JP3004183B2 - Manufacturing method of molded composite - Google Patents

Manufacturing method of molded composite

Info

Publication number
JP3004183B2
JP3004183B2 JP31044094A JP31044094A JP3004183B2 JP 3004183 B2 JP3004183 B2 JP 3004183B2 JP 31044094 A JP31044094 A JP 31044094A JP 31044094 A JP31044094 A JP 31044094A JP 3004183 B2 JP3004183 B2 JP 3004183B2
Authority
JP
Japan
Prior art keywords
resin layer
thermoplastic resin
core material
skin material
temperature
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 - Fee Related
Application number
JP31044094A
Other languages
Japanese (ja)
Other versions
JPH08164562A (en
Inventor
陽世 橋本
文男 西谷
秀明 田中
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.)
Sekisui Chemical Co Ltd
Original Assignee
Sekisui Chemical Co 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
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Application filed by Sekisui Chemical Co Ltd filed Critical Sekisui Chemical Co Ltd
Priority to JP31044094A priority Critical patent/JP3004183B2/en
Publication of JPH08164562A publication Critical patent/JPH08164562A/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined

Description

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

【０００１】[0001]

【産業上の利用分野】本発明は芯材と表皮材との接着強
度が高く、軽量で賦形性に優れ、建築物、船舶、車両等
の内装材等として好適に使用される成形複合体の製造方
法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded composite which has a high adhesive strength between a core material and a skin material, is lightweight, has excellent shapeability, and is suitably used as an interior material for buildings, ships, vehicles and the like. And a method for producing the same.

【０００２】[0002]

【従来の技術】内装材としては、例えば特開平２−５７
３３３号公報に記載のような、無機繊維が熱可塑性樹脂
で相互に接着されて板状に形成されたマット状物に、ホ
ットメルト接着剤層が全面に接着され、さらに表皮材が
接着されてなる吸音材が知られている。ここで用いられ
るホットメルト接着剤層は、ポリオレフィン系、ポリア
ミド系、ポリエステル系、ポリウレタン系等であり、
０．２〜３ｍｍの孔径を有し、開口率が０．５〜２０％
の通気性のものである。マット状物表面に該ホットメル
ト接着剤層及び表皮材を接着するには、マット状物の表
面温度が熱可塑性樹脂の融点以上となるように加熱し、
次にこの加熱した表面にホットメルト接着剤層と表皮材
とを接着する。或いは、ホットメルト接着剤と表皮材と
を予め加熱して接着するものである。このようにしてな
る吸音材を賦形するには、マット状物の熱可塑性樹脂及
びホットメルト接着剤層の融点以上の温度に加熱し、比
較的低温のプレス機でプレスすることが行われる。2. Description of the Related Art As interior materials, for example, Japanese Unexamined Patent Publication No. 2-57
No. 333, a hot-melt adhesive layer is adhered to the entire surface of a mat-like material in which inorganic fibers are mutually adhered with a thermoplastic resin and formed into a plate shape, and a skin material is further adhered. There are known sound absorbing materials. The hot melt adhesive layer used here is a polyolefin-based, polyamide-based, polyester-based, polyurethane-based, or the like,
Has a hole diameter of 0.2 to 3 mm and an aperture ratio of 0.5 to 20%
It is breathable. In order to bond the hot melt adhesive layer and the skin material to the surface of the mat-like material, heating is performed so that the surface temperature of the mat-like material is equal to or higher than the melting point of the thermoplastic resin,
Next, the hot melt adhesive layer and the skin material are bonded to the heated surface. Alternatively, the hot melt adhesive and the skin material are heated and bonded in advance. In order to shape the sound absorbing material thus formed, the material is heated to a temperature equal to or higher than the melting points of the thermoplastic resin of the mat-like material and the hot melt adhesive layer, and pressed by a relatively low temperature press.

【０００３】[0003]

【発明が解決しようとする課題】上記公報に記載の吸音
材は、通気性を得るために多くの貫通孔を有するので、
マット状物と表皮材に対しては完全な全面接着ではな
く、ホットメルト接着剤層の開口部分は非接着状態であ
る。そして所定の形状に賦形された成形複合体の曲面部
分では、該接着剤層及びその貫通孔が引き伸ばされ、非
接着部分が拡大する。その結果、この部分の接着強度が
著しく低下して、マット状物と表皮材とが剥離し易くな
り、深いプレス成形や、使用中の高温等、過酷な条件に
は対応できなくなることがある。The sound-absorbing material described in the above publication has many through holes in order to obtain air permeability.
The entire surface of the hot melt adhesive layer is not adhered to the mat-like material and the skin material, but is not completely adhered. Then, at the curved surface portion of the molded composite formed into a predetermined shape, the adhesive layer and its through-hole are elongated, and the non-adhered portion is enlarged. As a result, the adhesive strength of this portion is remarkably reduced, and the mat-like material and the skin material are easily peeled off, which may make it impossible to cope with severe conditions such as deep press molding and high temperature during use.

【０００４】また、上記吸音材を製造するには、マット
状物の表面温度が熱可塑性樹脂の融点以上となるように
加熱し、該表面にホットメルト接着剤層と表皮材とを接
着する工程と、これをプレス機に移してプレス成形する
工程とが必要である。ところが、加熱温度がホットメル
ト接着剤層の融点以上であっても、その流動性が小さい
場合には表皮材との接着強度が十分確保できないことが
ある。また、プレス機に移す間に熱可塑性樹脂の温度が
融点以下に下がるので、プレス成形する前に、マット状
物と表皮材とが貼り合わされたものを再び熱可塑性樹脂
の融点以上に加熱しなければならないという問題があ
る。In order to produce the above-mentioned sound absorbing material, a step of heating the mat-like material so that the surface temperature thereof is equal to or higher than the melting point of the thermoplastic resin and bonding the hot melt adhesive layer and the skin material to the surface is carried out. And a step of transferring this to a press and press-molding it. However, even when the heating temperature is equal to or higher than the melting point of the hot-melt adhesive layer, if the fluidity is low, the adhesive strength to the skin material may not be sufficiently secured. In addition, since the temperature of the thermoplastic resin drops below the melting point during transfer to the press, the mat-like material and the skin material must be heated again to a temperature equal to or higher than the melting point of the thermoplastic resin before press molding. There is a problem that must be.

【０００５】本発明は、上記従来の問題点を解消し、深
いプレス成形や過酷な条件にも耐え得るように芯材と表
皮材とが強固、且つ均一に接着され、接着と賦形とを一
工程で行うことができる成形複合体の製造方法を提供す
ることを目的とする。The present invention solves the above-mentioned conventional problems, and the core material and the skin material are firmly and uniformly adhered so that they can withstand deep press molding and severe conditions. An object of the present invention is to provide a method for producing a molded composite that can be performed in one step.

【０００６】[0006]

【課題を解決するための手段】請求項１記載の本発明成
形複合体の製造方法は、加熱加圧により賦形可能なシー
ト状の芯材に、熱可塑性樹脂層（a1）と、該熱可塑性樹
脂層（a1）よりも溶融温度の高い耐熱樹脂層（ｂ）と、
熱可塑性樹脂層（ｃ）とがこの順に積層されてなる複合
フィルムを、その熱可塑性樹脂層（ｃ）が芯材側になる
ように重ね合わせ、さらに熱可塑性樹脂層（a1）側に表
皮材を重ね合わせるとともに、耐熱樹脂層（ｂ）の融点
以下であって、熱可塑性樹脂層（a1）の樹脂の流れ度が
３ｇ／１０分以上となる温度に加熱、溶融し、加圧する
ことにより、芯材と表皮材とを接着すると同時に賦形す
るものである。According to a first aspect of the present invention, there is provided a method for producing a molded composite according to the present invention, wherein a thermoplastic resin layer (a1) is provided on a sheet-like core material which can be formed by heating and pressing. A heat-resistant resin layer (b) having a higher melting temperature than the plastic resin layer (a1);
Composite formed by laminating a thermoplastic resin layer (c) in this order
In the film, the thermoplastic resin layer (c) is on the core material side.
As shown on the left, and the surface is placed on the thermoplastic resin layer (a1) side.
The melting point of the heat-resistant resin layer (b)
The core material and the skin material are bonded and shaped at the same time by heating, melting, and pressing to a temperature at which the flow rate of the resin in the thermoplastic resin layer (a1) is 3 g / 10 minutes or more. Things.

【０００８】請求項２記載の本発明成形複合体の製造方
法は、加熱加圧により賦形可能なシート状の芯材に、熱
可塑性樹脂層（a1）と、酸変性された熱硬化性可塑性樹
脂層（a2）と、該酸変性熱可塑性樹脂層（a2）よりも溶
融温度の高い耐熱樹脂層（ｂ）と、熱可塑性樹脂層
（ｃ）とがこの順に積層されてなる複合フィルムを、そ
の熱可塑性樹脂層（ｃ）が芯材側になるように重ね合わ
せ、さらに熱可塑性樹脂層（a1）側に表皮材を重ね合わ
せるとともに、耐熱樹脂層（ｂ）の融点以下であって、
熱可塑性樹脂層（a1）の樹脂の流れ度が３ｇ／１０分以
上となる温度に加熱、溶融し、加圧することにより、芯
材と表皮材とを接着すると同時に賦形するものである。According to a second aspect of the present invention, there is provided a method for producing a molded composite according to the present invention, wherein a thermoplastic resin layer (a1) and an acid-modified thermosetting thermoplastic A composite film in which a resin layer (a2), a heat-resistant resin layer (b) having a higher melting temperature than the acid-modified thermoplastic resin layer (a2), and a thermoplastic resin layer (c) are laminated in this order , So
Are laminated so that the thermoplastic resin layer (c) is on the core material side.
And then overlay the skin material on the thermoplastic resin layer (a1) side
And not more than the melting point of the heat-resistant resin layer (b),
By heating, melting, and pressing to a temperature at which the flow rate of the resin of the thermoplastic resin layer (a1) is 3 g / 10 minutes or more, the core material and the skin material are bonded and shaped at the same time.

【０００９】本発明について以下に詳細を説明する。本
発明で使用される芯材は加熱加圧により賦形可能なもの
で、無機質繊維又は有機質繊維もしくはこれらの混合繊
維が熱可塑性樹脂により相互に接着された不織布、又は
これら繊維による編布、織布が挙げられる。また、パル
プからなる例えば厚紙、段ボール紙、チップボード、更
には、これらの２種以上が積層されたものも用いること
ができる。The present invention will be described in detail below. The core material used in the present invention can be shaped by heating and pressing, and is made of a nonwoven fabric in which inorganic fibers or organic fibers or a mixed fiber thereof are mutually bonded by a thermoplastic resin, or a knitted fabric or woven fabric made of these fibers. Cloth. Further, for example, cardboard, corrugated cardboard, chipboard made of pulp, and those obtained by laminating two or more of these can also be used.

【００１０】上記不織布、編布、織布（以下「布製品」
という）に用いられる無機質繊維としてはガラス繊維、
岩綿、石綿、炭素繊維等が挙げられ、有機質繊維として
は植物繊維、動物繊維などの天然繊維、セルロース系、
ポリアミド系、ポリエステル系、ポリアクリル系、ポリ
プロピレン系等の合成樹脂繊維が挙げられる。The above non-woven fabric, knitted fabric, woven fabric (hereinafter referred to as “cloth product”)
Glass fiber as the inorganic fiber used for
Rock wool, asbestos, carbon fiber and the like, and as the organic fiber, natural fiber such as plant fiber and animal fiber, cellulosic,
Synthetic resin fibers such as polyamide-based, polyester-based, polyacryl-based, and polypropylene-based resins may be used.

【００１１】上記無機質繊維と有機質繊維とは適宜混抄
されたものでもよい。成形複合体の耐熱変形性、寸法安
定性等の点では無機質繊維を主体とするものが好まし
い。これら布製品の繊維密度は低すぎると強度が不足し
て破れ易く、高すぎると賦形し難くなるので、３００〜
７００ｇ／ｍ2 であることが好ましい。また、不織布の
場合には強度を高めるため、所望によりニードルパンチ
が施されてもよい。The above-mentioned inorganic fibers and organic fibers may be appropriately mixed. From the viewpoint of heat deformation resistance, dimensional stability, and the like of the molded composite, a composite mainly composed of inorganic fibers is preferable. If the fiber density of these cloth products is too low, the strength is insufficient and it is easy to break.
It is preferably 700 g / m2. In the case of a non-woven fabric, needle punching may be performed as desired to increase the strength.

【００１２】不織布の繊維同士を相互に接着する熱可塑
性樹脂は、例えばポリエチレン、ポリプロピレン、飽和
ポリエステル、ポリアミド、ポリスチレン、ポリビニル
ブチラール等が挙げられ、粉末、繊維、エマルジョン等
の状態で用いることができる。不織布に嵩高さを付与し
たり、賦形性をよくするために合成樹脂繊維が用いられ
る場合には、該熱可塑性樹脂は合成樹脂繊維よりも融点
の低いものを用いるのが好ましい。The thermoplastic resin for bonding the fibers of the nonwoven fabric to each other includes, for example, polyethylene, polypropylene, saturated polyester, polyamide, polystyrene, polyvinyl butyral, etc., and can be used in the form of powder, fiber, emulsion or the like. When synthetic resin fibers are used to impart bulkiness to the nonwoven fabric or improve shapeability, it is preferable to use a thermoplastic resin having a lower melting point than the synthetic resin fibers.

【００１３】芯材側に重ねられる複合フィルムの熱可塑
性樹脂層（ｃ）が溶融しても、芯材の種類、即ち材質や
表面状態によっては、溶融樹脂の芯材内部への含浸が不
充分であったり、又は芯材との接着性が悪い場合がある
ので、例えば芯材として段ボール紙やチップボードを用
いる場合には予めその表面を接着可能な状態にする必要
がある。そのため本発明では芯材として上記の他に、上
記芯材の片面もしくは両面に熱可塑性樹脂層が設けられ
たものも芯材として用いられる。この熱可塑性樹脂層と
しては、ポリプロピレン、ポリエチレン、エチレン−酢
酸ビニル共重合体、エチレン−アクリル酸アミド共重合
体、エチレン−アクリル酸エチル共重合体等のポリオレ
フィン系樹脂、ポリ塩化ビニル、ポリアミド、ポリスチ
レン、ポリビニルブチラール等が挙げられる。[0013] Even if the thermoplastic resin layer (c) of the composite film laminated on the core material is melted, impregnation of the molten resin into the core material is insufficient depending on the type of the core material, that is, the material and the surface condition. In some cases, for example, when corrugated paper or chipboard is used as the core material, the surface thereof must be in a state in which it can be bonded. For this reason, in the present invention, in addition to the core material described above, a core material provided with a thermoplastic resin layer on one or both surfaces is also used as the core material. Examples of the thermoplastic resin layer include polyolefin resins such as polypropylene, polyethylene, ethylene-vinyl acetate copolymer, ethylene-acrylamide copolymer, ethylene-ethyl acrylate copolymer, polyvinyl chloride, polyamide, and polystyrene. And polyvinyl butyral.

【００１４】複合フィルムの熱可塑性樹脂層（a1）は、
ホットメルト型接着剤として用いられるものが選択で
き、このようなものとしては高密度ポリエチレン、中低
密度ポリエチレン、線状低密度ポリエチレン、ポリプロ
ピレン、エチレン−酢酸ビニル共重合体等のポリオレフ
ィン系樹脂の１種又は２種以上の混合物、ポリアミド、
ポリ塩化ビニル、及びこれら熱可塑性樹脂の酸変性物等
が挙げられる。The thermoplastic resin layer (a1) of the composite film comprises :
One used as a hot melt adhesive can be selected, such as one of polyolefin-based resins such as high-density polyethylene, medium-low density polyethylene, linear low-density polyethylene, polypropylene, and ethylene-vinyl acetate copolymer. Species or mixtures of two or more, polyamides,
Examples thereof include polyvinyl chloride, and acid-modified products of these thermoplastic resins.

【００１５】複合フィルムの酸変性熱可塑性樹脂層（a
2）に使用される樹脂としては、例えば酸変性ポリエチ
レン、酸変性エチレン−酢酸ビニル共重合体等が挙げら
れ、酸変性ポリエチレンのベースになるポリエチレンと
しては直鎖状低密度ポリエチレン又は高密度ポリエチレ
ンが好ましい。酸変性熱可塑性樹脂層（a2）は耐熱樹脂
層（ｂ）と熱可塑性樹脂層（ｃ）との間にも設けること
が好ましい。The acid-modified thermoplastic resin layer of the composite film (a
Examples of the resin used in 2) include acid-modified polyethylene, acid-modified ethylene-vinyl acetate copolymer, and the like. As the polyethylene on which the acid-modified polyethylene is based, linear low-density polyethylene or high-density polyethylene is used. preferable. The acid-modified thermoplastic resin layer (a2) is preferably provided between the heat-resistant resin layer (b) and the thermoplastic resin layer (c).

【００１６】複合フィルムの耐熱樹脂層（ｂ）は前記熱
可塑性樹脂層（a1）、酸変性熱可塑性樹脂層（a2）及び
熱可塑性樹脂層（ｃ）よりも溶融温度が３０℃以上、好
ましくは５０℃以上高いものが好ましい。これにより芯
材、複合フィルム、表皮材との積層物全体を加熱して耐
熱樹脂層（ｂ）以外の樹脂層を溶融させることができ
る。The heat-resistant resin layer (b) of the composite film has a melting temperature of 30 ° C. or more, preferably, more than that of the thermoplastic resin layer (a1), the acid-modified thermoplastic resin layer (a2) and the thermoplastic resin layer (c). Those having a temperature higher than 50 ° C. are preferred. This makes it possible to heat the entire laminate including the core material, the composite film, and the skin material to melt the resin layers other than the heat-resistant resin layer (b).

【００１７】このような耐熱樹脂層（ｂ）の樹脂として
は、例えばポリブチレンテレフタレート、ポリエチレン
テレフタレート、ポリカーボネート、ポリアミド等、及
びこれらの変性物等の耐熱樹脂が挙げられる。このう
ち、酸変性熱可塑性樹脂層（a2）との接着強度を大きく
できる点で、最も好ましいのは極性の大きいポリアミド
である。Examples of the resin for the heat-resistant resin layer (b) include heat-resistant resins such as polybutylene terephthalate, polyethylene terephthalate, polycarbonate, polyamide, and modified products thereof. Among them, polyamide having a large polarity is most preferable in that the adhesive strength with the acid-modified thermoplastic resin layer (a2) can be increased.

【００１８】熱可塑性樹脂層（ｃ）に関しては、芯材表
面の熱可塑性樹脂と熱融着するものであればよく、この
ような樹脂としては、高密度ポリエチレン、中低密度ポ
リエチレン、線状低密度ポリエチレン、ポリプロピレ
ン、エチレン−酢酸ビニル共重合体等のポリオレフィン
系樹脂の１種又は２種以上の混合物、ポリアミド、ポリ
塩化ビニル、及びこれら熱可塑性樹脂の酸変性物等が挙
げられる。The thermoplastic resin layer (c) is only required to be heat-sealed with the thermoplastic resin on the surface of the core material. Examples of such a resin include high-density polyethylene, medium-low-density polyethylene, and linear low-density polyethylene. Examples thereof include one or a mixture of two or more of polyolefin resins such as density polyethylene, polypropylene, and ethylene-vinyl acetate copolymer, polyamide, polyvinyl chloride, and acid-modified products of these thermoplastic resins.

【００１９】複合フイルムの製造方法は特に限定される
ものではなく、共押出法、押出ラミネート法、ドライラ
ミネート法等が適用される。好ましくは，インフレーシ
ョン法やＴダイ法等の共押出法が採用される。The method for producing the composite film is not particularly limited, and a coextrusion method, an extrusion lamination method, a dry lamination method and the like are applied. Preferably, a co-extrusion method such as an inflation method or a T-die method is employed.

【００２０】本発明で使用される表皮材は植物繊維、動
物繊維などの天然繊維、セルロース系、ポリアミド系、
ポリエステル系、ポリアクリル系、ポリプロピレン系等
の合成樹脂繊維等からなる織布もしくは不織布が好適に
用いられる。このような織布もしくは不織布等の繊維系
の表皮材を用いると、複合フィルムの熱可塑性樹脂層
（a1）が溶融して繊維間に食い込むアンカー効果により
芯材との接着強度が大となる。また、例えばポリウレタ
ン発泡体のように連続気泡を有する発泡シートを織布も
しくは不織布の芯材と貼り合わせる面に設けておけば、
芯材の凹凸を吸収し、表皮材表面の意匠性を高め、且つ
クッション性を付与することもできる。表皮材の厚みは
１〜２ｍｍのものが適当である。The skin material used in the present invention includes natural fibers such as plant fibers and animal fibers, cellulosic materials, polyamide materials, and the like.
A woven or non-woven fabric made of a synthetic resin fiber of polyester, polyacryl, polypropylene or the like is preferably used. When a fiber-based skin material such as a woven or nonwoven fabric is used, the thermoplastic resin layer of the composite film is used.
Due to the anchor effect of (a1) melting and biting between the fibers, the adhesive strength with the core material is increased. Also, for example, if a foam sheet having open cells such as a polyurethane foam is provided on a surface to be bonded to a woven or nonwoven core material,
It can also absorb irregularities of the core material, enhance the design of the surface of the skin material, and provide cushioning. The thickness of the skin material is suitably 1 to 2 mm.

【００２１】本発明でいう流れ度とは、ＪＩＳ Ｋ ７
２１０に規定される測定条件のうち温度を除くすべての
条件を採用したときの、所定温度における１０分間に押
出される樹脂の質量として定義する。従って、本発明で
は複合フィルムの熱可塑性樹脂層（a1）のこの数値が３
ｇ／１０分以上となる接着温度を採用することが必要で
ある。これにより溶融状態において流動性がよく十分な
接着力が確保されるとともに、深い賦形がなされる場合
でも全面を均一な接着状態に保ちながら充分対応し得る
という効果が顕著である。The flow rate in the present invention refers to JIS K7
It is defined as the mass of resin extruded at a predetermined temperature for 10 minutes when all conditions except temperature among the measurement conditions specified in 210 are adopted. Therefore, in the present invention
Indicates that this value of the thermoplastic resin layer (a1) of the composite film is 3
It is necessary to employ an adhesion temperature of at least g / 10 minutes. This has a remarkable effect that, in the molten state, sufficient fluidity is secured and sufficient adhesive force is secured, and even when deep shaping is performed, it is possible to sufficiently cope with the entire surface while maintaining a uniform adhesive state.

【００２２】本発明成形複合体の製造方法では、複合フ
ィルムの熱可塑性樹脂層（ｃ）側を を芯材に重ね、複合
フィルムの熱可塑性樹脂層（a1）及び熱可塑性樹脂層
（ｃ）が溶融状態のままで表皮材を重ねて賦形すること
が必要である。即ち、加熱による熱可塑性樹脂層（ｃ）
と熱可塑性樹脂（a1）の溶融による芯材と表皮材との接
着と、所望の形状に賦形することを同時に行うので一工
程だけで成形複合体を得ることができる。また、接着の
ために加熱し、賦形時にも加熱するという無駄をなくす
こともできる。In the method for producing a molded composite according to the present invention, the composite
Laminate the thermoplastic resin layer (c) side of the film on the core
Thermoplastic resin layer (a1) and thermoplastic resin layer of film
It is necessary that the skin material is overlapped and shaped while (c) is in a molten state. That is, the thermoplastic resin layer (c) by heating
Since the bonding of the core material and the skin material by melting of the resin and the thermoplastic resin (a1) and the shaping into a desired shape are simultaneously performed, a molded composite can be obtained in only one step. Further, it is possible to eliminate the waste of heating for bonding and heating at the time of shaping.

【００２３】加熱の手段は赤外線ヒーター、遠赤外線ヒ
ーター、熱風、電熱等種々のものが使用できるが、遠赤
外線ヒーターを用いるのが好ましい。Various heating means such as an infrared heater, a far-infrared heater, hot air, and electric heating can be used, but it is preferable to use a far-infrared heater.

【００２４】[0024]

【作用】本発明成形複合体の製造方法は、複合フィルム
の熱可塑性樹脂層（a1）の流れ度が３ｇ／１０分以上と
なる加熱接着温度を採用するとともに、同時に加圧しな
がら賦形するものであるから、該熱可塑性樹脂層（a1）
は溶融状態において流動性がよいので賦形され易く、曲
部における芯材または表皮材の変形に伴う伸縮に追随
し、接着面において該フィルムが破断したりせず、芯材
の繊維組織に食い込み、完全且つ均一な面接着状態が保
たれる。このため芯材と表皮材との接着強度が強い成形
複合体が得られる。The method for producing a molded composite according to the present invention comprises a composite film
The thermoplastic resin layer along with the flow of the (a1) to adopt heat bonding temperature to be 3 g / 10 min or more, since it is intended to shaping under pressure at the same time, the thermoplastic resin layer (a1)
Is easy to shape because it has good fluidity in the molten state, follows the expansion and contraction of the core material or skin material in the curved part due to deformation, and the film does not break at the bonding surface, and cuts into the fiber structure of the core material A perfect and uniform surface adhesion state is maintained. Therefore, a molded composite having a strong adhesive strength between the core material and the skin material can be obtained.

【００２５】また、請求項２記載の成形複合体の製造方
法では、酸変性された熱可塑性樹脂層（a2）が熱可塑性
樹脂層（a1）と耐熱樹脂層（ｃ）との間に介在すること
により、両層間の一層強固な接着が確保できる。In the method for producing a molded composite according to the second aspect , the acid-modified thermoplastic resin layer (a2) is interposed between the thermoplastic resin layer (a1) and the heat-resistant resin layer (c). Thereby, stronger adhesion between both layers can be secured.

【００２６】[0026]

【実施例】次に本発明の実施例を図面を参照しながら説
明する。（実施例１） 図１は請求項１記載の本発明成形複合体の実施例を示す
断面図であり、２は成形複合体で、ガラス繊維を主体と
しポリエステル繊維が混抄された不織布よりなる芯材１
１の片面に、複合フィルム２０を介して、ポリエステル
繊維よりなる表 皮材１３が該複合フィルム２０により全
面接着されてなる。直鎖状低密度ポリエチレン（ＬＬＤ
ＰＥ）樹脂層２１が表皮材１３に、ＨＤＰＥ樹脂層２３
が芯材１１にそれぞれ全面接着され、ＬＬＤＰＥ樹脂層
２１は溶融された状態で表皮材１３に加圧賦形されたの
で、表皮材１３にその一部が含浸されてなる。 Next, an embodiment of the present invention will be described with reference to the drawings. (Embodiment 1) FIG. 1 shows an embodiment of the molded composite according to the present invention.
It is a cross-sectional view, 2 is a molded composite, mainly composed of glass fiber.
Material 1 made of non-woven fabric mixed with polyester fiber
1 on one side via a composite film 20
Full table skin material 13 made of fibers by the composite film 20
It is surface bonded. Linear low density polyethylene (LLD
PE) The resin layer 21 is provided on the skin material 13 and the HDPE resin layer 23
Are respectively adhered to the core material 11 and the LLDPE resin layer
21 was pressed into the skin material 13 in a molten state.
Thus, the skin material 13 is partially impregnated.

【００２７】上記芯材１１としては、ガラス繊維（直径
２０〜４０μｍ、長さ２０〜１００ｍｍ）７０重量部と
ポリエステル繊維（６デニール、長さ２０〜８０ｍｍ）
３０重量部を混抄してウェブ状にしたものに、ニードル
パンチ（密度３０点／ｍ2 ）を施した厚さ約９ｍｍ、重
さ５００ｇ／ｍ2 のフェルト状物を用い、これを熱可塑
性樹脂エマルジョン貯槽中に通してエマルジョンを含浸
させた後、挟着ロールに通して上記エマルジョン量を固
形分で３０ｇ／ｍ2 に調整し、これを熱風乾燥装置内で
約１００℃で加熱してエマルジョン中の水分を乾燥する
とともに、フェルト状物中に含浸、分散された熱可塑性
樹脂で繊維同士を部分的に結着せしめた不織布からなる
ものである。The core material 11 includes 70 parts by weight of glass fiber (20 to 40 μm in diameter, 20 to 100 mm in length) and polyester fiber (6 denier, 20 to 80 mm in length).
30 parts by weight were mixed and formed into a web, and a needle-punched (density: 30 points / m 2 ) felted material having a thickness of about 9 mm and a weight of 500 g / m 2 was used. After passing through an emulsion storage tank to impregnate the emulsion, the amount of the emulsion is adjusted to a solid content of 30 g / m 2 by passing through a sandwiching roll, and the emulsion is heated at about 100 ° C. in a hot-air drying apparatus to obtain an emulsion. And a nonwoven fabric in which fibers are partially bound with a thermoplastic resin impregnated and dispersed in a felt-like material while drying the moisture.

【００３３】上記複合フィルム２０は、溶融温度１２５
℃、ＭＩ＝１０のＬＬＤＰＥ樹脂層（厚さ７０μｍ）２
１、溶融温度２２５℃のポリアミド樹脂層（厚さ１０μ
ｍ）２２、ＭＩ＝１のＨＤＰＥ樹脂層（厚さ１００μ
ｍ）２３が共押出成形によりこの順に積層されてなるも
のである。得られた成形複合体２について評価試験を行
った。その結果を併せて表１に示す。The composite film 20 has a melting temperature of 125
LLDPE resin layer (thickness: 70 μm) with a temperature of 10 ° C. and MI = 10
1. Polyamide resin layer with a melting temperature of 225 ° C (thickness 10μ)
m) 22, HD = 1 resin layer of MI = 1 (thickness 100 μm)
m) 23 are laminated in this order by co-extrusion molding. An evaluation test was performed on the obtained molded composite 2. Table 1 also shows the results.

【００２９】接着性試験：芯材と表皮材との端部を剥離
し、８５℃雰囲気下において一方を固定、他方に１０ｇ
／ｍｍの静荷重を架けた状態で１８０度剥離試験を行
い、破壊する場合を×、破壊しない場合は○とする。Adhesion test: peel off the ends of the core material and the skin material, fix one in an atmosphere of 85 ° C., and 10 g on the other
A 180 ° peel test is carried out with a static load of / mm applied, and x indicates that the sample is broken and ○ indicates that the sample is not broken.

【００３４】また、接着温度１６０℃で得られた成形複
合体の芯材と表皮材との接着強度について、常温で引張
速度２００ｍｍ／分の１８０度剥離強度を測定し、併せ
て表１に示した。With respect to the adhesive strength between the core material and the skin material of the molded composite obtained at an adhesive temperature of 160 ° C., a 180 ° peel strength at a normal temperature of 200 mm / min was measured. Was.

【００３５】（実施例２） ＭＩ＝１０のＬＬＤＰＥに代えて、溶融温度１３０℃、
ＭＩ＝１３のＨＤＰＥを用いた以外は実施例１同様に成
形複合体を得、評価試験を行った。その結果を併せて表
１に示す。 Example 2 Instead of LLDPE with MI = 10, a melting temperature of 130 ° C.
A molded composite was obtained and an evaluation test was performed in the same manner as in Example 1 except that HDPE with MI = 13 was used. Table 1 also shows the results.

【００３６】（実施例３） 図２は請求項２記載の 本発明成形複合体の実施例を示す
断面図であり、この成形複合体５は実施例１で用いられ
た複合フィルム２０の代わりに、図２に示す複合フィル
ム５０が用いられた以外は実施例１と同じ構成のもので
あり、ＬＬＤＰＥ樹脂層５１が表皮材１３に、ＨＤＰＥ
樹脂層５４が芯材１１にそれぞれ全面接着され、ＬＬＤ
ＰＥ樹脂層５１は溶融された状態で表皮材１３に加圧賦
形されたので、表皮材１３にその一部が含浸されてな
る。 (Embodiment 3) FIG. 2 is a cross-sectional view showing an embodiment of the molded composite of the present invention according to claim 2 , and this molded composite 5 is used in Example 1.
The composite film shown in FIG.
The LLDPE resin layer 51 is the same as that of the first embodiment except that the
A resin layer 54 is adhered to the entire surface of the core material 11 by LLD.
Since the PE resin layer 51 is press-formed on the skin material 13 in a molten state, the skin material 13 is partially impregnated.

【００３７】上記複合フィルム５０は、溶融温度１２５
℃、ＭＩ＝１０のＬＬＤＰＥ樹脂層（厚さ７０μｍ）５
１、ＭＩ＝３の酸変性ＬＬＤＰＥ樹脂層（厚さ１０μ
ｍ）５２、溶融温度２２５℃のポリアミド樹脂層（厚さ
１０μｍ）５３、ＭＩ＝１のＨＤＰＥ樹脂層（厚さ１０
０μｍ）５４が共押出成形によりこの順に積層されてな
るものである。得られた成形複合体５について評価試験
を行った。その結果を併せて表１に示す。The composite film 50 has a melting temperature of 125
LLDPE resin layer (thickness: 70 μm) with a temperature of 10 ° C. and MI = 10
1, MI = 3 acid-modified LLDPE resin layer (10 μm thick)
m) 52, polyamide resin layer (thickness 10 μm) 53 with a melting temperature of 225 ° C., HDPE resin layer with MI = 1 (thickness 10
0 μm) 54 are laminated in this order by coextrusion molding. An evaluation test was performed on the obtained molded composite 5. Table 1 also shows the results.

【００３８】また、接着温度１６０℃で得られた成形複
合体の芯材と表皮材との接着強度について、常温で引張
速度２００ｍｍ／分の１８０度剥離強度を測定し、併せ
て表１に示した。As for the adhesive strength between the core material and the skin material of the molded composite obtained at an adhesive temperature of 160 ° C., a 180 ° peel strength at a tensile speed of 200 mm / min was measured at room temperature. Was.

【００３９】（実施例４） ポリアミドに代えて、溶融温度２２５℃のポリブチレン
テレフタレートを用いた以外は実施例３同様にして成形
複合体を得、評価試験を行った。その結果を併せて表１
に示す。また、接着温度１６０℃で得られた成形複合体
の芯材と表皮材との接着強度について、常温で引張速度
２００ｍｍ／分の１８０度剥離強度を測定し、併せて表
１に示した。 Example 4 A molded composite was obtained and evaluated in the same manner as in Example 3 except that polybutylene terephthalate having a melting temperature of 225 ° C. was used instead of polyamide. Table 1 shows the results.
Shown in Further, regarding the adhesive strength between the core material and the skin material of the molded composite obtained at an adhesive temperature of 160 ° C., the 180 ° peel strength at a tensile speed of 200 mm / min at room temperature was measured.

【００４０】[0040]

【表１】 [Table 1]

【００４１】[0041]

【発明の効果】本発明複合成形体の製造方法は叙上の通
りであり、芯材と表皮材とが完全且つ均一に全面接着さ
れ、凹部や凸部においても接着強度が非常に優れたもの
となる。また、溶融樹脂面に表皮材を重ねると同時に加
圧して、芯材と表皮材との接着と賦形とを同時に行うの
で、一工程だけで成形複合体を得ることができる。その
ため、接着工程の後で賦形時にもう一度加熱するという
無駄をなくすこともできる。The manufacturing method of the composite molded article of the present invention is as described above, and the core material and the skin material are completely and uniformly adhered over the entire surface, and the adhesive strength is extremely excellent even in the concave portions and the convex portions. Becomes Further, since the skin material is superimposed on the molten resin surface and pressed simultaneously, the bonding and the shaping of the core material and the skin material are performed simultaneously, so that a molded composite can be obtained in only one step. For this reason, it is possible to eliminate the waste of heating again at the time of shaping after the bonding step.

【００４２】又、請求項２記載の本発明成形複合体の製
造方法によると、芯材と表皮材との接着強度を一層向上
させることが可能となる。Further, according to the method for producing a molded composite according to the present invention, the adhesive strength between the core material and the skin material can be further improved.

【００４３】[0043]

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

【図１】請求項１記載の本発明成形複合体の実施例を示
す断面図。FIG. 1 is a sectional view showing an embodiment of the molded composite of the present invention according to claim 1.

【図２】請求項２記載の本発明成形複合体の実施例を示
す断面図。 FIG. 2 shows an embodiment of the molded composite of the present invention according to claim 2;
FIG.

【符号の説明】２，５：成形複合体 １１ ：芯材 １３ ：表皮材 ２０，５０：複合フィルム ２１，５１：線状低密度ポリエチレン樹脂層 ５２：酸変性線状低密度ポリエチレン樹脂層 ２２，５３：ポリアミド樹脂層 ２３，５４：高密度ポリエチレン樹脂層[Description of Signs] 2,5: Molded composite 11: Core material 13: Skin material 20, 50: Composite film 21, 51: Linear low-density polyethylene resin layer 52: Acid-modified linear low-density polyethylene resin layer 22, 53: polyamide resin layer 23, 54: high-density polyethylene resin layer

フロントページの続き (58)調査した分野(Int.Cl.7，ＤＢ名) B29C 51/00 - 51/14 B29C 65/02 - 65/70 B29D 9/00,31/00 B32B 31/00 - 31/20 Continuation of the front page (58) Field surveyed (Int. Cl. 7 , DB name) B29C 51/00-51/14 B29C 65/02-65/70 B29D 9/00, 31/00 B32B 31/00-31 / 20

Claims (2)

(57)【特許請求の範囲】(57) [Claims] 【請求項１】 加熱加圧により賦形可能なシート状の芯
材に、熱可塑性樹脂層（a1）と、該熱可塑性樹脂層（a
1）よりも溶融温度の高い耐熱樹脂層（ｂ）と、熱可塑
性樹脂層（ｃ）とがこの順に積層されてなる複合フィル
ムを、その熱可塑性樹脂層（ｃ）が芯材側になるように
重ね合わせ、さらに熱可塑性樹脂層（a1）側に表皮材を
重ね合わせるとともに、耐熱樹脂層（ｂ）の融点以下で
あって、熱可塑性樹脂層（a1）の樹脂の流れ度が３ｇ／
１０分以上となる温度に加熱、溶融し、加圧することに
より、芯材と表皮材とを接着すると同時に賦形する成形
複合体の製造方法。1. A thermoplastic resin layer (a1) and a thermoplastic resin layer (a)
High heat-resistant resin layer melting temperature than 1) and (b), the thermoplastic resin layer (c) and are laminated in this order composite fill
So that the thermoplastic resin layer (c) is on the core material side.
Laminate and apply a skin material on the thermoplastic resin layer (a1) side
At the same time as the melting point of the heat-resistant resin layer (b)
The flow rate of the resin in the thermoplastic resin layer (a1) is 3 g /
A method for producing a molded composite in which a core material and a skin material are adhered to each other by heating, melting, and pressurizing to a temperature of 10 minutes or more, and pressing the same. 【請求項２】 加熱加圧により賦形可能なシート状の芯
材に、熱可塑性樹脂層（a1）と、酸変性された熱可塑性
樹脂層（a2）と、該酸変性熱可塑性樹脂層（a2）よりも
溶融温度の高い耐熱樹脂層（ｂ）と、熱可塑性樹脂層
（ｃ）とがこの順に積層されてなる複合フィルムを、そ
の熱可塑性樹脂層（ｃ）が芯材側になるように重ね合わ
せ、さらに熱可塑性樹脂層（a1）側に表皮材を重ね合わ
せるとともに、耐熱樹脂層（ｂ）の融点以下であって、
熱可塑性樹脂層（a1）の樹脂の流れ度が３ｇ／１０分以
上となる温度に加熱、溶融し、加圧することにより、芯
材と表皮材とを接着すると同時に賦形する成形複合体の
製造方法。2. A sheet-like core material which can be formed by heating and pressing, a thermoplastic resin layer (a1) and an acid-modified thermoplastic
A composite film in which a resin layer (a2), a heat-resistant resin layer (b) having a higher melting temperature than the acid-modified thermoplastic resin layer (a2), and a thermoplastic resin layer (c) are laminated in this order , So
Are laminated so that the thermoplastic resin layer (c) is on the core material side.
And then overlay the skin material on the thermoplastic resin layer (a1) side
And not more than the melting point of the heat-resistant resin layer (b),
Heating, melting, and pressing to a temperature at which the flow rate of the resin in the thermoplastic resin layer (a1) is 3 g / 10 minutes or more, thereby bonding the core material and the skin material and simultaneously forming a molded composite. Method.
JP31044094A 1994-12-14 1994-12-14 Manufacturing method of molded composite Expired - Fee Related JP3004183B2 (en)

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JP3004183B2 true JP3004183B2 (en) 2000-01-31

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Publication number Priority date Publication date Assignee Title
JP2002240180A (en) * 2001-02-15 2002-08-28 Kawasaki Steel Corp Porous laminate and adhesive dispersion method stampable sheet

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