JP4469899B2 - Method for producing composite molded body - Google Patents

Description

The present invention is suitable for such as automobile body or part, the bending rigidity is excellent, a method of manufacturing a lightweight multi synthetic form.

  Conventionally, a lightweight composite in which a foamed resin is sandwiched between two aluminum alloy plates to reduce weight compared to using an aluminum alloy plate alone, as well as to provide vibration damping performance and sound insulation performance. Plates or lightweight composite molded panels have been proposed.

  These lightweight composite molded panels are first laminated as a material laminate by sandwiching a foamable resin (foamable resin) as a core material between two flat aluminum alloy plates via an adhesive resin, Bond and integrate. Thereafter, the material laminate is formed into a desired shape by plastic working such as press or roll forming, and heated at a foaming temperature of the foamable resin higher than that at the time of bonding after or before the molding. Thus, the foamable resin is foamed. Here, the foamable resin means a resin that foams by heating or can be foamed by heating.

  In order to improve the appearance, lightness, impact resistance, heat resistance, heat retention, durability and other properties of this lightweight composite molded panel against this basic structure, the expansion ratio of these foamed resins is controlled. It has also been proposed to laminate foamed resins having different foaming ratios (see Patent Document 1). Further, in order to suppress exfoliation of the foamable resin layer after foaming, it has also been proposed to interpose an adhesive layer and a non-foamable resin layer between the aluminum alloy plate and the foamable resin layer ( Patent Document 2).

Here, as a specific application, if such a lightweight composite molded panel can be applied also to the field of automobile body panels, the weight can be reduced, and fuel consumption and maneuverability can be improved. However, automobile body panels have a relatively large area of 2 m ² or more, as is well known, such as outer panels such as hoods and doors, inner panels, roof panels, undercover panels, deck boards, and bulkheads. Further, it has a complicated outer peripheral shape, a curved surface or a large molding area. For this reason, it is sometimes difficult to perform press forming such as stretch forming or draw forming even with a single steel sheet actually used as a panel material for an automobile body or an aluminum alloy sheet with a lower formability than a steel sheet. .

  In this respect, the lightweight composite molded panel made of the foamed resin can also be molded when a relatively simple shape such as a sound absorbing member or a vibration damping member of an automobile or a molding area is small. However, in the case of a vehicle body panel having a relatively large area as described above, it is necessary to be able to form a panel having a large area without causing wrinkles or cracks. For this reason, there exists a subject which improves the moldability to the above-mentioned various automotive body panels of the predetermined shape of the laminated board which laminated | stacked the foamable resin of the unfoamed state.

  On the other hand, the shape, construction location, and weight are not restricted, and the laminate is thin as a whole, has good plastic workability such as press work, and is sufficient in the final use state after the heating and foaming process. A lightweight composite molded panel (foamed resin laminated soundproof board) that has vibration damping performance and exhibits soundproof performance has also been proposed (Patent Document 3).

In general, in order to improve the press formability of aluminum alloy plates that are less formable than steel plates, there is also a lightweight molded panel that is embossed on an aluminum alloy plate and provided with numerous irregularities on the plate surface. It has been proposed (Patent Document 4).
Japanese Patent Laid-Open No. 10-29258 JP 2006-56121 A JP 2004-42649 A JP 2005-246418 A

  According to the above-described Patent Document 3, by heating the material laminate and expanding the foamable resin sheet in the plate thickness direction, the moment of inertia of the cross section increases and the bending rigidity can be increased. When the expandable resin is in an unfoamed state, this material laminated plate can reduce the thickness of the laminated plate. Therefore, it is possible to increase the thickness by forming a predetermined panel shape by press molding or the like in the state of the material laminate, and then heating the composite panel to set the foaming resin as the foaming resin as the resin foaming temperature. As a result, a lightweight composite molded panel that is lightweight and highly rigid can be obtained. The same applies to Patent Document 4 in which embossing is performed on the surface of the aluminum alloy plate laminated on the foamable resin.

  However, the above-described automotive body panel having a relatively large area is required to be lightweight, and is required to have durability as a structural material and bending rigidity for collision safety. In order to meet such demands and improve the bending rigidity, it is necessary to increase the thickness of the foamed resin layer having a lower density than the aluminum alloy plate and relatively reduce the thickness of the aluminum alloy plate. is there. However, it is difficult to say that the conventional lightweight composite molded panel described above still satisfies the required bending rigidity with respect to such an automobile body panel.

  In addition, the metal plate to be laminated on the foamable resin is thinned as described above, and an aluminum alloy material or steel material having good moldability and relatively high elongation is used. There is also a problem that the surface is likely to be dented or scratched during molding or handling.

  In this regard, especially when the resin is foamed, when the impact is applied to the lightweight composite molded panel surface and the metal plate is pressed, the foamed resin behind the metal plate plays the role of a cushion. There is a problem that it becomes easier to deform, such as a dent.

In view of these points, the present invention increases the thickness of the foamed resin layer as compared to the metal plates to be laminated, and even if the metal plate is relatively thin, the bending rigidity is excellent, and hard luck is dents and scratches, an object of the present invention to provide a lightweight composite molding panel.

Furthermore, in order to achieve the above object, the gist of the method for producing a composite molded body of the present invention is that an unfoamed foamable resin that becomes a core foamed resin is placed between metal plates through an adhesive resin. Laminate to form a material laminate, and plastic processing is performed on the material laminate to form a large number of irregularities on the surface of each of the metal plates. The concave portions or convex portions facing each other are made to coincide with each other, the concave and convex portions are made into a corrugated shape, the concave portions and / or the convex portions have the same shape and pitch, and the corrugated shape in the concave and convex portions. Where R is the radius of curvature and t is the thickness of the metal plate, t is in the range of 0.05 to 0.6 mm, and the ratio R / t of R to t is in the range of 1 to 25. and with the uneven with material laminated plate, further, with the uneven Prior to heating the foamable resin into a core foam resin by heating the foamable resin, plastic processing is performed into a predetermined molded body shape, and metal plates having a large number of irregularities on the surface are formed on both sides of the core foam resin. It is a composite molded body that is bonded and foamed with a core foam resin, and is a composite in which the positions of the concave portions or the convex portions facing each other in the same direction are matched among the concaves and convexes on each metal plate It is to produce a molded body. In addition, an unfoamed foamable resin that becomes the core foamed resin is laminated between metal plates via an adhesive resin to form a material laminate, and plastic processing is performed on this material laminate subjected to, said plurality of irregularities formed on another of the metal plate surface, of irregularities in these mutual metal plates, each to match the relative position of or recesses between or convex portions toward the same direction, the When the concave and convex portions are corrugated shapes, the concave portions and / or the convex portions have the same shape and pitch, the radius of curvature of the corrugated shape in the concave and convex portions is R, and the thickness of the metal plate is t. Is in the range of 0.05 to 0.6 mm and the ratio R / t of R and t is in the range of 1 to 25. After heating the foamable resin to make the core foam resin A composite molded body in which a metal plate having a large number of irregularities on the surface is bonded to both surfaces of the core material foamed resin by plastic processing into a fixed molded body shape, and the core material foamed resin is foamed. It is to manufacture a composite molded body in which the positions of the concave portions or the convex portions facing each other in the same direction among the concaves and convexes in the metal plate are matched.

  In the present invention, with respect to the unevenness in the metal plate, an upwardly convex portion of the unevenness in each metal plate is used regardless of the position of the metal plate on either the upper or lower side with respect to the foamable resin or the foamed resin. A convex portion or a convex portion is referred to, and a downwardly convex portion is referred to as a concave portion or a concave portion. In other words, in the concavo-convexities of each metal plate, each convex or convex portion is commonly (absolutely) upwardly convex, and each concave or concave portion is commonly (absolutely) downwardly. Convex. Therefore, for example, in a horizontal composite plate or a composite molded body, even if it is an uneven portion of the metal plate located on either the upper or lower side of the foamable resin or the foamed resin, the upward convex portion is common ( Both are convex or convex portions as referred to in the present invention, and the downward convex portions are commonly referred to as concave or concave portions according to the present invention.

  In the present invention, the surface of the metal plate laminated on the foamable resin is provided with a large number of irregularities, the metal plate is thinned, and the metal plate has good moldability and has a relatively high elongation. Even if a steel material is used, the bending rigidity of the composite plate or composite molded body is made excellent. In addition, the surface of the material laminate, composite plate, or composite molded body is less likely to be dented or scratched during molding or handling.

  However, the present inventors, when providing a large number of unevenness on the surface of the metal plate laminated on the foamable resin, the effect of improving the bending rigidity of the composite plate or the composite molded body decreases depending on how the unevenness is provided. I found out. For example, in a horizontal composite plate or composite molded body, it is assumed that the concave or convex portion of the upper metal plate of the foam resin and the convex or convex portion of the lower metal plate of the foam resin (the convex or convex portion of the upper metal plate of the foam resin). When the portion and the concave or concave portion of the lower metal plate of the foamed resin are made to coincide with each other, the panel plate thickness is reduced at the coincident portion. Further, when the distance between the convexes or the convex portions adjacent to each other is constant, the valley portions where the panel plate thickness becomes thin are arranged in a straight line, so that they are easily folded or bent at the arrangement portions of the valley portions. Become. Therefore, in the method of providing such unevenness, the bending rigidity of the composite plate or composite molded body is decreased.

  That is, in the case of a composite plate or a composite molded body in which the thickness of the foamed resin layer is increased and the thickness of the metal plate is relatively thin, the above-described many irregularities are provided on the surface of the metal plate laminated on the foamable resin. In such a case, the technical problem that contradicts the prevention of surface dents and scratches and the improvement of bending rigidity.

  In order to solve this contradiction, in the present invention, the positions of the concavities and convexities in the metal plates that are laminated on the foamable resin are made to coincide with each other. In the present invention, of the concaves and convexes on the metal plates, the opposing positions of the concaves (the concaves convex downward) or the convexes (the convexs convex upward) that match in the same direction are matched. Let That is, as will be described later, in each metal plate, in the upward direction, upward directions (protruding convex portions), and in the downward direction, downward directions (concave concave portions), each in the same direction. The concaves and the concaves are made to coincide with each other, or the convexes heading to the same direction and the convexes facing each other are made to coincide with each other. In other words, the positions of the convexes and the concaves facing each other in different directions on the metal plates are not matched with each other (the convex part projecting upward and the concave part projecting downward).

  As a result, the thickness of the core foam resin layer is increased, and the thickness of the laminated metal plates is made relatively thin. It is difficult for dents and scratches to form on the surface, and the bending rigidity can be improved.

(Basic structure)
Hereinafter, embodiments of the present invention will be described with reference to the drawings. 1-3, is a prerequisite for multiple synthetic forms of the present invention, showing the basic structure of the composite to lamination. Figure 1 is a material of the onset Akirafuku synthetic form is a perspective view showing an uneven with material laminated plate having irregularities on the metal plate. Here, when referring to a material laminated plate with unevenness, as shown in FIG. 1, it means a laminated plate with a large number of unevenness on the surface of the metal plate, and when simply saying a material laminated plate, This refers to a laminated board without many irregularities.

As shown in FIG. 1, which is a material of the onset Akirafuku synthetic form, irregularities with the material laminate 1 has two metal plates 2a, during 2b, in order from the top of the figure, the adhesive resin (resin layer ) 4a, a foamable resin (non-foamed resin layer) 3a, and an adhesive resin (resin layer) 4b are stacked and sandwiched. That is, the adhesive resin 4a is interposed between the metal plate 2a and the foamable resin (resin layer) 3a, and the adhesive resin 4b is interposed between the metal plate 2b and the foamable resin 3a. Yes. And the surface of these two metal plates 2a and 2b is made into the uneven | corrugated raw material laminated board 1 by which the unevenness | corrugation 6 was provided in the surface by uneven | corrugated process.

  FIG. 2 is a perspective view showing a material laminate formed body 1a with unevenness obtained by plastic processing (molding) the material laminated plate 1 with unevenness of FIG. 1 into a desired shape. In the uneven material laminated molded body 1a of FIG. 2, the core material foamed resin 3a is still unfoamed.

FIG. 3 is a perspective view showing an embodiment of the composite molded body 1b in a form in which the core material foamable resin 3a is foamed by heating to form the core material foamed resin 3b of the material laminated molded body 1a with unevenness of FIG. is there. Incidentally, FIG. 1 is not plastically working the concave convex with material laminate 1a to the desired shape, and the core material resin foam 3b by foaming the core foamable resin 3a, a flat composite plate.

  In this way, when two metal plates 2a and 2b are used and the unfoamed foamable resin 3a and the adhesive resin 4b are laminated (sandwiched) between the two metal plates 2a and 2b, The effect of improving the press formability and the effect of improving the bending rigidity of the composite plate or composite molded body after foaming of the resin are greater than in the case of only one metal plate 2a or 2b (single side).

(Metal plate surface irregularities)
On the premise of the above-mentioned composite plate or composite molded body, or a composite or laminated basic structure of a material laminated plate with projections and depressions, which is a characteristic configuration of the present invention, each of the positions where the projections and depressions in the metal plate are opposed to each other This will be described below with reference to FIGS.

4, the present invention embodiment, sectional partially showing a double synthetic form having irregularities on the metal plate surface (after foaming of the foamable resin as a core material, after the panel molding). Figure 6 is a material of the double synthetic form of Figure 4 of the present invention example was irregularities on the metal plate surface, irregularities with the material laminate (before foaming of the foamable resin as a core material, the panel before molding) A cross section is shown partially. In contrast, FIG. 5, in the comparative example, sectional partially showing a double synthetic form having irregularities on the metal plate surface (after foaming of the foamable resin as a core material, after the panel molding). Moreover, FIG. 7 is the raw material of the composite molded body of FIG. 5 of the comparative example, and a material laminated board with unevenness provided with unevenness on the surface of the metal plate (before foaming of the foamable resin as the core material, before panel molding) The cross section of is partially shown.

4 to 7, the unevenness 6 on the surfaces of the metal plates 2a and 2b, and the protrusions 6a and the recesses 6b are present continuously and alternately on the surfaces of the metal plates 2a and 2b. It is uneven. Moreover, the convex portions 6a and the concave portions 6b have the same shape and the same pitch as the metal plates 2a and 2b.

  Here, in this invention, even if it is the metal plate 2a, 2b of the upper and lower sides with respect to the foamable resin 3a or the core material foamed resin 3b, among these unevenness | corrugations 6, it is a convex part on the drawing Is referred to as a convex or convex portion 6a, and a downwardly convex portion in the drawing is referred to as a concave or concave portion 6b. Thus, in the description and drawings of the present invention, each protrusion or protrusion 6a of the unevenness 6 of the metal plates 2a and 2b is commonly upward, and each recess or recess 6b is common. It is assumed that the projection is downward.

  In the example of FIG. 4, the composite molded body 1 b (which may be a composite plate) is either upward or downward with respect to each other in the metal plates 2 a and 2 b sandwiching the core material foamed resin (resin after foaming) 3 b. The opposing positions of the concave portions or the convex portions in the same direction are made to coincide with each other. More specifically, the opposing positions of the convex portion 6a of the metal plate 2a and the convex portion 6a of the metal plate 2b that are directed in the same upward direction are made to coincide with each other. Furthermore, the opposing positions of the concave portion 6b of the metal plate 2a and the concave portion 6b of the metal plate 2b that are directed in the same downward direction are made to coincide with each other.

As a result, as shown in FIG. 4, the distance t2 between the convex portion 6a of the metal plate 2a and the convex portion 6a of the metal plate 2b and the distance t1 between the concave portion 6b of the metal plate 2a and the concave portion 6b of the metal plate 2b are the same . is there. In other words, the convex portions and the convex portions of both metal plates, and the opposing positions of the concave portions and the concave portions are made to coincide with each other. For this reason, the distance between the metal plates 2a and 2b = the foamed resin (resin after foaming) thickness is uniform over the entire composite molded body 1b (composite plate), and the entire composite molded body 1b (composite plate). The thickness is uniform over time. As a result, the bending rigidity is improved over the entire composite molded body 1b (composite plate).

  On the other hand, in the comparative example of FIG. 5, the composite molded body 20b (which may be a composite plate) is either upward or downward with respect to each other in the metal plates 2a and 2b sandwiching the foamed resin (resin after foaming) 3b. The positions of the concavities and convexities facing in the same direction are not matched. More specifically, the opposing positions of the convex portion 6a directed upward in the metal plate 2a and the concave portion 6b directed downward in the metal plate 2b are made to coincide with each other. In addition, the opposing positions of the concave portion 6b directed downward of the metal plate 2a and the convex portion 6a directed upward of the metal plate 2b are made to coincide with each other. As a result, in these coincident portions, the distance t3 between the convex portion 6a of the metal plate 2a and the concave portion 6b of the metal plate 2b and the distance t4 between the concave portion 6b of the metal plate 2a and the convex portion 6a of the metal plate 2b are as follows. They are greatly different from each other, and t4 is significantly smaller than t3. That is, at the distance t4, the thickness (plate thickness) of the composite molded body 20b (composite plate) is reduced.

  For this reason, in the comparative example of FIG. 5, the distance between the metal plates 2a and 2b = the thickness of the foamed resin (resin after foaming) becomes non-uniform throughout the composite molded body 20b (composite plate). The thickness of the entire molded body 20b (composite plate) is not uniform. As a result, the bending rigidity is lowered at the portion of the distance t4 between the thin concave portion 6b of the metal plate 2a and the convex portion 6a of the metal plate 2b, and the bending rigidity is reduced over the entire composite molded body 1b. . Furthermore, when the distance (distance) between the convex portions 6a and 6a adjacent to each other is constant, the valley portions (t4 portion) where the panel plate thickness becomes thin are arranged in a straight line. It is easy to bend or bend at the arrangement part of the part.

Such an uneven arrangement state is each material of the composite molded body (FIGS. 4 and 5), and the laminated sheets with unevenness of the invention examples of FIGS. 6 and 7 and the comparative example (before resin foaming, before panel molding) ) Is the same. In the example of the invention in FIG. 6, the uneven material laminated plate 1 matches the positions of the concavities and convexities facing each other in the same direction on the metal plates 2 a and 2 b sandwiching the foamable resin (resin before foaming) 3 a. I am letting. More specifically, the opposing positions of the convex portion 6a that protrudes on the metal plate 2a and the convex portion 6a that protrudes on the metal plate 2b are made to coincide with each other. In addition, the opposing positions of the concave portion 6b protruding below the metal plate 2a and the concave portion 6b protruding below the metal plate 2b are made to coincide with each other. As a result, the distance t2 between the convex portion 6a of the metal plate 2a and the convex portion 6a of the metal plate 2b and the distance t1 between the concave portion 6b of the metal plate 2a and the concave portion 6b of the metal plate 2b are the same . In other words, the convex portions and the convex portions of both metal plates, and the opposing positions of the concave portions and the concave portions are made to coincide with each other. For this reason, the distance between the metal plates 2a and 2b = the foamable resin (resin before foaming) thickness is uniform over the entire material laminate 1 with unevenness, and the entire material laminate 1 with unevenness is spread over. The thickness of each is uniform.

  On the other hand, in the comparative example of FIG. 7, the uneven material laminated plate 20 has a position where the concavities and convexities facing each other in the same direction in the metal plates 2 a and 2 b sandwiching the foamable resin (resin before foaming) 3 a. They do not match each other. That is, the convex and concave positions (the upward convex part and the downward convex part) facing each other are made to coincide with each other. More specifically, the opposing positions of the convex portion 6a that protrudes upward from the metal plate 2a and the concave portion 6b that protrudes downward from the metal plate 2b are made to coincide with each other. Further, the opposing positions of the concave portion 6b that protrudes below the metal plate 2a and the convex portion 6a that protrudes above the metal plate 2b are made to coincide with each other. As a result, the distance t4 between the convex portion 6a of the metal plate 2a and the concave portion 6b of the metal plate 2b and the distance t3 between the concave portion 6b of the metal plate 2a and the convex portion 6a of the metal plate 2b are greatly different from each other, compared with t4. As a result, t3 is significantly reduced. For this reason, the gap between the metal plates 2a and 2b = the foamable resin (resin before foaming) thickness becomes non-uniform throughout the uneven material laminate 20 and the uneven material laminate 20 is overwhelmed. The thickness becomes uneven.

(Uneven shape)
Figure 4 described above, in the embodiment of FIG. 6, when viewed metal plate 2a, the irregularities 6 2b surface in cross section of the plate, you are uneven waveform.

However, many irregularities provided on the surface of the metal plate are repeated with the same shape and the same pitch in a regular or uniform arrangement, regular or uniform irregular pattern over the entire surface of the metal plates 2a and 2b. It will be provided in . If these are different over the entire surface of the metal plates 2a and 2b, the protrusions 6a of the metal plate 2a and the protrusions of the metal plate 2b are formed on the surfaces of the metal plates 2a and 2b and facing the same direction. It becomes difficult to match the positions of the portions 6a, the concave portions 6b of the metal plate 2a, and the concave portions 6b of the metal plate 2b. For this reason, in the above-described embodiments of FIGS. 4 and 6, the convex portions 6a and the concave portions 6b have the same shape and the same pitch over the entire surfaces of the metal plates 2a and 2b.

(Rough surface)
Speaking of typical corrugated irregularities, in order to increase the bending rigidity improvement effect of the corrugated irregularities, the radius of curvature of the corrugated irregularities is R, and the thickness of the metal plate is t. The ratio R / t of t to t is in the range of 1-25 .

  FIG. 8 shows R and t of the corrugation 6 of this waveform. In FIG. 8, the composite molded body 1b in FIG. 4, an enlarged view of the unevenness 6 on the metal plate 2a side of the composite molded body 1b, and an enlarged view of the convex portion 6a are shown simultaneously. In the enlarged view of the convex portion 6a, the radius of curvature of the convex portion 6a of the corrugated irregularity 6 is indicated as R, and the thickness of the metal plate 2a is indicated as t.

Here, when t is in a predetermined range ( 0.05 to 0.6 mm), when R / t is less than 1, R is small, the unevenness is too small, and strain is applied during uneven processing on the metal plate. The effect is small, and the effect of improving the bending rigidity of the corrugated irregularities does not appear. On the other hand, when the R / t exceeds 25, R is too large, the unevenness is too large, and it is difficult to form the unevenness on the metal plate.

  The process of providing a large number of irregularities on the surface of the metal plate, which will be described later, plastically processes the metal plate and imparts strain. When strain is imparted, the yield strength of the metal plate is usually improved. How much the proof stress of the metal plate is improved depends on the shape of the unevenness and the composition and physical properties of the metal plate, but if the proof stress of the metal plate can be improved by processing when providing unevenness on the surface of the metal plate, it is hard and not easily damaged, As shown in the diagram on the right side of FIG. 8, the composite molded body 1 b can be made difficult to be dented when pressure such as finger pressure by the fingertip is applied from above (in the direction of the arrow).

  For example, in the case of processing corrugated irregularities, in order to give a strain of 2%, the shape having the R which is 25 times the metal plate thickness t is used. On the other hand, to give a strain of 25%, the R / t has a curvature radius R that is twice the thickness t of the metal plate, and the R / t is 2 or more.

(Size of unevenness, pitch)
The preferred height of the convex and concave portions 6a (depth of the concave portions 6b) and the pitch between the concave and convex portions (between the concave and convex portions, between the convex and concave portions, and the pitch between the concave and convex portions) depend on the thickness of a metal plate such as an aluminum alloy plate. Now, the height of the convex portion 6a (the depth of the concave portion 6b) is h, and the width (pitch) between the convex portions 6a (the concave portions 6b) is w. In this case, if the plate thickness of the metal plate is in the range of 0.05 to 0.6 mm, h is in the range of 0.1 to 0.5 mm, and the pitch w is It is preferable to set it as the range of 0.1-0.5 mm.

  If the height h of the convex portion 6a (concave portion 6b) is too small or the pitch w is too large with respect to the thickness of the metal plate, the effect of improving the formability and bending rigidity is reduced. Further, if the h is too large or the pitch w is too small with respect to the thickness of the metal plate, the uneven processing of the plate itself becomes difficult.

(Method to match unevenness)
In order to match the opposing positions of the concavities and convexities that are formed on each metal plate surface and face in the same direction, the foamable resin and the adhesive resin are previously placed between the metal plates with flat surfaces. Each is a laminated material stack, and after that, the formation of a large number of irregularities on the surface of each metal plate and the processing for matching the opposing positions of the irregularities facing in the same direction can be performed simultaneously. preferable. At this time, depending on the processing method, the lamination of the foamable resin, the adhesive resin, and the metal plate may be performed simultaneously with the formation of the unevenness.

  On the other hand, when the surface of each metal plate is formed with a large number of irregularities, and the metal plate on which the irregularities are formed, and the foamable resin and the adhesive resin are laminated, the irregularities are fine (small), As the number increases, it becomes very difficult to match the positions of the concavities and convexities facing in the same direction. For this reason, the bending rigidity improvement effect of the uneven | corrugated raw material laminated plate, composite molded object, and composite plate by the unevenness | corrugation of the metal plate surface will be impaired.

  In the case of a manufacturing method in which a foamed resin and an adhesive resin are laminated on a metal plate having a large number of irregularities on the surface in advance, air can be trapped at the interface between the metal plate and the foamable resin. The adhesiveness with the resin after foaming is impaired. That is, as shown in FIG. 12, the metal plates 2a and 2b on which a large number of irregularities 6 are formed on the surface in advance are shown in FIG. Depending on the size of the projections and depressions 6, the space in the convex portion 6 a of the metal plate 2 a on the upper side of the drawing together with the space in the concave portion 6 b of the metal plate 2 b on the upper side of the drawing is an air pocket 20. It becomes. When such an air pocket 20 is formed, the foamable resin 3a of the uneven laminate 1 is foamed and remains even when the composite molded body 1b is formed, and the metal plates 2a, 2b and the foamed resin 3b are in close contact with each other. Impairs sex.

  Therefore, there is a possibility that the metal plates 2a, 2b and the foamable resin 3a are peeled off during the molding of the uneven material laminated plate 1, or the metal plates 2a, 2b and the foamed resin 3b are peeled off during use. There is also. Further, the effect of improving the bending rigidity of the composite plate or composite molded body due to the unevenness on the surface of the metal plate is also impaired.

  Therefore, in order to match the opposing positions of the concavities and convexities facing in the same direction formed on each metal plate surface, and also to ensure the adhesion between the metal plate and the resin after foaming, In advance, a foamed resin and an adhesive resin are each formed into a material laminate in which metal surfaces having flat surfaces are laminated, and thereafter, formation of numerous irregularities on each metal plate surface and irregularities It is preferable to perform the processing for matching the positions where the two are opposed to each other at the same time.

  In addition, after making the position where the unevenness | corrugations which are formed in the mutual metal plate surface and which face in the same direction correspond each other, foaming resin is the vertical direction (one direction of a board) also by foaming of foaming resin. ), The positions where the projections and depressions are aligned are not easily misaligned.

(Roughing method)
9 and 10 exemplify a mode in which formation of a large number of irregularities on each metal plate surface and processing for making the positions of the irregularities coincide with each other are performed simultaneously. FIG. 9 shows an embodiment using the press 10. FIG. 10 shows an embodiment using rolls.

  In FIG. 9, the same direction as that of the foamed resin 3 a, the lamination of the adhesive resin (not shown) and the metal plates 2 a and 2 b, and the formation of a large number of projections and depressions 6 on the surfaces of the metal plates 2 a and 2 b by the press 10 The processing for matching the opposing positions of the projections 6 facing each other is performed at the same time. That is, irregularities 13 and 14 for forming irregularities 6 are provided in advance on the surfaces of the upper mold 11 and the lower mold 12 of the press 10. At this time, the irregularities on the mold surface irregularities 13, 14 are relative to each other between the convex part 13 a of the upper mold 11 and the convex part 14 a of the lower mold 12, and the concave part 13 b of the upper mold 11 and the concave part 14 b of the lower mold 12. The positions to be matched are provided. Then, the foamable resin 3a, the adhesive resin, and the metal plates 2a and 2b are laminated in these molds, respectively, and then pressed to be integrated as the material laminate 1 with unevenness. At this time, the projections 6a of the metal plate 2a and the projections 6a of the metal plate 2b, the recesses 6b of the metal plate 2a, and the recesses 6b of the metal plate 2b of the material laminated plate 1 with unevenness facing in the same direction. The opposite positions of each other are matched. At this time, adhesion of the metal plates 2a and 2b to the adhesive resin and the foamable resin 3a and processing of the irregularities 6a and 6b on the surface of the metal plate may be simultaneously performed using a hot press.

  In FIG. 10, a process of laminating the metal plates 2a and 2b through the foamable resin 3a and an adhesive resin (not shown) by a pair of rolls 15, a large number on the surfaces of the metal plates 2a and 2b. The processing for making the concave and convex portions 6 (6a and 6b) and the concave and convex portions 6 (6a and 6b) facing in the same direction coincide with each other is performed at the same time. That is, irregularities 18 and 19 for forming irregularities 6 are provided in advance on the surfaces of the upper roll 16 and the lower roll 17 of the roll 15. At this time, each unevenness on the roll surface unevenness 18, 19 is a position where the convex part of the upper roll 16 and the convex part of the lower roll 17, the concave part of the upper roll 16 and the concave part of the lower roll 17 are opposed to each other. Provide to match. Then, after laminating the foamable resin 3a, the adhesive resin, and the metal plates 2a and 2b in these molds, roll processing is performed so as to be sandwiched between the upper roll 16 and the lower roll 17 of the roll 15. Thus, it is integrated as the material laminate 1 with unevenness. At this time, the projections 6a of the metal plate 2a and the projections 6a of the metal plate 2b, the recesses 6b of the metal plate 2a, and the recesses 6b of the metal plate 2b of the material laminate 1 with unevenness facing the same direction. The opposite positions of and are matched. In addition, by processing while heating, the adhesion between the metal plates 2a and 2b and the resin for bonding and the foamable resin 3a and the processing of the irregularities 6a and 6b on the surface of the metal plate may be performed at the same time.

(Core foam resin)
The expansion ratio of the core material foamed resin 3b is in the range of 2 to 10 times, and the thickness after the foaming is preferably twice or more the thickness of the metal plates 2a and 2b. In the case of a composite molded body or composite plate having a relatively large area such as the automobile body panel, the foaming ratio is set in this range in order to satisfy both weight reduction and improvement in bending rigidity.

(Type of expandable resin)
In the case where the resin constituting the foamable resin 3a is a thermoplastic resin, the melting point is preferably 100 ° C to 260 ° C. When the melting point is within this range, the foamable resin 3a can be foamed by heating at 120 ° C. to 300 ° C. to obtain the core material foamed resin 3b. A polyolefin-based resin is preferably used as the core foam resin. However, it can be changed to other resins depending on the use temperature.

  For example, a heat-decomposable foaming agent is blended into a resin and kneaded. As a polyolefin, polypropylene (homo PP, etc.), polyethylene, or a mixture thereof (random PP, etc.), polystyrene, polyester Each of these may be used alone, or may be a polymer blend in which these are mixed, or a blend of inorganic or metal fillers.

  Examples of the foamable resin preferable as the thermoplastic resin include polyolefin, polyethylene, polyester, and nylon. Among these, polyolefin, polypropylene, polyethylene, and a mixed system thereof are preferable because they are not polar and hardly cause chemical reaction. The melting point of polypropylene is 160 ° C to 170 ° C, the melting point of polyethylene is 100 ° C to 140 ° C, the melting point of polyester terephthalate (PET) is 250 ° C to 260 ° C, and the melting point of nylon is 179 ° C to 260 ° C. For this reason, these resins may be used alone or mixed and laminated as appropriate to adjust the melting point as the foamable resin.

  When both the thermoplastic resin and the thermosetting resin are used as the foamable resin 3a, the foaming temperature is preferably set to 120 ° C to 300 ° C. Since the foamable resin is likely to deteriorate when heated at a temperature about 40 to 50 ° C. higher than its melting point, the foaming temperature needs to be set to a temperature that is 40 to 50 ° C. higher than the melting point of the foamable resin. If it does so, it can be made to foam without deteriorating the foamable resin 3a by heating at 120 to 300 degreeC.

(Adhesive resin)
The adhesive resin 4 is made of an adhesive resin capable of bonding the foamable resin 3a and the metal plates 2a and 2b. When a polyolefin-based resin is used as the main component as the core material foamed resin 3b, a thermoplastic resin having a good compatibility and having polyethylene or polypropylene as the main component is preferably used as the adhesive resin 4.

(Resin shape)
These foamable resins and adhesive resins are not limited to films and sheets. Either foamed resin or adhesive resin (in this case, the other may be a film or sheet), or both of which are melted or dissolved in a solvent, are applied with a roll or spray. It is also possible. In this application, it is preferable that there is a step of drying after the application.

(Resin application example)
As a resin application example, by selecting the type of resin or adding an additive, the properties of the composite molded body can be made to have higher functions and multifunctions. For example, if a highly vibration-damping resin is used as the foamable resin or the adhesive resin, the vibration damping performance and sound insulation performance are enhanced. Moreover, if a conductive substance is used, welding performance will increase. When a metal powder is added as a conductive substance to the foamable resin 3a or the adhesive resin 4, the resin has a high density. For this reason, the sound insulation performance is enhanced and the weldability can be improved by using a conductive material.

(Metal plate)
The plate thickness of the metal plates 2a and 2b laminated with the foamable resin is 0 . The range is from 05 to 0.6 mm. When the thickness of the metal plate is less than 0.05 mm, the bending rigidity of the composite plate or the composite molded body having the relatively large area is remarkably lowered. On the other hand, if the thickness of the metal plate exceeds 0.6 mm, the weight becomes heavy and the weight reduction is sacrificed .

  As the metal plate, a commonly used aluminum alloy plate or steel plate is used. As these aluminum alloy plates and steel plates, materials that are generally used for this kind of structural member application and that are specified in AA or JIS standards or similar to the specifications can be used as appropriate. Examples of aluminum alloy plates include alloy plates of 1000 series, 3000 series, 5000 series, 6000 series, etc., and examples of steel sheets include mild steel sheets. In particular, it is necessary to select a material having high strength, high yield strength, or high tension. Absent.

  However, an aluminum alloy plate or a steel plate is preferably an age-hardening type material that is baked and hardened in a heat treatment for foaming the core foam resin. As the age-hardening material, a commonly used alloy plate such as 6000 series is suitably used for the aluminum alloy plate. As the steel plate, a dual phase steel plate or the like is preferably used.

(Production method)
Next, an example of a method for producing a material laminate with unevenness, a composite plate, and a composite molded body will be described below with reference to FIGS.

Foamable resin:
First, the resin material constituting the foamable resin 3a is kneaded. This material contains a resin and a pyrolytic foaming agent, and a substance imparting adhesive strength, vibration damping strength, and lubricity, or metal powder is added as necessary. After these materials are sufficiently kneaded, they are formed into a film or sheet. When filmed, it is wound into a coil. At this time, it is preferable that the melting point of the resin contained in the material is set to be 20 ° C. to 30 ° C. lower than the decomposition temperature of the foaming agent. If it does so, even if the temperature of resin rises by kneading | mixing, it can prevent that foaming arises.

Adhesive resin:
First, the resin material constituting the adhesive resin 4 is kneaded. In this material, a material for imparting adhesive strength and vibration damping properties and a metal powder for imparting conductivity are added to the resin as necessary. After these materials are sufficiently kneaded, they are formed into a film or a sheet. In the case of film formation, it is wound in a coil shape and laminated separately or applied to the surface of a metal plate. The foamable resin film or sheet and the adhesive resin may be heat-sealed and integrated into a coil shape. In the case where the foamable resin film and the adhesive resin film are already separate coils, by stretching each of these two coils, the metal plate 2 has a film-like adhesive resin 4; The film-shaped foamable resin 3a can be laminated simultaneously.

Production of material laminates:
The method of laminating the metal plates 2a and 2b, which are cut plates, and the film-like adhesive resin 4 and the film-like foamable resin 3a, which are also cut plates, in order, is the simplest method. . However, it may be laminated continuously if possible in terms of equipment. That is, either one or both of the metal plates 2a and 2b are unwound from the coil, while the film-like adhesive resin 4 and the film-like foamable resin 3a are each unwound from the coil and stretched. You may laminate | stack simultaneously from either one of board 2a, 2b or between metal plates 2a, 2b.

  If these are laminated and then heated by being sandwiched by, for example, a hot roll, the metal plate 2 and the foamable resin 3a in FIG. 1 are bonded together via an adhesive resin, and the material laminate 1 can be manufactured. The temperature of this hot roll is set lower than the foaming temperature of the foamable resin 3a. Note that these adhesions are not limited to heat. For example, a film-like adhesive resin 4 is applied, or an adhesive resin 4 is applied between the foamable resin 3a and between the adhesive resin 4 and a metal. The plates 2 may be bonded to each other, for example, by being pressed at room temperature.

Concavity and convexity processing method:
As described above with reference to FIGS. 9 and 10, the laminated plate manufactured in this way is subjected to a process for forming a large number of irregularities on the surface of each metal plate and matching the positions where the irregularities face each other. It is given simultaneously and it is set as the material laminated board 1 with an unevenness | corrugation.

(Plastic processing)
The manufactured uneven material laminate 1 is plastically formed (molded) as a whole, and formed into a predetermined shape as illustrated in FIG. The As the forming method, known press forming or bending such as bulging forming, drawing forming or bending forming can be used.

(Heating, foaming)
The uneven laminated material laminate 1a having a predetermined shape by the molding process is heated to the foaming temperature, whereby the foamable resin 3a is foamed to be a composite molded body 1b that becomes the core material foamed resin 3b. FIG. 11 has the core material foamed resin 3b, and the positions of the convex portions 6a of the metal plate 2a and the convex portions 6a of the metal plate 2b, and the concave portions 6b of the metal plate 2a and the concave portions 6b of the metal plate 2b are opposed to each other. The HAT type composite molded body 1b, which are matched with each other, is shown in a perspective view.

  Here, the composite material 1b may be obtained by first foaming the produced material laminate 1 with unevenness and molding the composite plate after foaming. That is, the laminate 1 may be either heated and foamed after being molded, or heated and foamed before being molded. Furthermore, the composite molded object 1b can also be obtained by performing press molding and heat foaming simultaneously or continuously in the metal mold | die with an unevenness | corrugation using the hot press.

As described above, the present invention can provide a lightweight composite molded body having excellent bending rigidity and capable of forming a material laminate into these composite molded bodies. In particular, the present invention is suitable for manufacturing automobile body panels having a relatively large area, such as outer panels such as hoods and doors, inner panels, roof panels, undercover panels, deck boards, and bulkheads.

It is a perspective view which illustrates the aspect of the raw material laminated board with an unevenness | corrugation which is a raw material of this invention composite molded object. It is a perspective view which shows the raw material laminated body with an unevenness | corrugation which shape | molded the uneven material laminated board of FIG. It is a perspective view which shows one Embodiment of the composite molded object of this invention which made the molded object of FIG. 2 foam. It is sectional drawing which shows the position state of the unevenness | corrugation of the composite molded object of this invention. It is sectional drawing which shows the position state of the mutual unevenness | corrugation of the composite molded object of a comparative example. It is sectional drawing which shows the position state of the mutual unevenness | corrugation of the raw material laminated molding board with an unevenness | corrugation used as the raw material of the composite molded object of this invention shown in FIG. It is sectional drawing which shows the position state of the mutual unevenness | corrugation of the raw material laminated molding board with an unevenness | corrugation used as the raw material of the composite molded object of this invention shown in FIG. It is explanatory drawing which expands and shows the unevenness | corrugation of FIG. It is explanatory drawing which shows the aspect of the uneven | corrugated shaping | molding process of the raw material laminated molding board with an unevenness | corrugation used as the raw material of the composite molded object of this invention. It is explanatory drawing which shows the aspect of the uneven | corrugated shaping | molding process of the raw material laminated molding board with an unevenness | corrugation used as the raw material of the composite molded object of this invention. It is a perspective view which shows an example of the composite molded object of this invention. It is sectional drawing which shows the cross section of the composite molded object of a comparative example.

Explanation of symbols

1: Material laminated plate with irregularities, 1a: Material laminated molded body with irregularities (unfoamed), 1b: Composite molded body (after foaming), 2: Metal plate, 3a: Expandable resin (resin before foaming), 3b: Core material foamed resin (resin after foaming), 4: Adhesive resin film, 6: Concavity and convexity, 6a: Convex portion (convex upward on the drawing), 6b: Concavity (convex downward on the drawing)

Claims (2)

An unfoamed foamable resin that becomes the core foam resin is laminated between metal plates via an adhesive resin to form a material laminate, and plastic processing is applied to this material laminate. Forming a large number of irregularities on the surfaces of the metal plates, of the irregularities on the metal plates, matching the positions of the concave portions or convex portions facing each other in the same direction. as waveform, when the凹同mechanic and / or shape of the convex between, the same as those of pitch, and the radius of curvature of the wave shapes in the irregularity R, the thickness of the metal plate was t, the t is 0 In the range of 0.05 to 0.6 mm, and the R / t ratio R / t is in the range of 1 to 25, the uneven material laminated plate, Before heating the resin to make the core foam A composite molded body in which a metal plate having a large number of projections and depressions is bonded to both surfaces of a core material foamed resin, and the core material foamed resin is foamed. A method of manufacturing a composite molded body, comprising manufacturing the composite molded body in which the positions of the concave portions or the convex portions facing each other in the same direction are matched. An unfoamed foamable resin that becomes the core foam resin is laminated between metal plates via an adhesive resin to form a material laminate, and plastic processing is applied to this material laminate. Forming a large number of irregularities on the surfaces of the metal plates, of the irregularities on the metal plates, matching the positions of the concave portions or convex portions facing each other in the same direction. as waveform, when the凹同mechanic and / or shape of the convex between, the same as those of pitch, and the radius of curvature of the wave shapes in the irregularity R, the thickness of the metal plate was t, the t is 0 In the range of 0.05 to 0.6 mm, and the R / t ratio R / t is in the range of 1 to 25, the uneven material laminated plate, After heating the resin to make a core foam resin, A composite molded body in which a metal plate having a large number of projections and depressions is bonded to both surfaces of a core material foamed resin, and the core material foamed resin is foamed. A method of manufacturing a composite molded body, comprising manufacturing the composite molded body in which the positions of the concave portions or the convex portions facing each other in the same direction are matched.

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