JPH04151215A - Glass fiber reinforced thermoplastic resin molded product and its manufacture - Google Patents

Abstract

PURPOSE:To upgrade hygenic qualities in handling and resistance to wear by coating at least a part of the surface of a glass fiber reinforced thermoplastic resin layer by means of a resin layer bonded with said part of the surface. CONSTITUTION:A molded material for a resin layer showing heat bonding properties to a matrix of a hot blank is disposed at least in one mold of a couple of molding tools, and while at least a part of the laminated hot blank composed of laminated hot blanks containing glass fiber as a reinforcing material is heat bonded with said molded material, stamping molding is carried out by means of a couple of molding tools. As at least a part of the surface of a glass fiber reinforced thermoplastic resin layer of a molded product thus manufactured is coated with the resin layer, glass fiber used as the reinforcing material for the hot blank is not exposed on the molding tool surface of said part, and hygenic qualities in handling and resistance to wear can be upgraded by said arrangement.

Description

Detailed Description of the Invention [Industrial Application Field] The present invention relates to a glass fiber-reinforced thermoplastic resin molded product and a method for producing the same, and particularly relates to a glass fiber-reinforced thermoplastic resin molded product and a method for producing the same, and particularly relates to a glass fiber-reinforced thermoplastic resin molded product made by stamping molding of a glass fiber-reinforced thermoplastic resin sheet. The present invention relates to a fiber-reinforced thermoplastic resin molded product and a method for manufacturing the same.

[Prior Art] Fiber-reinforced thermoplastic resin molded products have excellent mechanical strength and are therefore used in various fields. In particular, sheets made of thermoplastic resin reinforced with various fibers (generally FR
Molded products made by compression molding of TP stampable sheets (also known as TP stampable sheets) have a more pronounced reinforcing effect with fibers than injection molded products made of similar fiber-reinforced resins, so they require high strength and high impact resistance. It is used in various fields.

Among fiber-reinforced thermoplastic resin molded products, FRTP stampable sheet molded products made of polypropylene reinforced with glass fibers are characterized by a combination of physical properties such as mechanical properties, thermal properties, chemical resistance, and moldability, as well as production cost. Because of its good balance, it is used in fields such as automobiles, communication equipment, and civil engineering/construction.

In order to manufacture molded products using FRTP stampable sheets reinforced with glass fibers, first, FRT
The P stampable sheet is cut into an appropriate size according to the weight of the desired molded product and the shape of the mold (mold) used for molding, and this original plate (called a blank) is used. FRTP by heating with far infrared heater etc.
The thermoplastic resin that makes up the stampable sheet (Matri,
This is a hot blank in which the molten resin) is melted. next,
After a required number of hot blanks are stacked and placed in a mold, the mold is closed and the hot blanks are fluidized by compression to form a predetermined shape. Thereafter, by cooling and solidifying the mold with the mold closed, a molded FRTP stampable sheet is obtained. Such a molding method is generally called stamping molding.

Glass fiber-reinforced thermoplastic resin molded products made by stamping and molding FRTP stampable sheets reinforced with glass fibers are lightweight, have excellent mechanical strength, especially rigidity and impact resistance, and are said to have excellent productivity. On the other hand, a part of the reinforcing glass fiber is exposed on the surface of the molded product without being wrapped in the matrix resin, so if a sensitive person touches the molded product directly, it may cause irritation. The problem is that the molded product may feel itchy and itchy, which is undesirable from a hygienic standpoint, and that if the molded product is exposed outdoors, the exposure of the glass fibers becomes noticeable in a relatively short period of time.

Methods to solve these problems include coating the surface of the molded product and covering the exposed glass fibers with a coating layer, and fixing a resin sheet obtained in a separate process to the surface of the molded product using adhesive. Attempts have been made to cover the exposed glass fibers with this resin sheet, but none of these methods have been able to improve the handling hygiene and weather resistance of glass fiber reinforced thermoplastic resins. A molded product has been obtained.

[Problems to be Solved by the Invention] However, in the method of improving handling hygiene and weather resistance by painting the surface of glass fiber reinforced thermoplastic resin molded products, the wettability of glass fibers and the glass Because the wettability of the matrix resin of the fiber-reinforced thermoplastic resin differs, coating and drying must be repeated a considerable number of times in order to cover the exposed glass fibers with a coating layer, making it difficult to achieve the desired molded product. There is a problem in that the steps to obtain the product are complicated and the advantage of high productivity of the glass fiber reinforced thermoplastic resin molded product obtained by stamping molding is lost.

In addition, on the surface of glass fiber reinforced thermoplastic resin molded products,
In the method of improving handling hygiene and weather resistance by fixing the resin sheet obtained by a separate process with an adhesive, there are methods such as applying adhesive and crimping the glass fiber-reinforced thermoplastic resin molded product and the resin sheet.・Since additional processes such as holding and drying are required, the process to obtain the desired molded product becomes complicated, and it is said that the productivity of molded products made of glass fiber reinforced thermoplastic resin by stamping molding is higher. There is a drawback that it negates the advantages.

Therefore, an object of the present invention is to provide a glass fiber-reinforced thermoplastic resin molded product that has improved handling hygiene and weather resistance, and that can be manufactured with high productivity. Provides a method for manufacturing glass fiber reinforced thermoplastic resin molded products that enables high productivity production of glass fiber reinforced thermoplastic resin molded products with improved handling hygiene and weather resistance. It's about doing.

[Means for Solving the Problems] The present invention has been made to achieve the above object, and the glass fiber-reinforced thermoplastic resin molded product of the present invention comprises a glass fiber-reinforced thermoplastic resin layer and the glass fiber-reinforced thermoplastic resin layer. It has a fiber-reinforced thermoplastic resin layer and a thermally bonded resin layer, and is characterized in that at least a part of the surface of the glass fiber-reinforced thermoplastic resin layer is covered with the resin layer.

In addition, the method for manufacturing a glass fiber reinforced thermoplastic resin molded article of the present invention includes stamping molding a laminate formed by laminating a plurality of hot blanks reinforced with glass fiber using a pair of molds to form a glass fiber reinforced thermoplastic resin molded product. In producing a reinforced thermoplastic resin molded product, a molded product for a resin layer exhibiting thermal adhesiveness to the matrix resin of the hot blank is placed in at least one of the pair of molds, and The present invention is characterized in that the molded product for the resin layer and at least a portion of the book blank constituting the laminate are thermally bonded together and stamped using the pair of molds.

The present invention will be explained in detail below.

First, to explain the glass fiber reinforced thermoplastic resin molded product of the present invention, this glass fiber reinforced thermoplastic resin molded product has a glass fiber reinforced thermoplastic resin layer and a glass fiber reinforced thermoplastic resin layer. It has a resin layer and a thermally bonded resin layer.

The glass fiber-reinforced thermoplastic resin layer constituting the glass fiber-reinforced thermoplastic resin molded product of the present invention is formed by stamping a plurality of FRTP stampable sheets reinforced with glass fibers, that is, glass fiber It is made by stamping and molding a plurality of hot blanks that serve as reinforcing materials. The type of FRTP stampable sheet at this time is not particularly limited, and it can be manufactured by a method such as a lamination method, a dry method, or a wet method, which is conventionally used as a material for glass fiber reinforced thermoplastic resin molded products. An FRTP stampable sheet reinforced with glass fiber can be used.

Furthermore, the resin layer constituting the glass fiber-reinforced thermoplastic resin molded product of the present invention is for preventing the glass fibers contained in the glass fiber-reinforced thermoplastic resin layer from being exposed on the surface of the molded product. The thickness is not particularly limited as long as it can prevent the glass fibers from being exposed on the surface of the molded product. In addition, the composition of the resin layer is a hot blank (a material for the glass fiber reinforced thermoplastic resin layer).
It is not particularly limited as long as it has a composition that can be thermally bonded to the matrix resin of the FRTP stampable sheet), and is appropriately determined depending on the type of matrix resin of the hot blank used as the material.

For example, when the matrix resin of the hot blank is polypropylene, the raw materials for the resin layer include a propylene homopolymer, a copolymer polypropylene with an α-olefin containing propylene as a main component, and the copolymer polypropylene and the propylene homopolymer. A blend with
Individual resins such as modified polypropylene made by modifying polypropylene with unsaturated carboxylic acids or derivatives thereof,
Compositions made by adding various pigments, ultraviolet absorbers, light stabilizers, antioxidants, conductive fillers, etc. to the resin can be used.

Therefore, the term "resin layer" as used herein includes not only a layer made only of resin but also a layer made of a mixture containing pigments, ultraviolet absorbers, light stabilizers, antioxidants, conductive fillers, etc. in addition to resins. shall be included.

By using a pigment-added resin, it is possible to obtain a glass fiber-reinforced thermoplastic resin molded product that has improved handling hygiene and weather resistance as well as improved color appearance. In addition, by using resins to which ultraviolet absorbers, light stabilizers, antioxidants, etc. are added, it is possible to obtain molded products made of glass fiber-reinforced thermoplastic resins that have particularly improved weather resistance as well as handling hygiene. It becomes possible. Furthermore, by using a resin with conductive filler added, glass fiber-reinforced thermoplastic resin has improved handling hygiene and weather resistance, as well as EMI (electromagnetic interference) shielding and radio wave reflection properties. It becomes possible to obtain molded products.

The glass fiber-reinforced thermoplastic resin molded article of the present invention has the glass fiber-reinforced thermoplastic resin layer described above and a resin layer thermally bonded to the glass fiber-reinforced thermoplastic resin layer. At least a portion of the surface of the layer is covered with a resin layer. Therefore, on the surface of the molded product where the glass fiber-reinforced thermoplastic resin layer is covered with the resin layer, the glass fibers used as the reinforcing material of the hot blank (FRTP stampable sheet) are not exposed.

The glass fiber-reinforced thermoplastic resin molded article of the present invention thus obtained can be produced, for example, by the following methods (1) and (2).

■ Hot blank (FRT) reinforced with glass fiber
A molded product obtained by stamping a P stampable sheet) into a desired shape, and a resin molded product formed into a shape having one surface similar to one surface of this molded product, are brought into contact with the similar surfaces and subjected to vibration fusion. Manufactured by thermally adhering the two using the attachment method.

(2) Produced based on the method for producing a glass fiber-reinforced thermoplastic resin molded article of the present invention, which will be described later.

Next, the method for manufacturing a glass fiber-reinforced thermoplastic resin molded article of the present invention (hereinafter simply referred to as the manufacturing method of the present invention) will be explained. As mentioned above, in this manufacturing method, glass fiber is used as a reinforcing material. A laminate formed by laminating a plurality of hot blanks, and a molded product for a resin layer that exhibits thermal adhesiveness to the matrix resin of the hot blanks are stamped using a pair of molds while being thermally bonded.

The composition of the resin layer molding that is thermally adhesive to the hot blank matrix resin used in the manufacturing method of the present invention is one that can be thermally bonded to the hot blank matrix resin, that is, the FRTP stampable material used as the material. The material is not particularly limited as long as it can be thermally bonded to the matrix resin of the sheet, and the FRTP stampable used as the material is similar to the composition of the resin layer in the glass fiber reinforced thermoplastic resin molded product of the present invention described above. It is determined appropriately depending on the type of matrix resin of the sheet.

The molded product for the resin layer is a sheet-like or film-like molded product having an area that can cover the part whose appearance is to be improved in the target glass fiber reinforced thermoplastic resin molded product, or used for molding. It is preferable that the molded product has a shape similar to the inner surface shape of one of the molds constituting the pair of molds, and from the viewpoint of maintaining high productivity, it is preferable that the molded product be in the form of a sheet or film. It is particularly preferable. A sheet-like molded article for a resin layer or a film-like molded article for a resin layer can be obtained, for example, by an extrusion method. In addition, for resin layer moldings having one surface similar to the inner surface shape of one of the molds constituting a pair of molds, for example, a sheet-like resin layer molding obtained by extrusion molding can be formed by vacuum forming or pressure forming. It can be obtained by molding into a desired shape by a method such as the above, or by molding a resin, which is a raw material for a molded product for a resin layer, into a desired shape by a method such as blow molding.

A laminate formed by laminating hot blanks reinforced with glass fibers (hereinafter referred to as a hot blank laminate), which is formed while being thermally bonded to such a resin layer molding, is as follows:
It is made by laminating a plurality of hot blanks depending on the weight of the intended molded product and the shape of the mold used for molding.

The type and shape of the matrix resin of the hot blank that constitutes the hot blank laminate and the type and shape of the glass fiber that is the reinforcing material, that is, the FR whose reinforcing material is glass fiber used as a material for the glass fiber reinforced thermoplastic resin molded product.
The type of TP stampable sheet is not particularly limited, and similar to the glass fiber-reinforced thermoplastic resin layer in the glass fiber-reinforced thermoplastic resin molded product of the present invention described above, it may be formed by a lamination method, a dry method, a wet method, etc. An FRTP stampable sheet using glass fiber as a reinforcing material and manufactured by the method described above can be used.

In addition, the configuration of the hot blank laminate is as described above.
It is appropriately selected according to the weight of the intended molded product, the shape of the mold used for molding, etc. The structure of the hot blank laminate is designed to prevent air bubbles from remaining at the interface between the resin layer molding and the hot blank laminate during thermal bonding and molding, thereby improving handling hygiene and weather resistance. It is possible to obtain a molded product made of glass fiber reinforced thermoplastic resin that is excellent in appearance as well as properties.

The configuration of the hot blank laminate that can prevent air bubbles from remaining at the interface between the molded product for the resin layer and the hot blank laminate varies depending on the molding conditions, the shape of the intended glass fiber reinforced thermoplastic resin molded product, etc. Therefore, it cannot be specified, but for example, 300X300 as a molded product for the resin layer.
Using a sheet-like molded product with a thickness of 0.51 mm and a 300 x 300 mm flat plate mold, a pressing force of 9
0 to 270 tons (equivalent to 100 to 300 kg/c-),
When molding into a flat plate under the molding conditions of a pressing speed of 4 to 40 mm/sec, the hot blank that comes into direct contact with the sheet-like molded product during molding (in the hot blank laminate, the hot blank located closest to the sheet-like molded product) It is preferable to configure the hot blank laminate so that the area of the abutting surface of the blank is about 90% or less of the area of the entire abutting surface of the sheet-like molded product.

In addition, as a molded product for the resin layer, the size is 600 x 600 mm and the thickness is 0. Using a 5mm sheet-like molded product, 6
Using a flat plate mold of 00x600+nm, pressurizing force of 360
When molding into a flat plate under the molding conditions of ~1080 tons (equivalent to 100 to 300 kg/c++t) and a pressure rate of 4 to 40 cm/min, a hot blank (hot blank) that comes into direct contact with the sheet-like molded product during molding is used. The hot blank located closest to the sheet-shaped molded product in the laminate)
It is preferable that the hot blank laminate is constructed such that the area of the contact surface is about 25% or less of the area of the entire contact surface of the sheet-shaped molded product.

In the manufacturing method of the present invention, the above-mentioned resin layer molding and at least a part of the hot blank constituting the above-mentioned hot blank laminate are stamped using a pair of molds while being thermally bonded to each other as described above. do.

The molding conditions at this time are not particularly limited as long as the molded product for the resin layer and the hot blank laminate can be molded while being thermally bonded. can be set according to conventional methods. These thermal conditions are determined depending on the pressure during molding, the molding time, the melting point of the resin in the molded product for the resin layer, the thickness (weight) of the molded product, the weight of the hot blank laminate, etc. so that the molded product and the hot blank laminate are thermally bonded.
It can be adjusted by appropriately changing the temperature and amount of heat of the hot blank laminate, the temperature of the mold, etc.

At least a part of the surface of the glass fiber-reinforced thermoplastic resin molded product obtained in this way is covered with a resin layer consisting of a resin layer molding that is thermally bonded to the hot blank laminate, and this part , the glass fiber used as the FRTP stamper blanking material is not exposed.

[Function] The glass fiber reinforced thermoplastic resin molded product of the present invention has a glass fiber reinforced thermoplastic resin layer and a resin layer thermally bonded to the glass fiber reinforced thermoplastic resin layer, At least a portion of the surface of the plastic resin layer is covered with a resin layer.

Therefore, on the surface of the molded product where the glass fiber reinforced thermoplastic resin layer is covered with the resin layer, the resin layer is used as a reinforcing material for the hot blank (FRTP stampable sheet) which is the material for the glass fiber reinforced thermoplastic resin layer. No exposed glass fibers improve handling hygiene and weather resistance.

Furthermore, the glass fiber-reinforced thermoplastic resin molded product of the present invention is a hot blank (FRTP) using glass fiber as a reinforcing material.
A molded product obtained by stamping a stampable sheet) into a desired shape, and a resin molded product formed into a shape having one surface similar to one surface of this molded product, are brought into contact with the similar surfaces and vibration fused. It can be manufactured by thermally adhering the two using a method, or by the manufacturing method of the present invention, and can be manufactured by coating the exposed glass fibers with a coating layer, or by applying a resin sheet obtained by a separate process to the surface of the molded product. Compared to conventional methods such as methods of fixing with adhesives, fewer steps are required to produce the desired molded product.

Therefore, the glass fiber-reinforced thermoplastic resin molded product of the present invention can be manufactured with higher productivity than conventional molded products that have improved handling hygiene and weather resistance.

According to the manufacturing method of the present invention, the thermal adhesion and shaping of the molded product for the resin layer and the hot blank laminate can be performed by stamping molding in one step, so that particularly high productivity can be obtained.

Furthermore, in the manufacturing method of the present invention, by using a molded product made of a resin containing a pigment that develops a desired color as a molded product for the resin layer, it is possible to improve the handling hygiene and weather resistance as well as improve the color appearance. A glass fiber reinforced thermoplastic resin molded product having an excellent appearance can be obtained. In addition, by using a molded product made of resin containing ultraviolet absorbers, light stabilizers, antioxidants, conductive fillers, etc. as the molded product for the resin layer, it not only improves hygiene in handling but also has excellent weather resistance. It is possible to obtain an improved glass fiber-reinforced thermoplastic resin molded product, and a glass fiber-reinforced thermoplastic resin molded product that has improved handling hygiene and weather resistance as well as other functions.

[Example] Examples of the present invention will be described below.

Example 1 An FRTP stampable sheet using glass fiber, which is the material of the glass fiber-reinforced thermoplastic resin layer, as a reinforcing material was obtained by laminating polypropylene as a matrix resin (product name: Azdel P11378K,
Ethylene propylene random copolymer (product name:
100 parts by weight of UBE Polypro FL453 (made by Ube Industries ■) and TPM, a red masterbatch made by Tokyo Ink ■
50209 (trade name, red pigmented polypropylene) extruded from a pigment-containing resin consisting of 1 part by weight. Using a 5 mm sheet-like molded product, a glass fiber reinforced thermoplastic resin molded product of the present invention was manufactured in the following manner based on the manufacturing method of the present invention.

First, the above-mentioned sheet-like molded product is cut into a size of 300 x 300 mm to form a resin layer molded product, and this resin layer molded product is molded from a pair of male and female molds whose surface temperature is controlled at 90°C by a heat medium circulation device. It was placed in the lower mold of a 300 mm square flat plate mold. In addition, the FRTP stampable sheet 2
Four blanks cut to a size of 00 x 200 mm were heated with a far-infrared heater to a surface temperature of 200±10° C. to obtain four hot blanks.

Next, these four hot blanks (weight near 04g)
were sequentially laminated on a sheet-like molded product placed in a lower mold to obtain a hot blank laminate.

After this, the mold was closed under the conditions of a pressing force of 135 tons and a pressing speed of 12 mm/sec, and in this state, the mold was cooled under pressure for 120 seconds to form four hot blanks containing the glass fiber reinforced polypropylene layer and the pigment. A 300X300X7. A glass fiber-reinforced polypropylene molded product having a size of 0 mm was obtained.

On the surface of the glass fiber-reinforced polypropylene molded product thus obtained, the portion where the glass fiber-reinforced polypropylene layer is covered with the resin layer is covered with FRTP.
The glass fibers used as the stamped blank material were not exposed.

In addition, the part covered by the resin layer has a red color due to the red pigment contained in the resin layer molded product (sheet-like molded product), and the interface between the glass fiber reinforced polypropylene layer and the resin layer. No air bubbles were observed and the product had an excellent appearance.

Furthermore, we made cross-shaped cuts in the resin layer and attempted to separate the resin layer from the glass fiber reinforced polypropylene layer, but
It did not peel off easily.

In addition, F, which is reinforced with glass fiber, was used as a material.
Table 1 lists the type of RTP stampable sheet, the type of resin contained in the molded product for the resin layer, the configuration and weight of the hot blank laminate, the surface temperature of the mold, and the cooling and pressing time. .

Examples 2 to 6 The type of FRTP stampable sheet using glass fiber as a reinforcement, the type of resin contained in the molded product for the resin layer, the configuration and weight of the hot blank laminate, the surface temperature of the mold, and the cooling process. 300X300X5.4~
A glass fiber-reinforced polypropylene molded product having a size of 7.4 mm was obtained.

One surface of each glass fiber-reinforced polypropylene molded product obtained is covered with a resin layer thermally bonded to the glass fiber-reinforced polypropylene layer, as in Example 1, and this part is covered with a FRTP stampable sheet. The glass fibers used as reinforcement were not exposed.

In addition, this part has a red color due to the red pigment contained in the molded material for the resin layer, and no air bubbles are observed at the interface between the glass fiber reinforced polypropylene layer and the resin layer, giving it an excellent appearance. It was showing.

Examples 7 to 9 A 600 mm square flat plate mold consisting of a pair of male and female molds was used, and the sheet-like molded product used in Example 1 was cut into a size of 600 x 600 w + m as a molded product for the resin layer. Table 1 shows the composition and weight of the blank laminate.
The same procedure as in Example 1 was carried out except for various changes as shown in
A glass fiber-reinforced polypropylene molded product with dimensions of 600 x 600 x 5 and 6 mm was obtained.

One surface of each glass fiber-reinforced polypropylene molded product obtained is covered with a resin layer thermally bonded to the glass fiber-reinforced polypropylene layer, as in Example 1, and this part is covered with a FRTP stampable sheet. The glass fiber used as a reinforcing material was not exposed.

In addition, this part has a red color due to the red pigment contained in the molded product for the resin layer, and in the glass fiber-reinforced polypropylene molded product obtained in Example 7, the glass fiber-reinforced polypropylene layer and the resin No air bubbles were observed at the interface with the layer, and the product had an excellent appearance.

[Effects of the Invention] As explained above, the glass fibers used as the reinforcing material of the FRTP stampable sheet material are exposed on at least a part of the surface of the glass fiber reinforced thermoplastic resin molded product of the present invention. Not yet.

In addition, this glass fiber reinforced thermoplastic resin molded article can be manufactured by the manufacturing method of the present invention in a smaller number of steps than the conventional method, which can improve handling hygiene and weather resistance.

Therefore, according to the glass fiber-reinforced thermoplastic resin molded article and the manufacturing method thereof of the present invention, a glass fiber-reinforced thermoplastic resin molded article with improved handling hygiene and weather resistance can be provided with high productivity. becomes possible.

Applicant: Ube Nitto Kasei Co., Ltd. Agent: Patent Attorney Shizuo Nakamura

Claims (2)

[Claims] (1) It has a glass fiber-reinforced thermoplastic resin layer and a resin layer thermally bonded to the glass fiber-reinforced thermoplastic resin layer, and at least a part of the surface of the glass fiber-reinforced thermoplastic resin layer is formed by the resin layer. A glass fiber-reinforced thermoplastic resin molded product characterized by being coated. (2) In producing a glass fiber-reinforced thermoplastic resin molded product by stamping a laminate formed by laminating a plurality of hot blanks reinforced with glass fibers using a pair of molds, the hot blanks are: A resin layer molding exhibiting thermal adhesiveness to the matrix resin is placed in at least one of the pair of molds, and the resin layer molding and the hot blank constituting the laminate are bonded together. A method for producing a glass fiber-reinforced thermoplastic resin molded product, characterized in that stamping molding is performed using the pair of molds while at least a portion of the product is thermally bonded.