JP3092922B1 - Structural material and method of manufacturing structural material - Google Patents

Abstract

Abstract: [PROBLEMS] While utilizing the buffering performance of agglomerated resin,
Provided is a structural material applicable to a portion where contact with agglomerated resin is desired to be avoided, and a method for manufacturing the same. SOLUTION: A structural material 1 is plate-shaped, and an agglomerated body portion 3 is provided.
Is embossed over the entire surface, thereby forming an embossed surface 5 having minute irregularities. Therefore, the structural material 1 is translucent due to the embossed surface 5. Glue-like part 3
Has a styrenic thermoplastic elastomer as a base polymer, and loses its flowability as a whole while containing a process as a flowable component in the interstices of the network structure of the base polymer to form a gel. When the structural material 1 is manufactured, it can be performed by normal injection molding using a mold having an embossed surface.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a structural material having a function as, for example, a cushioning material or a packing, and a method of manufacturing the structural material.

[0002]

2. Description of the Related Art Conventionally, an agglomerated resin has been used as a material for forming, for example, a cushioning material or a packing. The agglomerated resin is in a state where fluidity is lost due to inclusion of an oil component in the interstices of the network structure of the base polymer.

[0003] Such an agglomerated resin exhibits so-called viscoelasticity and has an anti-vibration effect. Therefore, if a buffer material is formed of this kind of agglomerated resin and interposed between two components, In addition, shock and vibration transmitted from one component to the other component can be effectively reduced. In addition, since the agglomerated resin has extremely high adhesion to the contact surface, if a gasket-like resin of this type is used to form a packing and be interposed between two components, excellent airtightness or liquid tightness will be obtained. Demonstrate the nature.

[0004]

By the way, although the agglomerated resin has the above-mentioned excellent properties, it has the following problems, and when it is actually applied to products, further improvement is required. Have been. Since the surface is sticky, workability may be impaired.

For example, in an electronic device having a cartridge-type device that can be inserted into the housing space of the main body, when a cushioning material is provided on the inner wall surface of the housing space or the outer peripheral surface of the cartridge-type device, the cushioning material is used. When formed with the agglomerated resin, the stickiness of the agglomerated resin surface makes it extremely difficult to insert and remove the cartridge-type device. Could not be formed.

[0006] Because of the transparency of the material, even a slight molding defect is very noticeable. Therefore, even if there is no practical problem such as a countermeasure against vibration, the product may not be recognized as a finished product. Because it is very flexible, it has poor shape retention and may cause problems in dimensional accuracy.

[0007] The fluid component of the agglomerated resin may ooze out from the surface. Due to the characteristics of the material, adhesive tape or adhesive does not stick to the surface. Therefore, there has been a problem that a buffer material or packing made of an agglomerated resin cannot be arranged in a place where these characteristics become obstacles.

The present invention has been made to solve the above-mentioned problems, and a main object of the present invention is to avoid the contact with the agglomerated resin while utilizing the buffering performance of the agglomerated resin. An object of the present invention is to provide a structural material applicable to a desired place and a method of manufacturing the structural material.

[0009]

Means for Solving the Problems and Effects of the Invention
(1) In order to achieve the above-mentioned object, the invention of claim 1 provides an agglomerate-like portion made of an agglomerate-like resin material obtained by adding a softener for imparting flexibility to a thermoplastic resin as a main component. And a non-agglomerated body made of a non-agglomerated resin material, wherein the aggregated body has an Asker FP hardness of 30 to 30.
90, and the height and depth of the agglomerated body are
Reduced adhesiveness of the agglomerated part of about 10 μm to 1 mm
The gist of the present invention is a structural material having an embossed surface on which embossing is performed to form minute irregularities .

I) In this structural material, the agglomerated portion can be formed by employing a agglomerated resin conventionally used as a cushioning material. The agglomerated resin is a resin material in which the constituent components of the thermoplastic resin as the base resin are agglomerated by a softener, more specifically,
The base resin forms a network structure, and a softening agent (for example, an oil component) is included in the gaps of the network structure to lose fluidity.

Examples of the base resin include styrene (isoprene-styrene (SIS), ethylene-propylene-styrene (SEPS), ethylene-butadiene-styrene (SEBS), olefin, ester, and the like. Amide type, various thermoplastic elastomers such as urethane type, and their hydrogenated and modified products by others, or styrene type, ABS type, olefin type,
Vinyl chloride type, acrylic type, carbonate type, acetal type, nylon type, halogenated olefin type (ethylene tetrafluoride type, fluorinated ethylene chloride type, fluoroethylene propylene type etc.), cellulose type (ethyl cellulose type etc.) Examples thereof include thermoplastic resins and rubber modified products of these resins. Among them, styrene elastomers are preferably used. These various thermoplastic resins may be used alone or as a blend of two or more.

[0012] The agglomerated body may be provided with
Furthermore, various fillers, various metal powders, wood chips, glass powder,
Incorporates ceramic powder, granular or powdered solid fillers such as granular or powdered polymers, and other various natural or artificial short or long fibers (eg, glass fibers, metal fibers, and various other polymer fibers). be able to. Further, weight reduction can be achieved by blending a hollow filler, for example, an inorganic hollow filler such as a glass balloon and a silica balloon, and an organic hollow filler made of polyvinylidene fluoride and a polyvinylidene fluoride copolymer. Further, in order to improve various physical properties such as weight reduction, it is also possible to mix various foaming agents, and it is also possible to mechanically mix gas during mixing.

In addition to the above components, known additives such as resin components can be used in combination for improving various properties. As the resin component, for example, a polyolefin resin or a polystyrene resin can be used in combination. By adding these, workability and heat resistance can be improved. Examples of the polyolefin resin include polyethylene, isotactic polypropylene, and a copolymer of propylene with a small amount of other α-olefin (for example, propylene-ethylene copolymer, propylene / 4-
Methyl-1-pentene copolymer), poly (4-methyl-
1-pentene), polybutene-1 and the like.

As other additives, if necessary,
Antibacterial agent, hindered amine light stabilizer, ultraviolet absorber,
Antioxidants, inorganic fillers, coloring agents, silicone oils,
Various tackifiers (tackifiers) such as coumarone resin, coumarone-indene resin, phenol terpene resin, petroleum hydrocarbon, and rosin derivative can be used in combination.

Ii) The softener is not particularly limited, and a known softener can be used. The softener may be either hydrophilic or hydrophobic, but usually a liquid or liquid material at room temperature is suitably used. Preferred softeners include various types of rubber or resin softeners such as mineral oils, vegetable oils, and synthetic systems, and these softeners may be used alone.
Two or more kinds may be used as a mixture as long as they have good compatibility with each other. The mineral oils include process oils such as naphthenic oils and paraffin oils, and the vegetable oil oils include cottonseed oil, castor oil, rapeseed oil, soybean oil, linseed oil, coconut oil, wood wax (Japanese wax), peanut oil, and olive oil. Can be Among them, mineral oils, and among them, certain process oils are preferably used. In addition, since the hardness of the agglomerated resin becomes lower as the amount of the softener added increases, it may be adjusted to a desired hardness.

Iii) In the present invention, the Asker FP hardness is set to 30 to 90. When the Asker FP hardness is lower than 30, a large amount of a softening agent is added, so that not only the compression set becomes large but also bleeding is feared. On the other hand, if it exceeds 90, the shock absorbing ability may be reduced or the formability may be deteriorated. The Asker FP hardness can be measured with a commercially available Asker FP hardness tester.

Particularly, in order to obtain the Asker FP hardness, when the thermoplastic resin is 100 parts by weight, 50 to 50 parts by weight.
It is desirable to include 2000 parts by weight of a softener,
0 to 1300 parts by weight are more preferred. That is, since the softener also acts as a plasticizer, if the amount is too small (below the above lower limit), not only the thermoplastic composition becomes hard, but also the moldability becomes poor. If the amount is too large, the softener may ooze out or the amount of outgas from the molded article may increase, and the range not more than the above upper limit is preferable.

Iv) In the present invention, the surface of the agglomerated body is embossed. The embossing is a process for forming minute irregularities over a wide area of the surface. The embossing reduces the adhesiveness of the agglomerated body, and has the following effects.

The degree of error Nbosu processing, as illustrated in FIG. 8, can for example height and with respect to a reference thickness of the sheet or the like, in defined by the depth to the reference thickness, in the present invention, the height <br/> and The depth (dimensions of unevenness) is about 10 μm to 1 mm. Further, in the case of an agglomerated body sheet (gel sheet) (for example, a thickness of 1.0 to 5.0 mm), the size of the irregularities is 30
The range of μm to 500 μm is preferred.

The workability is improved because the surface tackiness is reduced. Therefore, it does not easily stick to hands or the like during work.
In addition, when a cushioning material made of a structural material having an embossed surface (for a cartridge type device, for example) is used, insertion and removal of the cartridge type device becomes easy.

When the agglomerated body itself is transparent, molding defects are noticeable (even if use is not hindered), but by embossing, molding defects become inconspicuous and the product yield Is improved.・ Since the embossed surface has minute irregularities,
Glue-like part is used for other members (for example, wall surface on computer side)
When it is brought into close contact with the air, air can easily escape from it.
Therefore, since no large air bubbles remain between the two members, the desired vibration damping performance can be obtained as designed.

By embossing the surface,
Since the gap between the base resins on the surface is reduced, the fluid component of the agglomerated resin is less likely to exude. Also,
Extent of embossing (lower limit) is a 10μm or more
However, if it is out of this range, the above-described effects are reduced.

The structural material having the embossed surface can be used not only as a cushioning material or a packing but also as a heat transfer material (heat transfer sheet) placed on a semiconductor circuit or the like for heat dissipation. When a heat conductive material is used, it is preferable to add ceramic powder or the like in order to further improve the thermal conductivity.

(2) The invention according to claim 2 is the gist of the structural material according to claim 1, characterized in that the agglomerated resin material contains a bromine-based flame retardant. In the present invention, since the agglomerated resin material contains a brominated flame retardant, it has flame retardancy. Therefore, it can be applied to various uses.

Here, the degree of flame retardancy is UL94
The degree to which it has self-extinguishing properties in a vertical combustion test is mentioned. It is known that this UL94 vertical combustion test has self-extinguishing properties.
The evaluation of the L94 vertical burning test is V class (that is, 94V
−0 to 94V-2). UL is an abbreviation of Underwriters Laboratories Inc.
The 94 vertical burn test is a well-known test and will be briefly described below.

As a test piece, length 125 ± 5 mm, width 1
3.0 ± 0.3mm, minimum and maximum thickness (13m
m), and fix the test piece to the clamp at a position of 6 mm at the upper end. The lower end of the test piece was surgical cotton (50 mm x
50 mm, thickness 6 mm) to 300 mm above. Adjust so that a blue flame with a height of 20 ± 1 mm comes out of the burner. Apply the flame to the center point of the lower edge of the specimen,
The tip of the burner should be 10 mm below that point at the lower end of the test piece, and after indirectly burning at that distance for 10 seconds,
Immediately move the burner away from the test piece and simultaneously start measuring the afterflame time t ₁ in seconds and record that t ₁ . Immediately after the residual flame of the test piece stopped, the burner was moved below the test piece, and the burner was maintained at a position of 10 mm from the remaining part of the test piece for the next 10 seconds. Measurement of time t ₂ and afterglow time t ₃ is started, and t ₂ ,
the t ₃ record. Then, the after-flame time t ₁ after the first flame contact, the after-flame time t ₂ after the second flame contact, the afterglow time t ₃ after the second flame contact, whether the test piece burned up to the clamp, Observe and record whether the specimen has ignited the cotton by dripping flammable material. Evaluation is performed according to Table 1 below using one set of five test pieces.

[0027]

[Table 1]

Therefore, the structural material of the present invention having the above-described structure can be used as a heat transfer sheet for promoting heat radiation of the apparatus, in addition to the cushioning material and the packing. (3) The invention of claim 3 is characterized in that the bromine-based flame retardant has a higher melting point than the melting point of the agglomerated resin material.

The brominated flame retardant is selected depending on the melting point of the agglomerated resin material (here, a mixture of a thermoplastic resin and a softening agent). Can be used without particular limitation as long as the melting point is higher. Some examples are decabromodiphenyl ether (melting point 310 ° C.), 2,2-bis (3,5-dibromo-4-hydroxyphenyl) (melting point 182 ° C.),
2,5,6,9,10-hexabromocyclododecane (melting point 190 ° C.), hexabromobenzene (melting point 310
° C), tetrabromophthalic anhydride (melting point 275 ° C), pentabromotoluene (melting point 280 ° C) and the like.

In selecting a brominated flame retardant, the condition that the melting point is higher than the melting point of the mixture is as follows.
Even when the mixture is melted by heating during molding, the brominated flame retardant is not melted to prevent compatibility with the softener component and to prevent bleeding and segregation due to the compatibility. . And thereby, a fall of a moldability and deterioration of an external appearance are prevented, and a flame-retardant and highly flexible molded article (agglomerated part) having a good external appearance can be obtained.

(4) The invention according to claim 4 is characterized in that the agglomerated resin material contains 5 to 50% by weight of the bromine-based flame retardant. Make a summary. If the compounding amount of the brominated flame retardant is too small, the desired flame retardancy may not be obtained.
It is preferred that the content be not less than% by weight. In addition, when the amount of the brominated flame retardant increases, various physical properties of the flame retardant composition decrease (for example, a decrease in tensile strength or tear strength, a decrease in elongation, etc.) or molding failure (burn, short shot, etc.). Therefore, the content is preferably 50% by weight or less in the flame-retardant composition.

(5) The invention according to claim 5 is characterized in that the structural material according to any one of claims 2 to 4, wherein the agglomerated resin material contains antimony trioxide. When antimony trioxide is added, a higher flame retardant effect can be exerted due to the synergistic effect of antimony trioxide and a brominated flame retardant. This effect is due to the oxygen blocking effect by SbBr ₃ gas, the dehydration and carbonization effect of SbOBr,
It is thought to be due to the free radical trapping effect of Br ₃ , and the glassy Sb ₂ O ₃ generated when antimony trioxide and a bromine-based flame retardant are heated also prevents the molten dripping from becoming molten. It seems to be involved in improving the effect.

The amount of antimony trioxide to be added may be appropriately determined according to the type and blending ratio of the thermoplastic resin, the brominated flame retardant, and the softening agent. ~
1/3 (weight) is preferred. (6) The invention of claim 6 is a gist of the structural material according to claim 1, wherein the agglomerated resin material contains a red phosphorus-based flame retardant.

In the present invention, since the agglomerated resin material contains a red phosphorus-based flame retardant, it has flame retardancy. Therefore, it can be applied to various uses. In particular, in the present invention,
Because a red phosphorus-based flame is used instead of a halogen-based flame retardant, no corrosive halogen-based gas is generated when the structural material of the present invention is molded or incinerated, and molding machines, molds, etc. It is also advantageous in terms of life and environment.

Here, the degree of flame retardancy is UL94.
The degree to which it has self-extinguishing properties in a vertical combustion test is mentioned. It is known that this UL94 vertical combustion test has self-extinguishing properties.
The evaluation of the L94 vertical combustion test was V class (that is, 94V-
0 to 94V-2).

(7) The invention of claim 7 is characterized in that the agglomerated resin material contains 2 to 10% by weight of the red phosphorus-based flame retardant. And The proportion of the red phosphorus-based flame retardant is preferably in the range of 2 to 10% by weight. If the amount is less than 2% by weight, the flame-retarding effect tends to decrease. If the amount exceeds 10% by weight, not only the flame-retarding effect decreases again, but also the original physical properties of the agglomerated body may be impaired. It is.

(8) The invention according to claim 8 is characterized in that the agglomerated resin material further contains 25 to 55% by weight of a flame retardant aid. Make a summary.
The proportion of the flame retardant aid is preferably in the range of 25 to 55% by weight. If the content is less than 25% by weight, sufficient self-extinguishing properties may not be obtained. If the content is more than 55% by weight, the intrinsic physical properties of the material of the agglomerated body may be impaired.

(9) The invention according to claim 9 is characterized in that the flame-retardant aid is a metal compound. Various metal compounds can be used as the flame retardant aid. For example, aluminum hydroxide, magnesium hydroxide, calcium hydroxide, tin hydroxide, metal hydroxides such as zirconium hydroxide, antimony oxide, molybdenum oxide, calcium oxide, tin oxide,
Metal oxides such as zirconium oxide and zinc oxide, metal carbonates such as magnesium carbonate and calcium carbonate, metal silicates such as calcium silicate and aluminum silicate,
Metal borates such as zinc borate and barium borate, ammonium salts such as ammonium polyphosphate and ammonium molybdate can be used, and other fillers such as dawsonite, kaolin, clay and silica can be used. Good.

Among these, metal hydroxides and metal borates release crystallization water at 200 ° C. or higher and absorb heat of vaporization at that time. Therefore, it is considered that the combustion substance is cooled to enhance the combustion effect. In this regard, it is preferred as a flame retardant aid. Zinc borate is also preferable because it forms a glassy boric acid compound film during combustion, and shuts off supply of oxygen and also prevents dripping of a thermoplastic resin or a softening agent by melting. Aluminum hydroxide is particularly preferred because it is not only very inexpensive, but also can reduce smoke when used in combination with a red phosphorus-based flame retardant.

(10) The invention according to a tenth aspect is characterized in that the non-agglomerated part made of a non-agglomerated resin material covers at least a part of the agglomerated part other than the embossed surface. The structural material according to any one of claims 1 to 9, wherein the aggregated portion and the non-agglomerated portion are welded to each other.

I) In the present invention, the non-agglomerated portion may be anything as long as it can be welded to the agglomerated portion. For example, if it is a thermoplastic resin, most of the non-agglomerated portion can be used. It is thought that it can be welded.・ Specifically, a resin such as an olefin resin, an ester resin, a styrene resin, a urethane resin, or the like, which is formed into a sheet shape, or a resin formed into another necessary shape can be used. For example, films such as PET, PC, and PP are preferable, but films such as PE, PVC, and urethane may be used.

-An elastic film can be used. The stretchable film is, for example, a urethane-based, PVC-based, or olefin-based flexible and stretchable film. -Further, a cloth or a nonwoven fabric can be used. This non-woven fabric is a fabric made by combining synthetic fibers, natural fibers, glass fibers, etc. into sheets or mats by an appropriate method and bonding the fibers together by an adhesive or the fusing force of the fibers themselves. is there. In addition, as a fiber to be used, a metal-deposited fiber can be used. As the cloth, for example, a stretchable jersey material can be used.

Also, felt can be used.
This felt is, for example, synthetic or natural fibers, glass fibers, etc., mechanically or chemically treated and torn, entangled with each other, and made into a cloth by applying moisture, heat, and pressure. is there. Further, if it can be welded to the agglomerated portion by an appropriate method, the non-agglomerated portion can be formed of a thermosetting resin or a metal foil. For example, in the case of a metal foil, the agglomerated portion can be welded by coating the surface with a thermoplastic resin in advance. A PET film on which metal deposition has been performed can also be used. Therefore, if this material is used, it is possible to secure conduction for grounding or the like by using a metal.

Ii) In the present invention, the agglomerated body and the non-agglomerated body are welded to each other, and the non-agglomerated body covers at least a part of the agglomerated body. I have. Therefore, the agglomerated part as a whole has excellent buffering performance and sealing performance, and there is no problem specific to the agglomerated part in the range of the non-agglomerated part. Therefore, when this structural material is used as a cushioning material, the range of the non-agglomerated portion is appropriately adjusted, and the non-agglomerated portion is contacted with the non-agglomerated portion. By arranging the cushioning material or the like so that the body-shaped portions come into contact with each other, problems such as workability caused by contact with the agglomerated body-shaped portions can be avoided. That is, although the agglomerated part has adhesiveness, workability is improved if its surface is covered with the non-agglomerated part.

To give a specific example, for example, by making the contact surface of the cushioning material with the cartridge type device a non-agglomerated portion, it becomes easy to insert and remove the cartridge type device. Conversely, when a cushioning material is provided on the outer peripheral surface of the cartridge type device, the insertion and removal of the cartridge type device can be performed by setting the contact surface of the cushioning material with the inner wall surface of the cushioning space as a non-agglomerated part. Becomes easier. In particular, even when the cartridge-type device is slid and attached / detached, the non-agglomerated part is pulled from the gelatinized part because the agglomerated part and the non-agglomerated part are welded to each other. Difficult to peel off.

Further, there is no danger that the fluid component contained in the agglomerated body portion will permeate and stain the portion where the non-agglomerated body portion of the buffer material is brought into contact. In particular, since the agglomerated body and the non-agglomerated body are welded to each other, the positional relationship between the agglomerated body and the non-agglomerated body is shifted, and the agglomerated body is unexpectedly placed. It can prevent that a shape part contacts.

Further, the non-agglomerated body portion is stuck with a double-sided tape or an adhesive. If this structural material is used as a cushioning material, the cushioning material can be fixed with a double-sided tape or an adhesive. Can also. In particular, since the agglomerated portion and the non-agglomerated portion are welded to each other, only the non-agglomerated portion is fixed with a double-sided tape or an adhesive, and the agglomerated portion is not bonded. Separation from the agglomerated body can be prevented.

In addition, the agglomerated part is very flexible and usually has little shape retention, but as in the present invention,
If the agglomerated part is covered with a non-agglomerated part, for example, a resin sheet, the shape retention of the composite structure is increased,
The dimensional accuracy is improved. Also, since the agglomerated part is usually transparent, even a slight molding failure is very noticeable, but by covering the agglomerated part with the non-agglomerated part, molding failure is likely to occur. Product yield is improved because there is no loss.

(11) The structure according to any one of claims 1 to 10, wherein the non-agglomerated part is a sheet-like member which can be deformed flexibly. Is the gist. According to such a structural material, of the surface of the agglomerated body, the area covered with, for example, a resin sheet that is a non-agglomerated body has no tackiness and no oozing of the fluid component, Application of a double-sided tape or an adhesive is also possible. In addition, for example, the resin sheet may be very thin, and most of the structural material may be formed as the agglomerated body. Therefore, the resin sheet can function as a cushioning material or packing by being interposed between two objects.

(12) In the twelfth aspect of the present invention, the agglomerated part is formed in a plate shape, and the sheet-like member is welded to one surface of the agglomerated part and the other is formed. The structural material according to claim 11, wherein the embossing is applied to a surface.

According to such a structural material, one surface of the plate-like agglomerated body is a sheet-like member (for example, a resin sheet).
And the other surface is embossed, so that almost all of the structure has reduced tackiness and no exudation of the fluid component. Moreover, since the agglomerated part is plate-shaped, the entire structural material is also plate-shaped, so that the versatility is enhanced, and it can be cut into an appropriate shape and sandwiched between two objects. It can function as a cushioning material or packing between them.

(13) The invention of claim 13 is characterized in that the agglomerated body is formed into a shape capable of holding an object corresponding to an object having a specific shape.
The gist is the structural material described in any one of 10 above.

According to such a structural material, an object having a specific shape can be held by the agglomerated body portion whose surface is embossed. (14) The invention of claim 14 is the method for producing a structural material according to any one of claims 1 to 13, wherein the agglomerated body is placed in a mold having a working surface for embossing. A gist of the present invention is a method for producing a structural material, characterized in that the embossing is performed and the agglomerated portion is formed by introducing a resinous material and keeping the inside of the mold at a predetermined temperature.

According to such a manufacturing method, for example, a fluid composition composed of a preheated (for example, 120 ° C.) agglomerated resin material is introduced into a mold, and a predetermined temperature (for example, (140 ° C.). Alternatively, for example, a preformed agglomerated resin material is placed in a mold and heated to a predetermined temperature (eg, 130 ° C.). Therefore, the agglomerated resin material softened (fluidized) in the mold is formed into the shape of the cavity in the mold (that is, the shape of the agglomerated portion). At the same time, the softened agglomerated resin material comes into contact with the processed surface of the inner surface of the mold, so that the processed surface embosses the surface of the agglomerated portion.

(15) The invention according to claim 15 is the invention according to claims 1 to
13. A method for producing a structural material according to any one of claims 13, wherein a processing member having a processing surface for embossing is disposed on an inner surface of a mold, and the agglomerated resin is placed in the mold. By introducing a material and keeping the inside of the mold at a predetermined temperature,
A gist of the present invention is a method of manufacturing a structural material, wherein the embossing is performed and the agglomerated body is formed.

According to such a manufacturing method, for example, a fluid composition composed of a preheated (eg, 115 ° C.) agglomerated resin material is introduced into a mold, and a predetermined temperature (eg, (130 ° C.). Alternatively, for example, the preformed agglomerated resin material is placed in a mold and heated to a predetermined temperature (for example, 120 ° C.). Therefore, the agglomerated resin material softened (fluidized) in the mold is formed into the shape of the cavity in the mold (that is, the shape of the agglomerated portion). At the same time, the softened agglomerated resin material comes into contact with the processed surface of the processed member disposed on the inner surface of the mold, and the embossed surface is applied to the surface of the agglomerated portion by the processed surface. .

In the invention of claim 14 or 15, when the agglomerated part is produced, various thermoplastic resins such as transfer molding, vacuum molding, etc. may be used in addition to well-known injection molding and compression molding. Molding method can be adopted. Specifically, for example, each component may be weighed and kneaded with, for example, a kneader (for example, a twin-screw kneader), or may be stirred with a mixer and then passed through a twin-screw extruder. Conditions such as temperature and time for kneading or stirring vary depending on the components to be blended, but are, for example, about 140 to 150 ° C. and about 15 minutes. Further, in order to prevent thermal deterioration during kneading or stirring, a heat stabilizer may be added in an amount of several percent. Note that these conditions may be set to suitable conditions based on experiments and the like. The apparatus used for kneading or stirring is not particularly limited. For example, a Banbury mixer, two rolls,
A pressure kneader or the like can also be used.

In the case of manufacturing a structural material in which the non-agglomerated part is welded to the surface of the agglomerated body, a processing surface for embossing is provided on one surface of the cavity of the mold, and the other surface is provided. For example, a resin sheet that becomes a non-agglomerated part is arranged on the surface of
In this state, a method of introducing the agglomerated resin material into the cavity and heating may be employed.

In the above description, the term "aggregate" is used. However, the agglomerate is sometimes called a gel, and these two terms are equivalent terms that can be replaced.
Further, the non-agglomerated substance is a term that can be replaced with a non-gel, and any substance that does not have the properties as a gelatinized substance is a non-agglomerated substance.

[0060]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, embodiments of the present invention will be described with reference to the drawings by giving some examples. In each of the drawings, the vertical and horizontal scales are not the same but are schematically drawn so as to clarify the contents of each embodiment.

A) First, the structure of the structural material will be described. The structural material 1 shown in FIG. 1 has a plate shape (for example, a thickness of 3 m).
One surface of the agglomerated body (m) is embossed over the entire surface, thereby forming an embossed surface 5 having minute irregularities. Therefore, the structural material 1 is translucent due to the embossed surface 5.

The degree of the emboss is 50 μm in depth.
It is. The tackiness is such that there is no problem in workability. The agglomerated body 3 loses its fluidity as a whole while using a styrene-based thermoplastic elastomer as a base resin (base polymer) and including a process oil as a fluid component in the gaps between the network structures of the base polymer. It is agglomerated. The compounding ratio of the oil and the base polymer is usually adjusted within the range of 1: 1 to 20: 1, and the physical properties of the agglomerated part 3 (for example, the hardness of the agglomerated part 3 and the like) are determined by this blending ratio. ) Can be adjusted.

In addition to the above, embossing may be performed on both sides of the plate-like agglomerated body 3. b) The structural material 1 having this configuration is used as follows. For example, as shown in FIG.
0 (the embossed surface 5 is on the outside) and the cushioning material 1
4 is formed.

Thus, the portable computer 10
When something crashes, the shock transmitted from the portable computer 10 to the replaceable hard disk drive 12 is reduced to protect the replaceable hard disk drive 12, or when the replaceable hard disk drive 12 is driven, Vibrations transmitted from the replaceable hard disk drive 12 to the portable computer 10 can be reduced.

Here, the cushioning material 14 is used for the agglomerated body 3
The side contacts the replaceable hard disk device 12 and the adhesiveness of the surface of the agglomerated body 3 causes the replaceable hard disk device 1
2 is in close contact with it. On the other hand, the embossed surface 5 comes into contact with the inner wall 16 which forms a storage space on the portable computer 10 side. That is, since the embossed surface 5 is formed on the outer peripheral surface of the cushioning material 14 arranged in a box shape, insertion and removal of the replaceable hard disk device 12 with respect to the portable computer 10 become easy.

Although not shown, the embossed surface 5 is opposite to the structural material 1 and the exchangeable hard disk drive 1
2 and the agglomerated body 3 is
You may make it contact the inner wall 16 of 0 side. That is,
In this case, since the embossed surface 5 is formed on the inner peripheral surface of the cushioning material 14 arranged in a box shape, the removable hard disk device 12 can be easily attached to and detached from the cushioning material 14.

Further, as shown in FIG.
One may have a structure 27 having an embossed surface 23 on one surface and a resin sheet 25 which is a non-agglomerated part made of a non-agglomerated material (eg, polyethylene) on the other surface. In this case, there is an advantage that the adhesiveness on the surface of the structure 27 is extremely low, and the shape retention by the resin sheet is high.

In addition, as shown in FIG. 4, a trapezoidal structural member 33 having a concave portion 31 capable of exactly accommodating the exchangeable hard disk drive 12 is manufactured, and this structural member 33 is disposed on the portable computer side. And may be used as a cushioning material. In the case of this structural material 33, the inner surface of the concave portion 31 (particularly, the portion in contact with the exchangeable hard disk device 12) is the embossed surface 35, and the outer surface is the surface where the agglomerated portion 37 is exposed. In the concave portion 31 of the structural member 33, the exchangeable hard disk drive 12 can be freely inserted and removed (with respect to the structural member 33). It is preferable that the upper surface 33a of the structure 33 is also embossed.

Although not shown, the inner surface of the concave portion 31 may be the agglomerated portion 37, and the outer surface (particularly, the portion in contact with the portable computer) may be the embossed surface 35. In this case, the portable computer (the exchangeable hard disk drive 12
Can be freely taken in and out).

The entire surface of the structural material 33 may be embossed. c) Next, a method for manufacturing a structural material will be described. The structural material 1 as shown in FIG. 1 can be manufactured by the following procedure (injection molding).

As shown in FIG. 5, first, of the surfaces (inner surfaces) facing the cavities 43 of the mold 41, the inner surface of the female die 45 is embossed (having minute irregularities) for embossing. A surface 45a is formed. In addition, the injection molding machine 4
The resin composition (agglomerated resin material) 3a to be the agglomerated body 3 is introduced into the cylinder 47a of No. 7 and heated to a molten state.

Then, the resin composition 3 a in the cylinder 47 a is injected into the mold 41 through the gate 49 of the mold 41. The resin composition 3a injected into the mold 41 is
Embossed surface 45a while filling cavity 1
Contact At this time, the temperature of the resin composition 3a is about 18
0 ° C or higher. Thereby, the embossing is performed on the surface of the structural material 1 while the structural material 1 is formed.

Thereafter, the molded article (structural material 1) in the mold 41 is left until the temperature reaches an appropriate temperature, and then the mold 41 is opened.
Take out the molded product. Thereby, the structural material 1 whose surface has been embossed can be obtained. When embossing is performed on both sides of the plate-shaped structural material 1, an embossed surface may be provided on the inner surfaces of both the female mold 45 and the male mold 46 of the mold 41.

Next, an example will be described in which an embossed surface for embossing is separately used instead of forming an embossed surface directly on the inner surface of a mold. Here, compression molding is mentioned as an example instead of the injection molding described above. For example, as shown in FIG.
Mold 57 composed of pot portion 53, upper mold 55 and lower mold 56
The device provided with is used.

In this apparatus, holes are provided from the material injection port 59 to the cavity 65 via the gate 61 and the runner section 63. Further, the cavity 65
The embossed member 6 is provided on the bottom surface (the inner surface of the lower mold 46).
7 are arranged. The embossed member 67 is
As shown in FIG. 5 (b), the sheet-shaped member is provided with an embossed surface 67a having a large number of irregularities on the surface, and is heat-resistant (for example, made of a fluororesin).
Especially when embossing is performed, a large number of air holes 69 are formed to allow air to escape from the embossed surface.

At the time of manufacturing, while the plunger 51 is heated to about 140 ° C., the agglomerated resin material is injected from the material injection port 59, and the material is pressed by the plunger 51. As a result, the material is filled into the cavity 65 via the gate 61 and the runner section 63. The inside of the cavity 65 is heated to about 130 ° C.

As a result, the agglomerated body 3 is formed in the cavity 65, and one surface of the agglomerated body 3 is embossed by the embossed member 67, so that the structural material A structural material similar to 1 is obtained. In the case of this manufacturing method, embossing can be easily performed by using the embossed member 67 without forming an embossed surface on the inner surface of the mold 57, which is advantageous in cost. Further, there is an advantage that the degree of embossing can be changed by replacing the embossing member 67.

In addition, the embossed member 67 has
Since a large number of air holes 69 are formed, air bleeding during embossing can be easily performed, and thus poor molding of the surface can be prevented. The method of using the embossed member 67 is not limited to the compression molding, but can be applied to the injection molding and the like.

Next, a method of manufacturing the structural material 27 shown in FIG. 3 (having one surface embossed and the other surface welded with a resin sheet 25) will be described. Here, the compression molding of FIG. 6 will be described as an example. As shown in FIG. 7, the bottom surface of the cavity 73 of the mold 71 (the lower mold 75
A sheet-like embossed member 77 similar to that shown in FIG. In addition, a resin sheet 25 made of a non-agglomerated resin material is attached to the upper surface of the cavity 73 (the inner surface of the upper mold 79).

In this state, an agglomerated resin material having a predetermined temperature or higher is introduced into the cavity 73. Thus, the agglomerated body 21 is formed, and one surface of the agglomerated body 21 is embossed by the embossing member 77. Further, the one surface of the agglomerated body 21 is formed. The resin sheet 25 is welded.

It should be noted that this method can be applied not only to compression molding but also to the above-mentioned injection molding and the like. When the box-shaped structural material 33 shown in FIG. 4 is manufactured, an embossed surface may be provided on the inner surface of the mold corresponding to the embossed surface to be formed.

In addition to the above methods, various thermoplastic resin molding methods such as transfer molding and vacuum molding can be employed. d) Hereinafter, the present invention will be described more specifically with reference to examples of components. (Example 1) Blended styrene-isoprene-styrene copolymer: 9.3% by weight Paraffin-based process oil: 56.1% by weight Decabromodiphenyl ether: 23.4% by weight Antimony trioxide: 11.2% by weight The ingredients are kneaded in a kneader (biaxial kneader) (1
(40 ° C., 40 minutes) to obtain an agglomerated resin material having an agglomerated body. This agglomerated resin material is UL (Underwriters Lab)
oratories Inc.) ASKER FP, which has self-extinguishing properties in a 94 vertical combustion test and can measure hardness appropriately with the FP type analog hardness tester (trade name: Asker) manufactured by Kobunshi Keiki Co.
It was a class of low hardness.

Further, the agglomerated resin material is melted,
It was injected into a mold having an embossed surface and molded to obtain a plate-like molded product (for example, a plate-like agglomerated body having an embossed surface on one surface). This agglomerated resin material had good fluidity, and the formed agglomerated portion had good releasability, no bleed, and no problem in appearance. Furthermore, the embossed surface of the agglomerated body had low tackiness and was excellent in workability.

The styrene-isoprene-styrene copolymer corresponding to the styrene-based elastomer has an average molecular weight of 100,000 to 450,000 and a paraffin-based process oil (C
_n H _{2n + 2} ) is n = 25 to 400 (average molecular weight is 35 2 to
560 2 ), the melting point of the mixture of the styrene - isoprene-styrene copolymer and the paraffin-based process oil is about 150 ° C. (Example 2) Compounded styrene-ethylene-propylene-styrene copolymer: 5.7% by weight Paraffin-based process oil: 45.3% by weight Pentabromotoluene (melting point: 280 ° C): 26.0% by weight Antimony trioxide: 13.0% by weight The above components were kneaded under the same conditions as in Example 1 to obtain an agglomerated resin material having an agglomerated body. This agglomerated resin material
Is UL94V-0 level flame retardant, Asker F
It was a P class low hardness.

Further, the agglomerated resin material is melted,
It was injected into a mold having an embossed surface and molded to obtain a plate-like molded product (for example, a plate-like agglomerated body having an embossed surface on one surface). The agglomerated resin material flowed well, and the formed agglomerated portion had good releasability, no bleed, and no problem in appearance. Furthermore, the embossed surface of the agglomerated body had low tackiness and was excellent in workability.

The average molecular weight of the styrene-ethylene-propylene-styrene copolymer corresponding to the styrene elastomer is 100,000 to 450,000, and n = 25 to 400 for paraffin-based process oil (C _n H _{2n + 2} ). in (average molecular weight of 35 2 to 56 0 2), the styrene - ethylene - propylene - the melting point of the styrene copolymer and mixtures of paraffin-based process oil is about 0.99 ° C.. (Example 3) Blend styrene-ethylene-propylene-styrene copolymer: 6.4% by weight Paraffin-based process oil: 63.6% by weight Pentabromotoluene: 20.0% by weight Antimony trioxide: 10.0% by weight The above components were kneaded under the same conditions as in Example 1 to obtain an agglomerated resin material having an agglomerated body. This agglomerated resin material
, It is self-extinguishing in U L94V- 2 levels, Asker F
It was a P class low hardness.

Further, the agglomerated resin material is melted,
It was injected into a mold having an embossed surface and molded to obtain a plate-like molded product (for example, a plate-like agglomerated portion having an embossed surface on one surface). The agglomerated resin material flowed well, and the formed agglomerated portion had good releasability, no bleed, and no problem in appearance. Furthermore, the embossed surface of the agglomerated body had low tackiness and was excellent in workability.

[0088] Incidentally, styrene corresponds to the styrene elastomer - ethylene - propylene - average molecular weight of the styrene copolymer is 100000 to 450000, paraffinic process oil (C _n H _{2n + 2)} is n = 25 to 400 in (average molecular weight of 35 2 to 56 0 2), the styrene - ethylene - propylene - the melting point of the styrene copolymer and mixtures of paraffin-based process oil is about 0.99 ° C.. (Example 4) Compounded styrene-ethylene-propylene-styrene copolymer: 13.8% by weight Paraffin-based process oil: 41.2% by weight Pentabromotoluene: 30.0% by weight Antimony trioxide: 15.0% by weight The above components were kneaded under the same conditions as in Example 1 to obtain an agglomerated resin material having an agglomerated body. The Nikawaka-like resin material was flame retardancy UL94H B level.

Further, the agglomerated resin material is melted,
It was injected into a mold having an embossed surface and molded to obtain a plate-like molded product (for example, a plate-like agglomerated portion having an embossed surface on one surface). The flexibility of the agglomerated resin material was slightly inferior to Examples 1 to 3, and the formed agglomerated portion had some problem in releasability, but had no bleed and no problem in appearance. . Furthermore, the embossed surface of the agglomerated body had low tackiness and was excellent in workability.

[0090] Incidentally, styrene corresponds to the styrene elastomer - ethylene - propylene - average molecular weight of the styrene copolymer is 100000 to 450000, paraffinic process oil (C _n H _{2n + 2)} is n = 25 to 400 in (average molecular weight of 35 2 to 56 0 2), the styrene - ethylene - propylene - the melting point of the styrene copolymer and mixtures of paraffin-based process oil is about 0.99 ° C.. (Example 5) Compounded styrene-ethylene-propylene-styrene copolymer: 7.9% by weight Paraffin-based process oil: 47.1% by weight Decabromodiphenyl ether: 30.0% by weight Antimony trioxide: 15.0% by weight The above components were kneaded under the same conditions as in Example 1 to obtain an agglomerated resin material having an agglomerated body. The Nikawaka-like resin material was flame retardancy UL94H B level.

Further, the agglomerated resin material is melted,
It was injected into a mold having an embossed surface and molded to obtain a plate-like molded product (for example, a plate-like agglomerated portion having an embossed surface on one surface). The flexibility of this agglomerated resin material is slightly inferior to those of Examples 1 to 3, and the formed agglomerated portion has some problem in releasability, but has no bleed and has no problem in appearance. Was. Furthermore, the embossed surface of the agglomerated body had low tackiness and was excellent in workability.

[0092] Incidentally, styrene corresponds to the styrene elastomer - ethylene - propylene - average molecular weight of the styrene copolymer is from 100000 to 450000, paraffinic process oil (C _n H _{2n + 2)} is n = 25 to 400 in (average molecular weight of 35 2 to 56 0 2), the styrene - ethylene - propylene - the melting point of the styrene copolymer and mixtures of paraffin-based process oil is about 0.99 ° C..

As described above, from the above Examples 1 to 5, the bleeding, the bleeding, and the flame retardant having a higher melting point than the melting point of the mixture of the thermoplastic resin and the softener were employed.
It was confirmed that a molded article with good appearance was provided, which was prevented from being deteriorated in formability and deterioration in appearance, was flame-retardant, had excellent flexibility, and was provided with a polyethylene sheet on the surface to improve handleability. (Example 6) blending styrene - ethylene - butadiene - styrene copolymer: 5.8% by weight paraffinic process oil: 57.8 wt% No-Bas Red 140 (manufactured by Rinkagakukogyo): 5.8 wt% hydroxide Aluminum: 28.9% by weight Phenolic antioxidant: 1.7% by weight Preliminarily kneading the above components, and φ5 mm with a twin screw extruder etc.
It was extruded at about 140 ° C. into strands of a suitable degree and cut into appropriate lengths with a pelletizer. The material is injected from the material supply port of the injection molding machine, plasticized at a cylinder temperature (from the lower part of the hopper) of 150 ° C. → 170 ° C. → 190 ° C., and a mold having a cavity of a desired shape and an embossed surface. The above molten material is injected at an injection pressure of 500 kgf / cm
^2. Injection was performed at an injection speed of 150 mm / s. The temperature of the mold was set at about 60 ° C. After an appropriate cooling time, the mold was opened, ejected from the mold with an ejector pin, and the product was received in a plastic container or the like.

Among the molded products (for example, a plate-like agglomerated portion having an embossed surface on one surface), the agglomerated portion was measured with an Asker FP hardness tester (manufactured by Kobunshi Keiki).
It had a low hardness of Asker FP hardness of 60. For the molded product obtained by applying such a manufacturing method, the aforementioned UL
94 results of performing the vertical combustion test, it was confirmed that the self-extinguishing properties of U L94V- 2 levels. Furthermore, the embossed surface of the agglomerated body had low tackiness and was excellent in workability.

It should be noted that styrene-ethylene-butadiene-
The average molecular weight of the styrene copolymer is about 150,000, and the specific gravity is 0.1.
90, a kinematic viscosity in the average molecular weight 750,40 ° C. paraffinic process oil (C _n H _{2n + 2)} is 370mm
² / s, this styrene-ethylene-butadiene-styrene
The softening point of emission copolymer and mixtures of paraffinic process oil was approximately 0.99 ° C.. (Example 7) Compounded styrene-ethylene-propylene-styrene copolymer: 5.8% by weight Paraffin-based process oil: 58.2% by weight Red phosphorus-based flame retardant (Nova Red 140): 6.0% by weight hydroxylated Aluminum: 30.0% by weight The above components were kneaded and molded in the same manner as in Example 6.
This molded product was tested in the UL94 vertical combustion test ,
2 shows the self-extinguishing properties of the level, Asker FP hardness 60-65
Was in the range. Also, the embossed surface of the agglomerated body had low tackiness and was excellent in workability.

Note that styrene-ethylene-propylene-
The styrene copolymer has an average molecular weight of about 250,000 and a specific gravity of about 0.2.
92, a kinematic viscosity in the average molecular weight 750,40 ° C. paraffinic process oil (C _n H _{2n + 2)} is 370mm
² / s, this styrene-ethylene-propylene-styrene
The softening point of emission copolymer and mixtures of paraffinic process oil was approximately 0.99 ° C.. (Example 8) Compounded styrene-ethylene-propylene-styrene copolymer: 4.5% by weight Paraffin-based process oil: 49.5% by weight Red phosphorus-based flame retardant (Nova Red 140): 6.0% by weight hydroxylated Aluminum: 40.0% by weight The above components were kneaded and molded in the same manner as in Example 6.
This molded product was tested in the UL94 vertical combustion test ,
2 shows the self-extinguishing properties of the level. In addition, Asker FP hardness was increased by about 15 compared to Example 2 to 75 to 80. Furthermore, the embossed surface of the agglomerated body has low tackiness,
Excellent workability. (Example 9) Compounded styrene-ethylene-propylene-styrene copolymer: 4.9% by weight Paraffin-based process oil: 49.1% by weight Red phosphorus-based flame retardant (Nova Red 140): 6.0% by weight boric acid Zinc: 40.0% by weight The above components were kneaded and molded in the same manner as in Example 6. This molded product was subjected to UL94V- 2 in a UL94 vertical combustion test.
Showed self-extinguishing properties of the level. The Asker FP hardness is 7
It was 5. Furthermore, the embossed surface of the agglomerated body had low tackiness and was excellent in workability.

[0097] Thus, from the Examples 6-9, by adopting the thermoplastic resin softener and red phosphorus-based flame retardant, bleeding, deterioration of the decrease and appearance of the formability is prevented, only rich in flame-retardant in and flexible, it was confirmed that the obtained the appearance good molded products.

While the embodiments of the present invention have been described above, various specific embodiments other than those described above are conceivable for the embodiments of the present invention.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a plate-shaped structural material.

FIG. 2 is a perspective view showing a use state when a plate-like structural material is used as a cushioning material.

FIG. 3 is a perspective view showing another structural member formed in a plate shape and having an embossed surface on one side and a resin sheet on the other side.

FIG. 4 is a perspective view showing still another box-shaped structural member having a concave portion.

FIG. 5 is an explanatory view showing a method for manufacturing a structural material.

6A and 6B illustrate another method of manufacturing a structural material, in which FIG. 6A is an explanatory diagram illustrating a mold and the like cut away, and FIG. 6B is an explanatory diagram illustrating a cut embossed member.

FIG. 7 is an explanatory view showing still another manufacturing method of the structural material.

FIG. 8 is an explanatory diagram showing the degree of embossing.

[Explanation of symbols]

 1, 27, 33: structural material 3, 21, 37: agglomerated part 5, 23, 35: embossed surface 25: resin sheet (non-agglomerated part) 31 Recesses 41, 57, 71: mold 45a: embossed surface 67: embossed member

────────────────────────────────────────────────── ─── Continuation of the front page (56) References JP-A-5-99258 (JP, A) JP-A-7-246683 (JP, A) JP-A 8-58189 (JP, A) JP-A 9-98 21439 (JP, A) JP-A-9-269029 (JP, A) JP-A-3-177448 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 1/00-35 / 00 F16F 15/02-15/08 F16J 15/10

Claims (15)

(57) [Claims] 1. An agglomerated body made of an agglomerated resin material obtained by adding a softening agent for imparting flexibility to a thermoplastic resin as a main component, and a non-agglomerated body made of a non-agglomerated resin material A glue-like part having an Asker FP hardness of 30 to 90, and a height and depth of 10 μm in the agglomerate-like part.
Microscopically reduced adhesiveness of the agglomerated body portion of about 1 mm
A structural material having an embossed surface that has been subjected to embossing for forming unevenness . 2. The structural material according to claim 1, wherein the agglomerated resin material contains a brominated flame retardant. 3. The brominated flame retardant has a higher melting point than the melting point of the agglomerated resin material.
The structural material described in the above. 4. The structural material according to claim 2, wherein the agglomerated resin material contains 5 to 50% by weight of the brominated flame retardant. 5. The structural material according to claim 2, wherein the agglomerated resin material contains antimony trioxide. 6. The structural material according to claim 1, wherein the agglomerated resin material contains a red phosphorus-based flame retardant. 7. The structural material according to claim 6, wherein the agglomerated resin material contains the red phosphorus-based flame retardant in an amount of 2 to 10% by weight. 8. The agglomerated resin material further comprises 25 to 55% by weight of a flame retardant aid.
The structural material described in the above. 9. The structural material according to claim 8, wherein the flame retardant aid is a metal compound. 10. A non-agglomerated part made of a non-agglomerated resin material covers at least a part of the agglomerated part other than the embossed surface. Characterized in that the body parts are welded to each other
10. The structural material according to any one of items 9. 11. The structural material according to claim 10, wherein the non-agglomerated body is a sheet-like member that can be flexibly deformed. 12. The agglomerated body is formed in a plate shape, the sheet-like member is welded to one surface of the agglomerated body, and the embossing is performed on the other surface. The structural material according to claim 11, wherein: 13. The structure according to claim 1, wherein the agglomerated body is formed into a shape capable of holding an object corresponding to an object having a specific shape. Wood. 14. The method for producing a structural material according to claim 1, wherein the agglomerated resin material is introduced into a mold having a working surface for embossing. A method for producing a structural material, wherein the embossing is performed and the agglomerated portion is formed by setting the inside of the mold to a predetermined temperature. 15. A method for manufacturing a structural material according to claim 1, wherein a processing member having a processing surface for embossing is arranged on an inner surface of a mold, and the metal member is provided with a metal. By introducing the agglomerated resin material into a mold and keeping the inside of the mold at a predetermined temperature, the embossing is performed and the agglomerated portion is formed. Production method.