JP2021020345A - Method for manufacturing composite body and composite body - Google Patents

Abstract

To provide a method for manufacturing a composite body that can enhance a design property of an obtained composite body, and give an appearance different from conventional ones.SOLUTION: A method for manufacturing a composite body comprises steps of: preparing a molding material impregnated with a thermoplastic resin between fibers; disposing a resin film contacting with the molding material; and joining the molding material with the resin film by heating and pressing the molding material and the resin film. In the method, the melting point of the thermoplastic resin is lower than the melting point of the resin film.SELECTED DRAWING: Figure 1

Description

The present invention relates to a method for producing a complex and a complex.

In order to change the appearance of the obtained composite when the pellet-shaped resin composition (molding material) is hot-press molded, a decorative sheet is simultaneously bonded to the resin composition to decorate the molded product. A method for producing (complex) is known.

For example, in Patent Document 1, a preform sheet for heat molding formed by laminating and integrating a decorative sheet and a sheet-like reinforcing material under heating and pressure, and a thermosetting resin molding material are laminated under heating and pressure. A method for manufacturing a fiber reinforced plastic (FRP) decorative molded product to be molded is described.

Further, in Patent Document 2, a pattern revealing pellet containing a vinyl chloride resin as a main material is arranged on a transparent or translucent plastic sheet containing a vinyl chloride resin as a main material and pressed by pressure. A method for manufacturing a plastic flooring material with an embossed surface is described.

In the method for producing these molded products, the melting point of the decorative sheet is usually made sufficiently higher than the melting point of the molding material (see, for example, Patent Document 3). This is because the melting point of the decorative sheet is raised to prevent deformation of the decorative sheet due to heat, while the melting point of the molding material is lowered so that the molding materials are sufficiently melted and joined to each other during molding. Is.

Japanese Unexamined Patent Publication No. 2004-202764 Japanese Unexamined Patent Publication No. 61-149328 JP-A-2015-160393

The methods described in Patent Documents 1 to 3 are carried out for the purpose of enhancing the aesthetic appearance (design) of the complex.

However, there is still a desire to enhance the design of the complex or to give it a different appearance.

In view of the above problems, the present invention provides a method for producing a composite capable of enhancing the design of the obtained composite and imparting an appearance different from the conventional one, and a composite produced by the manufacturing method. The purpose is to provide.

A method for producing a composite according to one aspect of the present invention for solving the above problems includes a step of preparing a pellet-shaped molding material in which thermoplastic resin A is impregnated between fibers arranged in one direction. A step of arranging a resin film containing the thermoplastic resin B in contact with the molding material, and a step of heating and pressurizing the molding material and the resin film to join the molding material and the resin film. Has. In the above method, the melting point of the thermoplastic resin B is lower than the melting point of the thermoplastic resin A.

Further, as a method for producing a composite according to one aspect of the present invention for solving the above problems, a pellet-shaped molding material in which thermoplastic resin A is impregnated between fibers arranged in one direction is prepared. The step, the step of arranging a plurality of resin films containing the thermoplastic resin B in contact with the molding material, and the molding material and the resin film being heated and pressed to heat and pressurize the molding material and the resin film. It has a step of joining. In the above method, the plurality of resin films sandwich the decorative material between different layers according to the appearance of the obtained composite.

Further, the composite according to one aspect of the present invention for solving the above problems is a composite having a base material layer and a surface layer. The base material layer is formed by orienting a plurality of fibers in a matrix containing the thermoplastic resin A, and a plurality of aggregates are dispersed, and the surface layer has a decorative material in the thermoplastic resin B. It is embedded and held, and the base material layer contains a thermoplastic resin B arranged in the gaps between the plurality of aggregates.

According to the present invention, there is provided a method for producing a composite capable of enhancing the design of the obtained composite and giving an appearance different from the conventional one, and a composite produced by the manufacturing method. ..

FIG. 1 is a flowchart showing a method for manufacturing a complex according to the first embodiment. FIG. 2 is a schematic cross-sectional view showing the configuration of a thermal pressure molding apparatus that can be used in the method for producing a composite according to the first embodiment. FIG. 3 is a schematic view showing a state in which a molding material is arranged in the thermal pressure molding apparatus in the first embodiment. FIG. 4 is a schematic view showing a state in which the resin film is arranged in the thermal pressure molding apparatus in the first embodiment. FIG. 5A is a partially enlarged view of the region A shown in FIG. 4, showing how a plurality of resin films are arranged in contact with the molding material in the first embodiment, and FIG. 5B is a partially enlarged view of the region A. Another partially enlarged view of the region A shown in FIG. 4 showing how the decorative material is arranged at different positions, and FIG. 5C shows how the decorative material is arranged at a position different from that of FIG. 5A. It is still another partial enlarged view of the region A shown in 4. FIG. 6 is a schematic view showing a state in which the molding material and the resin film arranged in the thermal pressure molding apparatus are pressurized and heated in the first embodiment. FIG. 7 is a schematic view showing a state in which the molded material and the resin film joined by pressurization and heating are cooled in the first embodiment. FIG. 8 is a schematic view showing a state in which the cooled complex can be taken out in the first embodiment. FIG. 9 is a schematic cross-sectional view of the composite produced in the first embodiment. FIG. 10 is a partially enlarged view of the region X shown in FIG.

Hereinafter, a method for producing a composite according to an embodiment of the present invention and a thermal pressure molding apparatus that can be used in the production method will be described in more detail using a plurality of embodiments.

1. 1. First Embodiment FIG. 1 is a flowchart showing a method for producing a complex according to the first embodiment of the present invention. FIG. 2 is a schematic cross-sectional view showing the configuration of a thermal pressure molding apparatus that can be used in the method for producing a composite according to the present embodiment.

The configuration of the thermal pressure molding apparatus according to the present embodiment will be described below, and then a method for producing a composite using the thermal pressure molding apparatus will be described.

1-1. Thermal pressure molding apparatus As shown in FIG. 2, the thermal pressure molding apparatus 100 used in the present embodiment has a pair of facing heating dies and a pair of facing cooling dies. The heating mold has an opposing heating lower mold (positioning plate) 112 and a heating upper mold (stripper plate) 114, and the cooling mold has an opposing cooling lower mold 122 and a cooling upper mold. It has a mold 124. The heating lower mold 112 is supported by the cooling lower mold 122 by a plurality of elastic bodies (coil springs) 132, and the heating upper mold 114 is supported by the cooling upper mold 124 by a plurality of elastic bodies 134. Further, the lower mold 112 for heating has a material frame 142.

The lower mold 112 for heating and the lower mold 122 for cooling are connected to each other by an elastic body 132. The upper mold 114 for heating and the upper mold 124 for cooling are connected to each other by an elastic body 134 and can be integrally moved in the vertical direction in the drawing. By moving the heating upper mold 114 and the cooling upper mold 124 downward in the drawing, the heating lower mold 112 and the heating upper mold 114 are brought closer to each other, and the heating lower mold 112 and the heating upper mold 114 are brought closer to each other. The molding material and the resin film arranged in the space surrounded by and can be pressed. Further, the molding material and the resin film can be heated by heating the lower mold 112 for heating and the upper mold 114 for heating. The molding material and the resin film are melted or softened by the pressurization and heating, and these are joined by fusion or the like to form a space (cavity) sandwiched between the lower mold 112 for heating and the upper mold 114 for heating. It can be molded into a composite having a shape.

The heating lower mold 112 and the heating upper mold 114 are a pair of stripper plates and positioning plates.

The surface of the heating lower mold 112 facing the heating upper mold 114 is a pedestal surface 112a on which the molding material to be molded and the resin film are arranged. Further, in the lower mold 112 for heating, an electric heater 152 is inserted inside, and the pedestal surface 112a is heated by the heat from the electric heater 152, thereby heating the molding material and the resin film arranged on the pedestal surface 112a.

The surface of the heating upper mold 114 facing the heating lower mold 112 is a processed surface 114a for processing the molding material and the resin film to be molded. Further, in the upper mold 114 for heating, a plurality of electric heating heaters 154 are inserted therein, and the processed surface 114a is heated by the heat from the electric heating heater 154, whereby the molding material and the resin film in contact with the processed surface 114a are pressed. Heat.

The pedestal surface 112a of the lower mold 112 for heating and the processed surface 114a of the upper mold 114 for heating are flat surfaces substantially parallel to each other in the present embodiment. However, the shapes of the pedestal surface 112a and the processed surface 114a are not limited to this, and can be formed according to the shape of the composite to be molded. For example, if either or both of the pedestal surface 112a and the processed surface 114a are surfaces on which irregularities are formed, the surface of the composite to be molded can be embossed or otherwise concavo-convex. Further, the thickness of the molded composite can be partially changed by partially changing the distance between the pedestal surface 112a and the processed surface 114a.

The material frame 142 is a frame formed on the surface of the lower heating mold 112 facing the upper heating mold 114. The material frame 142 is above the pedestal surface 112a so that the distance between the upper end thereof and the opposite machined surface 114a is smaller than the minimum value of the distance between the pedestal surface 112a and the opposite machined surface 114a. It protrudes to the machined surface 114a side). As a result, when the upper heating die 114 is moved toward the lower heating die 112, the upper end of the material frame 142 comes into contact with the machined surface 114a and is between the pedestal surface 112a and the machined surface 114a. In addition, a space (cavity) corresponding to the thickness of the composite to be molded is formed.

The cooling lower mold 122 is connected to the heating lower mold 112 by an elastic body 132, and is arranged so as to be in contact with and separated from the heating lower mold 112 due to a change in the shape of the elastic body 132. A plurality of cooling pipes 162 are inserted into the cooling lower mold 122, and the contacted heating lower mold 112 is cooled by a cooling medium that passes through the cooling pipe 162. As a result, the cooling lower mold 122 cools the composite formed by pressurization and heating to a temperature at which it is difficult to be deformed even if it is taken out from the thermal pressure molding apparatus 100.

Similarly, the cooling upper mold 124 is also connected to the heating upper mold 114 by the elastic body 134, and is arranged so as to be in contact with and separated from the heating upper mold 114 due to the shape change of the elastic body 134. A plurality of cooling pipes 164 are inserted into the cooling upper mold 124, and the contacted heating upper mold 114 is cooled by a cooling medium passing through the cooling pipes 164. As a result, the cooling upper mold 124 cools the composite formed by pressurization and heating to a temperature at which it is difficult to be deformed even if it is taken out from the thermal pressure molding apparatus 100.

The operation of each member of the thermal pressure forming apparatus 100 is controlled by a control unit (not shown). Details of control by the control unit will be described in the following manufacturing method.

1-2. Method for manufacturing composite As shown in FIG. 1, the method for manufacturing a composite according to the present embodiment includes a step of preparing a molding material (step S110), a step of arranging a resin film (step S120), and the molding material. It has a step of pressurizing and heating the resin film (step S130), and a step of cooling the bonded molding material and the resin film (step S140).

1-2-1. Step of preparing molding material (step S110)
In this step, a molding material is prepared.

The molding material is a composition (fiber reinforced plastic) in which the thermoplastic resin A is impregnated between the fibers.

The fiber may be any fiber that can be used for fiber reinforced plastics. Examples of the above fibers include carbon fibers, glass fibers, silicon carbide fibers, boron fibers, metal fibers (stainless fibers, etc.), metal oxide fibers (alumina fibers, etc.), mosheidi (basic magnesium sulfate inorganic fibers), and carbon dioxide. Inorganic fibers such as calcium whisker, synthetic resin fibers such as aramid fiber, polyethylene fiber, polyamide fiber, and polyester fiber, and natural fiber such as cellulose fiber are included. Of these, inorganic fibers are preferable, carbon fibers and glass fibers are more preferable, and carbon fibers are even more preferable.

The type of the carbon fiber is not particularly limited, and various carbon fibers such as polyacrylonitrile (PAN) type, rayon type, polyvinyl alcohol type, regenerated cellulose, and pitch type produced from mesophase pitch can be used. Of these, PAN-based, rayon-based, and pitch-based carbon fibers are preferable because of their higher strength and lighter weight.

The thermoplastic resin A may be any thermoplastic resin A that can be used as a matrix resin for fiber reinforced plastics.

Examples of the thermoplastic resin A include polyolefin resin, polyamide resin, polyester resin, polystyrene resin, thermoplastic polyimide resin, polyamideimide resin, polycarbonate resin, polyphenylene ether resin, polyphenylensulfide resin, polyacetal resin, and acrylic resin. Includes polyetherimide resin, polysulfone resin, polyetherketone resin, polyetheretherketone resin, polyarylate resin, polyethernitrile resin, vinyl chloride resin, ABS resin, fluororesin and the like. The resin may be an elastomer.

Examples of the polyolefin resin include ethylene-based polymers, propylene-based polymers, butylene-based polymers, 4-methyl-1-pentene-based polymers, and the like.

Examples of the above-mentioned polyamide resins include aliphatic polyamide resins (nylon 6, nylon 11, nylon 12, nylon 66, nylon 610 and nylon 612), semi-aromatic polyamide resins (nylon 6T, nylon 6I and nylon 9T, etc.) and Includes total aromatic polyamide resin.

Examples of the polyester resin include polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate and the like.

Among these, the thermoplastic resin A preferably contains an olefin-based resin containing an ethylene-based polymer, a propylene-based polymer, and other α-olefin-based polymers, and more preferably contains a propylene-based polymer. ..

The ethylene-based polymer includes a homopolymer of ethylene and a copolymer of ethylene and an α-olefin having 3 to 20 carbon atoms. As these ethylene-based polymers, only one type may be used, or a plurality of types may be used in combination.

The propylene-based polymer includes a homopolymer of propylene and a copolymer of propylene and ethylene or an α-olefin having 4 to 20 carbon atoms. As these propylene-based polymers, only one type may be used, or a plurality of types may be used in combination.

The α-olefin polymer includes a homopolymer of an α-olefin having 4 to 20 carbon atoms and a copolymer of an α-olefin having 2 to 20 carbon atoms (however, the ethylene polymer and propylene). The system polymer is excluded.) Is included.

Examples of the α-olefin include ethylene, propylene, 1-butene, 3-methyl-1-butene, 4-methyl-1-pentene, 3-methyl-1-pentene, and 4-methyl-1-hexene. , 4,4Dimethyl-1-hexene, 1-nonene, 1-octene, 1-hexene, 1-hexene, 1-decene, 1-undecene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, And 1-Eikosen and the like are included. Among these, the α-olefin polymer is preferably a copolymer containing 1-butene, ethylene, 4-methyl-1-pentene, and 1-hexene, and 1-butene and 4-methyl-. More preferably, it is a copolymer containing 1-pentene. The α-olefin polymer may be a random copolymer or a block copolymer, but a random copolymer is preferable.

The fiber and the thermoplastic resin A may be arbitrarily selected depending on the physical characteristics and appearance required for the composite to be molded. For example, when the molding material contains glass fiber as the fiber, the transparency of the composite to be molded can be further enhanced. On the other hand, when the molding material contains carbon fibers as the fibers, the strength of the molded composite can be further increased and the appearance of the composite can be blackened.

The molding material may contain additives such as fillers, hardeners, mold release agents, pigments or dyes, heat stabilizers, UV stabilizers, polymerization reaction inhibitors, hyposhrinkants, and thickeners.

In the present embodiment, the molding material is a pellet-like composition in which the thermoplastic resin A is impregnated between the fibers arranged in one direction. The molding material is, for example, a pellet-shaped molding material obtained by randomly cutting a known UD tape in which the thermoplastic resin A is impregnated between the fibers that are bundled and arranged in one direction. Can be done. By using such a molding material, the strength of the composite can be further increased.

The length of the pellet-shaped molding material (length in the direction in which the fibers are stretched) is preferably 5 mm or more and 100 mm or less, and more preferably 15 mm or more and 50 mm or less. The thickness of the pellet-shaped molding material is preferably 0.05 mm or more and 1.0 mm or less, and more preferably 0.1 mm or more and 0.5 mm or less. The width of the pellet-shaped molding material is preferably 0.5 mm or more and 100 mm or less, and more preferably 2.0 mm or more and 50 mm or less.

FIG. 3 is a schematic view showing a state in which the molding material 210 is arranged in the thermal pressure forming apparatus 100. As shown in FIG. 3, the molding material 210 is arranged on the pedestal surface 112a of the lower mold 112 for heating. From the viewpoint of suppressing variation in strength in the composite body, it is preferable that the molding materials are randomly arranged.

1-2-2. Step of arranging the resin film (step S120)
The resin film is a resin film used for decorating a molded product obtained by molding the molding material by pressurization and heating.

The resin film contains a thermoplastic resin B. Examples of thermoplastic resin B include polyolefins containing polyethylene, polypropylene, polybutylene, etc., polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and thermoplastic polyester resins containing polyethylene naphthalate (PEN), polyamide (PA). ), Polyvinyl chloride (PVC), polycarbonate (PC) and the like.

In addition to the thermoplastic resin B, the resin film contains additives such as a mold release agent, a pigment or dye, a heat stabilizer, a UV stabilizer, a polymerization reaction inhibitor, a low shrinkage agent, and a thickener. May be good. As will be described later, when the decorative material 230 is sandwiched and molded, the resin film is light-transmitting (particularly visible) so that the decorative material 230 embedded in the surface layer of the composite can be visually recognized. It is preferable to have transparency to light).

The melting point of the thermoplastic resin B constituting the resin film is lower than the melting point of the thermoplastic resin A contained in the molding material. When the melting point of the thermoplastic resin B is made lower than the melting point of the thermoplastic resin A, when the thermoplastic resin A contained in the molding material melts during molding by pressurization and heating, the thermoplastic resin B constituting the resin film is formed. It has already melted. Therefore, the thermoplastic resin B can be easily mixed with the thermoplastic resin A melted later without significantly disturbing the orientation of the fibers whose orientation is maintained by the thermoplastic resin A. As a result, bubbles are less likely to be generated in the gap between the thermoplastic resin A and the thermoplastic resin B, and it is considered that the appearance of the obtained composite is likely to be improved. Further, it is considered that the inside of the composite (particularly near the boundary between the molding material and the resin film) is filled more densely by eliminating the generation of air bubbles, and the strength of the obtained composite is also improved. Further, it is considered that the surface layer formed by fusing the resin film 220 is less likely to be peeled off from the composite because the resin film and the molding material can be sufficiently adhered to each other by making it difficult for bubbles to be generated.

At this time, the difference between the melting point of the thermoplastic resin A contained in the molding material and the melting point of the thermoplastic resin B constituting the resin film arranged in contact with the molding material is preferably 20 ° C. or less. .. As a result, the molten thermoplastic resin A and the thermoplastic resin B are easily mixed (or easily compatible with each other), and the strength of the molded composite can be further increased. In the present embodiment, the difference in melting points is more preferably 10 ° C. or lower, and even more preferably 5 ° C. or lower.

The melting points of the thermoplastic resin A and the thermoplastic resin B can be values obtained by measuring with a differential scanning calorimetry (DSC). When the molding material contains a plurality of types of thermoplastic resins A, the melting point of the thermoplastic resin A contained in the molding material is the thermoplastic resin A having the highest content among the plurality of types of thermoplastic resins A. Can be the melting point of. Similarly, when the resin film contains a plurality of types of thermoplastic resin B, the melting point of the thermoplastic resin B contained in the resin film is the heat having the highest content among the plurality of types of thermoplastic resin B. It can be the melting point of the plastic resin B.

FIG. 4 is a schematic view showing a state in which the resin film 220 is arranged in the thermal pressure molding apparatus 100. As shown in FIG. 4, the resin film 220 is arranged on the pedestal surface 112a of the lower mold 112 for heating in contact with the molding material 210. For example, the resin film 220 may be arranged so as to cover the surface of the randomly arranged molding material 210.

In the present embodiment, as shown in FIG. 4, a plurality of resin films 220 are arranged in contact with the molding material 210. The plurality of resin films may all be the same resin film, or may contain different resin films.

FIG. 5A is a partially enlarged view of the region A shown in FIG. 4, showing how a plurality of resin films are arranged in contact with the molding material 210. As shown in FIG. 5A, in the present embodiment, five resin films 220a, a resin film 220b, a resin film 220c, a resin film 220d, and a resin film 220e are laminated and arranged in contact with the molding material 210. Of these, at least the melting point of the thermoplastic resin B constituting the resin film 220a in contact with the molding material 210 may be lower than the melting point of the thermoplastic resin A contained in the molding material 210. The materials of the thermoplastic resins B constituting the plurality of resin films may be different from each other, but among the plurality of resin films, the thermoplastic resins constituting the plurality of (for example, more than half) resin films. The melting point of B is preferably lower than the melting point of the thermoplastic resin A contained in the molding material 210, and the melting point of the thermoplastic resin B constituting all the resin films is the melting point of the thermoplastic resin A contained in the molding material 210. It is more preferably lower than the melting point.

As shown in FIG. 5A, in the present embodiment, the plurality of resin films sandwich the decorative material 230 between the layers formed by laminating the resin films. By pressurizing and heating the molding material 210 and the resin film 220 in this state, the decorative material 230 is embedded in the surface layer formed by fusing the resin film 220 to the composite to be molded. A pattern of the decorative material 230 can be formed on the surface of the composite.

5B and 5C are another partially enlarged views of the region A shown in FIG. 4, showing how the decorative material 230 is arranged at a position different from that of FIG. 5A. As shown in these drawings, the layer on which the decorative material 230 is arranged is not particularly limited, and may be arranged between layers (positions) according to the appearance of the obtained composite. For example, as shown in FIG. 5A, by sandwiching the decorative material 230 on the surface side (the side farther from the molding material 210), the decorative material 230 is placed at a shallower position (closer to the surface of the composite) in the surface layer. The decorative material 230 can be arranged. Further, as shown in FIG. 5B, by sandwiching the decorative material 230 closer to the inner surface side (the side closer to the molding material 210), the deeper position of the surface layer (the side farther from the surface of the composite). The decorative material 230 can be arranged in the. Alternatively, as shown in FIG. 5C, by sandwiching the plurality of decorative materials 230a and 230b between different layers, a pattern having a sense of depth can be formed on the surface of the composite. At this time, as shown in FIG. 5C, if a plurality of decorative materials 230a and 230b sandwiched between different layers are arranged at positions where they overlap each other in the laminating direction of the resin film, a sense of depth is more noticeably felt. A pattern can be formed.

In any of the above embodiments, it is preferable that the plurality of resin films 220 sandwich the decorative material 230 between the layers of the resin films. As a result, the resin film arranged on the molding material 210 side of the decorative material 230 can be sufficiently bonded to the molding material 210 to prevent the surface layer from peeling off. Further, the resin film arranged on the side opposite to the molding material 210 with respect to the decorative material 230 coats the outermost surface of the composite layer, so that the decorative material 230 is peeled off from the composite and the decorative material 230 is peeled off. In addition to being able to suppress deterioration due to oxidation of the composite, the outermost surface of the composite can be smoothed to further enhance the design of the composite.

The type of the decorative material 230 is not particularly limited, and may be appropriately selected from metals, metal oxides, ceramic pieces, stones, glass, colored carbon, fibers, and the like according to the appearance of the obtained composite. The shape of the decorative material 230 is not particularly limited, and may be any shape such as a lump, a sheet (foil), and a fiber.

1-2-3. Step of pressurizing and heating the molding material and the resin film (step S130)
FIG. 6 is a schematic view showing a state in which the molding material and the resin film arranged in the thermal pressure molding apparatus 100 are pressurized and heated.

With the molding material 210 and the resin film 220 arranged on the pedestal surface 112a of the thermal pressure forming apparatus 100 (see FIG. 4), the lower heating die 112 is moved in a direction closer to the upper heating die 114. As a result, the molding material 210 and the resin film 220 are pressed against the pedestal surface 112a of the heating lower mold 112 and by the processed surface 114a of the heating upper mold 114. Further, at this time, the electric heating heater 152 heats the heating lower mold 112, and the electric heating heater 154 heats the heating upper mold 114. As a result, the molding material 210 and the resin film 220 are heated, the thermoplastic resin A constituting the molding material 210 is melted and the molding materials 210 are fused to each other, and the thermoplastic resin B constituting the resin film 220 is also formed. It melts and fuses to the molding material 210 or another resin film 220.

At this time, at the heating temperature of the upper mold 114 for heating and the lower mold 112 for heating, the thermoplastic resin A constituting the molding material 210 and the thermoplastic resin B constituting the resin film 220 are sufficiently melted, and the molding material 210 and the resin are sufficiently melted. The temperature may be such that the film 220 can be sufficiently fused, and the temperature may be higher than both the melting point of the thermoplastic resin A and the melting point of the thermoplastic resin B.

1-2-4. Step of cooling the bonded molding material and resin film (step S140)
FIG. 7 is a schematic view showing a state in which the molded material and the resin film joined by pressurization and heating are cooled, and FIG. 8 is a schematic view showing a state in which the cooled composite can be taken out.

After joining the molding material and the resin film by pressurizing and heating for a predetermined time, the cooling upper mold 124 is pressed toward the heating upper mold 114, and the cooling upper mold 124 is brought close to the heating upper mold 114. Or make contact. As a result, the heat from the heating lower mold 112 is removed to the cooling lower mold cooling pipe 162, and the heat from the heating upper mold 114 is removed to the cooling upper mold cooling pipe 164. The bonded molding material and resin film can be cooled. After that, as shown in FIG. 8, the composite 300 can be taken out by separating the heating lower mold 112 and the heating upper mold 114.

At this time, the cooling medium is passed through the cooling pipe 162 and the cooling pipe 162, and the cooling lower mold 122 and the cooling upper mold 124 adjusted to a predetermined temperature are pressed to the heating lower mold 112 and the heating mold 112, respectively. It is preferable to bring it into contact with the upper mold 114. As a result, deformation of the complex due to a pressure change during cooling can be suppressed.

1-3. Composite FIG. 9 is a schematic cross-sectional view of the composite produced by the above method. The composite 300 has a base material layer 310 in which the molding material is fused, and a surface layer 320 in which the resin film is fused.

In the base material layer 310, the fibers 314 are dispersed in a matrix formed by melting and integrating the thermoplastic resin A (the thermoplastic resin 312 that constitutes the base material layer) that constitutes the molding material. The fibers 314 are dispersed as aggregates oriented together for each molding material before being pressurized and heated, and a plurality of aggregates 316a, 316b, and aggregates oriented in different directions. The 316c and the aggregate 316d are stacked and arranged.

In the surface layer 320, the decorative material 230 is embedded and held in a resin (thermoplastic resin 322 constituting the surface layer: thermoplastic resin B) formed by melting and integrating a plurality of resin films. .. Although the position where the decorative material 230 is embedded changes during molding, it substantially corresponds to the layer of the resin film in which the decorative material is arranged (sandwiched) before molding. Therefore, for example, when a plurality of decorative materials are arranged and molded in different layers of a plurality of resin films, the plurality of decorative materials are embedded and held at different depths in the surface layer 320. ..

In the present embodiment, since the melting point of the thermoplastic resin B constituting the resin film is lower than the melting point of the thermoplastic resin A constituting the molding material, the thermoplastic resin B (surface layer) melted first during pressurization and heating. The thermoplastic resin 322) constituting the above is sufficiently penetrated between the pellet-shaped molding materials. Therefore, in the region of the base material layer 310 close to the surface layer 320, the thermoplastic resin A (thermoplastic resin 312 constituting the base material layer) and the thermoplastic resin B forming the surface layer (thermoplastic constituting the surface layer) are formed. Resin 322) is mixed.

At this time, the thermoplastic resin 322 constituting the surface layer enters the gap between the plurality of aggregates 316a laminated at the position closest to the surface layer 320 among the plurality of aggregates contained in the base material layer 310. Have been placed. Specifically, as shown in FIG. 9, the thermoplastic resin 322A constituting the surface layer is arranged in the gaps between the plurality of aggregates 316a. As shown in FIG. 9, the thermoplastic resin 322A constituting the surface layer may be arranged separately from the thermoplastic resin 312 constituting the base material layer, or may be arranged separately from the thermoplastic resin A at the time of molding. It may be integrally arranged with the thermoplastic resin 312 which is compatible and constitutes the base material layer.

Further, when the thermoplastic resin 322A constituting the surface layer and the thermoplastic resin 312 constituting the base material layer are separated, the boundary between these resins in the gaps of the plurality of aggregates 316a is typically amorphous. Is. At this time, a sea-island structure in which one resin is dispersed in the other resin may be partially formed. Further, the depth at which the thermoplastic resin 322A constituting the surface layer penetrates is not constant. At this time, it may enter into the gaps of other aggregates (for example, aggregates 316b and 316c) that are partially laminated at positions forming a deeper layer (positions away from the surface layer). ..

FIG. 10 is a partially enlarged view of the region X shown in FIG. 9, and is a configuration of a plurality of aggregates 316a laminated at a position closest to the surface layer 320 among the plurality of aggregates contained in the base material layer 310. It is a schematic diagram which shows. In the present embodiment, the resin component of the resin film (thermoplastic resin 322 constituting the surface layer) melted first during pressurization and heating is also formed inside the molding material when the pellet-shaped molding material is melted. Get in. Therefore, in the aggregate 316a, the fibers 314 are dispersed in a matrix containing the thermoplastic resin 312B constituting the base material layer and the thermoplastic resin 322B constituting the surface layer that has penetrated into the molding material. ing.

Also at this time, as shown in FIG. 10, the thermoplastic resin 322B constituting the surface layer may be separated from the thermoplastic resin 312B constituting the base material layer, and may enter the thermoplastic resin at the time of molding. It may be integrated with the thermoplastic resin 312B constituting the base material layer and enter there.

Also at this time, when the thermoplastic resin 322B constituting the surface layer and the thermoplastic resin 312B constituting the base material layer are separated, the boundary between these resins typically inside the aggregate 316a. It is amorphous. Further, a sea-island structure in which one resin is dispersed in the other resin may be partially formed. The degree to which the thermoplastic resin 322B constituting the surface layer enters is not constant, and even if the ratio of the thermoplastic resin 322B constituting the surface layer to the thermoplastic resin 312B constituting the base material layer is different for each aggregate. Good. Further, in part, the surface layer is also formed inside another aggregate (for example, an aggregate 316b or an aggregate 316c) laminated at a position forming a deeper layer (a position away from the surface layer). The thermoplastic resin 322B to be used may be contained therein.

It should be noted that the above embodiment is merely an exemplary embodiment for carrying out the present invention, and the present invention is not limited to the above embodiment.

For example, in the above embodiment, a molding material is placed in a hot-pressure molding device, and a resin film is placed on the molding material to form a composite. On the contrary, a resin film is placed in the hot-pressure molding device, A molding material may be placed on the molding material to form the composite.

Alternatively, resin films may be arranged above and below the molding material to form surface layers on both sides of the composite. As a result, the generation of air bubbles due to the air mixed in the molding material can be suppressed more effectively, so that the appearance and strength of the molded composite can be further enhanced.

Hereinafter, the present invention will be described in more detail with reference to Examples, but the scope of the present invention is not limited to the description of Examples.

1. 1. Exam 1
In Test 1, a pellet-shaped molding material and a plurality of resin films sandwiching a decorative material between layers were simultaneously heated and pressed to prepare a composite.

1-1. Materials A composite was prepared using the following materials.
Molding material: Carbon fiber impregnated polypropylene UD tape randomly cut to a length of 20 to 40 mm (melting point: 162.9 ° C.)
Resin film (high melting point): Polypropylene film (melting point: 161 ° C)
Resin film (low melting point): Polypropylene film (melting point: 138 ° C)
Decorative material: Silver foil

1-2. Molding The molding material and a plurality of laminated resin films were arranged on the surface of the lower heating mold of the thermal pressure molding apparatus shown in FIG. 2 facing the upper heating mold. The molding material was laid out in a flat surface and arranged, and the plurality of resin films were arranged so that one resin film was in contact with the surface of the laid-out molding material. A total of four decorative materials (silver foils) were sandwiched between the layers of the plurality of laminated resin films.

In this state, the upper mold for heating and the upper mold for cooling were integrally moved in the lower direction in FIG. 2, and the molding material and the resin film were heated and pressurized by the upper mold for heating and the lower mold for heating. .. At this time, the temperature of the upper mold for heating was adjusted to 180 ° C., and the temperature of the lower mold for heating was adjusted to 160 ° C. After heating for a predetermined time, the cooling upper mold was brought into contact with the heating upper mold to cool the heating upper mold, and the cooling lower mold was brought into contact with the cooling upper mold to cool the heating lower mold.

After cooling the upper mold for heating and the lower mold for heating to 70 ° C., the upper mold for heating was separated from the lower mold for heating, and the molded composite was taken out.

A plurality of composites were prepared by changing the type and number of resin films, and the presence / absence and placement position of the decorative material. Table 1 shows the preparation conditions for each complex. The position where the decorative material is arranged is such that the first layer, the second resin film, and the third resin film are placed between the first resin film and the second resin film from the side closer to the molding material side. It shows how many decorative materials (silver foils) are arranged in which layer when the space between the resin film and the resin film is the second layer.

When all the decorative materials are arranged in the same layer, a total of four decorative materials (silver foil) are arranged so that some of the arranged materials overlap each other, and one of the decorative materials is placed in a different layer. When they were arranged separately, they were arranged so that the positions of the decorative materials arranged in different layers overlapped in the laminating direction of the resin film.

1-3. Evaluation Complex 1 to 7 were subjected to the following tests and evaluations.

1-3-1. Visual observation test of the surface The surface of the obtained composite was visually observed to determine whether or not bubbles were generated on the surface.

Each of the composites had a black base material layer derived from carbon fiber and a transparent surface layer derived from a resin film. It was confirmed that the composites 1 to 6 formed by sandwiching the decorative material between the layers of the resin film were held by embedding the decorative material in the surface layer.

In the composite 2, the composite 4 and the composite 7 using the low melting point film as the resin film, bubbles were observed on the surface, but the composite 1, the composite 3 using the high melting point film as the resin film, In the composite 5 and the composite 6, the generation of bubbles was small or no bubbles were generated.

Further, in the composite 1 and the composite 2 in which all four decorative materials are arranged in the fourth layer, the decorative materials are arranged at a shallower position (the side closer to the surface of the composite). In the composite 1 and the composite 2 in which all four decorative materials were arranged in the first layer, the decorative materials were arranged at a deeper position (the side farther from the surface of the composite).

Further, in the composite 5 and the composite 6 in which the four decorative materials are arranged so that the positions of the decorative materials arranged in different layers overlap in the laminating direction of the resin film, the plurality of decorative materials have different depths. It was confirmed that it was placed in the air.

1-3-2. Strength test A test piece having a length of 250 mm and a width of 30 mm was cut out from the obtained composite. A position of the test piece 50 mm from one direction end in the length direction was fixed with a clamp, and a load of 300 g was applied to the other direction end. At this time, the length at which the end portion in the other direction was displaced vertically downward was measured due to the warp of the test piece generated by the load. In addition, three test pieces were cut out from each complex, and the average value of the displaced lengths measured for each test piece was obtained and used for evaluation.

Table 2 shows the results of the strength test on the test pieces cut out from the complex 6, the complex 2, the complex 3, and the complex 7.

As shown in Table 2, when a high melting point film was used as the resin film, the composite was less likely to warp, and the strength of the composite was higher.

According to the production of the composite of the present invention, a composite having high designability can be produced.

100 Thermo-pressure forming device 112 Lower mold for heating 112a Pedestal surface 114 Upper mold for heating 114a Machining surface 122 Lower mold for cooling 124 Upper mold for cooling 132, 134 Elastic body 142 Material frame 152, 154 Electric heater 162, 164 Cooling pipe 210 Molding material 220 Resin film 230, 230a, 230b Decorative material 300 Composite 310 Base material layer 312, 312B Thermoplastic resin 314 fiber 320 surface layer 322, 322A, 222B Thermoplastic material constituting the molding material resin

Claims (8)

A step of preparing a pellet-shaped molding material in which thermoplastic resin A is impregnated between fibers arranged in one direction, and
A step of arranging a resin film containing the thermoplastic resin B in contact with the molding material, and
A step of heating and pressurizing the molding material and the resin film to join the molding material and the resin film,
Have,
The melting point of the thermoplastic resin B is lower than the melting point of the thermoplastic resin A.
Method of manufacturing the complex. The resin film is a plurality of resin films.
The method for producing a composite according to claim 1, wherein the plurality of resin films sandwich a decorative material between layers according to the appearance of the obtained composite. The method for producing a composite according to claim 2, wherein the plurality of resin films sandwich the decorative material between a plurality of layers different from each other. 2. The difference between the melting point of the thermoplastic resin A and the melting point of the thermoplastic resin B contained in the resin film arranged in contact with the molding material among the plurality of resin films is 20 ° C. or less, claim 2. Alternatively, the method for producing a complex according to 3. The method for producing a composite according to any one of claims 2 to 4, wherein the plurality of resin films have light transmittance. A step of preparing a pellet-shaped molding material in which thermoplastic resin A is impregnated between fibers arranged in one direction, and
A step of arranging a plurality of resin films containing the thermoplastic resin B in contact with the molding material, and
A step of heating and pressurizing the molding material and the resin film to join the molding material and the resin film,
Have,
The plurality of resin films sandwich a decorative material between layers according to the appearance of the obtained composite.
Method of manufacturing the complex. A complex having a base layer and a surface layer,
The base material layer is formed by orienting a plurality of fibers in a matrix containing the thermoplastic resin A, and a plurality of aggregates are dispersed.
The surface layer is held by embedding a decorative material in the thermoplastic resin B.
The base material layer contains a thermoplastic resin B arranged in the gaps between the plurality of aggregates.
Complex. The plurality of aggregates include an aggregate in which the plurality of fibers are oriented in a matrix containing the thermoplastic resin A and the thermoplastic resin B.
The complex according to claim 7.

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