JP6163971B2 - Decorative molded product and method for producing decorative molded product - Google Patents

Description

  The present invention relates to a decorative molded product and a method for producing a decorative molded product. Specifically, the present invention relates to a fiber reinforced plastic molded body and a decorative molded product in which a decorative film is laminated on at least one surface of the fiber reinforced plastic molded body, and the fiber reinforced plastic molded body is a fiber reinforced plastic. The present invention relates to a decorative molded product formed from a molded body sheet.

In various electronic devices such as mobile phones, personal digital assistants (PDAs), and notebook computers, the surface of the housing is secondarily decorated to differentiate products in addition to improving surface strength. . Conventionally, such decoration processing of the housing surface has been performed by forming a coating film by painting. Above all, the spray coating method is one of the coating methods applied in a wide range of fields because of its excellent coating efficiency.
However, when a coating method such as spray coating is used, there is a problem that it is difficult to secure a coating place and the economic efficiency at the time of coating is poor. Moreover, when decorating a molded product by spray coating, since a plurality of coating films are formed, process management and the like are complicated.

  In recent years, it has been required to give various textures to the surface of the housing. For example, there is a demand for a surface texture that has a specific texture such as a soft, elastic, warmth, etc. surface of leather, cloth, wood, etc. For this reason, the method of decorating a molded article using the film (decorative film) with design property in recent years is proposed (for example, patent documents 1 and 2). Here, since a design layer can be formed at a time by adhering a decorative film to a molded product, the process can be simplified. In addition, since a variety of materials can be selected as the material of the decorative film, it is possible to give a special color to the surface feel and the like.

JP 2004-299220 A JP 2004-299223 A

  Since various electronic devices as described above are frequently carried and used in every situation, in addition to being lightweight, they are required to have a drop impact resistance and flame retardancy. In order to reduce the weight, it is conceivable to reduce the thickness of the casing (plastic molded body). However, the reduction in thickness causes a reduction in strength such as impact resistance. Although it is conceivable to use a plastic molded body in which reinforcing fibers are mixed, the conventional fiber reinforced plastic molded body is not sufficient in strength and flame retardancy, and has been required to be improved.

  Moreover, in the pasting process of the decorative film with a unique texture, it is necessary to use a vacuum forming method instead of pressing. During vacuum forming, high pressure may be applied to the plastic molded body. It is required to have strength so that deformation, warpage, and the like do not occur due to such pressure. Also from such a point, there has been a demand for a decorative molded product having a high-strength plastic molded body that does not cause deformation or warpage.

  Furthermore, the decorative molded product obtained by laminating a decorative film is required to have a smooth plastic molded body and excellent decoration suitability in order to enhance the designability after decoration. . Conventional decorative molded products may not have sufficient design properties, and further improvements have been demanded.

  Therefore, in order to solve the problems of the prior art, the present inventors are a decorative molded product that achieves both weight reduction and high strength, and has high flame retardancy and excellent design. The study was conducted with the aim of providing molded products.

As a result of earnest studies to solve the above problems, the present inventors have found that in a decorative molded product in which a decorative film is laminated on at least one surface of a fiber reinforced plastic molded product and a fiber reinforced plastic molded product. The present inventors have found that by making the configuration of the fiber-reinforced plastic molded body a specific one, it is possible to obtain a decorative molded product that achieves both weight reduction and high strength. Furthermore, the present inventors have found that such a decorative molded product has high flame retardancy and excellent design properties, and have completed the present invention.
Specifically, the present invention has the following configuration.

[1] A decorative molded product in which a decorative film is laminated on at least one surface of a fiber reinforced plastic molded body and the fiber reinforced plastic molded body, wherein the fiber reinforced plastic molded body includes a reinforced fiber component, a heat A plastic molded body obtained by heating and press-molding a sheet for a fiber-reinforced plastic molded body containing a matrix resin component containing a plastic super engineering plastic fiber and a binder component, and the limiting oxygen index of the thermoplastic super engineering plastic fiber is 24 or more. Decorative molded product characterized by that.
[2] The reinforcing fiber component includes inorganic fibers, the fiber diameter of the thermoplastic super engineering plastic fiber is 40 μm or less, and the fiber diameter of the thermoplastic super engineering plastic fiber is 5 times or less of the fiber diameter of the inorganic fiber. The decorative molded product according to [1], which is characterized in that
[3] The decorative molded product according to [1] or [2], wherein the thickness of the fiber-reinforced plastic molded body is 0.05 to 2 mm.
[4] JAPAN TAPPI paper pulp test method no. The decorative molded article according to any one of [1] to [3], wherein the air permeability defined in 5-2 is 250 seconds or less.
[5] Any one of [1] to [4], wherein the binder component is contained in an amount of 0.1 to 10% by mass with respect to the total mass of the fiber-reinforced plastic molded body. The decorative molded product according to the item.
[6] The decorative molded product according to any one of [1] to [5], wherein the binder component is compatible with the thermoplastic super engineering plastic fiber in a heated and melted state.
[7] The binder component contains a copolymer containing at least one of a repeating unit derived from a methyl (meth) acrylate-containing monomer and a repeating unit derived from an ethyl (meth) acrylate-containing monomer [1] ] The decorative molded product according to any one of [6].
[8] The additive according to any one of [1] to [7], wherein the binder component contains a binder fiber having a melting point lower than a glass transition temperature of the thermoplastic super engineering plastic fiber. Decorative molded product.
[9] The decorative molded product according to [8], wherein the binder fiber includes polyethylene terephthalate or modified polyethylene terephthalate.
[10] The decorative molded product according to [8] or [9], wherein the thermoplastic super engineering plastic fiber and the binder fiber are chopped strands.
[11] The fiber-reinforced plastic molded sheet has a surface layer region and an intermediate region sandwiched between the surface layer regions, and the binder component contained in the surface layer region is a binder component contained in the intermediate region. The decorative molded product according to any one of [1] to [10], which is more in number.
[12] The copolymer contained in the binder component is localized in the form of a drainage film at the intersection of the fibers constituting the reinforcing fiber component and the matrix resin component [7] to [7] 11]. The decorative molded product according to any one of [11].
[13] The decorative molded article according to any one of [1] to [12], wherein the thermoplastic super engineering plastic fiber is at least one selected from polyetherimide fiber or polycarbonate fiber. .
[14] The decorative molded article according to any one of [1] to [13], wherein the thermoplastic super engineering plastic fiber is a polyetherimide fiber.
[15] The decorative molded product according to any one of [1] to [14], wherein the decorative film is laminated on the fiber-reinforced plastic molded body through a bonding means. .
[16] A method for producing a fiber-reinforced plastic molded body and a decorative molded product in which a decorative film is laminated on at least one surface of the fiber-reinforced plastic molded body, comprising a reinforcing fiber component and a thermoplastic super engineering plastic fiber A step of heating and press-molding a sheet for a fiber-reinforced plastic molded body containing a matrix resin component and a binder component to form a fiber-reinforced plastic molded body, and a decorative film on at least one surface of the fiber-reinforced plastic molded body In the step of pasting the decorative film, the decorative film is pasted by a method selected from a vacuum forming method, a vacuum pressure forming method and a thermal transfer method, and the thermoplastic super engineering plastic fiber The limiting oxygen index of is 24 or more, The manufacturing method of the decorative molded product characterized by the above-mentioned.
[17] Before the step of forming the fiber-reinforced plastic molded body, the method further includes the step of forming a sheet for fiber-reinforced plastic molded body, and the step of forming the sheet for fiber-reinforced plastic molded body includes a dry nonwoven fabric method or Including a step of forming a nonwoven fabric sheet by any of the wet nonwoven fabric methods, and a step of internally adding, applying or impregnating the nonwoven fabric sheet with a solution containing the binder component or an emulsion containing the binder component, followed by drying by heating. [16] The method for producing a decorative molded product according to [16].
[18] The method according to [16] or [17], wherein in the step of forming the fiber-reinforced plastic molded body, heat pressing is performed at a temperature equal to or higher than a glass transition temperature of the thermoplastic super engineering plastic fiber. A method for producing a decorative molded product.
[19] In any one of [16] to [18], in the step of forming the fiber-reinforced plastic molded body, the sheet for fiber-reinforced plastic molded body is heated and pressurized at 150 to 600 ° C. The manufacturing method of the decorative molded product of description.

According to the present invention, a decorative molded product that is lightweight and has high strength can be obtained. Furthermore, according to the present invention, a decorative molded product having high flame retardancy and excellent design properties can be obtained.
As described above, the decorative molded product of the present invention has high flame retardancy, light weight, and high strength. Therefore, in addition to the housing of electronic equipment, sports equipment, leisure goods, aircraft materials, interior materials, etc. It is preferably used in various fields.

  Hereinafter, the present invention will be described in detail. The description of the constituent elements described below may be made based on representative embodiments and specific examples, but the present invention is not limited to such embodiments. In the present specification, a numerical range expressed using “to” means a range including numerical values described before and after “to” as a lower limit value and an upper limit value.

(Decorated molded product)
The present invention relates to a fiber-reinforced plastic molded body and a decorative molded product in which a decorative film is laminated on at least one surface of the fiber-reinforced plastic molded body. Here, the fiber reinforced plastic molded body includes a mixture of a reinforcing fiber component and a matrix resin component including a thermoplastic super engineering plastic fiber, and further a plastic molding obtained by heating and pressing a sheet for a fiber reinforced plastic molded body including a binder component. Is the body. Further, the limiting oxygen index of the thermoplastic super engineering plastic fiber is 24 or more. In the present invention, the fiber-reinforced plastic molded body of the decorative molded product has the above-described configuration, thereby succeeding in obtaining a lightweight and high-strength decorative molded product. Furthermore, the decorative molded product of the present invention has the advantages of high flame retardancy and excellent design.

  In the present invention, the decorative film is preferably provided on at least one surface of the fiber-reinforced plastic molded body, but may be provided on both surfaces. Thus, a decorative molded product having both surfaces covered with a decorative film can also be used for various purposes.

  Moreover, in this invention, the decorating film may be laminated | stacked so that the edge part of a fiber reinforced plastic molding may be covered. Here, the edge part of a fiber reinforced plastic molding means the area | region containing the edge of the upper surface of a fiber reinforced plastic molding, and a lower surface, and the side surface of the thickness direction of a fiber reinforced plastic molding. Thus, by covering the edge part of a fiber reinforced plastic molding with a decoration film, the adhesiveness of a decoration film and a fiber reinforced plastic molding can be improved, and design nature can be improved more.

It is preferable that the decorative film is laminated on the fiber-reinforced plastic molded body through a bonding means. As the bonding means, known bonding means can be appropriately employed.
There are many techniques for decorating plastic, and there are many techniques, but the film bonding / transfer decoration technique is the most active decoration technique at present. Conventionally, secondary decoration printing, painting, vapor deposition, plating, and the like have been used for surface decoration of plastic casings used in home appliances, OA devices, mobile phones, and the like. However, in recent years, the shape of products has become complicated, functionality has been demanded, and in addition, from the viewpoint of environmental burden, cost, etc., a technique for bonding a film to the surface of a molded product such as a fiber reinforced plastic molded body is used. It has become. Specifically, using a film or sheet (decorative film) decorated by printing, painting, vacuum deposition, coloring, etc., the film is bonded to the surface of a molded product such as a fiber reinforced plastic molded body. Yes. In addition, a film bonding / transfer decoration technique, which is a decoration technique for transferring a decorative surface such as printing, painting, and vacuum deposition, is also often used.

The molding method used for the film bonding / transfer decoration technique is classified into in-mold molding by injection molding and secondary decoration. In-mold molding is further classified into a laminate decoration method that leaves a film on a molded article and a transfer decoration (thermal transfer decoration) that transfers only the design surface to the molded article. Here, the laminate decorating method refers to a method in which all layers of a decorating sheet having a base film and a decorative layer provided thereon are laminated and integrated on the surface of a molded product. Transfer decoration is a decorative sheet laminated and integrated on the surface of a molded product, where the base film is peeled and removed, and only the transfer layer such as a decorative layer remains on the molded product and is laminated. Say.
Secondary decorations to be pasted and transferred to the molded product later include overlay molding, hot stamping, high pressure method, and water pressure transfer method. Conventionally, in-mold molding has been mainly used, but as a new vacuum and pressure bonding method (overlay molding), Fusa Vacuum Co., Ltd. has developed a TOM (Three Dimension Overlay Method) method, and shape adaptability has further expanded.
Among these, TOM molding is preferably used because it can be decorated in a complicated shape and can be wound into the edge portion, so that the edge processing of the molded fiber reinforced plastic is not necessary. .
Here, TOM molding is a method in which a heated and softened film is pressed against a mold by the pressure of atmospheric pressure / compressed air pressure to adhere to the mold. The hydraulic transfer is a method in which a water-soluble film is floated in a water tank, a substrate is submerged in the water tank from above the film, and transferred by water pressure to be taken out. In this case, it is preferable to perform coating processing for protecting the transfer part and finishing the gloss after removal.

(Fiber reinforced plastic molding)
The fiber-reinforced plastic molded body of the present invention is formed by heating and pressure-molding a sheet for fiber-reinforced plastic molded body containing a mixture of a reinforcing fiber component and a matrix resin component containing thermoplastic super engineering plastic fibers, and further containing a binder component. Plastic molded body. The sheet for fiber-reinforced plastic molded body may be formed by heating and pressing in a single layer, or may be laminated and heated and pressed to have a desired thickness.

The heating and pressing step is a step of applying pressure while heating the thermoplastic super engineering plastic fiber at a temperature preferably equal to or higher than the glass transition temperature. In the heating and pressing step, it is preferable to perform a hot press treatment.
In the heating and pressing step, it is preferable to heat the fiber reinforced plastic molded sheet so that the surface temperature is Tg to Tg + 100 ° C. Here, Tg represents the glass transition temperature of the thermoplastic resin. The heating temperature is preferably a temperature range in which the thermoplastic resin fibers flow and the reinforcing fibers do not melt.

  The film thickness of the fiber reinforced plastic molded body is preferably 0.05 to 2 mm, more preferably 0.1 to 1.5 mm, and further preferably 0.15 to 1 mm. The fiber-reinforced plastic molded article used in the present invention is characterized in that it is a thin film as described above but has high strength and flame retardancy. Moreover, although a fiber reinforced plastic molding is a thin film as described above, a decorative film can be bonded by vacuum molding or the like.

(Fiber-reinforced plastic molded sheet)
The sheet | seat for fiber reinforced plastic molded objects contains a reinforcement fiber component, the matrix resin component containing a thermoplastic super engineering plastic fiber, and a binder component.

  In the fiber-reinforced plastic molded sheet of the present invention, the mass ratio of the reinforcing fiber component and the thermoplastic super engineering plastic fiber is preferably 1: 0.2 to 1:10, and preferably 1: 0.5 to 1: 5. More preferably, it is more preferably 1: 0.7 to 1: 3. By setting the mass ratio of the reinforcing fiber component and the thermoplastic super engineering plastic fiber within the above range, a lightweight and high-strength decorative molded product can be obtained. Furthermore, the designability of the decorative molded product can be enhanced.

  In order to obtain sufficient strength after heating and pressing, the reinforcing fiber component and the matrix resin component are preferably mixed uniformly. For this purpose, it is preferable that the fiber diameters of the reinforcing fiber and the matrix resin fiber are close. From this viewpoint, the fiber diameter of the super engineering plastic fiber is preferably 5 times or less of the fiber diameter of the reinforcing fiber, more preferably 4 times or less, and most preferably the fiber diameter of the super engineering plastic fiber and the reinforcing fiber. The fiber diameter is almost the same.

  In general, since the matrix resin has a high melt viscosity, it is difficult to uniformly disperse the reinforcing fibers when a large amount of the reinforcing fibers are blended by a method such as injection molding, so that the blending ratio of the reinforcing fibers is limited. However, in the fiber-reinforced plastic molded sheet of the present invention, the ratio of reinforcing fibers to matrix resin fibers can be set relatively freely according to the required strength.

  JAPAN TAPPI Paper Pulp and Paper Test Method No. for Fiber Reinforced Plastic Molded Sheet The air permeability defined in 5-2 is preferably 250 seconds or less, more preferably 230 seconds or less, and even more preferably 200 seconds or less. This numerical value indicates that the smaller the number, the easier air can pass through (the better the air permeability). In the present invention, by setting the air permeability of the fiber-reinforced plastic molded sheet within the above range, the molding speed in the heating and pressing step can be increased, and the production efficiency can be increased.

  However, if the sheet before processing is adjusted to be bulky as a material for satisfying the above air permeability, there may be inconveniences when inserting the fiber reinforced plastic molded sheet into a heat press machine or the like in the heating and pressing step. There is. Moreover, there is also a problem that the storage cost is high until the sheet for fiber-reinforced plastic molded body is manufactured and used for the heating and pressing step. Such a problem can be solved by lightly pressing with a hot press or a heat calender before heat-press molding and appropriately increasing the density. In the case of this method, since air becomes somewhat difficult to pass, it is preferable to increase the density within a range in which the air permeability measured by a method based on the JAPAN TAPPI paper pulp test method can be maintained within a state of 250 seconds or less.

<Reinforcing fiber component>
The reinforcing fiber component includes inorganic fibers. Examples of inorganic fibers include glass fibers and carbon fibers. In addition, these inorganic fibers may use 1 type and may use multiple types. Furthermore, in the present invention, the reinforcing fiber component may contain organic fibers excellent in heat resistance such as aramid fibers and PBO (polyparaphenylene benzoxazole) fibers in addition to such inorganic fibers.
For example, when inorganic fibers such as carbon fibers are used as the reinforcing fiber component, fibers having high bending strength, tensile strength, and elastic modulus can be obtained by heating and pressing at the melting temperature of the thermoplastic super engineering plastic fibers contained in the nonwoven fabric sheet. A reinforced plastic molding can be obtained.
When high heat-resistant and high-strength organic fibers such as aramid fibers are used as the reinforcing fiber component, it is possible to obtain a fiber-reinforced plastic molded article suitable for precision polishing equipment that requires high smoothness. . A fiber-reinforced plastic molded article formed from a fiber-reinforced plastic molded sheet containing organic fibers such as aramid as a reinforcing fiber is generally formed from a fiber-reinforced plastic molded sheet using inorganic fibers as the reinforcing fiber. Excellent wear resistance compared to fiber reinforced plastics. Even if a part of the fiber reinforced plastic body is scraped off by rubbing or the like, the shaving wrinkles are softer than the inorganic fibers, so that there is little risk of damaging the object to be polished.

  The fiber length of the reinforcing fibers is preferably 1 mm or more, more preferably 2 mm or more, and further preferably 3 mm or more. Further, the fiber length of the reinforcing fiber is preferably 40 mm or less, more preferably 35 mm or less, and further preferably 30 mm or less.

<Matrix resin component>
The matrix resin component includes thermoplastic super engineering plastic fibers. The thermoplastic super engineering plastic fiber is melted by thermoforming to become a matrix resin.

  The thermoplastic super engineering plastic fiber is a fiber of a thermoplastic resin called a super engineering plastic (super engineering plastic), and is obtained by fiberizing a heat-resistant and flame-retardant thermoplastic resin. Examples of thermoplastic super engineering plastic fibers include polyetheretherketone (PEEK), polyamideimide (PAI), polyphenylene sulfide (PPS), polyetherimide (PEI), polyetherketoneketone (PEKK), and the like. Since polyphenylene sulfide (PPS) resin has high chemical resistance and high heat resistance, a fiber reinforced plastic excellent in chemical resistance and strength at high temperature can be obtained. When a polyether ketone ketone (PEKK) resin is used, a fiber reinforced plastic that is particularly superior in chemical resistance and strength at high temperatures than other super engineering plastics can be obtained. Polyetherimide (PEI) resin has excellent adhesion to carbon fiber and glass fiber, and its critical oxygen index is 47, which is very high in the resin block state. Can be obtained.

In the present invention, it is preferable to use at least one selected from polyetherimide (PEI) fibers or polycarbonate (PC) fibers. Among these, it is particularly preferable to use polyetherimide (PEI) fibers obtained by fiberizing a polyetherimide (PEI) resin. Polyetherimide (PEI) resin has a critical oxygen index of 40 or more in a melted and molded state, and a smoke generation amount of about 30 ds when burned for 20 minutes measured by the method described in ASTM E-662. It is preferably used because it emits less smoke.
Two or more kinds of the thermoplastic super engineering plastic fibers of the present invention can be used. Further, within the range not impairing the effect of the present invention, other than thermoplastic super engineering plastic fibers such as polyamide, polyacetal, polybutylene terephthalate, polyethylene terephthalate, phenol resin, polyurethane, polypropylene, polyethylene, epoxy resin, etc. can be added. .

  The thermoplastic super engineering plastic fiber preferably has a critical oxygen index of 24 or more in the fiber state, and more preferably 30 or more. By setting the critical oxygen index of the thermoplastic super engineering plastic fiber within the above range, a nonwoven fabric sheet excellent in flame retardancy can be obtained. In the present invention, the “limit oxygen index” represents an oxygen concentration necessary to continue combustion, and is a numerical value measured by the method described in JIS K7201. That is, a critical oxygen index of 20 or less is a numerical value indicating that combustion is performed in normal air.

  The glass transition temperature of the thermoplastic super engineering plastic fiber is preferably 140 ° C. or higher. The thermoplastic super engineering plastic fiber is required to be sufficiently fluid under a temperature condition of 300 ° C. to 400 ° C. when the reinforcing fiber plastic molded body is formed. In addition, even if it is a super engineering plastic fiber with a glass transition temperature of less than 140 ° C. such as PPS resin fiber, it can be used as long as the super engineering plastic having a resin deflection temperature of 190 ° C. or higher is made into a fiber. Such thermoplastic super engineering plastic fibers are melted by heating and pressurizing to form a resin block having a very high flame retardancy with a limiting oxygen index of 30 or more.

  The fiber diameter of the thermoplastic super engineering plastic fiber is preferably 40 μm or less. Furthermore, the fiber diameter of the thermoplastic super engineering plastic fiber is preferably 5 times or less, more preferably 4 times or less, and particularly preferably 3 times or less the fiber diameter of the inorganic fiber described above. By setting the fiber diameter of the thermoplastic super engineering plastic fiber within the above range, the strength of the fiber-reinforced plastic molded body can be further increased.

  The fiber diameter of the thermoplastic super engineering plastic fiber is preferably 40 μm or less, more preferably 35 μm or less, and further preferably 32 μm or less. Especially, it is preferable that the fiber diameter of a thermoplastic super engineering plastic fiber is 1-30 micrometers.

In the fiber-reinforced plastic molded sheet used in the present invention, there are voids in the sheet because the thermoplastic super engineering plastic fibers are in fiber form.
In the present invention, since the thermoplastic super engineering plastic fiber maintains its fiber form before heat-press molding, the sheet itself is supple and draped before the fiber-reinforced plastic molded body is formed. For this reason, it is possible to store and transport the sheet for a fiber-reinforced plastic molded body in the form of winding, and it is characterized by excellent handling properties.

  In addition, the sheet for a fiber-reinforced plastic molded body used in the present invention requires only a short time for heating and pressing when it is processed into a fiber-reinforced plastic molded body, and is excellent in productivity. In order to heat-press-mold a sheet for a fiber-reinforced plastic molded body in a short time, it is necessary that the thermoplastic super engineering plastic fiber used be melted quickly at a high temperature. Thinner fiber diameters are preferred. Since the number of contact points between fibers increases as the fiber diameter is thinner, the contact area between fibers increases, heat conduction becomes better, and the heat capacity of the fibers decreases, so the amount of heat required for melting is less It is to become.

  The fiber length of the thermoplastic super engineering plastic fiber is not particularly limited, but is preferably about 3 to 30 mm because it is produced by a wet or dry nonwoven fabric method. By setting the fiber length of the thermoplastic super engineering plastic fiber within the above range, the dispersibility of the fiber can be improved, and the breakage of the fiber reinforced plastic sheet or the like can be prevented. The fiber diameter and the fiber length may be single, or those having different fiber diameters and fiber lengths may be blended and used.

<Binder component>
In the present invention, an acrylic resin, a styrene-acrylic resin, a thermoplastic resin, a urethane resin, a PVA resin or the like that is generally used for manufacturing a nonwoven fabric can be used as the binder contained in the fiber-reinforced plastic molded sheet.

  The binder component is particularly preferably a resin component that is compatible with the resin when the thermoplastic super engineering plastic fiber that becomes the matrix after heat-pressure molding is melted by heat-pressure molding. When such a resin component is used as a binder, there is no interface between the matrix resin and the binder resin after the heat and pressure molding, and therefore the strength is increased. Furthermore, it has the characteristic that there is little fall of the glass transition temperature of matrix resin resulting from a binder component.

  In the present invention, the binder component is preferably contained in an amount of 0.1 to 10% by mass, more preferably 0.3 to 10% by mass with respect to the total mass of the fiber-reinforced plastic molded body. 0.4 to 9% by mass is more preferable, and 0.5 to 8% by mass is particularly preferable. By making the content rate of a binder component in the said range, the intensity | strength in a manufacturing process can be raised and handling property can be improved. Moreover, by making the content rate of a binder component into the said range, a flame retardance and low smoke generation property are not impaired. Note that as the amount of the binder component increases, both the surface strength and the interlayer strength increase, but conversely, the problem of odor during heat forming tends to occur. However, within the above range, there is hardly any problem of odor, and a fiber reinforced plastic molded sheet that does not cause delamination even after repeated cutting steps can be obtained.

The binder component preferably includes a copolymer obtained by polymerizing a monomer mixture containing at least one monomer of methyl methacrylate, ethyl methacrylate, methyl acrylate and ethyl acrylate. That is, the binder component contains a copolymer containing at least one of a repeating unit derived from a methyl (meth) acrylate-containing monomer and a repeating unit derived from an ethyl (meth) acrylate-containing monomer. Especially, it is preferable that a binder component contains the copolymer containing at least 1 among the repeating unit derived from a methyl methacrylate containing monomer and the repeating unit derived from an ethyl methacrylate containing monomer.
In the present invention, “(meth) acrylate” means containing both “acrylate” and “methacrylate”, and “(meth) acrylic acid” means “acrylic acid” and “methacrylic acid”. Is meant to include both.

  The binder component preferably contains a binder fiber having a melting point lower than the glass transition temperature of the thermoplastic super engineering plastic fiber. When the binder fiber is mixed with PEI fiber and dispersed in water and made by wet papermaking, it drops from the eyes of the papermaking wire like a granular binder, and the yield decreases or is unevenly distributed on the wire side. It is preferably used because it does not occur. Moreover, interlayer strength can be improved by using such a binder fiber.

As the binder fiber, a polyester resin is preferably used. As the polyester resin, polyethylene terephthalate (PET) is preferable. The modified polyester resin is not particularly limited as long as the melting point is lowered by modifying the polyester resin, but modified polyethylene terephthalate is preferable. As the modified polyethylene terephthalate, copolymerized polyethylene terephthalate (CoPET) is preferable, and examples thereof include urethane-modified copolymerized polyethylene terephthalate. The polyester resin is preferably used because it is compatible with the polyetherimide fiber at the time of heating and melting, so that it is difficult to impair the excellent points such as flame retardancy and low smoke generation property of the polyetherimide resin even after cooling.
The copolymerized polyethylene terephthalate preferably has a melting point of 140 ° C. or lower, more preferably 120 ° C. or lower. Moreover, you may use the modified polyester resin as described in Japanese Patent Publication No. 1-30926. As a specific example of the modified polyester resin, a trade name “Melty 4000” (a fiber in which all fibers are copolymerized polyethylene terephthalate) manufactured by Unitika Ltd. is particularly preferable. As the core-sheath-structured binder fiber, trade name “Melty 4080” manufactured by Unitika Co., Ltd., trade name “N-720” manufactured by Kuraray Co., Ltd. and the like can be suitably used.

  The copolymer obtained by polymerizing a monomer mixture containing at least one monomer of methyl methacrylate, ethyl methacrylate, methyl acrylate, and ethyl acrylate is 0.1 to 4 mass based on the total mass of the fiber-reinforced plastic molded body. %, And the binder fiber is preferably contained in an amount of 1.5 to 6% by mass relative to the total mass of the fiber-reinforced plastic molded body. By making the content rate of a copolymer and a binder fiber into the said range, the surface strength and interlayer strength of a fiber reinforced plastic molding can be raised. In addition, in said range, a preferable result is obtained from the relationship of an odor, when the compounding quantity of the binder which uses a copolymer as a component (liquid binder) is smaller than a polyester resin or a modified polyester resin. Since the polyester binder is compatible with the matrix resin, it is difficult to generate odor even if the addition amount is relatively large, and since the liquid binder tends to be concentrated and concentrated at the intersection of the fibers, such a result is obtained. Estimated.

  A preferable combination as the binder component is a combination of an acrylic emulsion and a chopped PET fiber as a low melting point thermoplastic resin fiber. Specifically, the acrylic binder is 0.3 to 4% by mass and the PET fiber is 1.5 to 6% by mass with respect to the total mass of the fiber-reinforced plastic molded body. Preferably they are 1 to 3 mass% of acrylic binders, 2 to 6 mass% of PET fibers, more preferably 1.5 to 2.5 mass%, and 3 to 5 mass% of PET fibers.

When the fiber reinforced plastic molded sheet has an intermediate region sandwiched between the surface layer region and the surface layer region, the binder component contained in the surface layer region may be more than the binder component contained in the intermediate region. preferable. In particular, among the binder components, a copolymer containing at least one of a repeating unit derived from a methyl (meth) acrylate-containing monomer and a repeating unit derived from an ethyl (meth) acrylate-containing monomer may be contained in a large amount in the surface layer region. preferable.
Here, the surface layer area | region of the sheet | seat for fiber reinforced plastic moldings is two area | regions located outside, when a nonwoven fabric sheet is divided | segmented into about 3 in the thickness direction (Z-axis direction). Note that the intermediate region refers to a region between these two regions. The binder component contained in the surface layer region is preferably more than the binder component contained in the intermediate region, and the binder component contained in the surface layer region is 1.1 of the binder component contained in the intermediate region. It is more preferable to be -1.5 times.

  In this way, by concentrating the binder component in the surface layer region, the binder component is effectively heated when being heated and pressed by a high-temperature mold or press-molded body. Decomposes and volatilizes. As a result, the binder component remaining in the thermoformed product is suppressed to a very small amount. For this reason, the fiber reinforced plastic molding of this invention has high flame retardance, and the smoke generation property is suppressed.

  The liquid binder comprising as a component a copolymer obtained by polymerizing a monomer mixture containing at least one monomer of methyl methacrylate, ethyl ethacrylate, ethyl acrylate and methyl acrylate is a surface layer of a sheet for fiber-reinforced plastic molding It is preferable to exist in a concentrated area. Moreover, it is preferable that these liquid binders are localized in the form of a drainage film at the intersection between the fiber components in both surface layer regions. That is, it is preferable that the copolymer is localized in the form of a water-repellent film at the intersection of the fibers constituting the reinforcing fiber component and the matrix resin component. By being localized in this manner, even if the binder component is small, even in the use process, the fibers falling off in both surface layer regions can be reduced. Moreover, it is suitable for the process which cuts and laminate | stacks in a Heisei form immediately after papermaking of the sheet | seat for fiber reinforced plastic moldings, and presses suitably.

  In addition, although it is preferable to concentrate the component containing a copolymer in a surface layer area | region among binder components, binder fiber can also be contained in the intermediate | middle area | region of the sheet | seat for fiber reinforced plastic moldings. Thereby, the interlayer intensity | strength of the sheet | seat for fiber reinforced plastic moldings increases, and the handling property at the time of a thermoforming process is further improved.

  The binder fiber can be contained in the fiber reinforced plastic molded sheet by a method (dry nonwoven fabric method) in which the binder fiber is dispersed in the air together with the reinforcing fiber, the PEI fiber, and the like and captured on the net to form a web. The binder fiber can also be contained in the fiber-reinforced plastic molded sheet by a method such as a method (wet nonwoven fabric method) in which the binder fiber is dispersed in a solvent and then the solvent is removed to form a web.

  Examples of the method for allowing a relatively large amount of the binder to be present in the surface layer of the fiber reinforced plastic molded sheet include the following methods. For example, a production method in which a liquid material in which a binder component is dissolved in a solvent or an emulsion (emulsion) of a binder component is internally added to, applied to, or impregnated into a web, and is heated and dried. In particular, after a web is formed by a wet nonwoven fabric method or a dry nonwoven fabric method, a liquid material in which a binder component is dissolved in a solvent, or an emulsion (emulsion) of a binder component is applied by dipping or spraying, and dried by heating. The manufacturing method is mentioned. According to this method, since the solvent inside the web moves to the surface layers on both sides and evaporates during heating and drying, the binder also concentrates relatively on the surface layer as the solvent moves.

As described above, in order to make the binder component unevenly distributed on the surface layer of the fiber-reinforced plastic molded sheet, a manufacturing method in which a liquid binder component such as a solution or an emulsion of the binder component is used and dried by heating is employed. Can do. In this case, it is preferable that the solvent move more because the uneven distribution of the binder component becomes stronger.
When such a method is employed, it is preferable to form a wet web by a wet nonwoven fabric method, and then apply an aqueous solution or emulsion of the binder to the web by a method such as dipping or spraying, followed by drying. In this case, the web moisture can be adjusted by adjusting the concentration of the binder solution in the aqueous solution or emulsion, or the moisture suction force by wet suction or dry suction in the wet nonwoven fabric manufacturing process.

  In order to make the binder component unevenly distributed, the moisture content in the web is preferably 50% or more, but if there is too much moisture, the drying load increases and the manufacturing cost increases. Is preferably adjusted.

When the above measures are insufficient, it is also preferable to wet-paper the fiber-reinforced plastic molded sheet to increase the strength aspect ratio as a method of reducing the amount of binder component added. Specifically, the strength ratio (strength aspect ratio) of the machine-making direction (MD direction) and the perpendicular direction (CD direction) can be increased by adjusting the jet wire ratio. In general, when the strength aspect ratio is increased, the fibers tend to line up in one direction, and the density of the nonwoven fabric tends to increase. As a result, the intersections between the fibers increase, so that a sufficient surface strength can be obtained even with a small amount of binder. Such an effect can be clearly obtained usually when the strength aspect ratio is 1.5 or more, more clearly is 3.0 or more, and more clearly is 5.0 or more.
On the other hand, if the strength aspect ratio is too strong, the transverse strength becomes weak and the handling property is poor. Considering this point, the preferred strength aspect ratio is 15 or less, more preferably 10 or less.

  The binder component is preferably a binder component that is compatible with the PEI fiber when heated and melted. According to the study by the present inventors, it has been found that when such a component is selected, the flame retardancy and low smoke generation of the PEI resin are hardly impaired after the heat and pressure molding.

(Fiber shape)
In the present invention, the thermoplastic super engineering plastic fiber and the binder fiber are preferably chopped strands cut to a certain length. In the present invention, the thermoplastic super engineering plastic fibers and the reinforcing fibers contained in the fiber-reinforced plastic molded sheet are also preferably chopped strands cut to a certain length. By setting it as such a form, various fibers can be mixed uniformly in the sheet | seat for fiber reinforced plastic moldings.

  In the above case, the fiber reinforced plastic molded sheet is a method of forming a web by dispersing chopped strands of thermoplastic super engineering plastic fibers, reinforcing fibers and binder fibers in the air and capturing them in a net (dry nonwoven fabric). Method). Further, it may be produced by a method (wet nonwoven fabric method) or the like in which a chopped strand of thermoplastic super engineering plastic fiber, reinforcing fiber, or binder fiber is dispersed in a solvent and then the solvent is removed to form a web.

(Decorative film)
The decorative film is a film that is bonded to the above-described fiber-reinforced plastic molded body. The decorative film is made of polycarbonate, polymethyl methacrylate, polystyrene, polyester, polyethylene terephthalate, polyethylene naphthalate, polyvinyl chloride, epoxy resin, melamine resin, triacetyl cellulose resin, polypropylene, ABS resin, AS resin, norbornene. Examples thereof include resins.
Among these, polyvinyl chloride resin is preferably used as a flame retardant material.

  The decorative film may have a single layer structure or a multilayer structure. The decorative film is preferably a thermoplastic film on the surface layer, a decorative layer such as ink on the second layer, and an adhesive layer on the third layer (back side), which is normally used as a decorative film for the TOM method. The

(Method for producing decorative molded products)
The manufacturing process of the decorative molded product of the present invention includes a step of forming a fiber-reinforced plastic molded body by heating and pressing a sheet for a fiber-reinforced plastic molded body in which at least one reinforcing fiber sheet and a nonwoven fabric sheet are bonded together. . Further, the method includes a step of bonding a decorative film to at least one surface of the fiber reinforced plastic molded body, and the step of bonding the decorative film is a method selected from a vacuum forming method, a vacuum / pressure forming method, and a thermal transfer method. It is preferable that a decorative film is bonded by. The nonwoven fabric sheet contains thermoplastic super engineering plastic fibers and a binder component, and the limiting oxygen index of the thermoplastic super engineering plastic fibers is 24 or more.

  The step of forming the fiber-reinforced plastic molded body includes a step of heating and pressing the sheet for fiber-reinforced plastic molded body. The heating and pressing step is a step of applying pressure while heating the thermoplastic super engineering plastic fiber at a temperature preferably equal to or higher than the glass transition temperature. Specifically, it is preferable to heat and pressurize the fiber-reinforced plastic molded sheet at 150 to 600 ° C. The heating temperature is preferably a temperature range in which the thermoplastic resin fibers flow and the reinforcing fibers do not melt.

  In the step of bonding the decorative film to at least one surface of the fiber reinforced plastic molded body, a known bonding method can be employed. Among them, it is preferable to use a press working method, a thermal transfer method, a vacuum forming method or a vacuum / pressure forming method, more preferably a thermal transfer method, a vacuum forming method or a vacuum / pressure forming method, and a vacuum forming method or a vacuum / pressure forming method. More preferably, it is used.

  Here, the press working method is a method of applying a mechanical pressure and an adhesive using a mold. In the press working method, since the material of the decorative film is crushed, the texture of the soft material is easily lost both in appearance and in touch, and the mold itself is also expensive.

  On the other hand, in the vacuum forming method, in a device in which two sealed spaces partitioned by a decorative film are formed, a fiber-reinforced plastic molded body is arranged on one sealed space side, and both sealed spaces are vacuum-depressed. This is a method in which the decorative film is radiantly heated with a heater or the like and bonded. Press the fiber reinforced plastic molded body surface against the decorative film adhesion surface from one sealed space side to the other sealed space side, and keep the pressed state on the side where the fiber reinforced plastic molded body is not placed. Only the other sealed space is returned to normal pressure. Thereby, an external pressure is uniformly applied to the decorative film, and the decorative film can be attached to the surface of the fiber-reinforced plastic molded body. Since the fiber-reinforced plastic molded body obtained by the present invention is lightweight and has high strength, the shape can be maintained even under such reduced pressure conditions, and deformation and warpage do not occur.

In the above process, without using the process of pressing the molded product against the decorative film adhesive surface from one sealed space side to the other sealed space side, simply place one sealed space in a vacuum. You can also. A method of attaching the decorative film to the surface of the fiber-reinforced plastic molded body by returning only the other sealed space on the side where the fiber-reinforced plastic molded body is not disposed to normal pressure is also possible depending on the application conditions. The above method is called a vacuum forming method.
Moreover, in the above, one decorative space side can be evacuated, only the other sealed space can be returned to normal pressure, and a decorative film can also be bonded to a fiber reinforced plastic molding. Thereafter, it is possible to apply the compressed air by introducing compressed air from normal pressure to secure the sticking. This is called a vacuum / pressure forming method.
These methods also make it possible to bond a decorative film to a fiber-reinforced plastic molded body having a three-dimensional shape (such as a corner portion of a fiber-reinforced plastic molded body). Vacuum forming (vacuum / pressure forming) is the most suitable method because it can maintain good texture when a soft sheet is laminated, including productivity.

  The thermal transfer method is a fiber reinforced plastic molded body in which the base film is peeled and removed from the decorative sheet laminated and integrated on the surface of the fiber reinforced plastic molded body, and only the transfer layer such as the decorative layer is heated. This is a method of remaining on the surface. The decorative sheet is preferably transferred to the surface of the fiber-reinforced plastic molded body at a temperature of 100 to 350 ° C. under a pressure condition of 0.1 to 25 MPa.

  In this invention, it is preferable to include the process of forming a nonwoven fabric sheet before the process of forming a fiber reinforced plastic molding. The step of forming the nonwoven fabric sheet includes the step of forming the nonwoven fabric sheet by either the dry nonwoven fabric method or the wet nonwoven fabric method, and internally adding, applying or impregnating the solution containing the binder component or the emulsion containing the binder component to the nonwoven fabric sheet. Including the step of Further, after the internal addition, coating or impregnation, a step of drying by heating is included. By providing such a process, scattering, fluffing, and dropping off of the surface fibers of the nonwoven fabric sheet can be suppressed, and a molded sheet excellent in handling properties can be obtained.

  It is preferable to trim an unnecessary part of the decorated molded product as necessary. In addition, TOM molding (vacuum and pressure molding method) is preferably used as a bonding means because it can be decorated and protected on the edge portion, and the processing of the edge portion of the molded plastic becomes unnecessary.

  The features of the present invention will be described more specifically with reference to examples and comparative examples. The materials, amounts used, ratios, processing details, processing procedures, and the like shown in the following examples can be changed as appropriate without departing from the spirit of the present invention. Therefore, the scope of the present invention should not be construed as being limited by the specific examples shown below.

Example 1
A PAN-based carbon fiber having a fiber diameter of 7 μm and a fiber length of 13 mm, and a PEI fiber (manufactured by Fiber Innovation Technology, fiber length of 13 mm, fiber diameter of 15 μm, critical oxygen index of 47), and a mass ratio of the PEI fiber 60 to the carbon fiber 40 Was weighed and put into water. The amount of water added was set to be 200 times the total mass of carbon fibers and PEI fibers (fiber slurry concentration 0.5%).
To this slurry, the product name “Emanon 3199” (manufactured by Kao Co., Ltd.) as a dispersant was added to 1 part by mass with respect to 100 parts by mass of the PEI fiber and stirred to obtain a fiber slurry in which the fibers were uniformly dispersed in water. Prepared.
Next, granular polyvinyl alcohol (PVA) (manufactured by Unitika, trade name “OV-N”) was added to water so as to have a concentration of 10%, and stirred to prepare a binder slurry.
The granular PVA slurry was put into the fiber slurry, a wet web was formed by wet papermaking, and heated and dried at 180 ° C. to prepare a nonwoven fabric having a basis weight of 120 g / m ² with the binder amount shown in Table 1. . Furthermore, the nonwoven fabric was heat-treated with a hot press at 220 ° C. to obtain a sheet for fiber-reinforced plastic molded body having a basis weight of 220 g / m ² .
Next, 8 sheets of fiber reinforced plastic molded body are laminated, inserted into a hot press preheated to 310 ° C., heated and pressurized for 60 seconds, cooled to 230 ° C., and fiber reinforced plastic molded body (plate). Got.

  Furthermore, TOM decoration was given to the obtained fiber reinforced plastic molding (vacuum pressure forming method). The film used was a vinyl chloride system (CI Kasei Co., Ltd., 200 μm thick), and was used as a testing machine by Fuse Vacuum Co., Ltd. (NGF0609). As a decoration condition, the film was heated at 90 ° C. for 30 seconds and then processed with compressed air at 200 kPa. In addition, the thickness of the fiber reinforced plastic molding (plate) was 1.0 mm.

(Example 2)
Instead of the carbon fibers of Example 1, decorative molding was performed in the same manner as in Example 1 except that glass fibers having a fiber diameter of 9 μm and a fiber length of 18 mm were used. In addition, the thickness of the fiber reinforced plastic molding was 1.0 mm.

(Example 3)
A decorative molded body was obtained in the same manner as in Example 1 except that transfer decoration was performed instead of TOM decoration in Example 1. The transfer film was subjected to transfer decoration at 180 ° C. and 0.5 MPa (thermal transfer). In addition, the thickness of the fiber reinforced plastic molding was 1.0 mm.

Example 4
Instead of the carbon fiber of Example 3, glass fiber having a fiber diameter of 9 μm and a fiber length of 18 mm was used. Four sheets of the obtained fiber reinforced plastic molded body were laminated, inserted into a hot press preheated to 310 ° C., heated and pressurized for 60 seconds, and then cooled to 230 ° C. to obtain a fiber reinforced plastic molded body. Obtained. Otherwise, the decorative molding was performed in the same manner as in Example 3. In addition, the thickness of the fiber reinforced plastic molding was 0.5 mm.

(Example 5)
A decorative molded body was obtained in the same manner as in Example 1 except that in Example 1, four sheets were used instead of eight sheets for fiber-reinforced plastic molded bodies. In addition, the thickness of the fiber reinforced plastic molding was 0.5 mm.

(Example 6)
A decorative molded body was obtained in the same manner as in Example 1 except that in Example 1, two sheets were used instead of the eight sheets for fiber-reinforced plastic molded bodies. In addition, the thickness of the fiber reinforced plastic molding was 0.25 mm.

(Example 7)
A decorative molded body was obtained in the same manner as in Example 1 except that polycarbonate fibers (fiber diameter: 15 μm, fiber length: 25 μm, critical oxygen index: 25) were used instead of PEI fibers. In addition, the thickness of the fiber reinforced plastic molding was 1.0 mm.

(Comparative Example 1)
Polycarbonate / ABS mixed resin (manufactured by Daicel Corporation: trade name “Novaloy S1100”) is melt-kneaded with a twin-screw kneading extruder to produce a compound, and injection molding is performed with FNX140 manufactured by Nissei Plastic Industries Co. A thick molded body was obtained. Furthermore, using the obtained molded body, a decorative molded product was obtained by the same method (TOM decoration) as in Example 1.

(Comparative Example 2)
A glass fiber reinforced polycarbonate / ABS mixed resin (manufactured by Daicel Corporation: trade name “Novaloy S1230”: glass fiber content 30%) is melt kneaded with a biaxial kneading extruder, and FNX140 manufactured by Nissei Plastic Industries Injection molding was performed to obtain a molded body having a thickness of 1.0 mm. In addition, the surface property of the obtained injection molded product was bad, and the protrusion of the glass fiber was seen. Using the obtained molded body, a decorative molded product was obtained by the same method (transfer decoration) as in Example 3.

(Comparative Example 3)
Except for adjusting the thickness to 0.5 mm by the same method as in Comparative Example 2, an attempt was made to obtain a decorative molded product in the same manner as in Comparative Example 2, but in the TOM molding method, a decorative film was formed with compressed air. When crimping, cracks occurred at the ends, and a decorative molded product could not be obtained.

(Evaluation)
(Molded shape)
The shape after molding was evaluated by sensory evaluation as follows.
A: Very good.
B: Good.
C: The smoothness of the surface is inferior, causing problems in practical use.
D: Cannot be molded.

(Aesthetics)
About the aesthetics after decoration processing, it evaluated by sensory evaluation as follows.
A: Very good.
B: Good.
C: The smoothness of the surface is inferior, causing problems in practical use.
D: Breakage occurs and cannot be processed.

(Bending strength of decorative molded products)
The bending strength of the decorative molded product was measured by a method based on JIS K7074.

(Flame retardance evaluation)
Evaluation of the flame retardancy of the decorative molded product was performed based on the limiting oxygen index test (ASTM D2863).

In Examples 1-7, it turns out that the shape of a molded product, the aesthetics of a decorative molded product, and further bending strength and flame retardancy (limit oxygen index) are excellent. Moreover, with the hot press molding method of the present invention, it is possible to obtain a decorative molded product having excellent strength while being a thin film. On the other hand, when injection molding is performed using the polycarbonate / ABS resin of Comparative Example 1 (limit oxygen index 22), the aesthetics deteriorate in vacuum molding, and the strength and flame retardancy also decrease.
In addition, when glass fiber is kneaded for improving the strength in Comparative Example 2, the surface property is deteriorated and the desired aesthetics cannot be obtained, and the strength and flame retardancy are still insufficient. Further, as is apparent from Comparative Example 3, a product having a thickness of 0.5 mm or less cannot be produced by the injection molding method.

  According to the present invention, a decorative molded product that is lightweight and has high strength can be obtained. Furthermore, according to the present invention, a decorative molded product having high flame retardancy and excellent design properties can be obtained. For this reason, the decorative molded product of the present invention has high flame retardancy, light weight, and high strength, so that it can be used for various sports equipment, leisure goods, aircraft materials, interior materials, etc. in addition to the housing of electronic equipment. It can be preferably used in various fields and has high industrial applicability.

Claims (18)

A decorative molded product in which a decorative film is laminated on at least one surface of a fiber reinforced plastic molded body and the fiber reinforced plastic molded body,
The fiber-reinforced plastic molded article is a fiber comprising a reinforcing fiber component, at least one thermoplastic resin fiber selected from thermoplastic super engineering plastic fibers and polycarbonate fibers having a limiting oxygen index of 24 or more, and a binder component. A plastic molded body obtained by heating and pressing a sheet for reinforced plastic molded body,
The mass ratio of the reinforcing fiber component and the fiber of at least one thermoplastic resin selected from the thermoplastic super engineering plastic fiber and the polycarbonate fiber is 1: 0.7 to 1: 3. Decorative molded product. The reinforcing fiber component includes inorganic fibers,
The fiber-reinforced plastic molded sheet includes the thermoplastic super engineering plastic fiber,
2. The additive according to claim 1, wherein a fiber diameter of the thermoplastic super engineering plastic fiber is 40 μm or less, and a fiber diameter of the thermoplastic super engineering plastic fiber is 5 times or less of a fiber diameter of the inorganic fiber. Decorative molded product.   The decorative molded article according to claim 1 or 2, wherein the fiber-reinforced plastic molded body has a thickness of 0.05 to 2 mm.   JAPAN TAPPI paper pulp test method no. The decorative article according to any one of claims 1 to 3, wherein the air permeability defined in 5-2 is 250 seconds or less.   5. The additive according to claim 1, wherein the binder component is contained in an amount of 0.1 to 10% by mass with respect to the total mass of the fiber-reinforced plastic molded body. Decorative molded product. The fiber-reinforced plastic molded sheet includes the thermoplastic super engineering plastic fiber,
The decorative molded product according to any one of claims 1 to 5, wherein the binder component is compatible with the thermoplastic super engineering plastic fiber in a heated and melted state.   The binder component contains a copolymer containing at least one of a repeating unit derived from a methyl (meth) acrylate-containing monomer and a repeating unit derived from an ethyl (meth) acrylate-containing monomer. The decorative molded product according to any one of the above. The fiber-reinforced plastic molded sheet includes the thermoplastic super engineering plastic fiber,
The decorative molded product according to any one of claims 1 to 7, wherein the binder component contains a binder fiber having a melting point lower than a glass transition temperature of the thermoplastic super engineering plastic fiber.   The decorative molded product according to claim 8, wherein the binder fiber includes polyethylene terephthalate or modified polyethylene terephthalate. The fiber-reinforced plastic molded sheet includes the thermoplastic super engineering plastic fiber,
The decorative molded article according to claim 8 or 9, wherein the thermoplastic super engineering plastic fiber and the binder fiber are chopped strands. The sheet for fiber-reinforced plastic molded body has a surface layer region and an intermediate region sandwiched between the surface layer region,
The decorative molded product according to any one of claims 1 to 10, wherein the binder component contained in the surface region is greater than the binder component contained in the intermediate region. The copolymer contained in the binder component is localized in the form of a drainage film at the intersection of the reinforcing fiber component, the thermoplastic super engineering plastic fiber, and the fibers of at least one thermoplastic resin selected from the polycarbonate fibers. The decorative molded product according to claim 7, wherein the decorative molded product is a decorative molded product. The decorative molded article according to any one of claims 1 to 12 , wherein the thermoplastic super engineering plastic fiber is a polyetherimide fiber. The decorative film is a decorative molded article according to any one of claims 1 to 13, characterized in that it is laminated on the fiber-reinforced plastic molded article through the laminating means. A method for producing a decorative molded article in which a decorative film is laminated on at least one surface of a fiber reinforced plastic molded article and the fiber reinforced plastic molded article,
Heating a fiber reinforced plastic molded sheet comprising a reinforcing fiber component, at least one thermoplastic resin fiber selected from thermoplastic super engineering plastic fibers and polycarbonate fibers having a critical oxygen index of 24 or more, and a binder component Forming a fiber-reinforced plastic molded body by pressure molding;
Including a step of bonding a decorative film to at least one surface of the fiber-reinforced plastic molded body, wherein the step of bonding the decorative film is a method selected from a vacuum forming method, a vacuum / pressure forming method, and a thermal transfer method. The decorative film is bonded by
The mass ratio of the reinforcing fiber component and the fiber of at least one thermoplastic resin selected from the thermoplastic super engineering plastic fiber and the polycarbonate fiber is 1: 0.7 to 1: 3. A method for producing a decorative molded product. Before the step of forming the fiber-reinforced plastic molded body, further comprising the step of forming a sheet for fiber-reinforced plastic molded body,
The step of forming the fiber-reinforced plastic molded sheet includes a step of forming a nonwoven sheet by a dry nonwoven fabric method or a wet nonwoven fabric method,
The method for producing a decorative molded product according to claim 15 , further comprising a step of internally adding, applying or impregnating the nonwoven fabric sheet with a solution containing the binder component or an emulsion containing the binder component, followed by heat drying. . The fiber-reinforced plastic molded sheet includes the thermoplastic super engineering plastic fiber,
In the step of forming the fiber-reinforced plastic molding, a decorative molded article according to claim 15 or 16, characterized in that it is heat and pressure molding at a temperature above the glass transition temperature of the thermoplastic super engineering plastic fiber Production method. The decorative molding according to any one of claims 15 to 17 , wherein in the step of forming the fiber-reinforced plastic molded body, the sheet for fiber-reinforced plastic molded body is heated and pressurized at 150 to 600 ° C. Product manufacturing method.