JP2005178167A - Composite panel - Google Patents
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Description
本発明は複合パネルに関するものであり、更に詳しくは、繊維強化発泡プラスチックを用いた複合パネルである。 The present invention relates to a composite panel, and more particularly, a composite panel using fiber-reinforced foamed plastic.
従来より、断熱性、遮音性を付与したドアや間仕切りパネル等のパネル構造として、芯材としてウレタン発泡体が用いられるのが一般的であり、これに代えて、ハニカム材を用いることもあり、一方、表面材として鋼板、木材、ＦＲＰ等の樹脂板を用いて構成されていた。 Conventionally, as a panel structure such as a door or partition panel provided with heat insulation and sound insulation, it is common to use urethane foam as a core material, and instead of this, a honeycomb material may be used, On the other hand, it was comprised using resin plates, such as a steel plate, wood, and FRP, as a surface material.
しかるに、これら従来のドアやパネルにあっては、芯材と表面材とが全く別部材であるため、即ち、複数の性質の異なる素材からなっているため、リサイクル時の処理工数が膨大な費用が掛かっていた。又、このため、製造工程は複雑化し、かつ、相互間での接着性を考慮する必要があった。 However, in these conventional doors and panels, since the core material and the surface material are completely different members, that is, made of materials having different properties, the processing man-hours during recycling are enormous. It was hanging. For this reason, the manufacturing process is complicated, and it is necessary to consider the adhesiveness between them.
更に性状的に言えば、芯材がウレタン発泡体であるため、外力に対抗する強度にやや難点があり、かつ、水分との接触によりウレタン発泡体が劣化するため、耐久性の点で問題があることも指摘される場合があった。 In terms of properties, since the core material is urethane foam, there is a slight difficulty in strength against external forces, and the urethane foam deteriorates due to contact with moisture, so there is a problem in terms of durability. It was sometimes pointed out.
本発明は以上のような従来技術の課題を解決するものであって、リサイクル性のよい、しかも性状的により強化された、かつ、耐久性の向上した繊維強化発泡プラスチックを用いた複合パネルを提供することを目的とするものである。 The present invention solves the problems of the prior art as described above, and provides a composite panel using a fiber-reinforced foamed plastic that is highly recyclable and that is reinforced in terms of properties and has improved durability. It is intended to do.
本発明の要旨は、パネルの芯材として、（Ａ）マトリックス樹脂として熱硬化性樹脂、（Ｂ）補強用繊維、（Ｃ）加熱膨張性マイクロカプセル、からなる発泡性予備成形体を加熱硬化してなる繊維強化発泡プラスチックを用い、パネルの表面材として、前記（Ａ）熱硬化性樹脂と同種の樹脂による表面材、鋼板、木材板を用いた繊維強化発泡複合パネルである。かかる芯材と表面材との一体化は芯材を発泡成形する金型内にて行って一体とすることもできるが、芯材の発泡後に表面材を接着することで複合パネルとすることも可能である。 The gist of the present invention is to thermally cure a foamable preform formed from (A) a thermosetting resin as a matrix resin, (B) a reinforcing fiber, and (C) a heat-expandable microcapsule. A fiber reinforced foam composite panel using a fiber reinforced foamed plastic and a panel surface material made of the same type of resin as the thermosetting resin (A), a steel plate, and a wood plate. Such core material and surface material can be integrated in a mold for foam molding of the core material, but it can also be integrated by bonding the surface material after foaming of the core material. Is possible.
そして、リサイクルの面では、表面材は好ましくは（Ａ）熱硬化性樹脂が不飽和ポリエステル樹脂であり、（Ｂ）成分の補強用繊維が、長さ３〜１００ｍｍのガラス繊維で、その含有量は発泡性予備成形体全体に基づき、１０〜７０重量部であるのがよい。又、（Ｃ）成分の加熟膨張性マイクロカプセルが、低沸点液状有機化合物を内包したコアシェル型のものであり、この含有量が（Ａ）成分１００重量部に対し、０．１〜５０重量部であるのがよい。尚、複合パネルの芯材としての密度が０．４〜１．５ｇ／ｃｍ3 である。 In terms of recycling, the surface material is preferably (A) the thermosetting resin is an unsaturated polyester resin, and the reinforcing fiber of the component (B) is a glass fiber having a length of 3 to 100 mm, and its content Is preferably 10 to 70 parts by weight based on the entire foamable preform. Further, the ripening expansible microcapsule of the component (C) is a core-shell type containing a low-boiling liquid organic compound, and the content is 0.1 to 50 weights with respect to 100 parts by weight of the component (A). Good part. In addition, the density as a core material of a composite panel is 0.4-1.5 g / cm < 3 >.
本発明によれば、発泡性予備成形体による繊維強化発泡プラスチック成形体を用いた複合パネルであって、特に芯材と表面材とをマトリックスを同じくすることによりリサイクル性に富んだものとなり、しかも強度的にかつ耐久性に優れた複合パネルを提供できたものである。 According to the present invention, a composite panel using a fiber-reinforced foamed plastic molded body made of a foamable preform, which is particularly recyclable by using the same matrix for the core material and the surface material, It was possible to provide a composite panel that was strong and excellent in durability.
さて、本出願人は既に繊維強化発泡プラスチックについて新しい技術を提供している。かかる新技術は、（Ａ）マトリックス樹脂として熱硬化性樹脂、（Ｂ）補強用繊維及び（Ｃ）加熱膨張性マイクロカプセルを含むシート状又はバルク状発泡性予備成形体であって、マトリックス樹脂である（Ａ）熱硬化性樹脂として、熱硬化性樹脂を含有する液状体を用いたものであり、かかる液状体を加熱硬化させてなる繊維強化発泡プラスチック成形体を提供した（特許出願中）。 The applicant has already provided new technology for fiber reinforced foamed plastic. Such a new technology is a sheet-like or bulk-like foamable preform containing (A) a thermosetting resin as a matrix resin, (B) reinforcing fibers and (C) a heat-expandable microcapsule, As a certain (A) thermosetting resin, a liquid material containing a thermosetting resin was used, and a fiber-reinforced foamed plastic molded body obtained by heat-curing the liquid material was provided (patent pending).
かかる既提案による繊維強化発泡プラスチックは、軽量でかつ高強度の性質をもち、しかもその製造も比較的簡便なことから、本発明にあっては、これをパネルの芯材として用い、かつ、表面材として繊維強化プラスチック、鋼板、木材板、好ましくは表面材をかかるマトリックス樹脂と同種の樹脂を用いて複合パネルとしたものであり、従来より指摘されていた点を解決したものである。 Such a proposed fiber-reinforced foamed plastic has light weight and high strength properties, and is relatively easy to manufacture. Therefore, in the present invention, the fiber reinforced foamed plastic is used as a core material for a panel and has a surface. As a material, a fiber reinforced plastic, a steel plate, a wood plate, and preferably a surface material is formed into a composite panel using the same kind of resin as the matrix resin.
本発明の発泡性予備成形体を作製するには、先ず発泡性成形材料を調製する。即ち、（Ａ）成分のマトリックス樹脂として、熱硬化性樹脂を含有する液状体を用い、これに前記（Ｃ）成分の加熱膨張性マイクロカプセルを配合し、更に従来ＳＭＣ、ＢＭＣ、ＴＭＣ用として慣用されている材料、例えば低収縮剤、無機充填剤、重合開始剤、硬化剤、増粘剤及び必要に応じて用いられる硬化促進剤やその他添加剤を配合することにより、調製することができる。 In order to produce the foamable preform of the present invention, a foamable molding material is first prepared. That is, a liquid material containing a thermosetting resin is used as the matrix resin of the component (A), and the heat-expandable microcapsules of the component (C) are blended therein, and further conventionally used for SMC, BMC, and TMC. It can be prepared by blending existing materials such as low shrinkage agents, inorganic fillers, polymerization initiators, curing agents, thickeners and curing accelerators and other additives used as necessary.
前記（Ａ）成分のマトリックス樹脂としては、不飽和ポリエステル樹脂、ビニルエステル樹脂、エポキシ樹脂、フェノール樹脂等があるが、これらの中で不飽和ポリエステル樹脂が好ましく使用される。 Examples of the matrix resin of the component (A) include unsaturated polyester resins, vinyl ester resins, epoxy resins, phenol resins, etc. Among them, unsaturated polyester resins are preferably used.
本発明において、発泡性成形材料に配合される（Ｃ）成分の加熱膨張性マイクロカプセルとしては、コアが低沸点液状有機化合物であり、これを熱可塑性樹脂からなるシェルで内包したコアシェル型の加熱膨張性マイクロカプセルが好ましい。コアの低沸点液状有機化合物としては、常温、常圧における沸点が１５０℃以下のものが好ましく、例えばイソブタン、ペンタン、ヘキサン等の炭化水素化合物やエーテル類等を挙げることができる。又、シエルを形成する熱可塑性樹脂としては、例えばポリエチレン、ポリプロピレン、エチレンープロピレン共重合体等のポリオレフィン系樹脂、アクリロニトリル系共重合体、ポリスチレン、ポリ塩化ビニル、エチレンー酢酸ビニル共重合体、ポリアミド樹脂、ポリエチレンテレフタレート、ポリウレタン等を用いることができるが、これらの中でアクリルニトリル系共重合体が好ましい。この加熱膨張性マイクロカプセルの製造法は、インサイト重合法により製造されたものが好ましい。 In the present invention, as the heat-expandable microcapsule of component (C) blended in the foamable molding material, the core is a low-boiling liquid organic compound, and the core-shell type heating in which the core is encapsulated with a shell made of a thermoplastic resin Swellable microcapsules are preferred. The core low-boiling liquid organic compound preferably has a boiling point of 150 ° C. or lower at normal temperature and normal pressure, and examples thereof include hydrocarbon compounds such as isobutane, pentane, and hexane, ethers, and the like. Examples of the thermoplastic resin that forms shells include polyolefin resins such as polyethylene, polypropylene, and ethylene-propylene copolymers, acrylonitrile copolymers, polystyrene, polyvinyl chloride, ethylene-vinyl acetate copolymers, and polyamide resins. , Polyethylene terephthalate, polyurethane and the like can be used, and among these, acrylonitrile-based copolymers are preferable. As the method for producing the heat-expandable microcapsules, those produced by an in situ polymerization method are preferable.
この加熱膨張性マイクロカプセルは、加熱膨張前の平均粒径が０．５〜１００μｍの範囲にあるものが好ましく、１〜７０μｍの範囲にあるものがより好ましい。又、加熱膨張後の外径は熱膨張前の外径の２倍以上が好ましく、３〜１０倍程度がより好ましい。膨張前の平均粒径が０．５μｍ未満では十分な発泡が得られにくいし、１００μｍを越えると均一に分散しにくく、均質な繊維強化発泡プラスチック成形体が得られない場合がある。尚、膨張開始温度は作業性の面から８０℃以上であることが好ましく、より好ましくは１００〜２３０℃である。 This heat-expandable microcapsule preferably has an average particle size before heat expansion in the range of 0.5 to 100 μm, more preferably in the range of 1 to 70 μm. Further, the outer diameter after the thermal expansion is preferably at least twice the outer diameter before the thermal expansion, and more preferably about 3 to 10 times. If the average particle size before expansion is less than 0.5 μm, it is difficult to obtain sufficient foaming, and if it exceeds 100 μm, it is difficult to uniformly disperse and a homogeneous fiber-reinforced foamed plastic molded product may not be obtained. The expansion start temperature is preferably 80 ° C. or higher, more preferably 100 to 230 ° C. from the viewpoint of workability.
本発明においては、（Ｃ）成分の加熱膨張性マイクロカプセルの配合量と、前記（Ａ）成分のマトリックス樹脂液状体１００重量部に対し、０．１〜５０重量部の範囲が好ましく、より好ましくは０．５〜２０重量部の範囲である。この配合量が０．５重量部未満では所望の低密度の繊維強化発泡プラスチック成形体が得られにくく、５０重量部を超えると該プラスチック成形体の強度が不十分となるおそれがある。 In the present invention, the range of 0.1 to 50 parts by weight is preferable, more preferably 100 parts by weight of the component (C) heat-expandable microcapsule and 100 parts by weight of the matrix resin liquid (A). Is in the range of 0.5 to 20 parts by weight. If the blending amount is less than 0.5 parts by weight, it is difficult to obtain a desired low-density fiber-reinforced foamed plastic molded body, and if it exceeds 50 parts by weight, the strength of the plastic molded body may be insufficient.
本発明における発泡性成形材料に配合される低収縮剤として、ポリスチレン、ポリエチレン、ポリ酢酸ビニル、ポリメタクリル酸メチル、飽和ポリエステル、スチレンーブタジエン共重合体、スチレンーメタクリル酸共重合体、ポリカプロラクトン、ポリブタジエン等の熱可塑性樹脂が挙げられる。又、その配合量は、得られる発泡プラスチック成形体の収縮率や表面平滑性等を考慮して選定されるが、前記マトリックス樹脂と該低収縮剤との重量比が、通常９０：１０乃至５０：５０、好ましくは８０：２０乃至６０：４０の範囲で選ばれる。 As a low shrinkage agent blended in the foamable molding material in the present invention, polystyrene, polyethylene, polyvinyl acetate, polymethyl methacrylate, saturated polyester, styrene-butadiene copolymer, styrene-methacrylic acid copolymer, polycaprolactone, Examples thereof include thermoplastic resins such as polybutadiene. The blending amount is selected in consideration of the shrinkage rate, surface smoothness, etc. of the obtained foamed plastic molding, but the weight ratio of the matrix resin to the low shrinkage agent is usually 90:10 to 50. : 50, preferably in the range of 80:20 to 60:40.
又、本発明における発泡性成形材料に配合される充填剤としては、炭酸カルシウム、シリカ、タルク、水酸化アルミニウム、クレ−、マイカ、中空バルーン（ガラス、シラス、セメント）、フェライト、亜鉛華等が挙げられるが、これらの中で、炭酸カルシウムが好ましい。又、その配合量は、前記のマトリックス樹脂と低収縮剤との合計量１００重量部に対し、通常５０〜２００重量部の範囲で選定される。 Examples of the filler to be blended in the foamable molding material in the present invention include calcium carbonate, silica, talc, aluminum hydroxide, clay, mica, hollow balloon (glass, shirasu, cement), ferrite, zinc white and the like. Among them, among them, calcium carbonate is preferable. The blending amount is usually selected in the range of 50 to 200 parts by weight with respect to 100 parts by weight of the total amount of the matrix resin and the low shrinkage agent.
本発明における発泡性成形材料が、不飽和ポリエステル樹脂系発泡性成形材料の場合、重合開始剤や硬化剤として通常有機過酸化物が用いられ、メチルエチルケトンパーオキシド、アセチルアセトンパーオキシド、ｔ−ブチルパーオキシベンゾエート、ベンゾ−ルパーオキシド、ジクミルパーオキシド、クメンハイドロパーオキシド等が挙げられる。この重合開始剤の配合量は、前記マトリックス樹脂１００重量部に対して通常０．３〜５重量部、好ましくは０．７〜３重量部の範囲で選定される。 When the foamable molding material in the present invention is an unsaturated polyester resin-based foamable molding material, an organic peroxide is usually used as a polymerization initiator or a curing agent, such as methyl ethyl ketone peroxide, acetylacetone peroxide, t-butylperoxy. Examples include benzoate, benzol peroxide, dicumyl peroxide, cumene hydroperoxide and the like. The blending amount of the polymerization initiator is usually selected in the range of 0.3 to 5 parts by weight, preferably 0.7 to 3 parts by weight with respect to 100 parts by weight of the matrix resin.
又、不飽和ポリエステル樹脂系発泡性成形材料の場合、それに配合される増粘剤の例としては、酸化マグネシウム、水酸化マグネシウム、酸化カリウム、水酸化カリウム等が挙げられる。この増粘剤の配合量は、前記マトリックス樹脂１００重量部に対し、通常０．５〜５重量部、好ましくは０．７〜２重量部の範囲で選定される。 In the case of an unsaturated polyester resin-based foamable molding material, examples of the thickener blended therein include magnesium oxide, magnesium hydroxide, potassium oxide, potassium hydroxide and the like. The blending amount of the thickener is usually selected in the range of 0.5 to 5 parts by weight, preferably 0.7 to 2 parts by weight with respect to 100 parts by weight of the matrix resin.
本発明における不飽和ポリエステル樹脂系発泡性成形材料においては、前記増粘剤を添加３０分後の温度２５℃における粘度が、５０〜３００Ｐａ・Ｓの範囲にあることが好ましく、この粘度が３００Ｐａ・Ｓを超えると補強用繊維への含浸性が不充分となってしまうからである。 In the unsaturated polyester resin-based foamable molding material in the present invention, the viscosity at a temperature of 25 ° C. 30 minutes after the addition of the thickener is preferably in the range of 50 to 300 Pa · S, and this viscosity is 300 Pa · It is because the impregnation property to the reinforcing fiber becomes insufficient when it exceeds S.
本発明における不飽和ポリエステル樹脂系発泡性成形材料においては、その他添加剤、例えば硬化促進剤、重合禁止剤、離型剤、酸化防止剤、紫外線吸収剤、着色剤等を所望により配合することができる。例えば、上記硬化促進剤としては、ナフテン酸コバルト、オクトエ酸コバルト、Ｎ，Ｎ−ジメチルアニリン、Ｎ，Ｎ一ジエチルアニリン等が挙げられる。又、重合禁止剤としては、ハイドロキノン、Ｐ−ベンゾキノン、メチルハイドロキノン、トリメチルハイドロキノン、ｔ−ブチルハイドロキノン等が挙げられる。 In the unsaturated polyester resin-based foamable molding material in the present invention, other additives such as a curing accelerator, a polymerization inhibitor, a mold release agent, an antioxidant, an ultraviolet absorber, a colorant and the like may be blended as desired. it can. For example, examples of the curing accelerator include cobalt naphthenate, cobalt octoate, N, N-dimethylaniline, N, N-diethylaniline, and the like. Examples of the polymerization inhibitor include hydroquinone, P-benzoquinone, methylhydroquinone, trimethylhydroquinone, t-butylhydroquinone and the like.
次に、本発明の発泡性予備成形体は、前記のようにして得られた発泡性成形材料を（Ｂ）成分の補強用繊維に含浸させ、シート状（ＳＭＣ、ＴＭＣ）又はバルク状（ＢＭＣ）に成形したものである。 Next, the foamable preform of the present invention is obtained by impregnating the foamable molding material obtained as described above into the reinforcing fiber of the component (B), to form a sheet (SMC, TMC) or bulk (BMC) ).
前記補強用繊維としては、例えばガラス繊維、炭素繊維、更にはポリエステル繊維、ナイロン繊維、アラミド繊推等の有機繊維等が挙げられるが、これらの中でガラス繊維が好適である。このガラス繊維としては、ロービングを切断した長繊維及び／又は短繊維が用いられる。長繊維は、長さが通常１５〜１００ｍｍ、好ましくは２０〜５０ｍｍの範囲のものであり、短繊維は、長さが通常５〜１５ｍｍ、好ましくは６〜１３ｍｍの範囲のものである。 Examples of the reinforcing fiber include glass fiber, carbon fiber, and organic fiber such as polyester fiber, nylon fiber, and aramid fiber, among which glass fiber is preferable. As the glass fiber, a long fiber and / or a short fiber obtained by cutting a roving is used. The long fiber has a length of usually 15 to 100 mm, preferably 20 to 50 mm, and the short fiber has a length of usually 5 to 15 mm, preferably 6 to 13 mm.
本発明の発泡性予備成形体においては、前記補強用繊維は、該予備成形体全体に基づき、通常１０〜７０重量％、好ましくは１５〜５０重量％の範囲で含有される。 In the foamable preform of the present invention, the reinforcing fiber is usually contained in the range of 10 to 70% by weight, preferably 15 to 50% by weight, based on the whole preform.
本発明の繊維強化発泡プラスチック成形体は、このようにして得られたシート状（ＳＭＣ、ＴＭＣ）又はバルク状（ＢＭＣ）の発泡性予備成形体を、加熱硬化させることにより得ることができる。特に、発泡性予備成形体を金型内にセットし、型締めを発泡後想定する成形品肉厚で中断し、発泡圧を利用する方法により成形すると、低圧で成形できるので成形体の製造設備や金型のコストを低減できる利点を有する。本発明の繊維強化発泡プラスチック成形体の密度は、好ましくは０．４〜１．５ｇ／ｃｍ3 であり、より好ましくは０．５〜１．２ｇ／ｃｍ3 である。 The fiber-reinforced foamed plastic molding of the present invention can be obtained by heat-curing the sheet-like (SMC, TMC) or bulk (BMC) foamable preform thus obtained. In particular, when a foamable preform is set in a mold, mold clamping is interrupted by the thickness of the molded product that is assumed after foaming, and molding is performed by a method that uses foaming pressure, molding can be performed at low pressure. It has the advantage that the cost of the metal mold can be reduced. The density of the fiber-reinforced foamed plastic molding of the present invention is preferably 0.4 to 1.5 g / cm 3 , more preferably 0.5 to 1.2 g / cm 3 .
次に、本発明の繊維強化発泡プラスチック成形体を作製する実施態様について、ＳＭＣの場合を例に挙げて説明する。
先ず、（Ａ）成分のマトリックス樹脂、（Ｃ）成分の加熱膨張性マイクロカプセル、低収縮剤、充填剤、重合開始剤や硬化剤及び必要に応じて用いられる硬化促進剤やその他の添加剤を混練して、コンパウンドペーストを調製する。次いでこれに増粘剤を混合して得られた発泡性成形材料を、ただちにＳＭＣ含浸機に供給する。
Next, an embodiment for producing the fiber-reinforced foamed plastic molded body of the present invention will be described taking the case of SMC as an example.
First, (A) component matrix resin, (C) component heat-expandable microcapsules, low shrinkage agent, filler, polymerization initiator and curing agent, and curing accelerators and other additives used as necessary. A compound paste is prepared by kneading. Subsequently, the foamable molding material obtained by mixing this with a thickener is immediately supplied to the SMC impregnation machine.
次に、２枚のキャリヤーフイルム夫々に上記発泡性成形材料を所定量塗布したのち、下フイルムの塗布層上に、ガラスローピングをカッターでチョップしながら降らせる。次いでその上に塗布層を有する上フイルムを該塗布層が内側になるように重ね合わせ、この重ね合わせたフィルムの上下にロールを押しつけて、サンドイッチ状になったガラス繊維に組成物を含浸させることにより、本発明のシート状発泡性予備成形体（ＳＭＣ）が得られる。このようにして得られた本発明のシート状発泡性予備成形体の厚さは、成形材料のガラス繊推への浸透性等の面から通常１〜１０ｍｍがよい。 Next, a predetermined amount of the foamable molding material is applied to each of the two carrier films, and then glass roping is dropped onto the application layer of the lower film while chopping with a cutter. Next, an upper film having a coating layer thereon is overlaid so that the coating layer is on the inside, and rolls are pressed on the top and bottom of the laminated film to impregnate the composition into sandwiched glass fibers. Thus, the sheet-like foamable preform (SMC) of the present invention is obtained. The thickness of the sheet-like foamable preform of the present invention thus obtained is usually 1 to 10 mm from the viewpoint of the permeability of the molding material to the glass fiber.
次いで、前記のようにして得られたシート状発泡性予備成形体を、通常複数枚を用い、金型内に重ねてセットし、１３０℃〜１６０℃で発泡後の厚さに合わせて型締めを中断するか、５〜１０ＭＰａで型縮めした後、約１分後に発泡後の厚さに合わせて型を上昇するという条件で、３〜５分間程度加熱加圧して、発泡させることにより、ガラス繊維強化発泡プラスチック成形体が得られる。 Next, the sheet-like foamable preforms obtained as described above are usually set in a mold by using a plurality of sheets, and clamped according to the thickness after foaming at 130 ° C to 160 ° C. Or after shrinking the mold at 5 to 10 MPa, after about 1 minute, the mold is raised in accordance with the thickness after foaming. A fiber-reinforced foamed plastic molding is obtained.
表面材としては特に限定はなく、鋼板、木材板、プラスチック板等が選択できるが、リサイクル性の面で言えば、ガラス繊維強化プラスチックが好ましく、更に言えば、発泡プラスチック成形体に採用したと同様のプラスチック板を用いるのが好ましいことは言うまでもない。表面材をプラスチック板とすることは、芯材としての発泡プラスチック成形体が成形される際に同じモ−ルド内に表面材のプラスチック材料を投入して一体に成形することが可能である。 The surface material is not particularly limited, and a steel plate, wood plate, plastic plate, etc. can be selected. However, in terms of recyclability, glass fiber reinforced plastic is preferable, and more specifically, the same as that adopted for the foamed plastic molded body. Needless to say, it is preferable to use a plastic plate. When the surface material is a plastic plate, when the foamed plastic molding as the core material is molded, the plastic material of the surface material can be put into the same mold and integrally molded.
「プラスチック成形体・１」
（１）発泡性予備成形体の作製
マトリックス樹脂（不飽和ポリエステル樹脂、数平均分子量：３０００）１００重量部、低収縮剤（ポリスチレンの３５％スチレンモノマー溶液）２５重量部、粘度調整剤（スチレンモノマー）１０重量部、硬化剤（ｔ−ブチルパーオキシベンゾエート）１重量部、重合禁止剤（パラベンゾキノン）０．０５重量部、加熱膨張性マイクロカプセル（松本油脂社製「マイクロスフェアーＦｌＯ５Ｄ」）を加え、更に、内部離型剤（ステアリン酸亜鉛）５重量部、改質剤（粉末ポリエチレン）４重量部及び充填剤（重質炭酸カルシウム）１４０重量部を混練してコンパウンドベーストを調製した。次いで、これに増粘剤ペーストとして、増粘剤（酸化マグネシウム）１重量部と樹脂（酸価０の不飽和ポリエステル樹脂）４重量部、の混合物を加え、発泡性成形材料を作製した。尚、上記の不飽和ポリエステル樹脂（マトリックス樹脂）は、ジカルボン酸分として、テレフタル酸とマレイン酸の組合わせを、グリコール成分として、プロピレングリコールとネオベンチルグリコールとの組合わせを用い、エステル反応させて得られたものである。
"Plastic molded body 1"
(1) Preparation of foamable preform A matrix resin (unsaturated polyester resin, number average molecular weight: 3000) 100 parts by weight, a low shrinkage agent (35% styrene monomer solution of polystyrene), 25 parts by weight, a viscosity modifier (styrene monomer) ) 10 parts by weight, 1 part by weight of a curing agent (t-butylperoxybenzoate), 0.05 part by weight of a polymerization inhibitor (parabenzoquinone), a heat-expandable microcapsule (“Microsphere FlO5D” manufactured by Matsumoto Yushi Co., Ltd.) In addition, 5 parts by weight of an internal mold release agent (zinc stearate), 4 parts by weight of a modifier (powder polyethylene) and 140 parts by weight of a filler (heavy calcium carbonate) were kneaded to prepare a compound base. Subsequently, as a thickener paste, a mixture of 1 part by weight of a thickener (magnesium oxide) and 4 parts by weight of a resin (unsaturated polyester resin having an acid value of 0) was added to produce a foamable molding material. The unsaturated polyester resin (matrix resin) is subjected to an ester reaction using a combination of terephthalic acid and maleic acid as the dicarboxylic acid component, and a combination of propylene glycol and neoventyl glycol as the glycol component. It was obtained.
次に、前記増粘剤ベースト添加約３０分後に、ガラスロービングをカッターでチョップしてなる長さ約２５ｍｍのガラス繊維を、発泡性予備成形体全量に対し３０重量％の割合で加え、常法に従ってシート状発泡性予備成形体（ＳＭＣ）を作製した。 Next, about 30 minutes after the addition of the thickener base, glass fiber having a length of about 25 mm obtained by chopping glass roving with a cutter was added at a ratio of 30% by weight with respect to the total amount of the foamable preform. Thus, a sheet-like foamable preform (SMC) was produced.
（２）繊維強化発泡プラスチック成形体の作製
上記（１）で得られたシート状発泡性予備成形体を１００×１００ｍｍにカットし、これを全量が１７０ｇになるように、２００×２００ｍｍ平板金型内に積層セットしたのち、４ｍｍのスペーサを介して、圧力約５ＭＰａでプレス成形し、繊維強化発泡プラスチック成形体を作製した。
成形条件及び得られた成形体の物性を第１表に示す。
(2) Fabrication of fiber-reinforced foamed plastic molding The sheet-like foamable preform obtained in (1) above was cut into 100 × 100 mm, and this was 200 × 200 mm flat plate mold so that the total amount was 170 g. After being laminated and set inside, it was press-molded at a pressure of about 5 MPa through a 4 mm spacer to produce a fiber-reinforced foamed plastic molded body.
Table 1 shows the molding conditions and the physical properties of the obtained molded body.
「プラスチック成形体・２」
実施例１において、繊維強化発泡プラスチック成形体の作製時に、スペ−サ厚さを６ｍｍとした以外は、実施例１と同様にして繊維強化発泡プラスチック成形体を作製した。
成形条件及び得られた成形体の物性を第１表に示す。
"Plastic molded body 2"
In Example 1, a fiber-reinforced foamed plastic molded body was manufactured in the same manner as in Example 1 except that the spacer thickness was 6 mm when the fiber-reinforced foamed plastic molded body was manufactured.
Table 1 shows the molding conditions and the physical properties of the obtained molded body.
「プラスチック成形体・３」
（１）発泡予備成形体の作製
実施例１（１）において、硬化剤としてｔ−ブチルパーオキシベンゾエートの代わりにジクミルパーオキシドを用い、かつ重合禁止剤のパラベンゾキノンの量を０．１重量部に変更した以外は、実施例１（１）と同様にしてシート状発泡性予備成形体（ＳＭＣ）を作製した。
"Plastic molded body 3"
(1) Preparation of foam preform In Example 1 (1), dicumyl peroxide was used instead of t-butylperoxybenzoate as a curing agent, and the amount of parabenzoquinone as a polymerization inhibitor was 0.1 weight. A sheet-like foamable preform (SMC) was produced in the same manner as in Example 1 (1) except that the part was changed to the part.
（２）繊維強化発泡プラスチック成形体の作製
上記（１）で得られたシート状発泡性予備成形体を１００×１００ｍｍにカットし、これを全量が１７０ｇになるように、２００×２００ｍｍ平板金型内に複数層セットしたのち、８ｍｍのスペーサを介して、圧力約５ＭＰａでプレス成形し、繊維強化発泡プラスチック成形体を作製した。
成形条件及び得られた成形体の物性を第１表に示す。
(2) Fabrication of fiber-reinforced foamed plastic molding The sheet-like foamable preform obtained in (1) above was cut into 100 × 100 mm, and this was 200 × 200 mm flat plate mold so that the total amount was 170 g. After setting a plurality of layers inside, press molding was performed at a pressure of about 5 MPa through an 8 mm spacer to prepare a fiber-reinforced foamed plastic molded body.
Table 1 shows the molding conditions and the physical properties of the obtained molded body.
「プラスチック成形体・４」
実施例１において、繊維強化発泡プラスチック成形体の作製時に、スペ−サを用いずに、かつ型締め４５秒後に型を８ｍｍ開けた以外は、実施例１と同様にして繊維強化発泡プラスチック成形体を作製した。
成形条件及び得られた成形体の物性を第１表に示す。
"Plastic molded body 4"
In Example 1, a fiber-reinforced foamed plastic molded body was prepared in the same manner as in Example 1 except that a spacer was not used and the mold was opened 8 mm after clamping for 45 seconds in the production of the fiber-reinforced foamed plastic molded body. Was made.
Table 1 shows the molding conditions and the physical properties of the obtained molded body.
表１中、密度の測定はＪＩＳ Ｋ７２２２に準拠して行った。 In Table 1, the density was measured according to JIS K7222.
「複合パネルの製造・１」
表面材として木材板（厚さ４ｍｍ）を用い、エポキシ系、ウレタン系、ゴム系等の接着材をもって一体化した。いずれも満足する複合材が得られた。
"Manufacture of composite panels-1"
A wood board (thickness: 4 mm) was used as the surface material, and it was integrated with an epoxy, urethane, rubber or other adhesive. A composite material satisfying both cases was obtained.
「複合パネルの製造・２」
表面材としてＦＲＰ板（厚さ４ｍｍ）を用い、プラスチック発泡成形体を得る金型の表面にセットし、発泡成形を行った。接着も十分であり、満足する複合体が得られた。
"Manufacture of composite panels 2"
An FRP plate (thickness 4 mm) was used as the surface material and set on the surface of a mold for obtaining a plastic foam molded article, and foam molding was performed. Adhesion was sufficient and a satisfactory composite was obtained.
「複合パネルの製造・３」
表面材としてプラスチック発泡成形体の発泡剤を配合していない未架橋シ−ト（ＳＭＣ）を用いた。即ち、金型内にプラスチック発泡性シ−ト（ＳＭＣ）とこのし−トを積層し発泡した。得られた複合体は中央が発泡体であり、その表面に約４ｍｍ程度の非発泡層のＦＲＰ表面材が積層された複合体となった。
“Manufacture of composite panels 3”
As the surface material, an uncrosslinked sheet (SMC) that does not contain a foaming agent for a plastic foam molded article was used. That is, a plastic foamable sheet (SMC) and this sheet were laminated in a mold and foamed. The resulting composite was a foam at the center, and a composite in which a non-foamed FRP surface material of about 4 mm was laminated on the surface.
リサイクルの際、全体がマトリックス樹脂と同種とすれば、両者を剥離する作業を必要としないという優れた特徴がある。 In the case of recycling, if the whole is the same type as the matrix resin, there is an excellent feature that it is not necessary to remove both.
本発明による繊維強化発泡プラスチック成形体を用いた複合パネルは、特に芯材と表面材とをマトリックスを同じくすることによりリサイクル性に富み、しかも強度的にかつ耐久性に優れた複合パネルであって、断熱性、遮音性を付与したドアや間仕切りパネル等の各種のパネル構造として広く使用可能である。
The composite panel using the fiber reinforced foamed plastic molding according to the present invention is a composite panel which is particularly excellent in recyclability, strength and durability by using the same matrix for the core material and the surface material. In addition, it can be widely used as various panel structures such as doors and partition panels provided with heat insulation and sound insulation.
Claims (11)
The fiber-reinforced foam composite panel according to any one of claims 1 to 10, wherein the content of the heat-expandable microcapsule (C) is 0.1 to 50 parts by weight with respect to 100 parts by weight of the component (A).
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Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2005206765A (en) * | 2004-01-26 | 2005-08-04 | Sanyo Chem Ind Ltd | Heat-expansible microcapsule and hollow resin particle |
| JP2009248306A (en) * | 2008-04-01 | 2009-10-29 | Shirogane Kasei Kk | Laminated sheet |
| KR101147909B1 (en) | 2010-10-19 | 2012-05-24 | 한일이화주식회사 | The multi layer for interior base of automobile |
| WO2013108170A1 (en) * | 2012-01-16 | 2013-07-25 | Manifattura Del Seveso Spa | Multifunctional structure and method for its manufacture |
| JP2014144644A (en) * | 2009-09-30 | 2014-08-14 | Dainippon Printing Co Ltd | Sheet before foaming for foamed decorative sheet, production method of sheet before foaming for foamed decorative sheet and production method of foamed decorative sheet |
| WO2017209300A1 (en) * | 2016-06-03 | 2017-12-07 | 積水化学工業株式会社 | Sheet and rod-shaped member |
| CN113858728A (en) * | 2021-10-18 | 2021-12-31 | 长春城际轨道客车配件有限公司 | 3D woven composite floor and manufacturing process thereof |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2005206765A (en) * | 2004-01-26 | 2005-08-04 | Sanyo Chem Ind Ltd | Heat-expansible microcapsule and hollow resin particle |
| JP4567980B2 (en) * | 2004-01-26 | 2010-10-27 | 三洋化成工業株式会社 | Thermally expandable microcapsules and hollow resin particles |
| JP2009248306A (en) * | 2008-04-01 | 2009-10-29 | Shirogane Kasei Kk | Laminated sheet |
| JP2014144644A (en) * | 2009-09-30 | 2014-08-14 | Dainippon Printing Co Ltd | Sheet before foaming for foamed decorative sheet, production method of sheet before foaming for foamed decorative sheet and production method of foamed decorative sheet |
| KR101147909B1 (en) | 2010-10-19 | 2012-05-24 | 한일이화주식회사 | The multi layer for interior base of automobile |
| WO2013108170A1 (en) * | 2012-01-16 | 2013-07-25 | Manifattura Del Seveso Spa | Multifunctional structure and method for its manufacture |
| WO2017209300A1 (en) * | 2016-06-03 | 2017-12-07 | 積水化学工業株式会社 | Sheet and rod-shaped member |
| JPWO2017209300A1 (en) * | 2016-06-03 | 2019-05-09 | 積水化学工業株式会社 | Sheet and rod member |
| CN113858728A (en) * | 2021-10-18 | 2021-12-31 | 长春城际轨道客车配件有限公司 | 3D woven composite floor and manufacturing process thereof |
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