JP2986564B2 - Composite molded product, its production method and its intermediate material, and backing material for panel - Google Patents

Composite molded product, its production method and its intermediate material, and backing material for panel

Info

Publication number
JP2986564B2
JP2986564B2 JP3031382A JP3138291A JP2986564B2 JP 2986564 B2 JP2986564 B2 JP 2986564B2 JP 3031382 A JP3031382 A JP 3031382A JP 3138291 A JP3138291 A JP 3138291A JP 2986564 B2 JP2986564 B2 JP 2986564B2
Authority
JP
Japan
Prior art keywords
resin
separation membrane
bag
particles
expandable particles
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
JP3031382A
Other languages
Japanese (ja)
Other versions
JPH04214338A (en
Inventor
至郎 山本
正隆 井上
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Teijin Ltd
Original Assignee
Teijin Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to JP2-409665 priority Critical
Priority to JP40966590 priority
Application filed by Teijin Ltd filed Critical Teijin Ltd
Publication of JPH04214338A publication Critical patent/JPH04214338A/en
Application granted granted Critical
Publication of JP2986564B2 publication Critical patent/JP2986564B2/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Description

【発明の詳細な説明】DETAILED DESCRIPTION OF THE INVENTION

【0001】[0001]

【産業上の利用分野】本発明は、近年盛んに用いられて
いる、多孔質コアを主とする複合成形物その製造法及び
その方法で使用する中間素材並びにそれを利用したパネ
ルの裏打ち材に関する。
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a composite molded article mainly composed of a porous core, an intermediate material used in the method, and a backing material for a panel using the composite article, which has been widely used in recent years. .

【0002】[0002]

【従来の技術】多孔質コアを主とする成形物は、軽量材
料として、そのまま、もしくは他の材料と組み合わせて
複合材料、例えばサンドイッチ材として、各種の用途、
例えば建築や車輌等の構造材料や部品、航空宇宙用材
料、スポーツ用品、その他の分野に近年盛んに用いられ
ている。
2. Description of the Related Art Molded articles mainly composed of a porous core are used as a lightweight material, as it is or in combination with other materials, as a composite material such as a sandwich material, for various uses.
For example, it has been actively used in recent years for structural materials and parts such as architecture and vehicles, aerospace materials, sports equipment, and other fields.

【0003】かかる多孔質コアを主とする成形物は、通
常、工業的には樹脂成形物の一種である。従来、これは
工業的には発泡樹脂を用いて成形、つまり、発泡成形さ
れている。この方法は大別すると、加熱または減圧する
と発泡する樹脂又は樹脂原料(以下、これらを「樹脂」
と総称する)を金型に入れて成形する方法、これらの樹
脂の特定のものを粒子状に発泡成形した一次発泡体を金
型に入れて更に発泡させ(二次発泡)、成形する方法と
に分けられる。これを多孔質コアを有するサンドイッチ
材等の軽量構造材料にする方法としては、発泡成形物を
表皮材料、例えば予め成形した繊維補強樹脂成形物(以
下必要に応じてFRPと略称する)と貼り合わせるか、
発泡成形物をプリプレグ等で覆って成形するか、予め成
形した外殻中空体に発泡性樹脂を注入して発泡成形する
のが普通である。
[0003] A molded product mainly comprising such a porous core is usually a type of resin molded product industrially. Conventionally, this is industrially molded using a foamed resin, that is, foamed. This method is roughly classified into a resin or resin raw material that foams when heated or decompressed (hereinafter, these are referred to as “resin”
And a method of molding by molding a primary foam obtained by foaming and molding a specific one of these resins into particles, and further foaming (secondary foaming) the mold. Divided into As a method of converting this into a lightweight structural material such as a sandwich material having a porous core, a foam molded product is bonded to a skin material, for example, a fiber-reinforced resin molded product molded in advance (hereinafter abbreviated as FRP as necessary). Or
It is common to cover the foamed molded article with a prepreg or the like or to mold it, or to inject a foamable resin into a preformed outer shell hollow body to carry out foaming molding.

【0004】近年、これらの方法の改良方法として、発
泡膨張を用いた内圧成形や熱膨張性フォームコアを用い
る方法が提案されている(例えば特開平1−25553
0号,特開昭63−162207号)。これらの方法を
更に改良した方法として、本発明者らは先に熱膨張性粒
子と液状の硬化性樹脂を用いるサンドイッチ材の成形方
法を開発した提案した(特願平1−179830号,ど
う同255305号,同1−229425号)。このよ
うな多孔質コアを樹脂や繊維補強樹脂等の表皮材で挟ん
だサンドイッチ材は断熱性,遮音性にすぐれているが、
別の観点、つまりサンドイッチ材の機械物性においては
全く異なる別の問題が提起されている。即ちサンドイッ
チ材ではしばしばフォームコア部の物性が不足し、広い
面積の薄板状である場合には強度等の物性が不足するこ
とが知られている(例えば、特開昭62−104737
号,特開平1−110943号,特開平1−11094
3号参照)。この問題の少ない高物性のサンドイッチ材
を得ようとすれば多孔質(発泡)フォーム部の強度を上
げる必要があるが、一般にはフォームコアの物性は密度
に関係し、軽量では高物性のものは得難い。つまりフォ
ーム自体は軽量化と強度を両立させることは困難であ
る。また、別の解決策として、フォーム層を厚くするこ
とも考えられるが、例えばこの方法で自動車のドア、ト
ランクリッド等を作れば客室、トランクの容積を減らす
ことになる。
[0004] In recent years, as an improvement method of these methods, a method using internal pressure molding using foam expansion or a method using a thermally expandable foam core has been proposed (for example, Japanese Patent Application Laid-Open No. 1-255553).
0, JP-A-63-162207). As a further improvement of these methods, the present inventors have previously proposed the development of a method for forming a sandwich material using thermally expandable particles and a liquid curable resin (Japanese Patent Application No. 1-179830, No. 198830). No. 255305, No. 1-229425). Sandwich materials in which such a porous core is sandwiched between skin materials such as resin and fiber reinforced resin are excellent in heat insulation and sound insulation.
Another problem is raised in another respect, namely the mechanical properties of the sandwich material. That is, it is known that the properties of the foam core portion are often insufficient with a sandwich material, and the properties such as strength are insufficient when the material is a thin plate having a large area (for example, Japanese Patent Application Laid-Open No. 62-104737).
No., JP-A-1-110943, JP-A-1-11094
No. 3). It is necessary to increase the strength of the porous (foamed) foam part in order to obtain a sandwich material having high physical properties with less of this problem. However, generally, the physical properties of the foam core are related to the density. It is hard to get. That is, it is difficult for the foam itself to achieve both weight reduction and strength. As another solution, it is conceivable to increase the thickness of the foam layer. For example, if a car door, a trunk lid and the like are formed by this method, the volume of the passenger compartment and the trunk will be reduced.

【0005】[0005]

【発明が解決しようとする課題】この解決策としてFR
P等の表皮材にリブを取付ける方法があり、例えばこの
実用的な方法として特開平2−281913号に記載の
方法等がある。しかしながら、リブを取付けるとともに
リブ付フォームコアサンドイッチ材にする実用的な方法
は知られておらず、したがって、表皮材とリブとフォー
ムコアを同時に成形する方法は工業化されてはいない。
As a solution to this problem, FR
There is a method of attaching a rib to a skin material such as P. For example, as a practical method, there is a method described in JP-A-2-281913. However, there is no known practical method for attaching a rib and forming a ribbed foam core sandwich material. Therefore, a method of simultaneously forming the skin material, the rib, and the foam core has not been industrialized.

【0006】すなわち、リブを取付けること、及び裏打
ち材シートを用いてサンドイッチ材化する場合に、リブ
を避けて分割して裏打ちすることは、合理的な工作方法
としては好ましいことではない。
That is, when attaching a rib and forming a sandwich material using a backing material sheet, it is not preferable to rationalize the backing by dividing the rib to avoid the rib.

【0007】本発明は、フォームコア部もリブ状物で補
強された、薄板状でも物性上の問題の少ないサンドイッ
チ材を開発し、これを安価に、容易に成形する方法とそ
の中間素材を提供することを目的とするものである。さ
らに、本発明は上記中間素材を用いたパネルの裏打ち材
を提供することをも目的とするものである。
The present invention has developed a sandwich material in which the foam core portion is reinforced with a rib-like material and which has a small physical property problem even in a thin plate shape, and provides a method for easily and inexpensively molding the same and an intermediate material thereof. It is intended to do so. Still another object of the present invention is to provide a backing material for a panel using the above-mentioned intermediate material.

【0008】[0008]

【課題を解決するための手段】本発明者らは、これらの
目的を達成すべく研究の結果、発泡性粒子を、必要に応
じ樹脂とともに、該発泡性粒子を通さないが流動化した
樹脂は通す分離膜の袋であって、かつ複数の部分に仕切
られている袋に収め、この仕切られた袋に収めた発泡性
粒子を成形時に流動性を示す樹脂とともに成形用の領域
内に置き、該領域を加熱し上記粒子を発泡させることに
より、樹脂又は繊維補強樹脂からなる上下の表皮層と該
表皮層の間に存在するコア層とからなる複合成形物であ
って、コア層には上下の表皮層を連結するシンタクチッ
クフオーム部と上下の表皮層を連結する樹脂部とが並存
し、かつシンタクチックフオーム部と樹脂部との間は分
離膜によって仕切られていることを特徴とする複合成形
物を製造する本発明に到達した。
Means for Solving the Problems The inventors of the present invention have conducted studies to achieve these objects. As a result, the expandable particles, if necessary, together with the resin, are not allowed to pass through the expandable particles, but are not fluidized. It is a bag of a separation membrane to be passed, and stored in a bag partitioned into a plurality of portions, and the expandable particles stored in the partitioned bag are placed in a molding region together with a resin showing fluidity during molding, By heating the region to expand the particles, a composite molded article comprising upper and lower skin layers made of a resin or a fiber-reinforced resin and a core layer existing between the skin layers. Wherein the syntactic foam connecting the outer skin layers and the resin connecting the upper and lower skin layers coexist, and the syntactic foam and the resin are separated by a separation membrane. The main source for manufacturing molded products It has been reached.

【0009】本発明では、上記分離膜の袋の外側に他の
補強繊維材料を存在させることにより、表層部が繊維補
強樹脂(FRP)層で芯部がシンタクチックフォーム部
とリブの機能をもつ樹脂部とが平面方向で並存する強靭
なサンドイッチ材となし得る。この際、非発泡性の軽量
中空粒子やミルドファイバー等の短繊維を発泡性粒子と
共に併用することにより更に成形品の物性を改善でき
る。また、分離膜の袋の内に、予め樹脂の全部又は一部
を入れておくことや、発泡性粒子を袋詰めした分離膜の
袋及び他の補強繊維材料を金型に収めた後、金型に樹脂
を注入することにより、作業性を改善できる。
In the present invention, the surface layer portion has a fiber reinforced resin (FRP) layer and the core portion has the function of a syntactic foam portion and a rib by allowing another reinforcing fiber material to exist outside the bag of the separation membrane. A tough sandwich material in which the resin portion coexists in the plane direction can be formed. At this time, the physical properties of the molded article can be further improved by using non-expandable lightweight hollow particles or short fibers such as milled fibers together with the expandable particles. In addition, the whole or a part of the resin is put in advance in the bag of the separation membrane, or the bag of the separation membrane packed with the expandable particles and the other reinforcing fiber material are placed in a mold, and The workability can be improved by injecting the resin into the mold.

【0010】また、本発明では、発泡性粒子を該発泡性
粒子を通さない(阻止する)分離膜の袋に収め、この分
離膜の袋が複数の部分に仕切られている中間素材、特に
分離膜袋の被融着部にある発泡粒子を発泡させながらこ
の分離膜を融着し、分離膜の袋を複数の部分に仕切った
ことを特徴とする中間素材を使用することが便利であ
る。
In the present invention, the expandable particles are contained in a bag of a separation membrane that does not allow (block) the expandable particles, and the separation material bag is divided into a plurality of portions, particularly an intermediate material. It is convenient to use an intermediate material characterized by fusing the separation membrane while foaming the foamed particles in the portion to be fused of the membrane bag, and dividing the bag of the separation membrane into a plurality of portions.

【0011】本発明に於ける分離膜袋の仕切り(区分
け)は例えば分離膜の袋を部分的にヒートシール等によ
り融着させるか、縫糸等で縫合することにより行う。こ
の仕切部(区分け)は一定間隔をおいて平行に配列させ
て位置させてもよいが、成形物の物性から、必要とする
最適の位置にあるように設けることが一層好ましい。成
形物の任意の方向に荷重、負荷がかかった場合に、常に
所要の物性であるためには必要な分布条件がある。同様
に、分離袋の仕切部は一定の幅であっても良いが、軽量
化と物性を満足させるためには、仕切部の幅、即ち成形
後の樹脂部の幅は目的に合わせ適宜選択することが一層
好ましい。
In the present invention, separation (separation) of the separation membrane bag is performed, for example, by partially fusing the separation membrane bag by heat sealing or by sewing with a sewing thread or the like. The partitions (partitions) may be arranged in parallel at regular intervals, but it is more preferable to provide them at the required optimum positions in view of the physical properties of the molded product. When a load is applied in an arbitrary direction of the molded product, there are necessary distribution conditions so that the physical properties are always required. Similarly, the partition part of the separation bag may have a constant width, but in order to satisfy the weight reduction and physical properties, the width of the partition part, that is, the width of the resin part after molding is appropriately selected according to the purpose. Is more preferred.

【0012】本発明において使用する発泡性粒子は、成
形に使用する樹脂には溶解しない素材からなる発泡膨張
する粒子、例えばダウケミカル社、松本油脂製薬(株)
の「マイクロスフェア」、エクスパンセル社の「エクス
パンセル」、積水化成品(株)の「エスレンビーズ」の
ような熱可塑性樹脂の表皮と膨張する有機物からなる粒
子、共和化成(株)の「ポリスレン」のように発泡材料
を溶かし込んだ熱可塑性樹脂粒子、炭酸水素ナトリウム
の粉末のような無機発泡剤、JSP(株)のポリオレフ
ィンビーズPB−MG15P等のような二次膨張可能な
一次発泡ビーズ等があげられる。
The expandable particles used in the present invention are expanded particles made of a material which does not dissolve in the resin used for molding, for example, Dow Chemical Company, Matsumoto Yushi Pharmaceutical Co., Ltd.
"Microsphere", "Expancel" by Expancel, "Eslen Beads" by Sekisui Plastics Co., Ltd. Thermoplastic resin particles in which a foaming material is dissolved, such as "Polythrene"; inorganic foaming agents such as sodium bicarbonate powder; and secondary expandable primary foaming beads such as polyolefin beads PB-MG15P of JSP Co., Ltd. And the like.

【0013】また、発泡剤を、成形に使用する樹脂には
溶解し難い別の樹脂に溶解又は混合して粉砕した粒子を
用いられる。ここで用いる発泡剤としては、アゾジカル
ボンアミド、アゾビスイソブチロニトリル等のアゾ化合
物、パラトルエンスルホニルヒドラジド、4,4′オキ
シビスベンゼンスルホニルヒドラジド等のヒドラジド、
ジニロペンタメチレンテトラミン等のニトロ化合物等の
公知の有機発泡剤、炭酸水素ナトリウム等の無機発泡剤
があげられる。かかる粒子としては、例えばABS樹脂
に有機発泡剤を溶解して粉砕したもの等が用いられる。
Further, particles obtained by dissolving or mixing a foaming agent in another resin which is hardly dissolved in a resin used for molding or by pulverization are used. Examples of the foaming agent used here include azo compounds such as azodicarbonamide and azobisisobutyronitrile, hydrazides such as paratoluenesulfonyl hydrazide and 4,4'oxybisbenzenesulfonyl hydrazide,
Known organic foaming agents such as nitro compounds such as diniopentamethylenetetramine and the like, and inorganic foaming agents such as sodium hydrogen carbonate and the like can be mentioned. As such particles, for example, particles obtained by dissolving and pulverizing an organic foaming agent in an ABS resin are used.

【0014】本発明では非膨張性の有機又は無機粒子を
発泡性粒子と共に併用して分離膜袋の中に収めて用いる
ことが好ましい場合がある。非膨張性の粒子は、特に中
空粒子であることが好ましい。この様な粒子は、成形に
際しての必要以上の発泡を抑えることやシンタクチック
フオームコアの補強、コスト合理化などの目的で用いら
れる。この様な粒子としてはガラスバルーン、シリカバ
ルーン、シラスバルーン等があげられ、市販の商品とし
ては旭硝子(株)のQ−Cell、日本フィライト社の
「フィライト」等があげられる。
In the present invention, in some cases, it is preferable to use non-expandable organic or inorganic particles in combination with the expandable particles and house them in a separation membrane bag. The non-expandable particles are particularly preferably hollow particles. Such particles are used for the purpose of suppressing unnecessary foaming during molding, reinforcing a syntactic foam core, and rationalizing costs. Examples of such particles include glass balloons, silica balloons, shirasu balloons, and the like, and commercially available products include Q-Cell manufactured by Asahi Glass Co., Ltd., and “Philite” manufactured by Nippon Philite.

【0015】また、ポリ塩化ビニリデンの膨張済みの粒
子、例えばエクスパンセル社の商品名「エクスパンセル
DE」等も用いられる。
In addition, expanded particles of polyvinylidene chloride, for example, "Expancel DE" (trade name, manufactured by Expancel) may be used.

【0016】本発明において使用する分離膜としては、
無機繊維、例えばガラス繊維、炭素繊維、アルミナ繊
維、炭化珪素繊維等や、有機繊維、例えばアラミド繊
維、アリレート繊維、ポリエステル繊維、ポリアミド繊
維、ポリオレフィン繊維、ポリビニルアルコール繊維、
ポリアクリロニトリル繊維等の目開きの小さい織物、編
物、不織布等があげられる。この他、綿、麻等の天然繊
維の織物、編物、不織布等でもよい。また、その目的に
合致した多孔質膜等も用いられる。この分離膜形成繊維
として強度及びモジュラスの大きいものを用いればこの
分離膜自体に補強材としての機能をもたせることがで
き、多くの場合その方が好ましい。
The separation membrane used in the present invention includes:
Inorganic fibers such as glass fibers, carbon fibers, alumina fibers, silicon carbide fibers and the like, and organic fibers such as aramid fibers, arylate fibers, polyester fibers, polyamide fibers, polyolefin fibers, polyvinyl alcohol fibers,
Examples thereof include woven fabrics, knitted fabrics, and nonwoven fabrics having small openings such as polyacrylonitrile fibers. In addition, a woven fabric, a knitted fabric, or a nonwoven fabric of natural fibers such as cotton and hemp may be used. Further, a porous membrane or the like that meets the purpose is also used. If fibers having high strength and modulus are used as the separation membrane forming fibers, the separation membrane itself can have a function as a reinforcing material, and in many cases, it is preferable.

【0017】本発明で使用する成形時に流動性を示す樹
脂としては、多くの場合、熱硬化性樹脂を用いるのが普
通であり、このような樹脂としては、エポキシ樹脂、不
飽和ポリエステル樹脂、ビニルエステル樹脂等があげら
れる。
In many cases, a thermosetting resin is generally used as the resin having fluidity during molding used in the present invention. Examples of such a resin include an epoxy resin, an unsaturated polyester resin, and a vinyl resin. Ester resins and the like.

【0018】裏打ち材を製造する場合は、用いる熱硬化
性樹脂は、裏打ち材として裏打ちされるべきパネルに接
着や粘着可能な、発泡性粒子の発泡温度付近で硬化す
る、該粒子が発泡する温度で流動する樹脂であればよ
く、この条件が満たされる限りにおいて、熱可塑性の樹
脂を混合併用することも出来る。このような樹脂として
は不飽和ポリエステル樹脂、エポキシ樹脂、ビニルエス
テル樹脂、ポリウレタン樹脂等があげられ、混合可能な
熱可塑性樹脂としてはポリ塩化ビニル樹脂等があげられ
る。
In the case of producing a backing material, the thermosetting resin to be used is a material which can be adhered or adhered to a panel to be backed as a backing material, cures at around the foaming temperature of foamable particles, and a temperature at which the particles foam. Any resin can be used as long as this condition is satisfied. Examples of such resins include unsaturated polyester resins, epoxy resins, vinyl ester resins, polyurethane resins, and the like, and examples of thermoplastic resins that can be mixed include polyvinyl chloride resins.

【0019】この樹脂にはまた、樹脂の補強材料、例え
ばミルドファイバー、ウィスカー等の短繊維を加えるこ
とが出来、好ましい場合がある。このようなものの例と
して、ガラス繊維、炭素繊維、炭素ケイ素繊維、アルミ
ナ繊維等のミルドファイバーや短繊維、炭素、窒化ケイ
素、炭化ケイ素、アルミナ等のウィスカーがあげられ
る。剥離破砕した雲母等でもよい。
The resin may be added with a reinforcing material of the resin, for example, short fibers such as milled fiber and whisker, which is preferable in some cases. Examples of such a material include milled fiber such as glass fiber, carbon fiber, carbon silicon fiber, and alumina fiber, and whisker such as short fiber, carbon, silicon nitride, silicon carbide, and alumina. Peeled and crushed mica may be used.

【0020】本発明では、分離膜の他に補強材料を、発
泡性粒子を包蔵した仕切りのある分離膜袋の外側に位置
するようにして、ともに実質的に密閉した成形領域(例
えば金型やプレス等)に入れ、該領域へ液状の樹脂を注
入して硬化させる方法も採用される。この方法は特にあ
る程度の生産を繰り返す場合に有効である。
According to the present invention, in addition to the separation membrane, the reinforcing material is located outside the separation membrane bag having the partition containing the expandable particles, so that the molding region (for example, a mold or a mold) which is substantially sealed together. Press, etc.) and injecting a liquid resin into the area to cure the resin. This method is particularly effective when a certain amount of production is repeated.

【0021】補強材料は一般には高強度高モジュラス繊
維の織物、不織布、ウエブ等であるが、これは金型内で
の液状の樹脂の導入通路を兼ねることが出来る。このよ
うな際には、エポキシ樹脂、不飽和ポリエステル樹脂な
どのほかに、ジシクロペンタジエン樹脂等を用いること
も好ましい。このような場合には樹脂の粘度が低く、反
応速度がある程度高いことが生産上好ましいためであ
る。
The reinforcing material is generally a woven fabric, a nonwoven fabric, a web or the like of high-strength and high-modulus fibers, which can also serve as a passage for introducing a liquid resin in a mold. In such a case, it is also preferable to use a dicyclopentadiene resin or the like in addition to the epoxy resin and the unsaturated polyester resin. In such a case, it is preferable in terms of production that the viscosity of the resin is low and the reaction rate is high to some extent.

【0022】しかしながら、本発明では、場合によって
は、樹脂として熱可塑性樹脂を用いてもよく、またこれ
を熱硬化性樹脂と併用してもよい。この場合、熱可塑性
樹脂の流動点は発泡性粒子の発泡点以下であることが必
要で、かかる熱可塑性樹脂としては例えばポリオレフィ
ン樹脂、ポリスチレン樹脂、フェノキシ樹脂等が用いら
れる。
However, in the present invention, a thermoplastic resin may be used as the resin, and this may be used in combination with a thermosetting resin. In this case, the pour point of the thermoplastic resin needs to be lower than the foaming point of the expandable particles. As such a thermoplastic resin, for example, a polyolefin resin, a polystyrene resin, a phenoxy resin, or the like is used.

【0023】成形時に補強繊維材料を配して表層FPR
を有する成形物とする場合、表層FRPになる部分の補
強材料は、例えばガラス繊維、炭素繊維、アルミナ繊
維、炭化珪素繊維、窒化珪素繊維、金属繊維等の無機繊
維や、例えばポリエステル繊維特にアリレート繊維、ポ
リアミド繊維特にアラミド繊維、ポリオレフィン繊維特
に高重合度ポリエチレン繊維、ポリビニルアルコール繊
維、ポリアクリロニトリル繊維等の有機合成繊維が用い
られる。この他、綿、麻等の天然繊維を用いてもよい、
これらは、通常、織物、編物、UD糸として用いられ
る。
A reinforcing fiber material is arranged at the time of molding to form a surface FPR.
In the case of a molded product having the following, the reinforcing material of the surface layer FRP is, for example, an inorganic fiber such as a glass fiber, a carbon fiber, an alumina fiber, a silicon carbide fiber, a silicon nitride fiber, a metal fiber, or a polyester fiber, particularly an arylate fiber Organic synthetic fibers such as polyamide fibers, especially aramid fibers, polyolefin fibers, particularly high-polymerized polyethylene fibers, polyvinyl alcohol fibers, and polyacrylonitrile fibers are used. In addition, natural fibers such as cotton and hemp may be used.
These are usually used as woven fabric, knitted fabric, and UD yarn.

【0024】シンタクチックフォーム部は、必要によ
り、非膨張性中空粒子の他、ウィスカー、ミルドファイ
バーその他の短繊維を混合し補強することができる。こ
のような短繊維としては、アルミナ、炭化珪素、窒化珪
素等のウィスカー、炭素繊維、アルミナ繊維、ガラス繊
維等のミルドファイバー、剥離マイカ片等があげられ
る。
The syntactic foam part can be reinforced by mixing non-expandable hollow particles, whiskers, milled fibers and other short fibers, if necessary. Examples of such short fibers include whiskers such as alumina, silicon carbide and silicon nitride, milled fibers such as carbon fiber, alumina fiber and glass fiber, and exfoliated mica pieces.

【0025】次に、金型を用いて回分式に本発明方法を
実施する態様を説明する。
Next, an embodiment in which the method of the present invention is carried out batchwise using a mold will be described.

【0026】この実施態様では成形に際して上記の発泡
性粒子を入れた仕切部を有する分離膜袋と樹脂とを金型
に収めるが、樹脂を分離膜袋と共にそのまま金型に入れ
て金型を閉じる他、補強繊維に含浸させて分離膜袋と積
層して金型に収める方法や、分離膜袋のみを金型に入れ
て金型を閉じ、後から樹脂を金型に注入する方法が採ら
れる。樹脂を後から注入する方法は作業性の面から好ま
しい場合が多い。
In this embodiment, during molding, the separation membrane bag having the partition portion containing the expandable particles and the resin are placed in a mold, but the resin is put into the mold together with the separation membrane bag and the mold is closed. In addition, a method of impregnating reinforcing fibers with a separation membrane bag and stacking it in a mold, or a method of putting only the separation membrane bag in a mold, closing the mold, and injecting a resin into the mold later are adopted. . The method of injecting the resin later is often preferred from the viewpoint of workability.

【0027】成形に際して分離膜袋の中に少なくとも樹
脂の一部を入れておくことが好ましい場合がある。特に
金型に樹脂を後から注入する場合にはシンタクチックフ
ォーム部の組成を調整する方法として一部の樹脂を予め
分離膜袋内に入れておくことが好ましい。この様な場
合、予め入れておく樹脂は後から注入する樹脂と全く同
一のものであってよいが、樹脂が低粘度の場合などは袋
に入れる際取扱いに問題が生じるので、同じ樹脂を半硬
化させたり、同系統の固形ないし半固形樹脂を用いた
り、場合によっては注入する樹脂と相溶性のある別の樹
脂を用いることも出来る。例えばエポキシ樹脂をマトリ
ックス樹脂とする場合、注入する樹脂を「エピコート82
6 」(油化シェル社製)を主としたものとし、分離膜袋
に入れる樹脂を「エピコート1001」(油化シェル社製)
とする方法等が好ましい。また、発泡性粒子等を収めた
分離膜袋を液状の樹脂に浸して樹脂を含浸させることも
便利な方法である。
At the time of molding, it may be preferable to put at least a part of the resin in the separation membrane bag. In particular, when the resin is injected into the mold later, it is preferable to put a part of the resin in the separation membrane bag in advance as a method of adjusting the composition of the syntactic foam portion. In such a case, the resin to be put in advance may be exactly the same as the resin to be injected later, but when the resin has a low viscosity, for example, there is a problem in handling when putting it in a bag. It is also possible to cure, use a solid or semi-solid resin of the same type, or use another resin compatible with the resin to be injected in some cases. For example, when epoxy resin is used as the matrix resin, the resin to be injected is referred to as “Epicoat 82
6 "(made by Yuka Shell) and the resin to be put into the separation membrane bag is made of" Epicoat 1001 "(made by Yuka Shell)
Is preferred. It is also a convenient method to immerse the separation membrane bag containing the expandable particles and the like in a liquid resin to impregnate the resin.

【0028】発泡性粒子等を入れた分離膜袋は、均等に
発泡性粒子を均しヒートシールして仕切を入れて、区分
けすることが出来る。発泡性粒子はヒートシールに際し
て加熱圧壊するので容易に分離膜袋をシールすることが
出来、この方法は実用上有意義である。この際用いる分
離膜袋はポリエステル、ポリアミド、ポリオレフィン等
の不織布、目の詰んだ織物、例えばタフタ等が挙げられ
る。樹脂を分離膜袋に入れる場合には、このヒートシー
ルに際してシール部の樹脂を硬化させることも好まし
い。こうすれば樹脂の硬化で接着を兼ねることができ
る。
The separation membrane bag containing the expandable particles and the like can be divided by uniformly leveling the expandable particles, heat-sealing and partitioning. Since the expandable particles are heated and crushed during heat sealing, the separation membrane bag can be easily sealed, and this method is practically significant. The separation membrane bag used at this time includes non-woven fabrics such as polyester, polyamide and polyolefin, and tightly woven fabrics such as taffeta. When the resin is put into the separation membrane bag, it is also preferable to cure the resin at the sealing portion during the heat sealing. In this case, the resin can be cured to serve as an adhesive.

【0029】次に、本発明の別の実施態様(金型を使用
しないで成形する態様)について説明する。分離膜とな
る一対の不織布、織物等の間に、発泡性粒子例えば熱膨
張粒子と、必要ならば樹脂例えば常温で固体の未硬化の
エポキシ樹脂粉末とを均一に挟み、所定の融着点を決め
たプレスで所定部分を融着させる。この際発泡性粒子は
破壊し、エポキシ樹脂によって接着硬化させる。これに
更に樹脂を添わせるか含浸させ、必要に応じて繊維クロ
ス、化粧表皮材料等を積層し、例えばカレンダー等でシ
ート化する。これらは全て連続的に実施出来る。なお、
予め分離膜の袋を作り、この袋の所定の位置を融着させ
てから発泡性粒子や樹脂を入れることも出来る。この際
には非発泡性中空粒子例えばガラス中空体粒子を加える
ことも出来る。
Next, another embodiment of the present invention (an embodiment in which molding is performed without using a mold) will be described. Between a pair of nonwoven fabrics and woven fabrics serving as a separation membrane, foamable particles such as thermally expandable particles and, if necessary, a resin such as an uncured epoxy resin powder which is solid at room temperature are evenly sandwiched, and a predetermined fusion point is set. A predetermined portion is fused by a predetermined press. At this time, the expandable particles are broken, and are bonded and hardened with an epoxy resin. This is further impregnated or impregnated with a resin, and if necessary, a fiber cloth, a decorative skin material and the like are laminated, and formed into a sheet using, for example, a calendar. All of these can be performed continuously. In addition,
It is also possible to prepare a bag of the separation membrane in advance, fuse the predetermined position of the bag, and then put the expandable particles or resin. In this case, non-expandable hollow particles such as glass hollow particles may be added.

【0030】この素材を加熱、発泡、硬化させてサンド
イッチ材を成形する具体的な方法としては、例えば連続
して作られた上記シート素材を加熱してシート中の樹脂
を流動可能にして連続ベルトプレスの間で発泡性粒子を
発泡させると共に、加熱により樹脂を硬化させ、必要あ
れば予め準備されている表皮材例えば化粧材料の裏に接
着し、成形する。これらは全てをほぼ同時に実施出来
る。
As a specific method of forming a sandwich material by heating, foaming, and curing this material, for example, a continuous belt is prepared by heating the above-mentioned sheet material which is made continuously to make the resin in the sheet flowable. The foamable particles are foamed during pressing, and the resin is cured by heating, and if necessary, adhered to the back of a previously prepared skin material, for example, a decorative material, and molded. All of these can be performed almost simultaneously.

【0031】上述の如く連続的に実施する方法の一例を
図1により更に詳しく説明する。図1において、(1)
は発泡性粒子(と非膨張性中空粒子、固形の樹脂)の混
合槽(ホッパー)である。分離膜となる不織布(2a)
(2b)の間に上記混合物が混合槽(1)から均一に散
布され、プレス機(3)で部分的に加熱加圧して予め決
められている位置を融着させる。当然ながらこのプレス
機(3)はカレンダー等の連続設備を用いることも出来
る。補強繊維(5a)(5b)はそれぞれ樹脂含浸槽
(4a)(4b)で樹脂を含浸した後、上記の発泡性混
合物を入れて融着した分離膜袋の両面に重ねられる。更
に化粧用表皮材(6)を重ねてカレンダー(7)で圧搾
されて中間素材シート(8)となる。補強繊維(5a)
(5b)に樹脂を含浸させて重ね合わせる代わりに樹脂
シート、例えば半固化している熱硬化性樹脂シートを重
ね合わせてもよい。また化粧用表皮材と共に別途に補強
繊維クロス等を用いることも出来、それが好ましい場合
がある。
An example of the method for performing the above-described continuous operation will be described in more detail with reference to FIG. In FIG. 1, (1)
Is a mixing tank (hopper) for expandable particles (and non-expandable hollow particles and solid resin). Nonwoven fabric used as separation membrane (2a)
During (2b), the mixture is uniformly dispersed from the mixing tank (1), and partially heated and pressed by a press machine (3) to fuse at a predetermined position. Naturally, the press (3) can use continuous equipment such as a calendar. After the reinforcing fibers (5a) and (5b) are impregnated with the resin in the resin impregnation tanks (4a) and (4b), respectively, they are stacked on both sides of the separation membrane bag into which the above-mentioned foamable mixture has been put and fused. Furthermore, the skin material for makeup (6) is overlaid and pressed by a calender (7) to form an intermediate material sheet (8). Reinforcing fiber (5a)
Instead of (5b) being impregnated with a resin and being superposed, a resin sheet, for example, a semi-solidified thermosetting resin sheet may be superposed. Further, a reinforcing fiber cloth or the like can be separately used together with the cosmetic skin material, which may be preferable in some cases.

【0032】図1の例ではこの中間素材シート(8)は
引続き予熱ヒーター(E1 )で暖められ、ヒーター(E
2 )を備える発泡成形用のベルトプレス(9)で加熱、
発泡、硬化される。このベルトプレス(9)相当装置は
機能を分割して用いることが好ましい場合が多い。この
ようにして連続的に生産されるサンドイッチ材は、裁断
機(10)で所定の大きさに裁断され、製品(11)の
サンドイッチ材となる。
In the example of FIG. 1, the intermediate material sheet (8) is continuously heated by the preheating heater (E 1 ), and the heater (E 1 )
2 ) Heating with foaming belt press (9) equipped with
Foamed and cured. In many cases, it is preferable to use the device corresponding to the belt press (9) with divided functions. The sandwich material thus continuously produced is cut into a predetermined size by the cutting machine (10), and becomes a sandwich material of the product (11).

【0033】図2及び図3はそれぞれ本発明の説明のた
めに示した中間素材と製品サンドイッチ材の断面図であ
る。図2は未発泡の中間素材の断面の一部であり、図2
における(20)は分離膜、(21)は発泡性粒子及び
樹脂の混在相、(22)は融着部、(23)は補強繊維
である。図3は発泡後の成形物の断面の一部であり、図
3における(24)はシンタクチックフォームコア部、
(25)は柱状又は壁状の樹脂部、(26)は表層の繊
維補強樹脂(FRP)であり、(20)は分離膜、(2
2)は融着部である。
FIGS. 2 and 3 are cross-sectional views of the intermediate material and the product sandwich material, respectively, for explaining the present invention. FIG. 2 shows a part of the cross section of the unfoamed intermediate material.
(20) is a separation membrane, (21) is a mixed phase of expandable particles and a resin, (22) is a fused portion, and (23) is a reinforcing fiber. FIG. 3 shows a part of the cross section of the molded product after foaming, and (24) in FIG. 3 shows a syntactic foam core portion,
(25) is a columnar or wall-shaped resin portion, (26) is a fiber reinforced resin (FRP) of a surface layer, (20) is a separation membrane, (2)
2) is a fused portion.

【0034】本発明方法により表皮材を柱状又は壁状の
樹脂部で連結したサンドイッチ材を作る場合、樹脂部の
位置と形状の設計次第ではハニカムコアの空洞をフォー
ムで埋めた成形物等を一段で得ることが出来る。つま
り、本発明における樹脂部(25)は円断面、角断面等
の柱状に限らず、壁状のものも含む。図4〜図6はこの
説明に用いるために例示したもので、例えば図4のごと
く円断面のもの、図5のように断面が線状である不連続
のもの、図6のようにつながったもの等が挙げられる。
この図6の如く樹脂部を配置したサンドイッチ材は具体
的にはハニカムコアの空洞部をフォームで埋めたものに
なる。
When a sandwich material in which the skin material is connected by a columnar or wall-shaped resin portion by the method of the present invention is used, depending on the position of the resin portion and the design of the shape, a molded article or the like in which the cavity of the honeycomb core is filled with foam is formed in one step. Can be obtained at That is, the resin portion (25) in the present invention is not limited to a columnar shape such as a circular cross section or a square cross section, but also includes a wall shape. FIGS. 4 to 6 are exemplarily used for this description. For example, those having a circular cross section as shown in FIG. 4, those having a discontinuous cross section having a linear shape as shown in FIG. 5, and those having a connection as shown in FIG. And the like.
The sandwich material in which the resin portions are arranged as shown in FIG. 6 specifically has a hollow portion of the honeycomb core filled with a foam.

【0035】次に本発明の裏打ち材及びその使用方法に
ついて説明する。
Next, the backing material of the present invention and the method of using the same will be described.

【0036】本発明の裏打ち材は、すでに述べた所から
明らかなように、リブの位置を樹脂のみ、他の部位を樹
脂と発泡した粒子からなるシンタクチックフォームとし
た裏打ち材である。しかし、このものは実用してみる
と、裏打ちに際し発泡させた後に発泡部と樹脂部の厚さ
が異なる問題があり、この解決方法として発泡部の樹脂
の一部をリブ部に移動させることが好ましい。この方法
として発泡性粒子の移動を抑制する分離膜で発泡性粒子
の集合体を覆い、これを上述の図2の如く裏打ち材に埋
め込み、シート化したものを用いればよい。これを用い
てパネルの裏打ち(成形)を行うに際しては、裏打ち材
を金型等で覆って表皮材に添わせて成形することが好ま
しく、樹脂の移動を助ける目的で裏打ち材の片面(非接
着側)に樹脂の通る織物等の繊維群を積層することが好
ましい。但し、裏打ち樹脂層の厚さの均一化は必須では
なく、場合によっては非発泡部の厚さを薄く、発泡部の
厚さを厚くすることが寧ろ好ましい場合もある。例えば
凹凸をファッション性などに用いる場合などがこれに当
る。
As is clear from the above description, the backing material of the present invention is a backing material made of a syntactic foam composed of particles formed by foaming particles with resin only at the ribs and at other positions. However, when this is put to practical use, there is a problem that the thickness of the foamed portion and the resin portion are different after foaming at the time of lining, and as a solution to this, it is necessary to move a part of the resin of the foamed portion to the rib portion. preferable. As this method, an aggregate of the expandable particles may be covered with a separation membrane that suppresses the movement of the expandable particles, embedded in a backing material as shown in FIG. 2, and formed into a sheet. When lining (molding) a panel using this, it is preferable to cover the lining material with a mold or the like and mold it along with the skin material. One side of the lining material (non-adhesive It is preferable to laminate a fiber group such as a woven fabric through which resin passes on the side). However, it is not essential to make the thickness of the backing resin layer uniform, and in some cases, it is rather preferable to make the thickness of the non-foamed portion thinner and the thickness of the foamed portion thicker. For example, this corresponds to a case where unevenness is used for fashionability or the like.

【0037】図7に本発明の裏打ち材の製造を連続的に
実施する方法の一例を示して説明する。図7において、
(31)は発泡性粒子(と中空粒子、固形の樹脂)の混
合槽ホッパーである。分離膜となる不織布(32a)
(32b)の間に発泡性混合物は均一に散布され、プレ
ス機(33)で予め決められている位置を融着させる。
補強繊維(35a)(35b)はそれぞれ樹脂含浸槽
(34a)(34b)で樹脂を含浸した後、この発泡性
混合物を入れて融着した袋の両面に重ね合わせられる。
更に補強クロス(36)と金属薄葉(37)を添えてカ
レンダー(38)で圧搾されて裏打ち材(39)として
巻き取られる。補強繊維に樹脂を含浸させて重ねる代わ
りに、樹脂シート、例えば半固化している熱硬化性樹脂
シートを重ねてもよい。
FIG. 7 shows an example of a method for continuously producing the backing material of the present invention. In FIG.
(31) is a mixing tank hopper for foamable particles (and hollow particles and solid resin). Nonwoven fabric to be a separation membrane (32a)
During (32b), the foamable mixture is evenly dispersed and fused at a predetermined position by a press (33).
The reinforcing fibers (35a) and (35b) are impregnated with the resin in the resin impregnation tanks (34a) and (34b), respectively, and then superimposed on both sides of the bag in which the foamable mixture is put and fused.
Further, it is squeezed by a calender (38) with a reinforcing cloth (36) and a thin metal leaf (37), and wound up as a backing material (39). Instead of impregnating the reinforcing fibers with a resin and stacking them, a resin sheet, for example, a semi-solidified thermosetting resin sheet may be stacked.

【0038】裏打ち(成形)時に金型を用いない方法と
して、裏打ち材の非接着側に金属薄膜を添加することが
好ましい場合がある。
As a method not using a mold at the time of backing (molding), it is sometimes preferable to add a metal thin film to the non-adhesive side of the backing material.

【0039】このような素材を作る方法として、上述の
図7の例に示すように発泡性粒子として樹脂に溶解しな
いものを選び、この発泡性粒子が透過しない分離膜の袋
に入れ、リブにすべき部位を例えば熱融着あるいは縫合
等で区切ると同時にその部分の発泡性粒子を破壊する。
これに樹脂を積層し若しくは樹脂に浸して、含浸させ、
必要に応じて繊維クロス等と金属薄葉を積層して、カレ
ンダー等でシート化する。
As a method for producing such a material, as shown in the example of FIG. 7 described above, foamable particles that do not dissolve in a resin are selected, put in a bag of a separation membrane through which the foamable particles do not pass, and the ribs are formed. At the same time, the portion to be formed is separated by, for example, heat welding or suturing, and at the same time, the expandable particles in that portion are destroyed.
Laminate this with resin or immerse it in resin to impregnate it,
If necessary, a fiber cloth or the like and a thin metal leaf are laminated and sheeted with a calendar or the like.

【0040】この素材を用いて裏打ちしたパネルを成形
する具体的な方法の例を説明すれば、連続して作られた
シート素材であれば、所定の位置で切り取り、予め成形
されている表皮材例えばトランクリッドの裏に接着し、
加熱して樹脂を流動可能にして発泡性粒子を発泡させ、
硬化、成形する。この際、必要に応じて金属薄葉は剥が
す。
A specific example of a method for forming a backing panel using this material will be described. If a sheet material is made continuously, it is cut off at a predetermined position, and a preformed skin material is used. For example, glued to the back of the trunk lid,
Heating to make the resin flowable and expand the expandable particles,
Cure and mold. At this time, the thin metal leaf is peeled off if necessary.

【0041】図8には本発明方法による裏打ち材の使用
方法の例を示す。裏打ち材(39)はカッター(40)
で所定の位置で所定の大きさに切りとられ、切りとられ
た材料(41)として表皮材(43)に接着又は粘着さ
れ、加熱炉(42)で加熱溶融発泡成形される。この様
にして樹脂製リブ(45)の入った発泡フォーム(4
6)で裏打ちされたサンドイッチ材(44)が得られ
る。
FIG. 8 shows an example of a method of using a backing material according to the method of the present invention. Backing material (39) is cutter (40)
Is cut into a predetermined size at a predetermined position, adhered or adhered to a skin material (43) as a cut material (41), and is heated and melt-foamed in a heating furnace (42). In this manner, the foam (4) containing the resin rib (45) is formed.
A sandwich material (44) backed by 6) is obtained.

【0042】[0042]

【発明の効果】上述の如き本発明によれば、分離膜の仕
切部にはシンタクチックフォームが形成されず樹脂が充
填した状態となるため、シンタクチックフォーム部の所
々に樹脂部があたかも柱又は壁の如く配置された軽量成
形物となるため、通常のシンタクチックフォームコアを
有する成形物に比べて成形物の機械的物性、特に曲げ強
度及び曲げ弾性率の改良された成形物となる。したがっ
て、本発明方法による成形物は、各種構造材料、スポー
ツ用品、車輌部品等の各種の分野で広く使用することが
できる。しかも、本発明方法は発泡性粒子を袋に入れて
使用するため、作業性も良好である。
According to the present invention as described above, since the syntactic foam is not formed in the partition portion of the separation membrane and the resin is filled, the resin portion may be formed in places of the syntactic foam portion as if it were a column or a column. Since the molded article is a lightweight molded article arranged like a wall, the molded article has improved mechanical properties, particularly flexural strength and flexural modulus, as compared with a molded article having a normal syntactic foam core. Therefore, the molded product according to the method of the present invention can be widely used in various fields such as various structural materials, sporting goods, and vehicle parts. In addition, since the method of the present invention uses the expandable particles in a bag, the workability is good.

【0043】すなわち、本発明により、補強リブとサン
ドイッチ材のフォームコアとを同時に成形し、補強サン
ドイッチ材を一気に成形でき、優れた軽量成形物が容易
に得られる。しかも、この方法は容易に連続生産に適用
出来る。
That is, according to the present invention, the reinforcing ribs and the foam core of the sandwich material are simultaneously formed, and the reinforcing sandwich material can be formed at a stretch, and an excellent lightweight molded product can be easily obtained. Moreover, this method can be easily applied to continuous production.

【0044】このようにして得る成形物はまた、分離膜
の融着部を適当に設計することにより、例えばハニカム
コアの空洞部をシンタクチックフォームで埋めた構造材
料とすることも出来る。
The molded product thus obtained can also be made into a structural material in which the cavity of the honeycomb core is filled with a syntactic foam, for example, by appropriately designing the fused portion of the separation membrane.

【0045】また、この方法ではフォームコアと表皮材
料との間に気泡を阻止する分離膜があるので層間の接着
が良好であり(特開昭63−246212号参照)、表
皮材料に取り着けたリブは外周を補強繊維で取りまいた
FRPになっているので丈夫である。
In this method, since there is a separation membrane between the foam core and the skin material to prevent air bubbles, the adhesion between the layers is good (see Japanese Patent Application Laid-Open No. 63-246212). The ribs are made of FRP in which the outer periphery is covered with reinforcing fibers, so that they are strong.

【0046】かくして、本発明により、補強リブとフォ
ームでの裏打ちとを同時に実行でき、優れた軽量成形物
が容易に得られるという格別の効果が得られる。
Thus, according to the present invention, the reinforcing rib and the backing with the foam can be carried out simultaneously, and a remarkable effect that an excellent lightweight molded product can be easily obtained is obtained.

【0047】[0047]

【実施例】次に本発明の実施例をあげる。これらは本発
明の説明のためのものであり、本発明の範囲を制限する
ものではない。なお、実施例中の部は特に断りのない限
り、重量部である。
Next, examples of the present invention will be described. These are for explanation of the present invention and do not limit the scope of the present invention. Parts in the examples are parts by weight unless otherwise specified.

【0048】[0048]

【実施例1及び比較例1】発泡性粒子「マツモトマイク
ロスフェアF−30D」(松本油脂製薬(株)製)を入手
した。これは70℃で発泡膨張するものである。一方、
ガラスクロス(旭ファイバーグラス製MS142E-1040-2NT-
10FS)を入手した。これは目付け約500g/m2 のも
のである。さらに、エポキシ樹脂を準備した。この樹脂
は油化シェル製の「エピコート807 」と「エポメートYL
H006」(硬化剤)である。
Example 1 and Comparative Example 1 Expandable particles "Matsumoto Microsphere F-30D" (manufactured by Matsumoto Yushi Seiyaku Co., Ltd.) were obtained. This expands at 70 ° C. on the other hand,
Glass cloth (Asahi Fiberglass MS142E-1040-2NT-
10FS). This has a basis weight of about 500 g / m 2 . Further, an epoxy resin was prepared. This resin is made of Yuka Shell “Epicoat 807” and “Epomate YL”.
H006 "(curing agent).

【0049】次に、2枚のアルミニウム板と「テフロ
ン」で金型を作った。これは2枚のアルミニウム板の間
に「テフロン」のスペーサーを挟んだものである。大き
さはほぼ180mm×200mm、厚さは3mm(スペーサー
厚みによる)である。アルミ板の上下にノズルを取り付
けた。この金型に合わせて織布(ユニセル(株)製のポ
リエステルを主とした不織布「ユニセルBT0404」)を切
取り、袋状となし、これに4.4部の発泡性粒子F−30
Dを入れた。袋内のF−30Dを均等に均して、ヒートシ
ールにより10mm間隔で融着線を作り区分けした。
Next, a mold was made from two aluminum plates and “Teflon”. This is one in which a “Teflon” spacer is sandwiched between two aluminum plates. The dimensions are approximately 180 mm x 200 mm and the thickness is 3 mm (depending on the spacer thickness). Nozzles were installed above and below the aluminum plate. A woven fabric (a non-woven fabric made mainly of polyester, Unicell BT0404, manufactured by Unicell Corp.) was cut out in accordance with the mold to form a bag, and 4.4 parts of expandable particles F-30 were added thereto.
D was added. The F-30D in the bag was evenly leveled, and a fusion line was formed at intervals of 10 mm by heat sealing to be separated.

【0050】金型に合わせてガラスクロスを2枚切りと
った。これに「エピコート807 」100部と「エポメー
トYLH006」31部とを混合した樹脂を充分に含浸させ、
樹脂含浸ガラスクロス/発泡性粒子を入れた不織布袋/
樹脂含浸ガラスクロスの順に金型を納めた。この際、余
分の樹脂は排出させた。
Two glass cloths were cut in accordance with the mold. This is fully impregnated with a resin obtained by mixing 100 parts of "Epicoat 807" and 31 parts of "Epomate YLH006".
Resin-impregnated glass cloth / nonwoven fabric bag containing expandable particles /
The dies were placed in the order of the resin-impregnated glass cloth. At this time, excess resin was discharged.

【0051】金型を閉じて80℃の湯浴に入れ、金型を
約1時間後に湯浴から取り出した。冷却後、金型を開い
て成形物を取り出した。得られた複合成形物は良好な外
見と、相応の強度をもっていた。成形物の比重は約0.
67、曲げ強度は11.2kg/mm2 、曲げ弾性率667
kg/mm2 であった。
The mold was closed and placed in a water bath at 80 ° C., and the mold was removed from the water bath after about one hour. After cooling, the mold was opened and the molded product was taken out. The obtained composite molded article had a good appearance and a corresponding strength. The specific gravity of the molded product is about 0.
67, flexural strength 11.2 kg / mm 2 , flexural modulus 667
kg / mm 2 .

【0052】比較のため、発泡性粒子を入れた不織布袋
を融着させずにそのまま用いた他は実施例1と全く同様
にして成形した成形物は、曲げ強度7.7kg/mm2 、曲
げ弾性率566kg/mm2 であった。
For the purpose of comparison, a molded article molded in exactly the same manner as in Example 1 except that the nonwoven fabric bag containing the expandable particles was used as it was without fusing, had a bending strength of 7.7 kg / mm 2 and a bending strength of 7.7 kg / mm 2 . The elastic modulus was 566 kg / mm 2 .

【0053】[0053]

【実施例2】実施例1と同様に、エポキシ樹脂、発泡性
粒子を包んだ分離膜の袋(10mm間隔の融着線を作ったも
の)、ガラスクロス及び金型を準備した。
Example 2 In the same manner as in Example 1, an epoxy resin, a bag of a separation membrane wrapped with expandable particles (with a fusion line formed at intervals of 10 mm), a glass cloth and a mold were prepared.

【0054】エポキシ樹脂を含浸させずに、ガラスクロ
スを用い、実施例1と同様に、ガラスクロス/発泡性粒
子を入れた袋/ガラスクロスの順に金型を収めた。上方
のノズルを開き、下方のノズルからエポキシ樹脂を注入
した。樹脂の排出を確認して注入を止めた。
Using a glass cloth without impregnating the epoxy resin, the mold was placed in the order of glass cloth / bag containing foamable particles / glass cloth in the same manner as in Example 1. The upper nozzle was opened, and the epoxy resin was injected from the lower nozzle. After confirming the resin discharge, the injection was stopped.

【0055】上方のノズルを開けたまま90℃の湯浴に
入れた。少量の樹脂を排出した。金型を約1時間後に浴
中から取り出した。冷却後、金型を開いて成形物を取り
出した。得られた成形物は良好な外見と、相応の強度
(12.2kg/mm2 )と弾性率(746kg /mm2 )を示した。
The sample was placed in a hot water bath at 90 ° C. with the upper nozzle open. A small amount of resin was discharged. The mold was removed from the bath after about one hour. After cooling, the mold was opened and the molded product was taken out. Moldings and good appearance was obtained, showing the intensity of the corresponding (12.2kg / mm 2) and elastic modulus (746kg / mm 2).

【0056】[0056]

【実施例3】実施例1と同様にエポキシ樹脂、補強ガラ
スクロス及び金型を準備した。ただし、発泡性粒子を入
れた不織布の袋にはエポキシ樹脂「エピコート1001」を
加えた。「エピコート1001」と発泡性粒子F−30Dの比
(重量比)は2.2対4.4とした。実施例1と同様に
袋はヒートシールにより10mm間隔で融着させたが、こ
の際「エピコート1001」は溶けて不織布の袋に滲み込ん
だ。
Example 3 An epoxy resin, a reinforcing glass cloth and a mold were prepared in the same manner as in Example 1. However, the epoxy resin “Epicoat 1001” was added to the nonwoven fabric bag containing the expandable particles. The ratio (weight ratio) between “Epicoat 1001” and the expandable particles F-30D was 2.2 to 4.4. As in Example 1, the bags were fused at intervals of 10 mm by heat sealing. At this time, “Epicoat 1001” melted and permeated into the nonwoven fabric bags.

【0057】実施例1と同様にガラスクロス/発泡性粒
子を入れた袋/ガラスクロスの順に金型に収めた。金型
の上方のノズルを開き、下方のノズルから実施例1で用
いたエポキシ樹脂を注入した。樹脂の排出を確認して注
入を止めた。
As in Example 1, the glass cloth / bag containing the expandable particles / glass cloth were placed in a mold in this order. The upper nozzle of the mold was opened, and the epoxy resin used in Example 1 was injected from the lower nozzle. After confirming the resin discharge, the injection was stopped.

【0058】次に、金型の上方のノズルを開けたまま9
0℃の湯浴に入れたところ、ノズルから少量の樹脂を排
出した。約1時間後に金型を浴中から取り出した。冷却
後、金型を開いて成形物を取り出した。得られた成形物
は良好な外見と、相応の強度(13.3kg/mm2 )と弾性率
(846kg/mm2 )を示した。
Next, with the nozzle above the mold open, 9
When placed in a water bath at 0 ° C., a small amount of resin was discharged from the nozzle. After about one hour, the mold was removed from the bath. After cooling, the mold was opened and the molded product was taken out. Moldings and good appearance was obtained, showing the intensity of the corresponding (13.3kg / mm 2) and elastic modulus (846kg / mm 2).

【0059】[0059]

【実施例4】2枚のポリエステル/ポリプロピレン不織
布「ユニセル」製の分離膜の間に発泡膨張材粒子である
「マツモトマイクロスフェアF−30D」と樹脂を散布
した。この際、樹脂としては油化シェル社の「エピコー
ト1001」の如き固形のエポキシ樹脂を用いて粒子と混合
した。この2枚の分離膜の所定の位置を紋様で融着させ
た。融着はプレスで行ったが、カレンダーの他、赤外
線、レーザー等を利用することも出来る。この場合の紋
様を連続亀甲紋様にすることにより、製品としてハニカ
ムコアをフォームで埋めたパネルが得られた。
Example 4 "Matsumoto Microsphere F-30D", which is a foam expander particle, and a resin were sprayed between two separation membranes made of polyester / polypropylene nonwoven fabric "Unicell". At this time, a solid epoxy resin such as “Epicoat 1001” manufactured by Yuka Shell Co. was used as the resin and mixed with the particles. A predetermined position of the two separation membranes was fused with a pattern. Although the fusion was performed by pressing, infrared rays, lasers, and the like can be used in addition to the calendar. By making the pattern in this case a continuous turtle pattern, a panel in which a honeycomb core was filled with foam as a product was obtained.

【0060】この素材に樹脂を添えた。この樹脂として
は油化シェル社のエポキシ樹脂「エピコート1001」「エ
ピコート348 」及び無水フタル酸、2−メチルイミダゾ
ールの混合物を用い、旭ファイバーグラス製の平織りガ
ラスクロスMS-253E1040-2NT-10FS等の織物に含浸させて
用いた。これをカレンダーでシート化した。この際、別
途に補強用の織物等や化粧用表皮材を積層してシート化
することも出来る。
A resin was added to this material. As the resin, a mixture of Yuka Shell Co. epoxy resin "Epicoat 1001""Epicoat348" and a mixture of phthalic anhydride and 2-methylimidazole, such as Asahi Fiberglass plain woven glass cloth MS-253E1040-2NT-10FS, etc. The fabric was used by impregnation. This was made into a sheet with a calendar. At this time, a woven fabric for reinforcement or a skin material for makeup can be separately laminated to form a sheet.

【0061】このシートを予熱した。これは次の発泡、
硬化工程の予備操作である。
The sheet was preheated. This is the next foam,
This is a preliminary operation of the curing step.

【0062】そのまま、若しくは補強用の織物等や化粧
用表皮材を積層して、ベルトプレス1らなる加熱、発泡
成形装置に導いた。ここで樹脂は溶融され、発泡性粒子
は膨張し、全体の厚さが増えて成形された。この際、面
間隔を制約されながら発泡性粒子が膨張し、かつ該粒子
の移動は分離膜で制約されているので、樹脂は分離膜を
融着させた部分に移動し樹脂部を成形した。この際、表
面に隣接する繊維層があれば樹脂はこの部分を通って移
動する。面間隔は当初制約され逐次所定の大きさに拡げ
ることが好ましく、ベルトプレスは逐次間隔が拡がるか
間隔の異なるものを複数個用いた。
As it was, or by laminating a reinforcing woven fabric or the like and a skin material for makeup, it was led to a heating and foaming apparatus such as a belt press 1. Here, the resin was melted, the expandable particles expanded, and the entire thickness was increased to be molded. At this time, since the expandable particles expand while restricting the surface spacing, and the movement of the particles is restricted by the separation membrane, the resin moved to the portion where the separation membrane was fused to form the resin portion. At this time, if there is a fiber layer adjacent to the surface, the resin moves through this portion. It is preferable that the surface spacing is initially restricted and is gradually increased to a predetermined size, and a plurality of belt presses whose width is gradually increased or whose spacing is different are used.

【0063】所定の厚さになったベルトプレスで発泡と
樹脂の硬化は完了させた。この成形物は所定の大きさに
カッターで切断した。
The foaming and the curing of the resin were completed by a belt press having a predetermined thickness. This molded product was cut into a predetermined size by a cutter.

【0064】このようにして得られた成形物は良好な、
リブ付きフォームコアサンドイッチ材であった。
The molding obtained in this way is excellent
It was a ribbed foam core sandwich material.

【0065】[0065]

【実施例5】松本油脂製薬(株)の発泡性粒子「マイク
ロスフェアF−30D」を準備した。これは70℃で膨張
する粒子である。
Example 5 Expandable particles "Microsphere F-30D" manufactured by Matsumoto Yushi Seiyaku Co., Ltd. were prepared. These are particles that expand at 70 ° C.

【0066】一方、油化シェル社のエポキシ樹脂、「エ
ピコート1001」「エピコート348 」及び無水フタル酸、
2−メチルイミダゾールを準備した。「エピコート100
1」70部と「エピコート348 」30部混合したものを
樹脂A、樹脂Aを100部と無水フタル酸を30部及び
2−メチルイミダゾールを1.5部を混合したものを樹
脂Bとする。
On the other hand, an epoxy resin manufactured by Yuka Shell Co., Ltd., "Epicoat 1001", "Epicoat 348" and phthalic anhydride,
2-Methylimidazole was prepared. "Epicoat 100
Resin A is a mixture of 70 parts of "1" and 30 parts of "Epicoat 348", and resin B is a mixture of 100 parts of resin A, 30 parts of phthalic anhydride and 1.5 parts of 2-methylimidazole.

【0067】ユニセル(株)の目開きの小さいポリエス
テル不織布「ユニセルBT0404」と旭硝子(株)製のガラ
ス繊維織物を準備した。金型より大きめにユニセルを2
枚、金型に合わせてガラス繊維織物を3枚切り取った。
A polyester nonwoven fabric “Unicell BT0404” having a small opening from Unicell Corporation and a glass fiber fabric manufactured by Asahi Glass Co., Ltd. were prepared. 2 unicells larger than the mold
Three glass fiber fabrics were cut out according to the number of sheets and the mold.

【0068】「マイクロスフェアF−30D」100 部と樹
脂Aの深冷粉砕物100部を混合して2枚のユニセルの
間に散布した。これをハンドシーラーを用いて所定の位
置を融着させた。これを金型に合わせて所定の大きさに
切断した。
100 parts of “Microsphere F-30D” and 100 parts of the cryogenically pulverized resin A were mixed and sprayed between two unicells. This was fused at a predetermined position using a hand sealer. This was cut into a predetermined size according to the mold.

【0069】所定の大きさに切り取ったガラス繊維2枚
を、樹脂Bの溶融液に浸した。この間に上記の「マイク
ロスフェアF−30D」の袋詰めを挟み、同じ大きさに切
った3枚目のガラスクロスとアルミ箔を重ねプレスし
た。これを試作裏打ち材とする。
Two glass fibers cut to a predetermined size were immersed in a melt of the resin B. During this time, the above-mentioned bag of "Microsphere F-30D" was sandwiched, and a third glass cloth cut into the same size and an aluminum foil were overlapped and pressed. This is used as a prototype backing material.

【0070】試作した裏打ち材を暖めてアルミ箔面を外
に、予め作っておいたアルミ製パネルに接着し、110
℃のオーブンに入れて加熱した。1時間後に取りだして
所期の通りに裏打ちされていることを確認した。
The prototype backing material was warmed, and the aluminum foil surface was adhered to the aluminum panel which had been prepared in advance.
Heated in an oven at ℃. One hour later, it was taken out and confirmed that it was lined as expected.

【0071】[0071]

【実施例6】実施例5で準備した各材料と旭硝子製の無
機中空バルーンMQ28を準備した。そして、樹脂Bをプ
レスで0.5mm厚さのシート化した。
Example 6 The materials prepared in Example 5 and the inorganic hollow balloon MQ28 made by Asahi Glass were prepared. Then, the resin B was formed into a sheet having a thickness of 0.5 mm by pressing.

【0072】上記「ユニセル」を2枚重ねてハンドシー
ラーで所定の位置を融着させ、非融着部に発泡性粒子と
無機中空バルーンを100/50で混合したものを収め
た。この袋詰めの両側に樹脂Bのシートを添わせ、更に
ガラス繊維織物をその両脇に添えた。これをプレスして
一体化した。これが裏打ち材のモデルに当る。
Two of the above “Unicells” were stacked and fused at a predetermined position with a hand sealer, and the non-fused portion contained a mixture of the expandable particles and the inorganic hollow balloon at a ratio of 100/50. A sheet of resin B was attached to both sides of the bag, and a glass fiber fabric was attached to both sides. This was pressed and integrated. This is the model of the backing material.

【0073】鉄板と裏打ち材モデルを重ね、圧力を掛け
ずにプレスに挟んで110℃まで昇温した。1時間後に
取り出し、冷却して裏打ちした成形物を得た。所期の裏
打ちになっていた。
The iron plate and the backing material model were overlapped, and the temperature was raised to 110 ° C. by applying a pressure without applying pressure. After 1 hour, it was taken out and cooled to obtain a backed molded product. It was the expected backing.

【図面の簡単な説明】[Brief description of the drawings]

【図1】本発明方法により連続的にサンドイッチ複合材
を製造する工程の一例を示す概略図
FIG. 1 is a schematic diagram showing an example of a process for continuously producing a sandwich composite according to the method of the present invention.

【図2】本発明方法の中間素材の断面を模式的に示す断
面模式図
FIG. 2 is a schematic cross-sectional view schematically showing a cross section of an intermediate material of the method of the present invention.

【図3】本発明方法により製造されるサンドイッチ材の
断面を模式的に示す断面模式図
FIG. 3 is a schematic cross-sectional view schematically illustrating a cross section of a sandwich material manufactured by the method of the present invention.

【図4】本発明方法により製造されるサンドイッチ材に
おける樹脂部の断面形状の一例を示す断面図
FIG. 4 is a sectional view showing an example of a sectional shape of a resin portion in a sandwich material manufactured by the method of the present invention.

【図5】本発明方法により製造されるサンドイッチ材に
おける樹脂部の断面形状の他の例を示す断面図
FIG. 5 is a cross-sectional view showing another example of the cross-sectional shape of the resin portion in the sandwich material manufactured by the method of the present invention.

【図6】本発明方法により製造されるサンドイッチ材に
おける樹脂部の断面形状の今一つの例を示す断面図
FIG. 6 is a cross-sectional view showing another example of the cross-sectional shape of the resin portion in the sandwich material manufactured by the method of the present invention.

【図7】本発明の裏打ち材の製造工程の一例を示す概略
FIG. 7 is a schematic view showing an example of a manufacturing process of a backing material of the present invention.

【図8】本発明の裏打ち材を用いてパネルの裏打ちを行
う方法の例を示す概略図
FIG. 8 is a schematic view showing an example of a method for backing a panel using the backing material of the present invention.

【符号の説明】[Explanation of symbols]

(1)発泡性混合物、(2a)(2b)分離膜、(3)
熱プレス、(4a)(4b)樹脂含浸槽、(5a)(5
b)補強繊維クロス、(6)化粧用表皮材料、(7)一
体化してシートとするカレンダー、(9)ベルトプレ
ス、(10)裁断機、(11)製品の複合成形物、(E
1 )予熱装置、(E2 )加熱装置。(20)分離膜、
(21)発泡性粒子及び樹脂、(22)融着部、(2
3)補強繊維、(24)シンタクチックフォーム部、
(25)繊維補強樹脂、(26)柱状又は壁状の樹脂
部。(31)発泡性混合物、(32a)(32b)分離
膜、(33)熱プレス、(34a)(34b)樹脂含浸
槽、(35a)(35b)補強繊維クロス、(36)金
属薄葉に沿って樹脂を流し易くする補強クロス、(3
7)金属薄葉、(38)一体化して裏打ち材とするため
のカレンダー、(39)製品裏打ち材。(40)裁断
機、(41)裏打ち材、(42)加熱炉、(43)表皮
材パネル、(44)裏打ちされた製品、(45)リブ
部、(46)フォーム部。
(1) foamable mixture, (2a) (2b) separation membrane, (3)
Hot press, (4a) (4b) resin impregnation tank, (5a) (5
b) a reinforcing fiber cloth, (6) a cosmetic skin material, (7) a calender integrated into a sheet, (9) a belt press, (10) a cutting machine, (11) a composite molded product of a product, (E)
1) pre-heating device, (E 2) heating device. (20) a separation membrane,
(21) expandable particles and resin, (22) fused part, (2
3) reinforcing fiber, (24) syntactic foam part,
(25) a fiber-reinforced resin, (26) a columnar or wall-shaped resin portion. (31) foamable mixture, (32a) (32b) separation membrane, (33) hot press, (34a) (34b) resin impregnation tank, (35a) (35b) reinforcing fiber cloth, (36) along metal thin sheet Reinforcement cloth to make resin easier to flow, (3
7) thin metal leaf, (38) calender for integrating into a backing, (39) product backing. (40) Cutting machine, (41) Backing material, (42) Heating furnace, (43) Skin material panel, (44) Backed product, (45) Rib portion, (46) Foam portion.

Claims (11)

(57)【特許請求の範囲】(57) [Claims] 【請求項1】樹脂又は繊維補強樹脂からなる上下の表皮
層と該表皮層の間に存在するコア層とからなる複合成形
物であって、コア層には該上下の表皮層を連結するシン
タクチックフォーム部と該上下の表皮層を連結する樹脂
部とが並存し、かつシンタクチックフォーム部と樹脂部
との間は分離膜によって仕切られていることを特徴とす
る複合成形物。
1. A composite molded article comprising upper and lower skin layers made of a resin or a fiber reinforced resin and a core layer existing between the skin layers, wherein the core layer has a syntax for connecting the upper and lower skin layers. A composite molded article characterized in that a tick foam part and a resin part connecting the upper and lower skin layers coexist, and the syntactic foam part and the resin part are separated by a separation membrane.
【請求項2】表皮層とシンタクチックフォーム部との間
も分離膜によって仕切られていることを特徴とする請求
項1記載の複合成形物。
2. The composite molded article according to claim 1, wherein a space between the skin layer and the syntactic foam portion is also separated by a separation membrane.
【請求項3】発泡性粒子を、必要ならば樹脂とともに、
該発泡性粒子を通さないが流動化した樹脂は通すシート
材からなりかつ複数の部分に仕切られている分離膜の袋
に収め、この仕切部を有する分離膜の袋に収めた発泡性
粒子を成形時に流動性を示す樹脂とともに成形用の領域
内に入れ、該領域を加熱し、上記粒子を発泡させて成形
し、シンタクチックフォームコア部と樹脂部とが並存す
る軽量成形物を製造することを特徴とする複合成形物の
製造法。
3. The method according to claim 1, further comprising the step of:
The resin that does not pass through the expandable particles but is fluidized is stored in a separation membrane bag made of a sheet material to be passed through and partitioned into a plurality of portions, and the expandable particles stored in the separation membrane bag having the partition portion are removed. Putting into a molding area together with a resin exhibiting fluidity during molding, heating the area, foaming the particles, and molding to produce a lightweight molded article in which a syntactic foam core portion and a resin portion coexist. A method for producing a composite molded article, characterized in that:
【請求項4】非発泡性の中空粒子を発泡性粒子と共に用
いることを特徴とする請求項3に記載の複合成形物の製
造法。
4. The method according to claim 3, wherein the non-expandable hollow particles are used together with the expandable particles.
【請求項5】分離膜の袋の中に、予め樹脂の全部又は一
部を入れておくことを特徴とする請求項3又は4に記載
の複合成形物の製造法。
5. The method for producing a composite molded product according to claim 3, wherein all or a part of the resin is put in a bag of the separation membrane in advance.
【請求項6】分離膜の袋の外側に補強繊維材料を配置す
るようにして成形用の領域に入れることを特徴とする請
求項3,4,又は5に記載の複合成形物の製造法。
6. The method for producing a composite molded article according to claim 3, wherein the reinforcing fiber material is placed outside the bag of the separation membrane in the molding area.
【請求項7】成形用の領域として金型を用い、分離膜の
袋に収めた発泡性粒子及び補強繊維材料を金型に入れた
後、金型に樹脂を注入することを特徴とする請求項6に
記載の複合成形物の製造法。
7. The method according to claim 7, wherein a mold is used as a molding area, and after the expandable particles and the reinforcing fiber material contained in the bag of the separation membrane are put into the mold, a resin is injected into the mold. Item 7. The method for producing a composite molded article according to Item 6.
【請求項8】発泡性粒子が該発泡性粒子を通さないが液
状化した樹脂は通す平坦な分離膜の袋に収められてお
り、かつこの分離膜の袋が複数の部分に仕切られている
ことを特徴とする請求項3に記載の方法で用いる中間素
材。
8. A flat separation membrane bag through which the expandable particles do not allow passage of the foamable particles but through which the liquefied resin passes, and the separation membrane bag is partitioned into a plurality of portions. An intermediate material used in the method according to claim 3, characterized in that:
【請求項9】分離膜を所定間隔で融着させて分離膜の袋
を複数の部分に仕切られていることを特徴とする請求項
8に記載の中間素材。
9. The intermediate material according to claim 8, wherein a bag of the separation membrane is partitioned into a plurality of parts by fusing the separation membrane at predetermined intervals.
【請求項10】発泡性粒子が該発泡性粒子を通さないが
液状化した樹脂は通す平坦な分離膜の袋に収められてお
り、かつこの分離膜の袋が複数の部分に仕切られてお
り、樹脂と一体として薄板状物品に成形されていること
を特徴とするパネルの裏打ち材。
10. A flat separation membrane bag through which the expandable particles do not allow passage of the expandable particles but through which the liquefied resin passes, and wherein the separation membrane bag is partitioned into a plurality of portions. A backing material for a panel, which is formed into a sheet-like article integrally with a resin.
【請求項11】上記薄板状物品の片面に金属薄葉が積層
されており、かつ該金属薄葉とシンタクチックフォーム
層との間に補強繊維層が存在する請求項10に記載の裏
打ち材。
11. The backing material according to claim 10, wherein a thin metal leaf is laminated on one surface of the sheet-like article, and a reinforcing fiber layer is present between the thin metal leaf and the syntactic foam layer.
JP3031382A 1990-12-11 1991-02-01 Composite molded product, its production method and its intermediate material, and backing material for panel Expired - Lifetime JP2986564B2 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
JP2-409665 1990-12-11
JP40966590 1990-12-11

Publications (2)

Publication Number Publication Date
JPH04214338A JPH04214338A (en) 1992-08-05
JP2986564B2 true JP2986564B2 (en) 1999-12-06

Family

ID=18518975

Family Applications (1)

Application Number Title Priority Date Filing Date
JP3031382A Expired - Lifetime JP2986564B2 (en) 1990-12-11 1991-02-01 Composite molded product, its production method and its intermediate material, and backing material for panel

Country Status (1)

Country Link
JP (1) JP2986564B2 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPWO2017191668A1 (en) * 2016-05-02 2019-04-25 日産自動車株式会社 Fiber-reinforced resin molded article and method for producing the same

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DK176541B1 (en) 2005-09-30 2008-07-28 Lm Glasfiber As Laminate or a sandwich structure with malleable core material
DE102010033627B4 (en) * 2010-08-06 2012-05-31 Daimler Ag Shaped plastic multilayer component with endlessly reinforced fiber layers and method for its production
EP3150370B1 (en) * 2014-05-26 2018-12-26 Nissan Motor Co., Ltd Methods for producing composite material molded article

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPWO2017191668A1 (en) * 2016-05-02 2019-04-25 日産自動車株式会社 Fiber-reinforced resin molded article and method for producing the same
EP3453738A4 (en) * 2016-05-02 2019-05-08 Nissan Motor Co., Ltd. Fiber-reinforced resin molded article and method for manufacturing same
US10723100B2 (en) 2016-05-02 2020-07-28 Nissan Motor Co., Ltd. Fiber-reinforced resin molded article and method for manufacturing same

Also Published As

Publication number Publication date
JPH04214338A (en) 1992-08-05

Similar Documents

Publication Publication Date Title
US11241867B2 (en) Multicomponent polymer resin, methods for applying the same, and composite laminate structure including the same
US5242637A (en) Process for the production of composite molded articles
US5665295A (en) Process for the production of composite molded article
US5019197A (en) Method of making composites having layers of the same or different firmness
WO2015181870A1 (en) Composite material molded article and method for producing same
JP2986564B2 (en) Composite molded product, its production method and its intermediate material, and backing material for panel
CN112969575A (en) High strength low heat release composite material
WO2001025055A1 (en) Sandwich structural door inner panel
JPH0712613B2 (en) Method for manufacturing composite molded article
JP5864324B2 (en) Method for producing fiber reinforced composite
JPH054291A (en) Manufacture of foamable-thermally-expandable web
JP3124301B2 (en) Manufacturing method of composite molded products
JP3148298B2 (en) Manufacturing method of lightweight composite molding
JPH08276524A (en) Manufacture of composite molded article with porous core
JP2553206B2 (en) Method for manufacturing lightweight composite molded article
JP2731006B2 (en) Manufacturing method for composite molded products
JP2776973B2 (en) Manufacturing method of composite molded product
JP2986563B2 (en) Panel backing material and method of manufacturing the same
JPH08276441A (en) Light-weight composite molding strengthened at peripheral edge and manufacture thereof
JP2986561B2 (en) Composite molded article and method for producing the same
US5225450A (en) Unfoamed foil suitable as an adhesive
JP3124312B2 (en) Manufacturing method of lightweight composite molding
JPH08207173A (en) Composite molded product having porous core susceptible to on-line electrostatic painting and production thereof
JPH09169057A (en) Production of composite molded product having porous core
JPH0740484A (en) Interior trim base material