明の第2実施例に係る加飾高剛性成形品(通常樹脂圧成形品)を示す部分断面図。The fragmentary sectional view which shows the decorating high-rigidity molded product (normal resin pressure molded product) which concerns on 2nd Example of this invention. この発明の第2実施例に係る加飾高剛性成形品(高樹脂圧成形品)を示す部分断面図。The fragmentary sectional view which shows the decoration highly rigid molded product (high resin pressure molded product) which concerns on 2nd Example of this invention. この発明の第3実施例に係る加飾高剛性成形品(通常樹脂圧成形品)を示す部分断面図。The fragmentary sectional view which shows the decorative high-rigidity molded product (normal resin pressure molded product) which concerns on 3rd Example of this invention. この発明の第3実施例に係る加飾高剛性成形品(高樹脂圧成形品)を示す部分断面図。The fragmentary sectional view which shows the decoration highly rigid molded product (high resin pressure molded product) which concerns on 3rd Example of this invention.

符号の説明Explanation of symbols

1 加飾シート
1a 透過シート
1b 織物シート
2、4、6、8、10、12 加飾高剛性成形品
3、5、7、9、11、13 高剛性成形品
3a、5a、7a、9a、11a、13a 合成樹脂
3b、5b、7b 9b、11b、13b 発泡アルミ
P 熱プレス体
M 成形金型
V 吸引通路
C キャビティ空間
DESCRIPTION OF SYMBOLS 1 Decorative sheet 1a Permeable sheet 1b Textile sheet 2, 4, 6, 8, 10, 12 Decorative high-rigidity molded product 3, 5, 7, 9, 11, 13 High-rigidity molded product 3a, 5a, 7a, 9a, 11a, 13a Synthetic resin 3b, 5b, 7b 9b, 11b, 13b Foamed aluminum P Hot press body M Molding die V Suction passage C Cavity space

Claims (11)

熱可塑性樹脂から成る透明又は半透明の透過シート(1a)と、炭素繊維含有の織物シート(1b)とを、少なくとも表面側に透過シート(1a)が位置するように二層又は多層構成にして重ね合わせた状態で、熱プレスを加えて接合したことを特徴とする加飾シートの製造方法。   A transparent or translucent transparent sheet (1a) made of a thermoplastic resin and a carbon fiber-containing woven sheet (1b) are formed in a two-layer or multilayer structure so that the transparent sheet (1a) is positioned at least on the surface side. A method for producing a decorative sheet, characterized by being joined by applying a heat press in a superposed state. 熱可塑性樹脂から成る透明又は半透明の透過シート(1a)と、炭素繊維含有の織物シート(1b)とを、少なくとも表面側に透過シート(1a)が位置するように二層又は多層構成にして重ね合わせた状態で、熱プレスを加えて接合することにより加飾シート(1)を形成し、
該加飾シート(1)を、高剛性成形品を形成するための合成樹脂の成形金型(M)内にインサートして、射出成形、スタンピングプレス成形、射出プレス成形の何れか又は組み合わせにより成形し、高剛性成形品(3、5、7、9、11、13)の表面に加飾シート(1)を接合した構造の加飾高剛性成形品(2、4、6、8、10、12)を製造することを特徴とする加飾高剛性成形品の製造方法。
A transparent or translucent transparent sheet (1a) made of a thermoplastic resin and a carbon fiber-containing woven sheet (1b) are formed in a two-layer or multilayer structure so that the transparent sheet (1a) is positioned at least on the surface side. In a superposed state, a decorative sheet (1) is formed by joining by applying a hot press,
The decorative sheet (1) is inserted into a synthetic resin mold (M) for forming a high-rigidity molded product and molded by any one or a combination of injection molding, stamping press molding, and injection press molding. The decorative high-rigidity molded products (2, 4, 6, 8, 10, 12). A method for producing a decorated high-rigidity molded article,
請求項2記載の加飾高剛性成形品(2、4、6、8、10、12)の製造方法であって、
高剛性成形品(3、5、7、9、11、13)が、合成樹脂(3a、5a、7a、9a、11a、13a)に発泡アルミ(3b、5b、7b、9b、11b、13b)を接合した構造であることを特徴とする加飾高剛性成形品の製造方法。
A method for producing a decorative high-rigidity molded product (2, 4, 6, 8, 10, 12) according to claim 2,
High rigidity molded products (3, 5, 7, 9, 11, 13) are made of synthetic resin (3a, 5a, 7a, 9a, 11a, 13a) and foamed aluminum (3b, 5b, 7b, 9b, 11b, 13b) A method for producing a decorative high-rigidity molded product characterized by having a structure in which
請求項3記載の加飾高剛性成形品(2、4、6、8、10、12)の製造方法であって、
合成樹脂(3a、5a、7a、9a、11a、13a)が強化フィラーを含んでいることを特徴とする加飾高剛性成形品の製造方法。
A method for producing a decorative high-rigidity molded product (2, 4, 6, 8, 10, 12) according to claim 3,
A synthetic resin (3a, 5a, 7a, 9a, 11a, 13a) containing a reinforcing filler, A method for producing a decorated high-rigidity molded product.
請求項3又は請求項4記載の加飾高剛性成形品(2、4)の製造方法であって、
高剛性成形品(3、5)が、合成樹脂(3a、5a)と発泡アルミ(3b、5b)から成る二層構造であることを特徴とする加飾高剛性成形品の製造方法。
It is a manufacturing method of the decorative high-rigidity molded product (2, 4) according to claim 3 or 4,
A method for producing a decorated high-rigidity molded article, wherein the high-rigidity molded article (3, 5) has a two-layer structure comprising a synthetic resin (3a, 5a) and foamed aluminum (3b, 5b).
請求項3又は請求項4記載の加飾高剛性成形品(6、8)の製造方法であって、
高剛性成形品(7、9)が、合成樹脂(7a、9a)の間に発泡アルミ(7b、9b)を挟んだ三層構造であることを特徴とする加飾高剛性成形品の製造方法。
A method for producing a decorative high-rigidity molded product (6, 8) according to claim 3 or 4,
High-rigidity molded product (7, 9) has a three-layer structure in which foamed aluminum (7b, 9b) is sandwiched between synthetic resins (7a, 9a). .
請求項3又は請求項4記載の加飾高剛性成形品(10、12)の製造方法であって、
高剛性成形品(11、13)が、発泡アルミ(11b、13b)の間に合成樹脂(11a、13a)を挟んだ三層構造であることを特徴とする加飾高剛性成形品の製造方法。
A method for producing a decorative high-rigidity molded product (10, 12) according to claim 3 or 4,
High-rigidity molded article (11, 13) has a three-layer structure in which synthetic resins (11a, 13a) are sandwiched between foamed aluminum (11b, 13b), and a method for producing a decorated high-rigidity molded article .
請求項5〜7のいずれか1項に記載の加飾高剛性成形品(2、6、10)の製造方法であって、
高剛性成形品(3、7、11)の合成樹脂(3a、7a、11a)が、成形時の樹脂圧により、発泡アルミ(3b、7b、11b)のセルを突き破り、発泡アルミ(3b、7b、11b)の内部へ浸透した状態になっていることを特徴とする加飾高剛性成形品の製造方法。
It is a manufacturing method of the decorative high-rigidity molded product (2, 6, 10) according to any one of claims 5 to 7,
The synthetic resin (3a, 7a, 11a) of the high-rigidity molded product (3, 7, 11) breaks through the cells of the foamed aluminum (3b, 7b, 11b) by the resin pressure during molding, and the foamed aluminum (3b, 7b) 11b), a method for producing a decorated high-rigidity molded product, characterized in that it has penetrated into the interior of 11b).
請求項5又は請求項7記載の加飾高剛性成形品(4、12)の製造方法であって、
高剛性成形品(5、13)の合成樹脂(5a、13a)が、成形時の樹脂圧により、発泡アルミ(5b、13b)のセルを突き破り、発泡アルミ(5b、13b)の反対側の面まで達してることを特徴とする加飾高剛性成形品の製造方法。
A method for producing a decorative high-rigidity molded product (4, 12) according to claim 5 or 7,
The synthetic resin (5a, 13a) of the high-rigidity molded product (5, 13) breaks through the cells of the foamed aluminum (5b, 13b) by the resin pressure during molding, and the surface on the opposite side of the foamed aluminum (5b, 13b) The manufacturing method of the decorative highly rigid molded product characterized by having reached to.
請求項6記載の加飾高剛性成形品(8)の製造方法であって、
高剛性成形品(9)の合成樹脂(9a)が、成形時の樹脂圧により、発泡アルミ(9b)のセルを突き破り、セル破壊部が貫通して二層の合成樹脂(9a)同士が連通した状態になっていることを特徴とする加飾高剛性成形品の製造方法。
It is a manufacturing method of the decorative high-rigidity molded product (8) according to claim 6,
The synthetic resin (9a) of the high-rigidity molded article (9) breaks through the cell of the foamed aluminum (9b) by the resin pressure at the time of molding, the cell destruction part penetrates and the two-layer synthetic resin (9a) communicates with each other A method for producing a decorated high-rigidity molded product characterized by being in a finished state.
請求項2〜10のいずれか1項に記載の加飾高剛性成形品(2、4、6、8、10、12)の製造方法であって、
加飾シート(1)の透過シート(1a)の表面に光触媒層が形成されていることを特徴とする加飾高剛性成形品の製造方法。
It is a manufacturing method of the decoration high-rigidity molded product (2, 4, 6, 8, 10, 12) of any one of Claims 2-10,
A method for producing a decorated high-rigidity molded product, wherein a photocatalyst layer is formed on the surface of a transmission sheet (1a) of a decorative sheet (1).
JP2003412086A 2003-12-10 2003-12-10 Decorative sheet and manufacturing method of decorative high rigidity molded product Pending JP2005169803A (en)

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JPH02229997A (en) * 1989-03-03 1990-09-12 Hitachi Ltd Composite panel
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