JPH03161575A - Production of light weight composite material - Google Patents
Production of light weight composite materialInfo
- Publication number
- JPH03161575A JPH03161575A JP1298507A JP29850789A JPH03161575A JP H03161575 A JPH03161575 A JP H03161575A JP 1298507 A JP1298507 A JP 1298507A JP 29850789 A JP29850789 A JP 29850789A JP H03161575 A JPH03161575 A JP H03161575A
- Authority
- JP
- Japan
- Prior art keywords
- thermoplastic resin
- mat
- composite material
- thermoplastic
- laminate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000002131 composite material Substances 0.000 title abstract description 27
- 238000004519 manufacturing process Methods 0.000 title description 8
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 29
- 229920002725 thermoplastic elastomer Polymers 0.000 claims abstract description 21
- 239000012784 inorganic fiber Substances 0.000 claims abstract description 20
- 239000000463 material Substances 0.000 claims abstract description 18
- 238000010438 heat treatment Methods 0.000 claims abstract description 16
- 238000010030 laminating Methods 0.000 claims abstract description 9
- 238000002844 melting Methods 0.000 claims abstract description 6
- 230000008018 melting Effects 0.000 claims abstract description 6
- 239000004745 nonwoven fabric Substances 0.000 claims description 18
- 238000003825 pressing Methods 0.000 claims description 2
- 239000000835 fiber Substances 0.000 abstract description 16
- -1 polyethylene Polymers 0.000 abstract description 6
- 239000004698 Polyethylene Substances 0.000 abstract description 5
- 229920000573 polyethylene Polymers 0.000 abstract description 5
- 229920001971 elastomer Polymers 0.000 abstract description 2
- 239000000806 elastomer Substances 0.000 abstract description 2
- 239000003365 glass fiber Substances 0.000 abstract description 2
- 239000004744 fabric Substances 0.000 abstract 4
- 239000003562 lightweight material Substances 0.000 abstract 1
- 229920001169 thermoplastic Polymers 0.000 abstract 1
- 239000004416 thermosoftening plastic Substances 0.000 abstract 1
- 238000000034 method Methods 0.000 description 18
- 230000006835 compression Effects 0.000 description 9
- 238000007906 compression Methods 0.000 description 9
- 229920005989 resin Polymers 0.000 description 6
- 239000011347 resin Substances 0.000 description 6
- 229920006262 high density polyethylene film Polymers 0.000 description 5
- 230000007423 decrease Effects 0.000 description 4
- 239000010410 layer Substances 0.000 description 4
- 239000000155 melt Substances 0.000 description 4
- 239000006260 foam Substances 0.000 description 3
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- 239000004809 Teflon Substances 0.000 description 2
- 229920006362 Teflon® Polymers 0.000 description 2
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 230000037303 wrinkles Effects 0.000 description 2
- 241000219122 Cucurbita Species 0.000 description 1
- 235000009852 Cucurbita pepo Nutrition 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000011490 mineral wool Substances 0.000 description 1
- 229920002037 poly(vinyl butyral) polymer Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 229920002397 thermoplastic olefin Polymers 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
Landscapes
- Manufacturing Of Multi-Layer Textile Fabrics (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Description
【発明の詳細な説明】
（産業上の利用分野）
本発明は、自動車用天井材などの各種内装材として好適
な軽皿廖合材の製造方法に関する。さらに本発明は、物
理的強度および成形性に優れた、軽ｆｆｉ複合材料を容
易に製造する方法に関する。DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for producing a light plate fitting material suitable for various interior materials such as ceiling materials for automobiles. Furthermore, the present invention relates to a method for easily manufacturing a lightweight ffi composite material with excellent physical strength and moldability.
（従来の技術）
例えば自動車用天井材に使用される複合材料は、軽量で
、剛性、耐熱性、吸音性、熱戊形性などの性能に優れて
いることが要求される。このような材料として、無機繊
維からなるシートに熱可塑性樹脂を含浸させて得られた
多孔性複合材料に、必要に応じて発砲スチレン、発泡ウ
レタンなどの発泡体からなるシートを積層して、さらに
その上層ニ軟質塩化ビニルシ一ト、ニットなどの表皮材
を接着した材料が用いられている。このような材料は吸
音性などの特性は優れているが、接着剤などを用いて表
皮材を積層しているため、強度や熱成形性に欠ける。さ
らに、製造工程が複雑であるという問題もある。(Prior Art) Composite materials used for automobile ceiling materials, for example, are required to be lightweight and have excellent properties such as rigidity, heat resistance, sound absorption, and thermal formability. As such a material, a porous composite material obtained by impregnating a sheet made of inorganic fibers with a thermoplastic resin is laminated with a sheet made of a foam such as styrene foam or urethane foam as necessary. The upper layer is made of a material in which a skin material such as soft vinyl chloride sheet or knit is bonded. Although such materials have excellent characteristics such as sound absorption, they lack strength and thermoformability because the skin material is laminated using an adhesive or the like. Furthermore, there is also the problem that the manufacturing process is complicated.
（発明が解決しようとする課題）
本発明は上記問題点を解決するものであり、その目的と
するところは、物理的強度および戊形性に優れた軽ｆｆ
ｉ複合材料を容易に製造する方法を提供することにある
。(Problems to be Solved by the Invention) The present invention is intended to solve the above-mentioned problems, and its purpose is to provide a lightweight FF with excellent physical strength and formability.
An object of the present invention is to provide a method for easily manufacturing an i-composite material.
（課題を解決するための手段）
本発明の軽ｆｆｉ複合材料の製造方法は、無機繊維を主
戊分とするマット状不織布の両面に熱可塑性樹脂フィル
ムを積層し、さらに該積層物の少なくとも片面に熱可塑
性エラストマーのシートを積層する工程；該熱可塑性エ
ラストマーのシートが積層された積層物を、該熱可讐性
樹脂および該熱可塑性エラストマーの融点以上の温度で
加熱した後、圧縮して、該熱可塑性樹脂をマット状不織
布に含浸させる工程；および，加熱時の温度を維持した
状態で圧力を解除して、該積層物の厚さを回復させる工
程；とを包含し、そのことにより上記目的が達成される
。(Means for Solving the Problems) The method for producing a light FFI composite material of the present invention includes laminating thermoplastic resin films on both sides of a mat-like nonwoven fabric mainly composed of inorganic fibers, and further laminating at least one side of the laminate. a step of laminating a sheet of thermoplastic elastomer on; heating the laminate of the sheets of thermoplastic elastomer at a temperature equal to or higher than the melting point of the thermoplastic resin and the thermoplastic elastomer, and then compressing; a step of impregnating the thermoplastic resin into the mat-like nonwoven fabric; and a step of releasing the pressure while maintaining the heating temperature to restore the thickness of the laminate; thereby achieving the above-mentioned effect. The purpose is achieved.
本発明で使用される無機ａ維としては、たとえばガラス
ｍ維、ロックウール繊維などがあげられ、その長さはマ
ットの形成の容易さの点から５〜ｚＱＯ印が好ましく、
５０ｍｍ以上の繊維が７０重１％含まれているのがより
好ましい。無機繊維の直径は５〜２０μ１が好ましく、
より好ましくは９〜１７μｍである。無８！繊維の直径
が小さくなり過ぎると、機械的強度が低下し、無機繊維
の直径が大きくなり過ぎると、マ・ット状不織布が重く
り、その結果得られる複合材料の嵩密度が大きくなる。Examples of the inorganic A fibers used in the present invention include glass M fibers and rock wool fibers, and the length thereof is preferably 5 to zQO mark from the viewpoint of ease of forming a mat.
More preferably, the fiber contains 70% by weight of fibers of 50 mm or more. The diameter of the inorganic fiber is preferably 5 to 20μ1,
More preferably, it is 9 to 17 μm. No 8! If the diameter of the fibers becomes too small, the mechanical strength decreases, and if the diameter of the inorganic fibers becomes too large, the mat-like nonwoven fabric becomes heavy and the bulk density of the resulting composite material increases.
上記無機繊維は、任意の方法によってマット状不織布と
される。このとき無機繊維に熱可塑性樹脂からなる有機
繊維を混繊−して用いることによって、無機繊維同士の
結合状態が良好となる。このような有ａｉｍとしてはポ
リエチレン繊維、ポリオレフィン系繊維などが用いられ
る。有機ａ堆の使用量は、マット状不織布の重量に対し
て５０’ｖｔｅ以下であることが好ましい。マット状不
織布の製造方法としては、たとえば無機繊維および必要
に応じて有機繊維をカードマシンに供拾し、解繊および
混繊してマットを製造する方法があげられる。The above-mentioned inorganic fibers are made into a mat-like nonwoven fabric by any method. At this time, by mixing the inorganic fibers with organic fibers made of thermoplastic resin, the bonding state between the inorganic fibers becomes good. As such an aim, polyethylene fibers, polyolefin fibers, etc. are used. The amount of organic a-compound used is preferably 50'vte or less based on the weight of the mat-like nonwoven fabric. An example of a method for producing a mat-like nonwoven fabric is a method of supplying inorganic fibers and, if necessary, organic fibers to a card machine, defibrating and mixing them to produce a mat.
さらに、厚み方向に繊維を配向させるために、ニードル
パンチを施すことが好ましい。ニードルパンチはｌｃＩ
１２当たり、３０〜６０棉所行われるのが好ましく、よ
り好ましくは５０〜６０１１１所である。マット状不織
布の密度は大きくなると重くなり、小さく？ると機械的
強度が低下するので、０，０４〜０．１ｇ／ｃ−が好ま
しく、より好ましくは０．０４〜０．０６ｇ／ｃ＋ｏ’
である。Further, in order to orient the fibers in the thickness direction, it is preferable to perform needle punching. Needle punch is lcI
It is preferable to carry out 30 to 60 strokes per 12, more preferably 50 to 60,111 strokes. As the density of mat-like nonwoven fabric increases, does it become heavier or smaller? If this happens, the mechanical strength will decrease, so it is preferably 0.04 to 0.1 g/c-, more preferably 0.04 to 0.06 g/c+o'
It is.
熱可塑性樹脂フィルムに使用される熱可■性樹脂は、加
熱により溶融し、無機繊維間に含浸して該無機繊維を相
互に結着させ得る樹脂であればよい。例えばポリエチレ
ン、ポリブロビレン、飽和ポリエステル、ポリアミド、
ポリスチレン、ポリビニルブチラールなどが用いられる
。好ましくは、熱可塑性樹脂のメルトインデックス（Ａ
ＳＴＭ Ｄ１２３ｇに従い、２ ３ ０ ’Ｃ、荷重２
． １６ｋｇで測定）がｉｏ以上の、溶融粘度の低い樹
脂が用いられる。上記熱可醜性樹脂フィルムの厚さは、
５０〜２００μ瓢が好ましく、より好ましくは１００〜
１５０μ重である。熱可塑性樹脂フィルムの厚さが厚く
なり過ぎると、最終的に複合材料が重くなり、薄くなり
過ぎると機械的強度が低下する。The thermoplastic resin used in the thermoplastic resin film may be any resin as long as it can be melted by heating and impregnated between inorganic fibers to bind the inorganic fibers to each other. For example, polyethylene, polybrobylene, saturated polyester, polyamide,
Polystyrene, polyvinyl butyral, etc. are used. Preferably, the melt index (A
According to STM D123g, 2 30'C, load 2
．． A resin with a low melt viscosity of io or higher (measured at 16 kg) is used. The thickness of the above thermoplastic resin film is
50-200μ gourd is preferable, more preferably 100-200μ
It weighs 150μ. If the thermoplastic resin film becomes too thick, the final composite material becomes heavy; if it becomes too thin, the mechanical strength decreases.
熱可塑性エラストマーのシートを構成する樹脂としては
、軟質塩化ビニルなどの弾性を有する熱可塑性樹脂が用
いられる。熱可塑性エラストマーは、溶融粘度の高い樹
脂であることが好ましく、特に好ましくは、メルトイン
デ・ノクスが、１以下である。As the resin constituting the thermoplastic elastomer sheet, an elastic thermoplastic resin such as soft vinyl chloride is used. The thermoplastic elastomer is preferably a resin with a high melt viscosity, and particularly preferably has a melt index of 1 or less.
本発明によれば複合材料は以下のようにして製造される
。まず、上記無機繊維を主成分とするマット状不織布の
両面に熱可塑性樹脂フィルムを積層し、この積層物の少
なくとも片面に熱可塑性エラストマーのシートを重ねる
。この積層物を熱可塑性樹脂および熱可塑性エラストマ
ーの融点以上の温度に加熱した後、圧縮する。上記フィ
ルムを積層する方法は、任意の方法が採用される。加熱
条件としては、熱可塑性樹脂および熱可塑性エラストマ
一の融点より ５０″ｃ − ｔｏｏ゜Ｃ高い昌度で１
〜２分間行うのが好ましい。また、加熱方法は、任意の
方法が採用されてよく、たとえばオーブン中で積層体の
全体を加熱する方法、遠赤外線ヒータ、赤外線ヒーター
などによる輻射加熱方法などがあげられる。圧縮方法は
任意の方法が採用されてよく、たとえばプレス圧縮、ロ
ール圧縮方法等があげられる。プレス圧縮法を採用する
際の圧縮条件は、好ましくは０．１〜５聰／ｃＩａ２で
あり、ロールで圧縮する際の一対のロール間距離はマッ
トの厚さの５〜１５％が好ましく、より好ましくは７〜
１０％である。圧縮時間は１〜ｌＯ秒が好ましい。また
、圧縮する際に熱可塑性樹脂が冷却されて固化するとマ
プトの厚さが回復しなくなり空隙率が低下するので、プ
レス金型及びロールも所定温度に加熱されているのが好
ましい。According to the invention, a composite material is manufactured as follows. First, thermoplastic resin films are laminated on both sides of the mat-like nonwoven fabric mainly composed of inorganic fibers, and a thermoplastic elastomer sheet is laminated on at least one side of this laminate. This laminate is heated to a temperature equal to or higher than the melting points of the thermoplastic resin and thermoplastic elastomer, and then compressed. Any method can be used to laminate the films. The heating conditions were 50"c-too°C higher than the melting point of the thermoplastic resin and thermoplastic elastomer.
It is preferable to do this for ~2 minutes. Further, any heating method may be employed, such as a method of heating the entire laminate in an oven, a method of radiant heating using a far-infrared heater, an infrared heater, or the like. Any compression method may be employed, including press compression, roll compression, and the like. The compression conditions when employing the press compression method are preferably 0.1 to 5 feet/cIa2, and the distance between a pair of rolls when compressing with rolls is preferably 5 to 15% of the thickness of the mat, and more Preferably 7~
It is 10%. The compression time is preferably 1 to 10 seconds. Furthermore, if the thermoplastic resin is cooled and solidified during compression, the thickness of the Maputo will not recover and the porosity will decrease, so it is preferable that the press mold and rolls are also heated to a predetermined temperature.
上記加熱によって溶融した熱可塑性樹脂は、溶融粘度が
低いため、マット状不織布内に含浸し、該樹脂が固化す
ると、該マット状不織布を構或する無機繊維が相互に結
合する。マット状不織布に上記有機繊維が添加されてい
る場合には、この加熱によって有機繊維も溶融して無機
繊維を相互に結合させる。圧縮を行うことによって、熱
可雪性樹脂フィルムはマット状不織布に効果的に含浸し
、熱可塑性樹脂による無機繊維相互の結合力が上がる。Since the thermoplastic resin melted by the heating has a low melt viscosity, it is impregnated into the mat-like nonwoven fabric, and when the resin is solidified, the inorganic fibers constituting the mat-like nonwoven fabric are bonded to each other. When the above-mentioned organic fibers are added to the mat-like nonwoven fabric, the organic fibers are also melted by this heating and the inorganic fibers are bonded to each other. By performing compression, the thermoplastic resin film effectively impregnates the mat-like nonwoven fabric, and the bonding strength between the inorganic fibers due to the thermoplastic resin increases.
得られた樹脂含浸マットを加熱時の温度に維持した状態
で圧力を解除することによって、その厚さを回復させる
。これによって、マット内に空隙が生じ、軽ｆｆｉ複合
材料が得られる。樹脂含浸マットの厚さを回復するには
任意の方法が採用されてよく、たとえば、樹脂含浸マッ
トを樹脂の融点以上の温度条件下でほぼ無加圧化状態で
所定時間保持する。主に無機繊維の弾性復元力によって
マ・ノトの厚さがほぼ元の状態に回復し、マット内には
空隙が生じる。通常、樹脂含浸マットの嵩密度が０，０
５〜Ｏ． Ｉｇ／ ｃｍ３程度となるまで厚さを回復さ
せることが望ましい。The resulting resin-impregnated mat is maintained at the heating temperature and the pressure is released to restore its thickness. This creates voids within the mat, resulting in a light ffi composite. Any method may be used to restore the thickness of the resin-impregnated mat, for example, the resin-impregnated mat is held for a predetermined period of time in a substantially non-pressurized state at a temperature equal to or higher than the melting point of the resin. Mainly due to the elastic restoring force of the inorganic fibers, the thickness of the mat returns to almost its original state, creating voids within the mat. Usually, the bulk density of the resin-impregnated mat is 0.0
5~O. It is desirable to restore the thickness to about Ig/cm3.
このようにして得られた複合材料は、無機繊維を主戊分
とするマプト状不織布内に熱可塑性樹脂が均一に分散し
て、無機繊維同士を少なくとも部分的に結合させている
。熱可盟性エラストマーは、溶融粘度が高いため７１ト
内部まで含浸せず、圧縮が解除された際にマット表面に
定着して表面層を形成する。第１図に本発明の方法によ
って得られた複合材料の断面図を示す。第１図において
、複合材料Ｉは、複数の無ｍ繊維２が熱可塑性樹脂３を
接着剤として相互に結着し、空隙５を有するマット状成
形体に、熱可塑性エラストマーの層４が積層されてなる
。In the composite material thus obtained, the thermoplastic resin is uniformly dispersed in the mapto-like nonwoven fabric mainly composed of inorganic fibers, and the inorganic fibers are at least partially bonded to each other. Since the thermoplastic elastomer has a high melt viscosity, it does not impregnate the inside of the mat, and when the compression is released, it is fixed on the surface of the mat to form a surface layer. FIG. 1 shows a cross-sectional view of a composite material obtained by the method of the present invention. In FIG. 1, a composite material I is composed of a plurality of non-molecular fibers 2 bound to each other using a thermoplastic resin 3 as an adhesive, and a thermoplastic elastomer layer 4 is laminated on a mat-like molded body having voids 5. It becomes.
本発明の方法によれば、得られる複合材料は、上記のよ
うな構造を有するため、軽量で、成形性に優れる。例え
ば、曲率半径が５ｍｍの絞り戊形機を用いて熱ブレス戊
形を行った場合、しわのない美麗な戊形品が得られる。According to the method of the present invention, the composite material obtained has the above-described structure and is therefore lightweight and has excellent moldability. For example, when heat press forming is performed using a drawing machine with a radius of curvature of 5 mm, a beautiful shaped product without wrinkles can be obtained.
物理的強度も他の同様の複合材料に匹敵する。さらに本
発明の方法は熱可塑性エラストマーが一体となって成形
されるため、表皮材を新たに′ｇｉ層する必要がなく容
易に軽量複合材料を得ることができる。得られた複合材
料は、自動車用の天井材などの内装用部材として好適に
用いられ得る。Physical strength is also comparable to other similar composite materials. Furthermore, in the method of the present invention, since the thermoplastic elastomer is integrally molded, it is not necessary to add a new layer of skin material, and a lightweight composite material can be easily obtained. The obtained composite material can be suitably used as an interior member such as a ceiling material for automobiles.
（実施例） 本発明を実施例について以下に説明する。(Example) The invention will now be described with reference to examples.
尖且ヱロ．
長さ２０−１００問、直径１０μ真のガラス繊維と、長
さ４０〜２００問、直径３０μ曽のポリエチレン繊維と
を、６５： ３５のｍｔＬ比でカードマシンに供給し
、混繊してマット状とした。このマット状物に１０一当
り６Ｏｆ２ｆｆ所の割合でニードルパンチ処理を行い、
厚さ６ｍｍ、単位面積当りの重量が４００ｇ／ｍ２のマ
ント状不織布を得た。Sharp lol. Glass fibers with a length of 20-100 strands and a diameter of 10 μm and polyethylene fibers with a length of 40-200 strands and a diameter of 30 µm are fed into a card machine at an mtL ratio of 65:35, and mixed to form a mat. And so. This mat-like material is subjected to needle punching at a rate of 6 of 2 ff per 10 pieces,
A cloak-like nonwoven fabric having a thickness of 6 mm and a weight per unit area of 400 g/m2 was obtained.
このマプト状不織布の片面に厚さが約１３０μｍの高密
度ポリエチレンフィルムを積層し、他の面に厚さが約８
０μ一の高密度ポリエチレンフイルムと模様印刷を施し
た厚さが約２００μ一の着色オレフィン系熱可塑性エラ
ストマーシ一トとを、該熱可塑性エラストマーシートが
外側となるように積層した。A high-density polyethylene film with a thickness of about 130 μm is laminated on one side of this Maputo-like nonwoven fabric, and a high-density polyethylene film with a thickness of about 8 μm is laminated on the other side.
A high-density polyethylene film having a thickness of 0 μm and a colored thermoplastic olefin elastomer sheet having a thickness of about 200 μm and having been printed with a pattern were laminated with the thermoplastic elastomer sheet on the outside.
用いた高密度ポリエチレンフィルムはメルトインデック
スが２０であり、熱可塑性エラストマーシ一トはメルト
インデックスが０．１以下であった。メルトインデック
スは、ＡＳＴＭ Ｄ１２３８に従い、２３０℃、２．１
６ｋｇ荷重の条件で測定した値である。この積層体をテ
フロンベルトにはさみ、２００℃の熱風をあてて熱可塑
性樹脂を溶融させた後、２００’Ｃ， ３ｋｇ／ｃｚ２
の条件にて５秒間熱プレスを行った。次いで、温度を２
００゜Ｃに保ちながら上下のテフロンベルトを威圧吸引
することによって、シートの厚さを６■まで回復させて
、本発明の軽ｆｆｉ？ｊ！合材料からなる成形体を得た
。The high density polyethylene film used had a melt index of 20, and the thermoplastic elastomer sheet had a melt index of 0.1 or less. Melt index is 2.1 at 230°C according to ASTM D1238.
This is a value measured under the condition of 6 kg load. This laminate was sandwiched between Teflon belts, and hot air at 200°C was applied to melt the thermoplastic resin.
Heat pressing was performed for 5 seconds under the following conditions. Then, the temperature was increased to 2
By forcefully suctioning the upper and lower Teflon belts while maintaining the temperature at 00°C, the thickness of the sheet is restored to 6 cm, and the light ffi? j! A molded body made of a composite material was obtained.
得られた成形体を以下の方法で評価した。成形体の両面
を、２００゜Ｃの赤外線ヒーターで３分間加熱した後、
深さＩＱ＋ｕ、金型間距離５１１１１１％ 凹部曲率半
径Ｓｍｍの表面シボ加工を施したコンクリート製金型に
供給し、０．０５〜ｌｋｇ／ａｍ２の圧力で１分間プレ
スし、深絞り加工を行った。得られた成形品の凹部（金
型の曲率半径が５Ｈの凸部に対応する部分）の曲率半径
を測定腰かつ深絞り加工部分のしわの有無を目視により
判定することにより、成形性を評価した。さらに、平坦
部分く厚さ約５ｍｍ）の曲げ強度および曲げ弾性率（Ｊ
ＩＳ ［？２２１）を測定して戊形品の強度を評価した
。これらの結果を後述の比較例ｌの結果とともに表１に
示す。The obtained molded body was evaluated by the following method. After heating both sides of the molded body with an infrared heater at 200°C for 3 minutes,
Depth IQ + u, distance between molds 511111% It was supplied to a concrete mold with a textured surface with a concave radius of curvature S mm, and was pressed for 1 minute at a pressure of 0.05 to 1 kg/am2 to perform deep drawing. . Measure the radius of curvature of the concave part (the part corresponding to the convex part with a radius of curvature of 5H of the mold) of the obtained molded product. Evaluate the formability by visually determining the presence or absence of wrinkles in the waist and deep drawing parts. did. Furthermore, the bending strength and bending elastic modulus (J
IS [? 221) was measured to evaluate the strength of the shaped product. These results are shown in Table 1 together with the results of Comparative Example 1 described below.
思怯皿上
実施例ｌと同様のマット状不織布の両面に、厚さが約１
００μ国の高密度ポリエチレンフイルム（メルトインデ
ノクスが約２０）を積層し、実施例１と同様の方法で成
形体を得た。得られた成形体の両面を２００“Ｃの赤外
線ヒーターで３分間加熱したのち、これに厚さ約２００
μ重の熱可塑性エラストマーシ一トと発泡ポリエチレン
シ一トとの複合表皮材を積層して成形品を得た。得られ
た成形品を実施例１と同様にして評価し、その結果を表
１に示す。On both sides of the mat-like nonwoven fabric similar to Example 1, a layer with a thickness of about 1
A molded article was obtained in the same manner as in Example 1 by laminating high-density polyethylene films of 00 μm (melt indenox: approximately 20). After heating both sides of the obtained molded body with an infrared heater at 200"C for 3 minutes,
A molded product was obtained by laminating a composite skin material of μ-weight thermoplastic elastomer sheet and foamed polyethylene sheet. The obtained molded article was evaluated in the same manner as in Example 1, and the results are shown in Table 1.
（以下余白）
（発明の効果）
本発明の方法は、このように、成形性に優れ、物理的強
度も他の同様の複合材料に匹敵する軽量複合材料の製造
方法を提供する。さらに本発明の方法によれば、熱可塑
性エラストマーが一体となって戊形されるため、表皮材
を新たに積層する必要がなく軽量複合材料が容易に製造
される。本発明の方法によって得られる軽量複合材料は
、自動車用の天井材などの内装用部材として好適に用い
られ得る。(Hereinafter in the margin) (Effects of the Invention) The method of the present invention thus provides a method for producing a lightweight composite material that has excellent formability and physical strength comparable to other similar composite materials. Further, according to the method of the present invention, since the thermoplastic elastomer is integrally shaped, a lightweight composite material can be easily produced without the need to newly laminate a skin material. The lightweight composite material obtained by the method of the present invention can be suitably used as an interior member such as a ceiling material for an automobile.
４． の。 な！Ｈ 第１図は本発明の複合材料の断面図である。4. of. What! H FIG. 1 is a cross-sectional view of the composite material of the present invention.
ｌ ・・・複合材料、２ ・・・無機ｗ４１（１、３
・・・熱可塑性樹脂、４ ・・・熱可塑性エラストマ−
５・・・空隙。l... Composite material, 2... Inorganic w41 (1, 3
...Thermoplastic resin, 4 ...Thermoplastic elastomer
5...Void.
以上 出願人 積水化学工業株式会社 代表者 廣 田 馨that's all Applicant: Sekisui Chemical Co., Ltd. Representative Kaoru Hirota
Claims (1)
可塑性樹脂フィルムを積層し、さらに該積層物の少なく
とも片面に熱可塑性エラストマーのシートを積層する工
程； 該熱可塑性エラストマーのシートが積層された積層物を
、該熱可塑性樹脂および該熱可塑性エラストマーの融点
以上の温度で加熱した後、圧縮して、該熱可塑性樹脂を
マット状不織布に含浸させる工程；および 加熱時の温度を維持した状態で圧力を解除して、該積層
物の厚さを回復させる工程；とを包含する、軽量複合材
料の製造方法。1. A step of laminating a thermoplastic resin film on both sides of a mat-like nonwoven fabric mainly composed of inorganic fibers, and further laminating a thermoplastic elastomer sheet on at least one side of the laminate; a laminate in which the thermoplastic elastomer sheets are laminated. A step of heating the material at a temperature equal to or higher than the melting point of the thermoplastic resin and the thermoplastic elastomer, and then compressing the material to impregnate the mat-like nonwoven fabric with the thermoplastic resin; and applying pressure while maintaining the temperature at the time of heating. a step of releasing the laminate to restore the thickness of the laminate.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1298507A JPH03161575A (en) | 1989-11-16 | 1989-11-16 | Production of light weight composite material |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1298507A JPH03161575A (en) | 1989-11-16 | 1989-11-16 | Production of light weight composite material |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH03161575A true JPH03161575A (en) | 1991-07-11 |
Family
ID=17860612
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP1298507A Pending JPH03161575A (en) | 1989-11-16 | 1989-11-16 | Production of light weight composite material |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH03161575A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7730996B2 (en) | 2006-04-12 | 2010-06-08 | Ocv Intellectual Capital, Llc | Long fiber thermoplastic composite muffler system with integrated crash management |
| JP2017071204A (en) * | 2015-10-10 | 2017-04-13 | 日本グラスファイバー工業株式会社 | Printing molding and method for manufacturing the same |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS6083832A (en) * | 1983-10-14 | 1985-05-13 | トヨタ自動車株式会社 | Ceiling material for automobile |
| JPS6426768A (en) * | 1987-07-21 | 1989-01-30 | Sekisui Chemical Co Ltd | Production of interior material for car |
| JPS6477664A (en) * | 1987-09-16 | 1989-03-23 | Sekisui Chemical Co Ltd | Production of heat moldable composite sheet |
-
1989
- 1989-11-16 JP JP1298507A patent/JPH03161575A/en active Pending
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS6083832A (en) * | 1983-10-14 | 1985-05-13 | トヨタ自動車株式会社 | Ceiling material for automobile |
| JPS6426768A (en) * | 1987-07-21 | 1989-01-30 | Sekisui Chemical Co Ltd | Production of interior material for car |
| JPS6477664A (en) * | 1987-09-16 | 1989-03-23 | Sekisui Chemical Co Ltd | Production of heat moldable composite sheet |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7730996B2 (en) | 2006-04-12 | 2010-06-08 | Ocv Intellectual Capital, Llc | Long fiber thermoplastic composite muffler system with integrated crash management |
| JP2017071204A (en) * | 2015-10-10 | 2017-04-13 | 日本グラスファイバー工業株式会社 | Printing molding and method for manufacturing the same |
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