JP3130181B2 - Method for manufacturing transparent resin member - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a transparent resin member used for a window glass of an automobile.

[0002]

2. Description of the Related Art Polycarbonate having good impact resistance is used for manufacturing conventional transparent resin members (for example, various windshields and canopies (transparent lids, so-called canopies), automobile sunroofs and window glasses). It is known that an acrylic resin or the like is used to form a predetermined shape by an injection molding die. Also, (1) Japanese Utility Model Laid-Open No. 50929/1989 discloses a windshield device using a sandwich-like laminate obtained by bonding an acrylic resin plate to both sides of a laminate made of polycarbonate via an adhesive layer. I have. (2) Japanese Unexamined Utility Model Publication No. 1-1115540 uses a laminate comprising a base material made of polycarbonate, a colored layer formed on the upper surface of the base material, and a transparent top coat layer made of polymethyl methacrylate. A sunroof and a window glass are disclosed. (3) Japanese Utility Model Application Laid-Open No. 62-69586 discloses a liquid raw material of a thermosetting resin such as epoxy after a fiber base and a reinforcing material for partially reinforcing the fiber base are arranged in a molding die. A window frame made of a fiber-reinforced plastic integrally formed by injecting and impregnating a resin is disclosed. (4) Japanese Utility Model Laid-Open Publication No. 63-189713 discloses an automotive windshield in which a rigid member such as a rod is integrally embedded.

[0003]

However, as a conventional method of manufacturing a transparent resin member used for a window glass of an automobile, for example, a product obtained by bonding to a sandwich-like laminate by hot pressing is bonded by reaction. Therefore, the rigidity was insufficient. Therefore, if the thickness of the laminate is increased to satisfy the rigidity, the weight cannot be reduced.

An object of the present invention is to provide a manufacturing method capable of improving the rigidity and weight of a transparent resin member.

[0005]

According to the present invention, there is provided a method of manufacturing a transparent resin member, comprising the steps of: placing an intermediate molded article made of polycarbonate in a mold, clamping the mold, and performing a polymerization reaction.
A step of feeding subjected to Kyabyiti formed by at least one surface of the forming die molding surface of the resin material comprising an acrylic resin and said intermediate molded article, the resin material by heating the forming die at a predetermined temperature To form an acrylic resin by a polymerization reaction, and after cooling the mold, open the mold, and release the transparent resin member in which the acrylic resin molded body is integrally joined to at least one surface of the intermediate molded product. And a process.

[0006]

According to the method for producing a transparent resin member of the present invention, the following steps are carried out in the order of a mold clamping step, a resin raw material supply step, a reaction step, and a release step. That is, in the mold clamping process,
After arranging a pre-manufactured polycarbonate intermediate molded product in the mold, the mold is clamped.

In the resin material supply step, after the mold is clamped, at least one surface of the intermediate molded product undergoes a polymerization reaction to be supplied into the molding die as an acrylic resin. As an example of this resin raw material, the structural formula is

[0008]

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[0009] Mixtures containing the monomers of This resin raw material fills the cavity space in the mold while being in contact with the surface of the intermediate molded product. In the reaction step, the mold is heated to a predetermined temperature. Then, the resin material in the mold is heated to reach the reaction temperature. Then, the resin raw material undergoes a polymerization reaction to become an acrylic resin, and also undergoes a polymerization reaction with at least one surface of the intermediate molded product to be integrally joined.

In the mold release step, the mold is cooled, the mold is opened, and the transparent resin member in which the acrylic resin molded body is integrally joined to at least one surface of the intermediate molded product is released.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for manufacturing a transparent resin member according to the present invention is shown in FIGS.
Based on the above, an example will be described in which a canopy 1 made of resin glass (hereinafter, referred to as a canopy) is manufactured as a transparent resin member. The manufacturing method of the embodiment can manufacture the resin glass canopy 1 shown in FIG. 1 by performing the following steps in the order of a mold clamping step, a resin raw material supply step, a reaction step, and a release step.

Prior to carrying out the manufacturing method, the canopy 1 obtained by this manufacturing method, the materials for manufacturing the canopy 1 and the mold 6 will be described first. As shown in FIG. 1, the canopy 1 is a product that constitutes an upper transparent wall structure of a vehicle compartment, and separates the vehicle compartment from the outside. The canopy 1 has a skeletal portion 10 (corresponding to a frame of a conventional vehicle body) made of FRP and a transparent windshield portion 1 integrally formed with the skeletal portion 10.
1, a roof glass part 12 and a rear glass part 13.

The canopy 1 corresponds to AA in FIG.
As shown in FIG. 2 as viewed in the direction of the line cross section, an intermediate molded product 2 made of polycarbonate (hereinafter, referred to as PC) serving as a transparent core member, and an indoor surface 20 and an outdoor surface 21 of the intermediate molded product 2 The indoor fiber base material 3 and the outdoor fiber base material 4 and the resin raw material 5 (see the black portion in FIG. 4) are arranged in the indoor fiber base material 3 and the outdoor fiber base material 4, respectively.
And by a polymerization reaction on the indoor side surface 20 and the outdoor side surface 21 of the intermediate molded product 2,
An indoor acrylic layer (acrylic resin molded body) 50 and an outdoor acrylic layer 51 are integrally connected to both surfaces 20 and 21.

The intermediate molded product 2 is preliminarily made of PC (Iupilon sheet clearer 552A-NFU manufactured by Mitsubishi Gas Chemical).
And is formed into a substantially similar shape to the canopy 1 by using a hot press to form a transparent core member having a thickness of 6 mm and forming an intermediate layer of the canopy 1. (Note that the intermediate molded product 2 is shown in FIG.
A flat portion 2a and a flat portion as shown in a positional relationship where the cross-sectional shape viewed from the position corresponding to the cross-section taken along the line B is arranged upside down in FIG. 2a
Are formed integrally at both end sides of the target object, and comprise a bent portion 2b and a side portion 2c having a target shape facing each other. This intermediate molded product 2 has a flat portion 2a with a 300 m
Through holes 22, 22 are formed at positions spaced apart by m. Further, through holes 23, 23 are also formed in the side part 2c. The through holes 22 and 23 are formed at the time of the hot pressing. The resin raw material 5 is formed around the indoor side surface 20 and the outdoor side surface 21 of the intermediate molded product 2 disposed in the molding die 6 described later. Acts as a passage for uniformly filling.

As shown in FIG. 2, the indoor fiber substrate 3 and the outdoor fiber substrate 4 are provided together with the indoor acrylic layer 50, the intermediate molded product 2, and the outdoor acrylic layer 51 together with the canopy 1 as shown in FIG. The FRP skeleton 10 is formed and the intermediate molded product 2 is reinforced in a frame shape. Each of the skeleton portions 10 is made of carbon fiber having a high elastic modulus and has a thickness of 1.0 mm and is formed in a predetermined shape in advance. ing. Note that the indoor fiber base material 3 and the outdoor fiber base material 4 may be satin weave, blind weave, or the like instead of the plain weave.

Indoor fiber base material 3 and outdoor fiber base material 4
Are the indoor surface 20 and the outdoor surface 21 at the bent portion 2b of the intermediate molded product 2 disposed in the accommodation space 65 of the molding die 6.
Are arranged respectively. The resin raw material 5 is provided on the indoor side surface 2 of the intermediate molded product 2 disposed in the accommodation space 65 of the molding die 6.
In addition to swelling the 0 and the outdoor surface 21 to cause a polymerization reaction, it becomes an acrylic resin, and forms the indoor acrylic layer 50 and the outdoor acrylic layer 51. The resin material 5 has a structural formula

[0017]

Embedded image

A mixture of a mixture containing the above monomer and a predetermined amount of peroxide. This mixed liquid has been subjected to a defoaming treatment in advance. The molding die 6 has cavities 60 a and 61 a having the same shape as the outer shape of the canopy 1, and forms a housing space 65 for housing the intermediate molded product 2, the indoor fiber base material 3, and the outdoor fiber base material 4. It comprises a lower mold 60 and an upper mold 61.

The lower mold 60 and the upper mold 61 have temperature medium passages 60b, 61b through which a temperature medium for controlling the mold temperature flows, respectively, along the cavities 60a and 60b, respectively. It is arranged at a predetermined interval in a meat portion at a close position. This temperature medium passage 60
b and 61b are connected to a circulation path (not shown) including a temperature medium circulation drive unit and a temperature control unit.

A sealing material 64 is provided on the mating surface 62 of the lower mold 60 so as to be sandwiched between the mating surface 63 of the upper mold 61 and compressed when the mold is closed, thereby closing the housing space 65. A pressure reducing passage 66 is formed in the upper mold 61 to reduce the pressure in the housing space 65 formed by the lower mold 60 when the mold is closed.
In addition, a liquid resin passage 67 and an injection hole 68 for injecting the resin raw material 5 into the housing space 65 are provided.
The pressure reducing passage 66 is connected to a pressure reducing system (not shown) provided with a pressure reducing pump.

According to the method for manufacturing a transparent resin member of the present embodiment, the following steps are performed in the order of a mold clamping step, a resin raw material supply step, a reaction step, and a release step. That is, first, when the lower mold 60 and the upper mold 61 are in the mold open state as shown in FIG. 3 in preparation for the transition to the mold clamping step, the polycarbonate intermediate molded article 2, the indoor fiber base material 3 and An outdoor fiber base material 4 is provided. Note that the indoor fiber base material 3 and the outdoor fiber base material 4 are disposed on the indoor surface 20 and the outdoor surface 21 at the bent portion 2b of the intermediate molded product 2, respectively.

In the mold clamping step, the lower mold 60 and the upper mold 61 are closed, and their mating surfaces 62 and 63 are sealed with the sealing material 6.
4, and hermetically seals the accommodation space 65 formed by the lower die 60 and the upper die 61. In the resin raw material supply step, the pressure of the housing space 65 of the molding die 6 in the hermetically closed state is reduced to at least 20 Torr or less through the reduced pressure passage 66. In this state, the resin raw material 5 sent out from the supply passage 67 is injected into the housing space 65 through the injection hole 68. Then, the resin raw material 5 quickly moves in the storage space 65 in a decompressed state, and around the indoor side surface 20 of the intermediate molded product 2, the through holes 22 and 23 of the intermediate molded product 2, and the intermediate molded product. 2 around the outside surface 21.

The resin raw material 5 comes into contact with the indoor side surface 20 and the outdoor side surface 21 of the intermediate molded product 2 and impregnates the indoor side fiber base material 3 and the outdoor side fiber base material 4. Then, in this state, the process proceeds to the reaction step. In the reaction process, lower mold 6
The temperature of the upper mold 61 and the upper mold 61 is controlled by the temperature medium circulating in the temperature medium passages 60b and 61b, and the temperature is maintained at 180 ° C. at which the polymerization reaction is promoted.

Accordingly, the resin raw material 5 is used for the intermediate molded product 2
A polymerization reaction occurs on a part of the indoor side surface 20 and a part of the outdoor side surface 21 and the resin is swelled and hardened, and the intermediate molded article 2 is placed in the middle and sandwiched between the indoor side acrylic layer 50 and the outdoor side acrylic layer. The layer 51 is formed. For this reason, the intermediate molded article 2 is impregnated into the boundary between the acrylic layers 50 and 51, which are made of acrylic resin on both surfaces 20 and 21, and the indoor fiber base material 3 and the outdoor fiber base material 4 to form acrylic resin. At these portions, a prototype material 1a (see FIG. 4) of the canopy 1 integrally and firmly joined is manufactured.

That is, a canopy 1 composed of an FRP frame 10 shown in FIG. 1 and a transparent front glass section 11, a roof glass section 12, and a rear glass section 13 surrounded by the FRP frame section 10. Prototype material 1a is formed. Next, the process proceeds to the release step. In the releasing step, the lower mold 60 and the upper mold 61 are connected to the temperature medium passages 60b and 61b.
The temperature of the mold is controlled by a temperature medium circulating in b to lower the mold temperature and is cooled to 70 ° C. Thereafter, the lower mold 60 and the upper mold 61 are opened, and then the prototype material 1a is released. The canopy 1 as a product is obtained by trimming the prototype material 1a into a predetermined external shape, and is used.

The obtained canopy 1 has an intermediate molded article 2 forming an intermediate layer of a laminate, and has a high elongation rate.
The room-side acrylic layer 50 and the outdoor-side acrylic layer 51 that form the surface layer of the laminate are light, hard, and capable of imparting rigidity. For this reason, the canopy 1 can be improved in weight reduction ratio by the thickness occupied by the indoor acrylic layer 50 and the outdoor acrylic layer 51, and the surfaces of the front glass 11, the roof glass 12, and the rear glass 13 can be improved. Hardness can be increased, and it is less susceptible to external influences such as scratches and impacts.

The canopy 1 has a skeletal portion 10 made of FRP formed around the front glass portion 11, the roof glass portion 12, and the rear glass portion 13, so that the overall rigidity (bending rigidity and torsional rigidity) is high. can do. Further, the windshield section 11 and the roof glass section 1
2. Since the rear glass portion 13 is surrounded and restrained by the skeletal portion 10 made of FRP, it is difficult to be thermally deformed, and dimensional stability can be improved.

Therefore, the canopy 1 is excellent in weight reduction rate, surface rigidity and impact resistance. In the manufacturing method of the embodiment,
Although the present invention has been described by applying to the case of manufacturing the canopy 1 of an automobile, the present invention is not limited to this, and a windshield, a side glass, a rear glass, a roof glass, which is conventionally configured using an inorganic glass as a single component, It can be applied as a separate part such as quarter glass.

(Comparative Example) The resin glass canopy 1
In order to confirm the effect of (1) to (4) below,
Confirmation test 1 (test for weight reduction rate, surface hardness, impact resistance, presence or absence of cracks during molding, etc. shown in Table 1), confirmation test 2 (impact resistance test shown in FIG. 5), and confirmation test 3
(A test of the relationship between the change in the thickness of the surface layer and the rigidity and a weight reduction rate shown in FIG. 6 and a confirmation test 4 (a test of an expression rate with respect to a bending elastic modulus and a theoretical value shown in Table 2) were performed. (1) Confirmation test 1 Test samples 1 and 2 of the example (hereinafter referred to as examples 1 and 2) and test samples 1 to 4 of the comparative example (hereinafter referred to as comparative examples 1 to 4). Using light weight rate, surface hardness,
Table 1 shows the results of a test 1 for confirming the impact resistance and the presence / absence of cracks during molding.

The weight reduction rate was compared on the basis that the weight reduction rate of the conventional example was set to 0. The impact resistance value is 3.
A 5 kg hard ball was dropped vertically on the conventional example, and a drop test was similarly performed on each sample based on a drop height of 100 cm when a crack occurred. Surface hardness is JIS K5
It was indicated by the hardness of the pencil lead according to 401. The presence or absence of cracks during molding was visually confirmed after molding.

(Explanation of each test sample) The conventional example is a 4.5 mm-thick laminated glass (unreinforced glass with a polyvinyl butyral film interposed therebetween) actually used in automobiles. . In Examples 1 and 2, the windshield portion 1 of the canopy 1 obtained by the manufacturing method of the above example was used.
1, a part of a laminate forming the roof glass part 12 and the rear glass part 13.

In Example 1, the total thickness T was 8 mm, the thickness t of the intermediate molded product 2 was 6 mm, the thickness t ₁ of the indoor acrylic layer 50 was 1 mm, and the thickness ts of the outdoor acrylic layer 51 was ts. 1
mm (the thicknesses T,
t, t ₁ and ts are shown in FIG. 2). In Example 2, the total thickness T was set to 8 mm, the thickness t of the intermediate molded product 2 was set to 4 mm, the thickness t ₁ of the indoor acrylic layer 50 was set to 2 mm, and the thickness ts of the outdoor acrylic layer 51 was set to 2 mm. It was done.

Comparative Examples 1-4 are laminates corresponding to one of the front glass part 11, the roof glass part 12, and the rear glass part 13 in the canopy 1 of the embodiment shown in FIG. It is created by adjusting the plate thickness so as to have rigidity. Comparative Example 1
The material configurations of Nos. To 4 are as follows. In other words, Comparative Example 1 does not have the intermediate layer corresponding to the PC-made intermediate molded product 2 of the example, but has only the acrylic layer, and the plate thickness of the surface layer having a high elastic modulus is set as large as 7.6 mm. It is.

In Comparative Example 2, the indoor acrylic layer 5 of the embodiment was used.
0 and no surface layer corresponding to the outdoor acrylic layer 51, and the thickness of the PC was set to 10 mm. Comparative Example 3 was formed using a thermoplastic acrylic resin used for eyeglasses and the like. Comparative Example 4 was formed using an epoxy resin based on BPA (bisphenol A) having improved transparency.

[0035] (Evaluation) As a result of the comparative test, as shown in Table 1 above, Examples 1 and 2 were superior to Comparative Examples 2 to 4 in the weight reduction ratio and Comparative Example 1 in the surface hardness (core hardness of the pencil). , 3, and 4 and cracking during molding was better than Comparative Examples 1 and 4.

In Examples 1 and 2, the reason why a high weight reduction rate and a high surface hardness are obtained is that the high elastic modulus integrally formed on the indoor side surface 20 and the outdoor side surface 21 of the intermediate molded product 2 is high. It is considered that the indoor acrylic layer 50 and the outdoor acrylic layer 51 are each a surface layer. In Examples 1 and 2, cracks did not occur during molding because the indoor acrylic layer 50 and the outdoor acrylic layer 5
It is considered that the thickness of the resin material 5 can be reduced to 1 to 2 mm and the internal heat storage generated at the time of curing after the reaction of the resin raw material 5 can be reduced.

Further, the reason why the impact resistance values of Examples 1 and 2 are large is that the intermediate molded product 2 made of PC having a large elongation is provided as the intermediate layer. Comparative Example 1 is a comparative example of P
Since there is no intermediate layer corresponding to the intermediate molded product 2 made of C and the thickness of the surface layer having a high modulus of elasticity is as large as 7.6 mm, there is a problem that the surface layer is broken at the time of molding, and the impact resistance is low.

In Comparative Example 2, the room-side acrylic layer 5
Since it does not have a surface layer corresponding to 0 and the outdoor acrylic layer 51, the weight reduction rate and the surface hardness are remarkably inferior. In Comparative Example 3, since the thermoplastic acrylic resin used for eyeglasses and the like is used, all the characteristics are inferior to those of the samples of Examples 1 and 2. Comparative Example 4 uses an epoxy resin based on BPA (bisphenol A) with improved transparency, so that the weight reduction rate, impact resistance, and surface hardness are inferior to those of Examples 1 and 2. . (2) Confirmation test 2 Test samples 3 to 8 of the example (hereinafter referred to as examples 3 to 8) and test samples 5 to 8 of the comparative example (hereinafter, referred to as examples).
These will be referred to as Comparative Examples 5 to 8. ) And 100 mm x
The size was 100 mm, and a 2.3 kg steel ball was dropped vertically on the surface, and the height at the time of breaking was measured.

Then, on the surface of the conventional test sample,
Drop a 2.3kg steel ball, 100cm in height at the time of destruction
FIG. 5 shows a comparison of the values of each of the examples and each of the comparative examples with reference to the reference value. (Explanation of each test sample) The conventional example is the same as that used in the confirmation test 1.

Examples 3 to 8 are the same constituent materials as those used in Examples 1 and 2 used in the above-mentioned confirmation test 1, and have a thickness T of the entire laminate, a thickness t of the intermediate molded product 2, and an acrylic layer on the outdoor side. 5
The thickness ts of 1 is set to the value shown in FIG.
In Comparative Examples 5 to 8, the thickness T of the entire laminate, the thickness t of the intermediate layer corresponding to the intermediate molded product 2 of the example, and the surface corresponding to the outdoor acrylic layer 51 were different except that the constituent materials were different. The thickness ts of the layer is set to the value shown in FIG.

Comparative Example 5 was prepared using a previously manufactured PC (Iupilon sheet clear 552A-N manufactured by Mitsubishi Gas Chemical Company).
FU) intermediate layer (corresponding to the intermediate molded product 2 of the embodiment);
After two resin plates made of acrylic resin (resin raw material 5) formed separately from the intermediate layer are arranged on both surfaces of the intermediate layer, these are heated to 160 ° C. of Tg or more and 2 to 5 kg.
It is integrated by fusing at a pressure of f / cm ² by hot pressing.

In Comparative Example 6, the same intermediate layer as that of Comparative Example 5 and two acrylic resin plates formed separately from the intermediate layer were disposed on both surfaces of the intermediate layer, and these were placed at Tm or more. Is heated to 260 ° C. and fused by a hot press at a pressure of ² to 5 kgf / cm ² to be integrated. In Comparative Example 7, between the same intermediate layer as that of Comparative Example 5 and two acrylic resin plates formed separately from the intermediate layer, a monomer reacting with them was 0.1 mm. It is applied to a thickness, cured, adhered and integrated.

In Comparative Example 8, the same intermediate layer as that of Comparative Example 5 and two resin plates made of PMMA (SUMIPEX manufactured by Sumitomo Chemical Co., Ltd.) separately formed from the intermediate layer were arranged on both surfaces of the intermediate layer. After heating these to 160 ° C,
It is integrated by fusing at a pressure of 5 kgf / cm ² by hot pressing. (Evaluation) As a result of the confirmation test 2 of the falling ball impact height (impact resistance value), the falling ball impact height is affected by the thickness t (see FIG. 1) of the PC-made intermediate molded product (intermediate layer) serving as the core member. Has been found to work. (3) Confirmation Test 3 Test Samples 9 and 10 of Examples (hereinafter, Examples 9 and 1)
Called 0. ) And test samples 9 to 12 of the comparative example (hereinafter, referred to as comparative examples 9 to 12), respectively, integrally on the outdoor surface of the intermediate layer (corresponding to the intermediate molded product 2 of the example). Bonded surface layer (outdoor acrylic layer 5 of Example)
FIG. 6 shows the results of a test 3 for confirming the relationship between the rigidity and the weight reduction ratio when the thickness ts (corresponding to 1) was changed to 1 to 4 mm, based on the conventional example.

(Explanation of Each Test Sample) The conventional example is the same as that used in the confirmation test 1. Examples 9 and 10 correspond to Example 1 used in the confirmation test 1 described above.
6. The thickness T of the entire laminated body is 8 mm with the same constituent material as that of 2.
5 mm.

Comparative Examples 9 to 12 correspond to Comparative Examples 5 to 8, respectively.
And the thickness T of the entire laminate is set to 8 mm. The stiffness was calculated from the values obtained by measuring the flexural modulus (E) of each of the test samples of the conventional example, Examples 9, 10 and Comparative Examples 9 to 12 according to the ASTM test method D790 three-point bending test. It was calculated by applying the formula.

(Evaluation) Calculation Formula Stiffness = EI = E × bh ³
/ 12 (where b represents a width and h represents a thickness in the calculation formula) The rigidity value 15833 · b of the conventional example calculated as follows by the above calculation formula is set to 1.0 for comparison, and the above calculation is performed. FIG. 6 shows the ratio of each stiffness value of Examples 9 and 10 and Comparative Examples 9 to 12 calculated with the above formula to 1.0.

1830 (kgf / mm ² ) × b · (4.
^{7) 3/12 = 15833 ·} b Consequently, Examples 9 and 10 can be the same weight ratio as in Comparative Example 9-12, was found to obtain a higher rigidity than that of the comparative example 9 to 12 . In Examples 9 and 10,
The conditions for obtaining values close to the rigidity, impact resistance and weight reduction rate of the conventional example are as follows: the thickness T of the entire laminate is 7 to 8.0 m.
m, the thickness ts of the outdoor surface layer is 1.0 to 2.0 m
It has been found preferable to set m. (4) Confirmation test 4 Using Example 9 and Comparative Examples 9 to 11 shown in FIG. 6, the flexural modulus and the expression rate with respect to the theoretical value were determined by ASTM.
The measurement was performed by a three-point bending test according to D790, and the result of confirmation test 4 was shown in Table 2.

[0048] (Evaluation) In the ninth embodiment, even if the weight reduction ratio shown in FIG. 6 is the same as that of the comparative examples 9 to 11, the rigidity can be made higher than that of the comparative examples 9 to 11.

[0049]

According to the method of manufacturing a transparent resin member of the present invention, the steps are carried out in the order of a mold clamping step, a resin raw material supply step, a reaction step, and a release step. In the production method of the present invention, an intermediate molded article made of polycarbonate and having a high elongation rate, and a resin material that undergoes a polymerization reaction on at least one surface (polycarbonate) of the intermediate molded article and swells one surface is formed on the surface by a surface layer. A transparent resin member made of an acrylic resin molded body integrally formed and having a high elastic modulus is manufactured.

As described above, according to the production method of the present invention, a resin material is polymerized and swelled into polycarbonate to form a transparent resin member by bonding and swelling. Therefore, the transparent resin member is bonded using a hot press. The balance between impact resistance and rigidity is better than that of a conventional transparent resin member manufactured by the manufacturing method. Further, according to the method for manufacturing a transparent resin member of the present invention, many low-cost and high-elongation materials can be used, and the overall material cost can be reduced.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a canopy of an automobile obtained by an embodiment of a method for manufacturing a transparent resin member of the present invention.

FIG. 2 is a sectional view taken along the line AA in FIG.

FIG. 3 shows a mold clamping step in the manufacturing method of the embodiment.
It is sectional drawing which shows the positional relationship of a shaping | molding die and the material for inserts arrange | positioned in a shaping | molding die.

FIG. 4 is a cross-sectional view showing a molding die showing a resin raw material supply step in the manufacturing method of the example.

FIG. 5 is a diagram showing impact resistance characteristics of each sample obtained by the manufacturing method of the example, a sample of the conventional example, and each sample of the comparative example.

FIG. 6 shows the relationship between the rigidity of the sample obtained by the manufacturing method of the example, the configuration, and the weight reduction rate, shows the skin thickness (ts) in the horizontal direction, and shows the rigidity (total) in the vertical direction. FIG.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Canopy 10 ... Frame part 11 ... Front glass part 12 ... Roof glass part 13 ... Rear glass part 2 ... Intermediate molded product made of polycarbonate 3 ... Indoor fiber base material 4 ... Outdoor fiber base material 5 ... Resin raw material 50 ... Room Inner acrylic layer 5
1: outdoor acrylic layer 6: mold 60: lower mold 6
1… Upper mold

──────────────────────────────────────────────────の Continued on the front page (72) Inventor Noboru Kawasaki 1190 Kasama-cho, Sakae-ku, Yokohama-shi, Kanagawa Prefecture Inside Mitsui Toatsu Chemical Co., Ltd. Within Chemical Co., Ltd. (72) Inventor, Yukiyuki Suzuki 1190, Kasama-cho, Sakae-ku, Yokohama-shi, Kanagawa Prefecture Inside (72) Inventor Kenichi Fujii 1190, Kasama-cho, Sakae-ku, Yokohama-shi, Kanagawa Mitsui Toatsu Chemical (56) References JP-A-2-176781 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B29C 45/14 B29C 45/00

Claims (1)

(57) [Claims] An intermediate molded product made of polycarbonate is placed in a molding die, and the molding die is clamped. A resin material which is to be an acrylic resin by a polymerization reaction is mixed with the molding die surface and the intermediate molding. a step of test feed on Kyabyiti formed by at least one surface of the article, after cooling the steps of an acrylic resin by polymerization reaction of the resin material by heating the forming die to a predetermined temperature, the forming die Opening the mold and releasing the transparent resin member having the acrylic resin molded body integrally joined to at least one surface of the intermediate molded product.