JP2022094842A - Sheet for molding, and molded article - Google Patents

Abstract

To provide a sheet for molding that is suitable for various uses.SOLUTION: A sheet for molding includes a nonwoven fabric 1 and a resin layer 2 laminated on the nonwoven fabric. The nonwoven fabric includes a fiber with a birefringence Δn of 0.005 or more and 0.050 or less. The resin layer includes an impregnation part 3 and a non-impregnation part 4. The impregnation part 3 includes a resin A with a number average molecular weight of 5,000 or more and 150,000 or less and a glass transition temperature (Tg) of 35°C or lower, the nonwoven fabric being impregnated with the impregnation part 3, while the nonwoven fabric not being impregnated with the non-impregnation part 4.SELECTED DRAWING: Figure 1

Description

The present invention relates to a molding sheet provided with a resin layer and a molded body.

Conventionally, various molding sheets are known. For example, Patent Document 1 discloses a spunbonded nonwoven fabric containing polyethylene terephthalate and a thermoplastic polystyrene-based copolymer, which is suitable for thermoforming applications. Further, in Patent Document 2, the shrinkage ratio of the length in the elongation direction after stretching for 30 minutes in an atmosphere of 20 ° C. after stretching is 5% or less with respect to the length in the stretching direction at the time of stretching at 150% in an atmosphere of 130 ° C. A spunbonded nonwoven fabric suitable for thermoforming applications is disclosed.

Japanese Unexamined Patent Publication No. 2017-22950 Japanese Unexamined Patent Publication No. 2017-222951

Patent Documents 1 and 2 describe that a spunbonded nonwoven fabric suitable for thermoforming is used as a coffee filter material or the like. In recent years, there has been an increasing desire to apply molding sheets to various other uses.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a molding sheet that is easy to use for various purposes.

The molding sheet according to the present invention comprises [1] a nonwoven fabric and a resin layer laminated on the nonwoven fabric, and the nonwoven fabric contains fibers having a double refractive index Δn of 0.005 or more and 0.050 or less. The impregnated portion contains the resin A having a number average molecular weight of 5,000 or more and 150,000 or less and a glass transition temperature (Tg) of 35 ° C. or less, and the non-woven fabric is impregnated. And a non-impregnated portion which is not impregnated in the nonwoven fabric. With this configuration, it is possible to provide a molding sheet that is easy to use for various purposes.

A preferred embodiment of the molding sheet is as one of the following [2] to [8].
[2] The molding sheet according to [1], wherein the resin layer contains a metal filler.
[3] The resin A is at least one selected from the group consisting of polyester resin, polyester urethane resin, polyamide resin, polyamideimide resin, phenoxy resin, olefin resin, and acrylic resin [1] or [2]. The molding sheet described in.
[4] The molding sheet according to any one of [1] to [3], wherein the resin layer contains a cross-linking agent.
[5] The molding sheet according to any one of [1] to [4], wherein the fiber contains a resin B having an intrinsic viscosity of 0.3 dl / g or more and 0.9 dl / g or less.
[6] The molding sheet according to [5], wherein the fiber contains a high Tg organic compound having a glass transition temperature higher than that of the resin B.
[7] The molding sheet according to any one of [1] to [6], wherein the average thickness of the non-impregnated portion is smaller than the average thickness of the nonwoven fabric.
[8] The molding sheet according to any one of [1] to [7], wherein the average thickness of the non-impregnated portion is larger than the average thickness of the impregnated portion.

The present invention also includes a molded body obtained by molding a molding sheet. A preferred embodiment of the molded body is as follows [9].
[9] A molded body obtained by molding any of the molding sheets of [1] to [8].

According to the present invention, it is possible to provide a molding sheet that is easy to use for various purposes by the above configuration. Further, various molded bodies can be obtained by molding using the molding sheet.

FIG. 1 is a cross-sectional view of a molding sheet according to an embodiment of the present invention. FIG. 2 is a drawing substitute photograph taken by magnifying a part of the surface of the resin layer of the molding sheet of Example 1 at a magnification of 100 times. FIG. 3 is a drawing substitute photograph of the molding sheet in which tearing was confirmed when a part of the surface of the resin layer of the molding sheet was magnified 100 times and photographed.

Hereinafter, the present invention will be described in more detail based on the following embodiments, but the present invention is not limited by the following embodiments as well as the present invention, and is appropriately modified to the extent that it can meet the purposes of the preceding and the following. Of course, it is also possible to carry out the above, and all of them are included in the technical scope of the present invention. It should be noted that the dimensions of the various members in the drawings may differ from the actual dimensions because the priority is given to contributing to the understanding of the features of the present invention.

The molding sheet according to the embodiment includes a nonwoven fabric and a resin layer laminated on the nonwoven fabric, and the nonwoven fabric contains fibers having a double refractive index Δn of 0.005 or more and 0.050 or less, and is a resin layer. Contains the resin A having a number average molecular weight of 5,000 or more and 150,000 or less and a glass transition temperature (Tg) of 35 ° C. or less, and is impregnated with the impregnated portion impregnated in the non-woven fabric and the non-woven fabric. It is provided with a non-woven fabric that is not impregnated.

The present inventors have found that the above configuration makes it possible to easily prevent the non-woven fabric and the resin layer of the molding sheet from being damaged during the molding process. Since the molded body molded using the molding sheet having the above configuration is provided with the resin layer, various properties such as moisture resistance, waterproofness, and durability are exhibited depending on the properties of the resin. To. Further, if the resin layer contains a filler having characteristics such as electromagnetic wave shielding property and sound absorbing property in the resin layer, these characteristics can be imparted to the molded body. As described above, the molding sheet having the above structure can be easily used for various purposes. Hereinafter, the molding sheet according to the embodiment will be described with reference to FIG. 1. FIG. 1 is a cross-sectional view of a molding sheet according to an embodiment.

As shown in FIG. 1, the molding sheet 10 according to the embodiment includes a nonwoven fabric 1 and a resin layer 2 laminated on the nonwoven fabric 1. Specifically, the resin layer 2 is laminated on the nonwoven fabric 1 in a form of being partially impregnated in the nonwoven fabric 1. That is, the resin layer 2 includes an impregnated portion 3 impregnated with the nonwoven fabric 1. Since the resin layer 2 includes the impregnated portion 3, the resin layer 2 is less likely to be peeled off from the nonwoven fabric 1.

The average thickness of the impregnated portion 3 is preferably 5 μm or more, more preferably 10 μm or more, and further preferably 12 μm or more. This makes it difficult for the resin layer 2 to peel off during molding. On the other hand, the upper limit of the average thickness of the impregnated portion 3 is not particularly limited, but may be, for example, 100 μm or less, 80 μm or less, 70 μm or less, or 40 μm or less. It may be 25 μm or less.

Further, the resin layer 2 includes a non-impregnated portion 4 which is not impregnated with the nonwoven fabric 1. By providing the non-impregnated portion 4 in the resin layer 2, the resin layer 2 is less likely to be damaged during molding.

The average thickness of the non-impregnated portion 4 is preferably 5 μm or more, more preferably 10 μm or more, still more preferably 15 μm or more, still more preferably 20 m or more. As a result, the resin layer 2 is less likely to be damaged during molding. On the other hand, the average thickness of the non-impregnated portion 4 is preferably 130 μm or less, more preferably 80 μm or less, still more preferably 75 μm or less, still more preferably 70 μm or less. As a result, the surface roughness of the non-impregnated portion 4 can be reduced.

The average thickness of the non-impregnated portion 4 is preferably smaller than the average thickness of the nonwoven fabric 1, and more preferably 1/2 or less of the average thickness of the nonwoven fabric 1. As a result, it is possible to reduce the bias of stress during elongation of the resin layer 2 and make it difficult to tear. Further, the average thickness of the non-impregnated portion 4 may be 1/50 or more of the average thickness of the nonwoven fabric 1.

The average thickness of the non-impregnated portion 4 is preferably larger than the average thickness of the impregnated portion 3, more preferably 1.2 times or more the average thickness of the impregnated portion 3, and the average thickness of the impregnated portion 3. It is more preferably 1.3 times or more of. As a result, the surface roughness of the non-impregnated portion 4 can be reduced. The average thickness of the non-impregnated portion 4 is preferably 6 times or less, more preferably 5 times or less, and further preferably 4 times or less the average thickness of the impregnated portion 3. As a result, the resin layer 2 is less likely to be damaged during molding.

The average thickness of the non-impregnated portion 4 can be measured by, for example, the following method. First, three points are selected and marked in a 10 mm square region on the surface 4s of the non-impregnated portion 4 of the molding sheet 10, and the molding sheet 10 is frozen in liquid nitrogen. Next, the molding sheet 10 is cut in the thickness direction T so that each point can be observed. After that, each cross section is observed with a stereomicroscope at a magnification of 2 times, and in the image, a straight line is drawn in the thickness direction T from one of the above three points (point A) on the surface 4s of the non-impregnated portion 4. Pull. The distance (μm) between the intersection (point B) of the straight line and the surface 1s of the non-woven fabric 1 and the point A may be measured, and the average value thereof may be taken as the average thickness (μm) of the non-impregnated portion 4.

The average thickness of the impregnated portion 3 is, for example, in the image of each cross section, the intersection (point C) between the straight line in the thickness direction T and the impregnated surface 3s of the impregnated portion 3 and the point B on the surface 1s of the non-woven fabric 1. The distance (μm) from the impregnated portion 3 may be measured, and the average value thereof may be used as the average thickness (μm) of the impregnated portion 3. The impregnated surface 3s in this case means the surface of the impregnated portion 3 on the side opposite to the surface 1s of the nonwoven fabric 1.

In FIG. 1, the nonwoven fabric 1 has a resin layer 2 on one side, but the nonwoven fabric 1 may have a resin layer 2 on both sides. It is preferable that the resin layer 2 is provided on one surface of the nonwoven fabric 1 because the weight can be reduced. Further, it is preferable that no other layer is formed on the surface 4s of the non-impregnated portion 4, and the surface 4s is exposed. This makes it easier to improve workability.

The nonwoven fabric 1 contains fibers having a birefringence Δn of 0.005 or more and 0.050 or less. When the birefringence (Δn) of the fiber is 0.005 or more, the rigidity of the nonwoven fabric 1 can be improved, and the shape retention of the molded body can be easily improved. The birefringence (Δn) is preferably 0.007 or more, more preferably 0.008 or more. On the other hand, when the birefringence (Δn) is 0.050 or less, the workability can be easily improved. The birefringence (Δn) is preferably 0.040 or less, more preferably 0.020 or less. The birefringence (Δn) can be specifically measured by the method described in Examples described later.

The content of the fiber having a birefringence Δn of 0.005 or more and 0.050 or less in 100% by mass of the non-woven fabric is preferably 70% by mass or more, more preferably 80% by mass or more, still more preferably 90% by mass or more. It is even more preferably 95% by mass or more, particularly preferably 98% by mass or more, and most preferably 100% by mass.

As the fibers contained in the non-woven fabric 1, polyester fibers, polyamide fibers and polyolefin fibers are preferable, polyester fibers are more preferable, and thermoplastic polyester fibers are further preferable. These may be used alone or in combination of two or more.

Examples of the polyester fiber include those containing polyethylene terephthalate as a main component. Polyethylene terephthalate is excellent in mechanical strength, heat resistance, shape retention and the like. In order to effectively exert such an effect, the content of polyethylene terephthalate in the polyester fiber is preferably 90% by mass or more, more preferably 93% by mass or more, still more preferably, when the polyester fiber is 100% by mass. Is 94% by mass or more. On the other hand, the content of polyethylene terephthalate is preferably 99.8% by mass or less in consideration of the content of the high Tg organic compound described later. The polyester fiber may contain polyester other than polyethylene terephthalate, such as polytrimethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalate. The description of the content can be referred to when polyamide, polyolefin or the like is used as the material of the fiber.

The fiber contained in the nonwoven fabric 1 preferably contains a resin B having an intrinsic viscosity of 0.3 dl / g or more and 0.9 dl / g or less. Further, the fiber preferably contains a high Tg organic compound having a glass transition temperature higher than that of the resin B. The resin B is preferably a thermoplastic resin. Examples of the resin B include polyester resin, polyamide resin, polyolefin resin and the like.

The content of the resin B is preferably 92% by mass or more, more preferably 93% by mass or more, still more preferably 94% by mass or more, when the fiber contained in the woven fabric 1 is 100% by mass. On the other hand, the content of the resin B is preferably 99.8% by mass or less, more preferably 99.5% by mass or less, considering the content of the high Tg organic compound.

The glass transition temperature of the resin B is preferably 120 ° C. or lower, more preferably 100 ° C. or lower, and even more preferably 90 ° C. or lower. This facilitates the effect of the high Tg organic compound. On the other hand, the glass transition temperature of the resin B may be 25 ° C. or higher, 35 ° C. or higher, or 50 ° C. or higher. The glass transition temperature can be determined by measuring at a heating rate of 20 ° C./min according to JIS K7122 (1987). The glass transition temperature is the midpoint glass transition temperature, which is the temperature at the intersection of a straight line at an equal distance in the vertical axis direction from the extended straight line of each baseline in the DSC curve and the curve of the stepwise change portion of the glass transition. It is preferable to have.

The intrinsic viscosity is preferably 0.3 dl / g or more and 0.9 dl / g or less. By setting the intrinsic viscosity to 0.3 dl / g or more, thermal deterioration is less likely to occur, and the durability of the nonwoven fabric 1 can be improved. Therefore, the intrinsic viscosity is more preferably 0.4 dl / g or more, further preferably 0.5 dl / g or more, and even more preferably 0.55 dl / g or more. On the other hand, when the intrinsic viscosity is 0.9 dl / g or less, it is possible to easily reduce the stress during thermoforming of the nonwoven fabric 1. Therefore, the intrinsic viscosity is more preferably 0.7 dl / g or less. The intrinsic viscosity is measured, for example, by weighing 0.1 g of the resin, dissolving it in a mixed solvent of 25 ml of phenol / tetrachloroethane (60/40 (weight ratio)), and measuring it three times at 30 ° C. using an Ostwald viscometer. It can be obtained by calculating the average value.

Examples of the high Tg organic compound include polystyrene, polystyrene-based copolymers, polycarbonates, polyacrylonitrile and the like. Of these, polystyrene-based copolymers are preferable. Further, the high Tg organic compound is preferably a thermoplastic organic compound. The glass transition temperature of the high Tg organic compound is preferably 100 ° C. or higher and 160 ° C. or lower. Further, it is more preferable that the high Tg organic compound is incompatible with the resin B. Since the high Tg organic compound has a higher glass transition temperature than the resin B, the high Tg organic compound can be solidified first when the melt spinning is cooled, thereby inhibiting the orientation and disturbing the crystallinity. As a result, the breaking elongation of the obtained nonwoven fabric 1 can be improved, and the stress during elongation can be further reduced. Therefore, the glass transition temperature of the high Tg organic compound is preferably 100 ° C. or higher, more preferably 110 ° C. or higher, still more preferably 120 ° C. or higher. On the other hand, the glass transition temperature is preferably 160 ° C. or lower, more preferably 150 ° C. or lower in consideration of spinning productivity. The glass transition temperature can be determined by measuring at a heating rate of 20 ° C./min according to JIS K7122 (1987). The glass transition temperature is the midpoint glass transition temperature, which is the temperature at the intersection of a straight line at an equal distance in the vertical axis direction from the extended straight line of each baseline in the DSC curve and the curve of the stepwise change portion of the glass transition. It is preferable to have.

Examples of the polystyrene copolymer include a styrene / conjugated diene block copolymer, an acrylonitrile / styrene copolymer, an acrylonitrile / butadiene / styrene copolymer, a styrene / acrylic acid ester copolymer, and a styrene / methacrylate ester copolymer. At least one selected from the group consisting of coalescing is preferred. Of these, at least one selected from the group consisting of a styrene / acrylic acid ester copolymer and a styrene / methacrylate copolymer is more preferable, and a styrene / methacrylate copolymer is even more preferable. Examples of the styrene / methacrylate copolymer include a styrene / methyl methacrylate / maleic anhydride copolymer. These may be contained alone or in combination. Commercially available products include ROHM GmbH & Co. KG's PLEXIGLAS HW
55 can be mentioned, and an excellent effect can be exhibited with a small amount of addition.

The content of the high Tg organic compound in the fiber contained in the nonwoven fabric 1 is preferably 0.02% by mass or more and 8% by mass or less when the fiber is 100% by mass. When it is 0.02% by mass or more, the effect of the above addition can be easily obtained. Therefore, the content of the high Tg organic compound is more preferably 0.05% by mass or more, still more preferably 0.2% by mass or more. On the other hand, when the content of the high Tg organic compound is 8% by mass or less, the difference in stretchability between the resin B and the high Tg organic compound can be reduced, and the fibers can be made difficult to break. Therefore, the content of the high Tg organic compound is more preferably 8% by mass or less, further preferably 7% by mass or less, still more preferably 6% by mass or less.

The fiber diameter of the fibers contained in the nonwoven fabric 1 is preferably 5 μm or more. By setting the fiber diameter to 5 μm or more, the shape retention of the molded body can be improved. Therefore, the fiber diameter is preferably 5 μm or more, more preferably 7 μm or more, still more preferably 12 μm or more. On the other hand, the upper limit of the fiber diameter is not particularly limited, but may be, for example, 80 μm or less, 60 μm or less, 50 μm or less, 40 μm or less, 35 μm or less. Specifically, the fiber diameter can be measured by the method described in Examples described later.

The nonwoven fabric 1 is preferably one in which the fibers are not entangled. This makes it easier to mold the nonwoven fabric 1. Further, the fibers contained in the nonwoven fabric 1 are preferably long fibers. Since the fibers are long fibers, the force applied during molding is uniformly dispersed, stress concentration can be easily prevented, and the shape retention of the molded body can be improved. Therefore, the non-woven fabric is preferably a spunbonded non-woven fabric or a melt-blown non-woven fabric, and more preferably a spunbonded non-woven fabric.

The basis weight of the nonwoven fabric may be adjusted in consideration of rigidity after molding and the like, and is not particularly limited, but is preferably 20 g / m ² or more and 500 g / m ² or less. If the basis weight is 20 g / m ² or more, it will not be easily damaged during molding. Therefore, the basis weight is more preferably 80 g / m ² or more, and further preferably 150 g / m ² or more. On the other hand, when the basis weight is 500 g / m ² or less, it is easy to stretch during molding. Therefore, the basis weight is more preferably 400 g / m ² or less, still more preferably 300 g / m ² or less. Specifically, the basis weight of the nonwoven fabric can be measured by the method described in Examples described later.

The average thickness of the non-woven fabric is preferably 100 μm or more and 3000 μm or less. If the thickness is 100 μm or more, it will not be easily damaged during molding. Therefore, the thickness is more preferably 200 μm or more, still more preferably 400 μm or more. On the other hand, if the thickness is 3000 μm or less, it tends to be elongated during molding. Therefore, the thickness is more preferably 2000 μm or less, still more preferably 1000 μm or less. Specifically, the average thickness of the nonwoven fabric can be measured by the method described in Examples described later.

The nonwoven fabric 1 preferably has a breaking elongation of 200% or more after heating at 130 ° C. for 1 minute. This makes it easier to follow the molding process such as deep drawing. It is more preferably 250% or more, further preferably 260% or more, still more preferably 280% or more, and particularly preferably 300% or more. On the other hand, the upper limit of the elongation at break may be approximately 500% or less, or may be 450% or less. The elongation is expressed as a percentage of the extension to the initial length, that is, it can be calculated by {(length after extension-initial length) / initial length} × 100. For example, when an object having a length of 100 mm is extended to 250 mm, the elongation is 150%.

The nonwoven fabric 1 preferably has a stress at 20% elongation after heating at 130 ° C. for 1 minute at a basis weight of 200 g / m ² or less of 40 N / 5 cm. This makes it possible to improve the mold followability during thermoforming. It is more preferably 39 N / 5 cm or less, further preferably 38 N / 5 cm or less, still more preferably 37 N / 5 cm or less, and particularly preferably 36 N / 5 cm or less. On the other hand, the lower limit thereof is not particularly limited, but is preferably 20 N / 5 cm or less in consideration of suppressing the generation of wrinkles after molding. The 20% stretched time means, for example, when the initial length is 100 mm, it is stretched to a length of 120 mm.

The breaking elongation and the stress at 20% elongation of the nonwoven fabric 1 can be measured by, for example, the following method. First, five sample pieces each having a sample width of 5 cm and a length of 20 cm are cut out from the nonwoven fabric 1 in the vertical direction and the horizontal direction. Next, the sample was set at a distance between chucks of 5 cm, placed in a furnace heated to 130 ° C., and after 1 minute had passed, the sample was transformed in a heating furnace using a universal tensile tester manufactured by Orientec Co., Ltd. at a tensile speed of 10 cm / min. To obtain a strain-stress curve. From the strain-strain curve, the elongation at break and the stress at 20% elongation may be read, and the average value of each of the five points in the vertical direction and the horizontal direction may be the above-mentioned elongation at break and the stress at 20% elongation. ..

In manufacturing the nonwoven fabric 1, the manufacturing methods described in JP-A-2017-222950 and JP-A-2017-222951 can be referred to.

The resin layer 2 laminated on the nonwoven fabric 1 contains a resin A having a number average molecular weight of 5,000 or more and 150,000 or less and a glass transition temperature (Tg) of 35 ° C. or less.

When the number average molecular weight of the resin A is 5,000 or more, the toughness of the resin layer 2 is likely to be improved, and the resin is likely to follow the deformation during molding. The number average molecular weight is preferably 10,000 or more, more preferably 20,000 or more. On the other hand, when the number average molecular weight is 150,000 or less, the viscosity of the solution can be easily reduced when the resin is mixed with a solvent and applied to the nonwoven fabric 1 to form the resin layer 2, so that the coating can be applied. It will be easier. Further, even when the resin layer 2 is formed by heating and melting the resin and adhering it to the nonwoven fabric 1, the viscosity of the resin in the molten state can be easily reduced, so that the resin easily permeates into the nonwoven fabric 1. As a result, the adhesive strength of the resin layer 2 to the nonwoven fabric 1 is improved, and the resin layer 2 is less likely to be peeled off during molding. The number average molecular weight can be determined in terms of polystyrene using, for example, a gel permeation chromatography (GPC) apparatus.

When the glass transition temperature (Tg) of the resin A is 35 ° C. or lower, the resin can easily follow the deformation during molding. The glass transition temperature (Tg) of the resin A is preferably 25 ° C. or lower, more preferably 10 ° C. or lower, still more preferably −5 ° C. or lower, still more preferably −10 ° C. or lower. On the other hand, the glass transition temperature (Tg) of the resin A may be −130 ° C. or higher, −50 ° C. or higher, or −30 ° C. or higher. The glass transition temperature is determined by measuring at a heating rate of 20 ° C./min according to JIS K7122 (1987). The glass transition temperature is the midpoint glass transition temperature, which is the temperature at the intersection of a straight line at an equal distance in the vertical axis direction from the extended straight line of each baseline in the DSC curve and the curve of the stepwise change portion of the glass transition. It is preferable to have.

The content of the resin A in 100% by mass of the resin layer is preferably 60% by mass or more, more preferably 70% by mass or more, still more preferably 90% by mass or more, still more preferably 95% by mass or more, and particularly preferably 98% by mass. It is mass% or more.

As the resin A, a thermoplastic resin is preferable, and an amorphous thermoplastic resin is more preferable. This makes the molding sheet 10 easy to heat-mold. As the resin A, specifically, at least one selected from the group consisting of polyester resin, polyester urethane resin, polyamide resin, polyamideimide resin, phenoxy resin, olefin resin, and acrylic resin is preferable, and polyester resin and olefin are preferable. At least one selected from the group consisting of resins is more preferable, and polyester resins are even more preferable.

The polyester resin is mainly formed by reacting a carboxylic acid component with a hydroxyl group component. Examples of the carboxylic acid component include terephthalic acid, isophthalic acid, adipic acid, azelaic acid, sebacic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanedicarboxylic acid, and 4-methyl-. Examples thereof include 1,2-cyclohexanedicarboxylic acid, dimer acid, hydrogenated dimer acid and naphthalenedicarboxylic acid. These may be used alone or in combination of two or more. As the hydroxyl group component, ethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,2-butanediol, 1,3-butanediol, 1,4-butanediol, 2-methyl-1,3 -Propanediol, 1,5-pentanediol, 1,6-hexanediol, 3-methyl-1,5-pentanediol, dipropylene glycol, diethylene glycol, neopentyl glycol, 2,2,4-trimethyl-1,3 -Pentanediol, tricyclodecanedimethanol, neopentyl glycol hydroxypivalic acid ester, 1,9-nonanediol, 2-methyloctanediol, 1,10-dodecanediol, 2-butyl-2-ethyl-1,3- Examples thereof include propanediol, polytetramethylene glycol, polyoxymethylene glycol, cyclohexanedimethanol and the like. These may be used alone or in combination of two or more.

Examples of the polyester urethane resin include those obtained by an addition polymerization reaction of a polyester polyol and a polyisocyanate. Polyester polyols include polybasic acids such as dipic acid, azelaic acid, sebacic acid, terephthalic acid, isophthalic acid, phthalic acid and succinic acid, and propylene glycol, ethylene glycol, tetramethylene glycol, butanediol, hexanediol and neopentyl glycol. Examples thereof include those obtained by condensation reaction of polyhydric alcohols such as. As the polyisocyanate, aromatic diisocyanates such as 4,4'-diphenylmethane diisocyanate (MDI), tolylene diisocyanate (TDI), xylylene diisocyanate (XDI); hexamethylene diisocyanate (HDI), lysine methyl ester diisocyanate (LDI) and the like. Examples of the aliphatic diisocyanate; dicyclohexamethylene diisocyanate (HMDI), isophorone diisocyanate (IPDI) and other alicyclic diisocyanates; and the like. These may be used alone or in combination of two or more.

The polyamide resin is a polymer having an amide bond in the molecule. Examples of the polyamide resin include nylon 6,6, nylon 6,9, nylon 6,10, nylon 6,12, nylon 6, nylon 12, nylon 11, nylon 4,6 and the like. These may be used alone or in combination of two or more.

The polyamide-imide resin is a polymer having an amide bond and an imide bond. Examples of the polyamide-imide resin include those obtained by reacting an acid component with a diamine.

The acid components include trimellitic acid, its anhydrides and chlorides; pyromellitic acid, biphenyltetracarboxylic acid, biphenylsulfonetetracarboxylic acid, benzophenonetetracarboxylic acid, biphenylethertetracarboxylic acid, ethylene glycol bistrimethylate and propylene glycol. Tetracarboxylic acids such as bistrimeritate, their anhydrides; oxalic acid, adipic acid, malonic acid, sebatic acid, azelaic acid, dodecanedicarboxylic acid, dicarboxypolybutadiene, dicarboxypoly (acrylonitrile-butadiene), dicarboxy An aliphatic dicarboxylic acid such as poly (styrene-butadiene); an alicyclic dicarboxylic acid such as 1,4-cyclohexanedicarboxylic acid, 1,3cyclohexanedicarboxylic acid, 4,4'-dicyclohexylmethanedicarboxylic acid, and dimer acid; terephthalic acid. , Isophthalic acid, diphenylsulfonic acid, diphenyletherdicarboxylic acid, aromatic dicarboxylic acid such as naphthalenedicarboxylic acid; and the like. These may be used alone or in combination of two or more.

Examples of the diamine include aliphatic diamines such as ethylenediamine, propylenediamine and hexamethylenediamine, and diamines thereof; alicyclics such as 1,4-cyclohexanediamine, 1,3cyclohexanediamine, isophoronediamine and 4,4′-dicyclohexylmethanediamine. Group diamines, these diamines; m-phenylenediamine, p-phenylenediamine, 4,4'-diaminodiphenylmethane, 4,4'-diaminodiphenyl ether, 4,4'-diaminodiphenylsulfone, benzidine, o-tridine, 2, Examples include aromatic diamines such as 4-tolylene diamine, 2,6-tolylene diamine, and xylylene diamine, and diisocyanates thereof. These may be used alone or in combination of two or more.

Examples of the phenoxy resin include a resin obtained by reacting epihalohydrin with a divalent phenol compound, and a resin obtained by reacting a divalent epoxy compound with a divalent phenol compound. Specifically, bisphenol A type phenoxy resin, bisphenol F type phenoxy resin, bisphenol S type phenoxy resin, bisphenol M type phenoxy resin, bisphenol P type phenoxy resin, bisphenol Z type phenoxy resin, phenoxy having two or more kinds of bisphenol skeletons. Examples thereof include bisphenol type phenoxy resin such as resin, novolak type phenoxy resin, naphthalene type phenoxy resin and the like. These may be used alone or in combination of two or more.

As the olefin resin, a homopolymer or copolymer of olefins such as ethylene, propylene, butene; a copolymer of these olefins and a copolymerizable monomer component; or a maleic anhydride-modified product thereof. Can be mentioned. As the olefin resin, polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, ethylene-acrylic acid copolymer, ethylene-methyl methacrylate copolymer, ethylene-α-olefin copolymer , At least one selected from the group consisting of ethylene-propylene copolymers, ethylene-butene copolymers, and propylene-butene copolymers.

Examples of the acrylic resin include (meth) acrylic acid, methyl (meth) acrylic acid, ethyl (meth) acrylic acid, n-propyl (meth) acrylic acid, n-butyl (meth) acrylic acid, and t-butyl (meth) acrylic acid. Butyl, 2-ethylhexyl (meth) acrylate, cyclohexyl (meth) acrylate, lauryl (meth) acrylate, tridecyl (meth) acrylate, stearyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, ( Examples thereof include polymerized or copolymerized (meth) acrylic monomers such as 2-hydroxypropyl (meth) acrylate, (meth) acrylamide, (meth) acrylic nitrile, and glycidyl (meth) acrylate. These may be used alone or in combination of two or more.

The resin A may have a reactive functional group capable of reacting with a cross-linking agent described later. Examples of the reactive functional group include a carboxyl group, a hydroxyl group, a methylol group, an amide group and the like. The resin A preferably exists in a form crosslinked by a crosslinking agent.

The resin layer 2 preferably contains a metal filler. Examples of the metal filler include metal fillers of single metals such as aluminum, zinc, iron, silver and copper, metal fillers of metal oxides such as zinc oxide, and metals of alloys such as Ni—Fe-based alloys and Si—Al—Fe-based alloys. Examples include fillers. The metal filler may or may not have magnetism, but it is preferably magnetic. These may be used alone or in combination of two or more.

The content of the metal filler is preferably 2 parts by mass or more, more preferably 5 parts by mass or more, preferably 200 parts by mass or less, more preferably 100 parts by mass or less, still more preferably, with respect to 100 parts by mass of the resin A. Is 50 parts by mass or less, particularly preferably 40 parts by mass or less.

The resin layer 2 preferably contains a cross-linking agent. Examples of the cross-linking agent include isocyanate-based cross-linking agents, melamine-based cross-linking agents, oxazoline-based cross-linking agents, aziridine-based cross-linking agents, epoxy-based cross-linking agents, polyamide-based cross-linking agents, and carbodiimide-based cross-linking agents. Of these, an isocyanate-based cross-linking agent is preferable. Examples of the isocyanate-based cross-linking agent include compounds having two or more isocyanate groups in one molecule. For example, diisocyanate compounds such as tolylene diisocyanate, hexamethylene diisocyanate and 4,4'-diphenylmethane diisocyanate, bullet-type polyisocyanate compounds such as BI-7960 manufactured by Baxenden Co., Ltd., and isocyanurates such as Coronate HX manufactured by Tosoh Corporation. Examples thereof include a polyisocyanate compound having a ring, an adduct-type polyisocyanate compound such as trimethylolpropane-added adduct-type trimerate Coronate HL manufactured by Tosoh Corporation. Further, the isocyanate-based cross-linking agent may be a blocked isocyanate in which the isocyanate group in the compound is inactivated by a blocking agent such as DMP (dimethylpyrazole).

The content of the cross-linking agent is preferably 2 parts by mass or more, more preferably 4 parts by mass or more, preferably 20 parts by mass or less, and more preferably 14 parts by mass or less with respect to 100 parts by mass of the resin A. The cross-linking agent may be contained in the resin layer 2 in a form capable of reacting with the reactive functional group of the resin A, or may be contained in the resin layer 2 in a form reacting with the reactive functional group. ..

The resin layer 2 is also a flame retardant such as antimony oxide, aluminum hydroxide, magnesium hydroxide; a plasticizer such as phthalate ester and adipate ester; a hydrolysis inhibitor such as carbodiimide; a sound absorbing filler such as silica; etc. May be included. These additives may be used alone or in combination of two or more.

It is preferable that the molding sheet 10 does not have a damaged portion in the resin layer 2 and the nonwoven fabric 1 after the following molding process according to the JIS 1096 (2010) 8.18.2B method. The following pushing amount is more preferably 17 mm, still more preferably 20 mm.
<Molding conditions>
Cut the molding sheet 10 into a circle with a diameter of 72 mm. Next, a convex mold having a cylindrical portion having a diameter of 25 mm, a hemispherical portion having a radius of 12.5 mm provided at the tip of the cylindrical portion, and a concave mold capable of fitting into the hemispherical portion. Prepare. Next, the molding sheet 10 is placed on the concave mold with the resin layer 2 side facing the concave mold, and a ring-shaped pressing plate is placed on the peripheral edge of the molding sheet 10. Next, the hemispherical portion and the cylindrical portion were pushed 13 mm perpendicularly to the molding sheet 10 at a speed of 20 mm / min at a heating temperature of 140 ° C. and a heating time of 1 minute, and then maintained for 30 seconds. Release from. Then, after cooling with cold air of a dryer for 1 minute, the molded body is taken out.

In the molding sheet, the peel strength of the resin layer 2 is preferably 1.0 N / cm or more. As a result, the resin layer 2 is less likely to be damaged during molding. Therefore, the peel strength of the resin layer 2 is more preferably 2.0 N / cm or more, still more preferably 3.0 N / cm or more, and even more preferably 4.0 N / cm or more. On the other hand, the upper limit is not particularly limited, but may be, for example, 15 N / cm or less, or 10 N / cm or less. The peel strength of the resin layer 2 can be measured by the method described in Examples described later.

In forming the resin layer 2 on the nonwoven fabric 1, it can be formed by a transfer method, a screen printing method, or the like. Further, in performing the transfer method or the like, the resin may be heated and melted, or a solvent such as methyl ethyl ketone may be mixed with the resin. For example, when performing a transfer method or the like, a resin layer paint may be applied on a release paper or a release film at a rate of 300 to 600 g / cm ² and dried at 120 ° C. to 160 ° C. for 2 to 4 minutes. preferable. The solid content of the resin is preferably 20% by mass to 40% by mass in 100% by mass of the coating material for the resin layer. After that, the resin layer side of the resin layer with the release layer is directed toward the surface of the non-woven fabric, bonded, thermocompression bonded under the conditions of 50 to 70 ° C. and 15 to 25 N / cm ² , and 24 at 50 ° C. to 70 ° C. It is preferable to leave it for about 72 hours. This makes it easy to control the thickness of the impregnated portion 3 and the non-impregnated portion 4 within a preferable range.

The present invention also includes a molded body obtained by molding the molding sheet 10. In molding, the molding sheet 10 may be drawn under a heating condition of, for example, 100 to 180 ° C., such as shallow drawing or deep drawing. Further, the shape of processing is not limited, and cylindrical drawing processing, square cylinder drawing processing, conical drawing processing, pyramid drawing processing, spherical head drawing processing, other irregular drawing processing, and the like can be performed.

Hereinafter, the present invention will be described in more detail with reference to examples, but the present invention is not limited to the following examples, and can be modified and carried out to the extent that it can meet the purposes of the preceding and the following. Yes, they are all within the technical scope of the invention.

Birefringence index (Δn): Select 10 points at any place on the non-woven fabric, take out a single fiber, read the fiber diameter and retardation using a Nikon deflection microscope OPTIPHOT-POL type, and read the birefringence index (Δn). Asked.

Fiber diameter: Five points of the sample (long fiber fleece before temporary crimping) were selected, the diameter of the single fiber was measured at n = 20 using an optical microscope, and the average value was obtained.

Intrinsic viscosity: 0.1 g of resin B is weighed, dissolved in a mixed solvent of 25 ml of phenol / tetrachloroethane (60/40 (weight ratio)), measured three times at 30 ° C. using an Ostwald viscometer, and the average thereof. The value was calculated.

Average thickness of non-woven fabric: The average thickness of the non-woven fabric was measured based on 6.1 of JIS L 1913 (2010).

Metsuke of non-woven fabric: Based on the "mass per unit area" of 6.2 of JIS L 1913 (2010), the basis weight of the non-woven fabric was obtained.

Average thickness of non-impregnated portion: Three points were selected and marked in a 10 mm square region on the surface of the non-impregnated portion of the molding sheet, and the molding sheet was frozen in liquid nitrogen. Next, the molding sheet was cut in the thickness direction so that each point could be observed. After that, each cross section is observed with a stereomicroscope manufactured by LEICA at a magnification of 2 times, and in the image, a straight line in the thickness direction from one of the above three points (point A) on the surface of the non-impregnated portion. Was pulled. The distance (μm) between the intersection (point B) and the point A between the straight line and the surface of the non-woven fabric was measured, and the average value was taken as the average thickness (μm) of the non-impregnated portion.

Average thickness of impregnated portion: In the image of each cross section, the distance (μm) between the intersection (point C) between the straight line in the thickness direction and the impregnated surface of the impregnated portion and the point B on the surface of the non-woven fabric is measured. The average value thereof was taken as the average thickness (μm) of the impregnated portion.

Number average molecular weight of resin: The chromatogram was measured using a gel permeation chromatography (GPC) device manufactured by Shimadzu Corporation, and the number average molecular weight (Mn) of resin A was obtained based on a calibration curve using standard polystyrene. rice field.

Peeling strength: The molding sheet was cut into a length of 100 mm and a width of 250 mm. Then, a hot melt tape manufactured by Sun Kasei Co., Ltd. having a width of 20 mm and a thickness of 25 μm was thermocompression bonded to the resin layer of the molding sheet with an iron heated to a surface temperature of 120 ° C. After that, using an autograph tensile tester manufactured by Shimadzu Corporation, the hot melt tape was peeled off together with the resin layer under the conditions of an autograph speed of 300 mm / min, a peeling distance of 50 mm, and a peeling angle of 180 °, and the measurement was performed. The measurement was repeated twice and the average value was taken as the peel strength (N / cm).

Surface Roughness: Based on JIS B 0601 4.2.1, the arithmetic mean height (roughness Ra) of the surface of the molding sheet on the resin layer side was determined.

Moldability evaluation: The moldability of the moldable sheet was evaluated by performing the following molding process according to the JIS 1096 (2010) 8.18.2B method.
<Molding conditions>
The molding sheet was cut into a circle with a diameter of 72 mm. Next, a convex mold having a cylindrical portion having a diameter of 25 mm, a hemispherical portion having a radius of 12.5 mm provided at the tip of the cylindrical portion, and a concave mold capable of fitting into the hemispherical portion. I prepared. Next, the molding sheet was placed on the concave mold with the resin layer side facing the concave mold, and a ring-shaped pressing plate was placed on the peripheral edge of the molding sheet. Next, the hemisphere and the cylinder are pushed 13 mm perpendicular to the molding sheet at a speed of 20 mm / min at a heating temperature of 140 ° C. and a heating time of 1 minute, and then maintained for 30 seconds. It was released. Then, after cooling with the cold air of the dryer for 1 minute, the molded body was taken out.

The surface of the removed molded body was observed to evaluate which of the following 〇, Δ, and × was applicable. Similarly, the molding process was performed under the condition of being pushed in 17 mm or 20 mm in the vertical direction, and the moldability of the molding sheet was evaluated.
× At least one of the resin layer and the non-woven fabric had a damaged part that could be visually confirmed. △ There was no damaged part that could be visually confirmed in the resin layer and the non-woven fabric, but a scanning electron microscope was used for at least one of the resin layer and the non-woven fabric. There was a damaged part that could be confirmed by 100x magnified observation (see Fig. 3).
〇 There were no damaged parts that could be visually confirmed in the resin layer and non-woven fabric, and there were no damaged parts that could be confirmed by 100x magnified observation using a scanning electron microscope.

FIG. 2 shows a drawing substitute photograph taken by magnifying a part of the surface of the resin layer of the molding sheet of Example 1 described later by 100 times.

Example 1
Using a spunbond spinning facility, polyethylene terephthalate (hereinafter referred to as "PET") having an intrinsic viscosity of 0.63 dl / g and a glass transition temperature of 80 ° C. is used as the resin B, and styrene methacrylic having a glass transition temperature of 122 ° C. A resin composition obtained by mixing a methyl / anhydride maleic acid copolymer (Rohm GmbH & Co. KG's PLEXIGLAS HW55 (hereinafter referred to as “HW55”) with PET in a proportion of 0.40% by mass was used. It was spun from a spinneret with an orifice diameter of 0.23 mm at a single hole discharge rate of 0.75 g / min. Further, dry air was supplied to the ejector at a pressure (jet pressure) of 0.6 kg / cm ² and stretched in one step. Then, the fibers were collected while being opened on the lower conveyor to obtain a long fiber fleece. The obtained long fiber fleece had a fiber diameter of 22.0 μm, a double refractive index Δn of 0.015, and a converted spinning speed. Was 1430 m / min.

The obtained long fiber fleece was temporarily crimped using a pair of temporary thermocompression bonding rolls composed of two flat rolls at a surface temperature of 80 ° C. and a pressing pressure of 8 kN / m, and then the surface temperature of the rolls: At 145 ° C., pressing pressure: 3.0 kgf / cm ² , processing time: 9.3 seconds, processing speed: 8.4 m / min, this pressure bonding was performed while surface restraining with a felt calendar to obtain a spunbonded non-woven fabric. rice field. The weight of the nonwoven fabric was 210 g / m ² , and the thickness was 650 μm.

Next, the following resin and solvent were mixed at the following ratios, then heated to 30 ° C., dissolved with a stirrer, and a cross-linking agent was added at the following ratios to obtain a coating material for a resin layer.
-Resin A: Byron BX-1001 (manufactured by Toyobo Co., Ltd.) 100 parts-Solvent: 200 parts of methyl ethyl ketone-Crosslinking agent: Block isocyanate 7960 (manufactured by Baxenden) 8 parts

Further, the release film SP3000 # 75 (manufactured by Toyo Cloth Co., Ltd.) was coated with a resin layer paint at a ratio of 450 g per square meter using a comma coater. Then, it was dried in a dryer at 150 ° C. for 3 minutes to obtain a resin layer with a release film.

Next, the resin layer side of the resin layer with a release film was directed toward the surface of the spunbonded non-woven fabric, bonded, and thermocompression bonded under the conditions of 60 ° C. and 20 N / cm ² , and the obtained laminate with a release film was obtained. Was left in a room heated to 60 ° C. for 48 hours to transfer the resin layer. Then, the release film was peeled off to obtain a molding sheet.

Example 2
A molding sheet was obtained in the same manner as in Example 1 except that Coronate HX (manufactured by Tosoh Corporation) was used as the cross-linking agent.

Example 3
A molding sheet was obtained in the same manner as in Example 1 except that Coronate HL (manufactured by Tosoh Corporation), which is an adduct-type polyisocyanate compound, was used as a cross-linking agent.

Example 4
In the spunbond spinning of Example 1, the long fiber fleece was applied under the same conditions except that the single-hole discharge rate was 0.25 g / min and the ejector was supplied with dry air at a pressure (jet pressure) of 0.75 kg / cm ² . Obtained. The fiber diameter of the obtained long fiber fleece was 12.5 μm, the birefringence Δn was 0.018, and the converted spinning speed was 1480 m / min. A non-woven fabric was obtained from the obtained long fiber fleece in the same manner as in Example 1. The weight of the nonwoven fabric was 220 g / m ² , and the thickness was 650 μm. A molding sheet was obtained in the same manner as in Example 3 except that the non-woven fabric was used.

Example 5
In the spunbond spinning of Example 1, the long fiber fleece was applied under the same conditions except that the single-hole discharge rate was 0.52 g / min and the ejector was supplied with dry air at a pressure (jet pressure) of 0.75 kg / cm ² . Obtained. The fiber diameter of the obtained long fiber fleece was 17 μm, the birefringence Δn was 0.018, and the converted spinning speed was 1650 m / min. A non-woven fabric was obtained from the obtained long fiber fleece in the same manner as in Example 1. The weight of the nonwoven fabric was 220 g / m ² , and the thickness was 650 μm. A molding sheet was obtained in the same manner as in Example 3 except that the non-woven fabric was used.

Example 6
A molding sheet was obtained in the same manner as in Example 3 except that Byron 670 (manufactured by Toyobo Co., Ltd.) was used as the resin A.

Example 7
A molding sheet was obtained in the same manner as in Example 3 except that the resin layer paint was applied to the release film at a ratio of 250 g per square meter.

Example 8
A molding sheet was obtained in the same manner as in Example 3 except that the resin layer paint was applied to the release film at a ratio of 450 g per square meter.

Example 9
A molding sheet was obtained in the same manner as in Example 3 except that the resin layer paint was applied to the release film at a ratio of 600 g per square meter.

Example 10 to Example 12
For molding in the same manner as in Examples 7 to 9, except that 10 parts by mass of soft magnetic flat powder (FME3D-AH) having an average particle size of 50 μm manufactured by Sanyo Special Steel Co., Ltd. was added to the resin layer paint while stirring. I got a sheet.

Examples 13 to 15
For molding in the same manner as in Examples 7 to 9, except that 30 parts by mass of soft magnetic flat powder (FME3D-AH) having an average particle size of 50 μm manufactured by Sanyo Special Steel Co., Ltd. was added to the resin layer paint while stirring. I got a sheet.

Comparative Example 1
In a room heated to 60 ° C., a laminate with a release film was obtained in the same manner as in Example 1 except that a polyester spunbonded non-woven fabric manufactured by Toyobo Co., Ltd. (Ecre (registered trademark) W6B61A) was used as the non-woven fabric. After leaving it for 48 hours, the release film was peeled off to obtain a molding sheet. The weight of the nonwoven fabric was 210 g / m ² , and the thickness was 650 μm.

Comparative Example 2
The following resin and solvent were mixed at the following ratios, then heated to 30 ° C., dissolved with a stirrer, and a cross-linking agent was added at the following ratios to obtain a paint for a resin layer.
・ Resin: Acrylic resin with a number average molecular weight equivalent to 180,000 (commercially available) 100 parts ・ Solvent: Methylethylketone 150 parts Dimethylformamide 50 parts ・ Crosslinking agent: Block isocyanate 7960 (manufactured by Baxenden) 8 parts

Next, using the same spunbonded nonwoven fabric as in Example 1, a laminate with a release film was obtained in the same manner as in Example 1, left in a room heated to 60 ° C. for 48 hours, and then the release film was peeled off. I got a sheet for molding.

Comparative Example 3
A molding sheet was obtained in the same manner as in Example 3 except that Byron 200 (manufactured by Toyobo Co., Ltd.) was used as the resin of the resin layer and the temperature at the time of transfer of the resin layer was 70 ° C.

Comparative Example 4
A molding sheet was obtained in the same manner as in Example 3 except that Byron GK-880 (manufactured by Toyobo Co., Ltd.) was used as the resin of the resin layer and the temperature at the time of transfer of the resin layer was 90 ° C.

Each evaluation was performed using the molding sheets of Examples 1 to 15 and Comparative Examples 1 to 4. The results are shown in Tables 1 and 2.

In Tables 1 and 2, A is an adduct-type isocyanate compound (Coronate HL), B is a block burette-type polyisocyanate compound (7960), and C is an isocyanurate-type polyisocyanate compound (Coronate HX). be.

As shown in the above results, the molding sheets of Examples 1 to 15 could be molded without any visually recognizable damaged portion in the spunbonded nonwoven fabric and the resin layer in the drawing process with a pushing amount of 20 mm or less. ..

On the other hand, the molding sheet of Comparative Example 1 has a birefringence Δn of the fibers of the spunbonded nonwoven fabric outside the range of 0.005 or more and 0.050 or less, and the spunbonded nonwoven fabric is subjected to drawing processing with a pushing amount of 20 mm. There was a tear that could be visually confirmed.

In the molding sheet of Comparative Example 2, the number average molecular weight of the resin in the resin layer exceeds the range of 5,000 or more and 150,000 or less, and the resin layer is peeled off and becomes a resin layer in the drawing process with a pushing amount of 20 mm. There was a tear that could be visually confirmed.

The molding sheets of Comparative Examples 3 and 4 had a glass transition temperature (Tg) of 35 ° C. or lower of the resin of the resin layer higher than 35 ° C. ..

1 Non-woven fabric 1s Non-woven fabric surface 2 Resin layer 3 Impregnated part 3s Impregnated part impregnated surface 4 Non-impregnated part 4s Non-impregnated part surface 10 Molded sheet

Claims (9)

A non-woven fabric and a resin layer laminated on the non-woven fabric are provided.
The nonwoven fabric contains fibers having a birefringence Δn of 0.005 or more and 0.050 or less.
The resin layer contains a resin A having a number average molecular weight of 5,000 or more and 150,000 or less and a glass transition temperature (Tg) of 35 ° C. or less, and is impregnated with an impregnated portion of the nonwoven fabric. A molding sheet comprising a non-impregnated portion which is not impregnated in the nonwoven fabric. The molding sheet according to claim 1, wherein the resin layer contains a metal filler. The molding for claim 1 or 2, wherein the resin A is at least one selected from the group consisting of polyester resin, polyester urethane resin, polyamide resin, polyamideimide resin, phenoxy resin, olefin resin, and acrylic resin. Sheet. The molding sheet according to any one of claims 1 to 3, wherein the resin layer contains a cross-linking agent. The molding sheet according to any one of claims 1 to 4, wherein the fiber contains a resin B having an intrinsic viscosity of 0.3 dl / g or more and 0.9 dl / g or less. The molding sheet according to claim 5, wherein the fiber contains a high Tg organic compound having a glass transition temperature higher than that of the resin B. The molding sheet according to any one of claims 1 to 6, wherein the average thickness of the non-impregnated portion is smaller than the average thickness of the nonwoven fabric. The molding sheet according to any one of claims 1 to 7, wherein the average thickness of the non-impregnated portion is larger than the average thickness of the impregnated portion. A molded body obtained by molding any of the molding sheets according to any one of claims 1 to 8.

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