JP2005169813A - Composite molded product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a composite molded product capable of obtaining a further function such as electrostatic shield properties, conductivity or the like and capable of suppressing the occurrence of voids. <P>SOLUTION: Since foamed aluminum 1b is joined to a synthetic resin 1a, functions such as the electrostatic shield properties, conductivity, sound-proof properties, heat insulating properties, impact absorbability and the like possessed by the foamed aluminum 1b can be imparted to the fundamental function of the synthetic resin 1a. Since the foamed aluminum 1b takes the heat of a molten resin at the time of molding, the solidifying speed of the resin is increased and the occurrence of voids can be suppressed. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a composite molded article suitable as a vehicle body component.

Conventionally, synthetic resin parts have been used as light-weight materials with good moldability as automobile body components. As for the synthetic resin, one type of material may be used as a single layer, and a plurality of types of materials may be used as a laminate. In some cases, reinforcing fillers such as fibers are mixed in the resin (for example, Patent Document 1).
JP-A-6-254887

  However, in a part molded only with a synthetic resin, the functions that can be obtained are limited, and further functions such as electrostatic shielding properties and conductivity cannot be obtained. Further, in the case of the synthetic resin layer, there is a problem that voids (holes) are easily generated by increasing the thickness.

  The present invention has been made by paying attention to such a conventional technique, and can provide a further function such as electrostatic shielding property and conductivity and can suppress generation of voids. Is to provide.

  The invention described in claim 1 is characterized in that it has a structure in which foamed aluminum is bonded to a synthetic resin.

  The invention described in claim 2 is characterized in that the synthetic resin contains a reinforcing filler.

  The invention described in claim 3 is characterized in that the synthetic resin and aluminum foam are joined by any one or a combination of injection molding, stamping press molding, and injection press molding.

  The invention according to claim 4 is characterized in that it has a two-layer structure made of synthetic resin and foamed aluminum.

  The invention according to claim 5 has a three-layer structure in which foamed aluminum is sandwiched between synthetic resins.

  The invention described in claim 6 has a three-layer structure in which a synthetic resin is sandwiched between foamed aluminum.

  The invention described in claim 7 is characterized in that the synthetic resin is in a state of penetrating into the foamed aluminum by piercing the cell of the foamed aluminum by the resin pressure at the time of molding.

  The invention according to claim 8 is characterized in that the synthetic resin 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.

  The invention according to claim 9 is that the synthetic resin breaks through the foamed aluminum cell due to the resin pressure at the time of molding, the cell destruction portion penetrates, and the two layers of synthetic resin are in communication with each other. Features.

  The invention according to claim 10 is characterized in that a photocatalyst layer is formed on the surface of the synthetic resin.

  According to the first aspect of the present invention, since foamed aluminum is joined to the synthetic resin, the basic functions of the synthetic resin include electrostatic shielding properties, electrical conductivity, sound insulation, heat retention, and shock absorption of the foamed aluminum. Functions such as sex 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.

  According to invention of Claim 2, since the synthetic resin contains the reinforcement filler, the intensity | strength of a resin part increases.

  According to the invention of claim 3, the synthetic resin and the foamed aluminum are joined by any one or combination of synthetic resin injection molding, stamping press molding, and injection press molding with the foamed aluminum inserted. Therefore, a reliable joining state between the foamed aluminum and the synthetic resin can be obtained.

  According to the fourth aspect of the invention, since it has a two-layer structure made of synthetic resin and foamed aluminum, the structure is simple and secondary processing is easy.

  According to the invention described in claim 5, since it 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.

  According to the invention described in claim 6, since it has a three-layer structure in which the synthetic resin is sandwiched between the foamed aluminum, the two-layered foamed aluminum is bonded by the intermediate synthetic resin, and the whole is constituted only by the foamed aluminum. Strength is improved compared to the case.

  According to the seventh aspect of the present invention, the synthetic resin breaks through the foamed aluminum cells and penetrates into the foamed aluminum due to the resin pressure at the time of molding. Bonding strength is increased.

  According to the invention described in claim 8, since the synthetic resin pierces 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, the bonding strength between the synthetic resin and the foamed aluminum Is further increased.

  According to the ninth aspect of the present invention, when a three-layer structure in which foamed aluminum is sandwiched between synthetic resins, the synthetic resin breaks through the cells of the foamed aluminum due to the resin pressure at the time of molding, and the cell destruction part Since the two layers of the synthetic resin are in communication with each other through, the bonding strength between the three layers is further increased.

  According to invention of Claim 10, since the photocatalyst layer is formed in the surface of a synthetic resin, the antifouling and antibacterial effect of the synthetic resin surface is acquired.

  It is a structure in which foamed aluminum is bonded to synthetic resin for the purpose of providing a composite molded product that can obtain further functions such as electrostatic shielding and electrical conductivity and can suppress the generation of voids. Realized by. DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, the best embodiment of the invention will be described with reference to the drawings.

  1 and 2 are views showing a first embodiment of the present invention. The first embodiment shows composite molded articles 1 and 2 basically having a two-layer structure of synthetic resins 1a and 2a and foamed aluminum 1b and 2b. A photocatalyst layer (not shown) is formed on the surfaces of the synthetic resins 1a and 2a. FIG. 1 shows a composite molded product 1 when the resin pressure during molding is normal, and FIG. 2 shows a composite molded product 2 when the resin pressure is increased.

  The foamed aluminum 1b and 2b are lightweight and have a specific gravity of 0.3 (variable in the range of 0.2 to 0.8), and have electrostatic shielding properties, electrical conductivity, sound insulation properties, heat retention properties, and shock absorption properties. The size of the foamed aluminum 1b, 2b is used by cutting or slicing a 2500 mm × 650 mm × 450 mm object as necessary.

  The cell cross section of the foamed aluminum 1b and 2b 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 1b, 2b. Since the volume is reduced by compression, the specific gravity is increased.

  The synthetic resins 1a and 2a are molded in a state where the foamed aluminum 1b and 2b are inserted or in-molded into a mold. The molding method may be normal injection molding, stamping molding, injection press molding, or a combination thereof. Since the foamed aluminum 1b and 2b are inserted or in-molded, the foamed aluminum 1b and 2b take away the heat of the molten resin at the time of molding, and the solidification speed of the synthetic resins 1a and 2a is increased. Occurrence is suppressed.

  The synthetic resins 1a and 2a 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 1a and 2a.

  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.

  Even if the resin pressure during molding is normal, the synthetic resin 1a breaks through the cells of the foamed aluminum 1b and partially penetrates into the foamed aluminum 1b (see FIG. 1). Therefore, the joint strength between the synthetic resin 1a and the foamed aluminum 1b is increased by the anchor effect of the synthetic resin 1a with respect to the foamed aluminum 1b.

  When the resin pressure at the time of molding is high, the synthetic resin 2a breaks through the cell of the foamed aluminum 2b and reaches the surface on the opposite side (see FIG. 2). Accordingly, the bonding strength between the synthetic resin 2a and the foamed aluminum 2b is further increased.

  According to this embodiment, since the foamed aluminum 1b, 2b is joined to the synthetic resins 1a, 2a, the basic functions of the synthetic resins 1a, 2a include the electrostatic shielding properties, conductivity, Functions such as soundproofing, heat retention and shock absorption can be added.

  Moreover, in this embodiment, since it is a two-layer structure consisting of synthetic resins 1a, 2a and foamed aluminum 1b, 2b, the structure is simple and secondary processing is easy.

  Furthermore, since the photocatalyst layer (not shown) is formed on the surfaces of the synthetic resins 1a and 2a, the antifouling and antibacterial effects on the surfaces of the synthetic resins 1a and 2a can be obtained.

  3 and 4 are views showing a second embodiment of the present invention. The second embodiment shows composite molded articles 3 and 4 basically having a three-layer structure in which foamed aluminum 3b and 4b are sandwiched between synthetic resins 3a and 4a. FIG. 3 shows the composite molded product 3 when the resin pressure during molding is normal, and FIG. 4 shows the composite molded product 4 when the resin pressure is increased.

  When the resin pressure in FIG. 3 is normal, the synthetic resin 3a breaks through the cells of the foamed aluminum 3b and partially penetrates into the foamed aluminum 3b. When the resin pressure in FIG. 4 is high, the synthetic resin 4a breaks through the cell of the foamed aluminum 4b, the cell destruction portion penetrates, and the two layers of the synthetic resin 4a communicate with each other. Accordingly, the bonding strength between the three layers made of the synthetic resin 4a and the foamed aluminum 4b is further increased.

  Further, the three-layer structure in which the foamed aluminum 3b and 4b are sandwiched between the synthetic resins 3a and 4a has the anti-oxidation effect of the foamed aluminum 3b and 4b because both surfaces of the foamed aluminum 3b and 4b are covered with the synthetic resins 3a and 4a. There is.

  5 and 6 are views showing a third embodiment of the present invention. The third embodiment basically shows composite molded products 5 and 6 having a three-layer structure in which synthetic resins 5a and 6a are sandwiched between foamed aluminum 5b and 6b. FIG. 5 shows the composite molded product 5 when the resin pressure during molding is normal, and FIG. 6 shows the composite molded product 6 when the resin pressure is increased.

  When the resin pressure in FIG. 5 is normal, the synthetic resin 5a breaks through the cells of the foamed aluminum 5b and partially penetrates into the foamed aluminum 5b. When the resin pressure in FIG. 6 is high, the synthetic resin 6a has penetrated the cell of the foamed aluminum 6b and has reached the opposite surface. Accordingly, the bonding strength between the synthetic resin 6a and the foamed aluminum 6b is further increased.

  Since the synthetic resin 5a, 6a is sandwiched between the foamed aluminum 5b, 6b, the two layers of foamed aluminum 5b, 6b are joined by the intermediate synthetic resin 5a, 6a, and only the foamed aluminum 5b, 6b The strength is improved as compared with the case where all the components are configured.

  The composite molded articles 1 to 6 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. In addition, because of its shock absorption, it can also be used for bumper beams (bumper armatures), front end modules, bonnets, trunks, under covers, back panels, trunk floors, etc.

The fragmentary sectional view which shows the composite molded product (normal resin pressure molded product) which concerns on 1st Example of this invention. The fragmentary sectional view which shows the composite molded product (high resin pressure molded product) which concerns on 1st Example of this invention. The fragmentary sectional view which shows the composite molded product (normal resin pressure molded product) which concerns on 2nd Example of this invention. The fragmentary sectional view which shows the composite molded product (high resin pressure molded product) which concerns on 2nd Example of this invention. The fragmentary sectional view which shows the composite molded product (normal resin pressure molded product) which concerns on 3rd Example of this invention. The fragmentary sectional view which shows the composite molded product (high resin pressure molded product) which concerns on 3rd Example of this invention.

Explanation of symbols

1, 2, 3, 4, 5, 6 Composite molded product 1a, 2a, 3a, 4a, 5a, 6a Synthetic resin 1b, 2b, 3b 4b, 5b, 6b Foamed aluminum

Claims (10)

  A composite molded article having a structure in which foamed aluminum (1b, 2b, 3b, 4b, 5b, 6b) is joined to a synthetic resin (1a, 2a, 3a, 4a, 5a, 6a). The composite molded article (1, 2, 3, 4, 5, 6) according to claim 1,
A composite molded article, wherein the synthetic resin (1a, 2a, 3a, 4a, 5a, 6a) contains a reinforcing filler. The composite molded article (1, 2, 3, 4, 5, 6) according to claim 1 or 2,
Bonding of synthetic resin (1a, 2a, 3a, 4a, 5a, 6a) and foamed aluminum (1b, 2b, 3b, 4b, 5b, 6b) is any one or combination of injection molding, stamping press molding, injection press molding A composite molded product characterized in that The composite molded article (1, 2) according to any one of claims 1 to 3,
A composite molded article having a two-layer structure comprising a synthetic resin (1a, 2a) and foamed aluminum (1b, 2b). The composite molded article (3, 4) according to any one of claims 1 to 3,
A composite molded article having a three-layer structure in which foamed aluminum (3b, 4b) is sandwiched between synthetic resins (3a, 4a). The composite molded article (5, 6) according to any one of claims 1 to 3,
A composite molded article having a three-layer structure in which synthetic resins (5a, 6a) are sandwiched between foamed aluminum (5b, 6b). The composite molded article (1, 3, 5) according to any one of claims 4 to 6,
The synthetic resin (1a, 3a, 5a) has penetrated into the foamed aluminum (1b, 3b, 5b) through the cells of the foamed aluminum (1b, 3b, 5b) due to the resin pressure during molding. Composite molded product characterized by The composite molded article (2, 6) according to claim 4 or 6,
Composite molding characterized in that the synthetic resin (2a, 6a) breaks through the cells of the foamed aluminum (2b, 6b) by the resin pressure during molding and reaches the opposite surface of the foamed aluminum (2b, 6b). Goods. A composite molded article (4) according to claim 5,
The synthetic resin (4a) breaks through the cell of the foamed aluminum (4b) by the resin pressure at the time of molding, and the cell destruction portion penetrates and the two-layer synthetic resin (4a) is in a state of communicating with each other. Characteristic composite molded product. The composite molded article (1, 2, 3, 4) according to claim 4 or 5,
A composite molded article, wherein a photocatalyst layer is formed on the surface of a synthetic resin (1a, 2a, 3a, 4a).

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