JPH04331138A - Laminated product and its manufacturing method - Google Patents

Abstract

PURPOSE:To provide a laminated product having excellent adhesive strength with an air-permeable decorative skin 5 and a manufacturing method thereof by using a sheet-shaped blank 1 manufactured through a paper making method. CONSTITUTION:In a laminated product, a fiber-reinforced thermoplastic resin layer pressed has a 5-75vol.% air gap under the state, in which the fiber- reinforced thermoplastic resin layer 9, a core section of which is composed of not less than 10vol.% reinforcing fiber content through a paper making method, is expanded by utilizing a spring back by the release of the residual stress of reinforcing fibers at the time of heating and a 3-30vol.% inorganic filler-contained thermoplastic resin 10 heated is interposed between an air- permeable decorative skin and the core section. Accordingly, adhesive strength is improved by an anchor effect by the intrusion of the thermoplastic resin in the inorganic filler-contained thermoplastic resin layer 10 as an intermediate layer into the air-permeable decorative skin 5 at the time of press and solidification and bonding.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a porous laminate molded product comprising a fiber-reinforced thermoplastic resin core and a breathable decorative skin, and a method for molding the same. The porous laminate molded product according to the present invention is widely used as interior materials for automobiles, housing parts for home appliances, etc., and industrial parts such as furniture.

0002

[Prior Art] Recently, there has been a trend for industrial parts manufactured by metal press processing to be replaced by press-molded products made of fiber-reinforced thermoplastic resin, which are composed of relatively long reinforcing fibers and thermoplastic resin. be. The characteristics of fiber-reinforced thermoplastic resin are that the heated fiber-reinforced thermoplastic resin sheet-shaped molding material (hereinafter, the molding material is referred to as sheet-shaped molding material),
It is possible to manufacture complex molded products by inserting it into a room temperature or heated mold and pressurizing it in a short time.
Furthermore, the molded product has high strength and is lightweight.

[0003] Furthermore, in order to improve the merit of weight reduction, the paper making method (Japanese Patent Publication No. 52-12283, Japanese Patent Publication No. 52-12283,
A method for manufacturing a porous molded product of a sheet-like molding material according to Japanese Patent Application Laid-Open No. 179234-1982,
JP-A-62-161529) has been proposed. The sheet-shaped molded material is made with a diameter of 3 to 3 by applying papermaking technology.
A nonwoven material is manufactured by uniformly dispersing reinforcing fibers with a diameter of 0 μm and a length of 3 to 50 mm and thermoplastic resin powder, and this nonwoven material is used as a raw material to be heated, pressurized, and further cooled. Porous molded products are molded by utilizing the sheet expansion that occurs when this sheet-like molding material is heated above the softening point or melting point of the thermoplastic resin that is the matrix before molding.

[0004] Nonwoven materials produced by papermaking methods exhibit the property of being extremely bulky because the reinforcing fibers are dispersed in the form of monofilaments (single fibers) and randomly oriented. The thickness of the nonwoven material varies depending on the reinforcing fiber content, its shape, and papermaking conditions, but it is about 10 times thicker than a sheet with voids removed, which is generally used as a sheet-shaped molding material. The sheet-shaped molding material is heated above the softening point or melting point of the thermoplastic resin matrix before molding, but as the bonding force of the thermoplastic resin to the reinforcing fibers is weakened, the residual stress in the reinforcing fibers is released and the original It expands due to springback as it tries to return to normal.

[0005] Sheet-shaped molding materials are generally heated in a far-infrared heating furnace, and the expanded heating sheet-shaped molding material is inserted into a mold to obtain the desired expansion ratio. A porous molded product is produced by pressure molding. Expansion of the sheet-shaped molding material starts from the surface of the sheet, and as heat gradually reaches the center of the sheet thickness, the entire sheet expands, and at the same time, an insulating air layer is formed, resulting in a decrease in thermal conductivity. On the surface of the sheet, the reinforcing fibers are exposed due to springback, and the thermoplastic resin is further deteriorated by local heating due to a decrease in the thermal conductivity of the sheet, resulting in a marked deterioration in appearance. As a result, the appearance of the porous molded product obtained by pressure molding the expanded heating sheet deteriorates because it inherits the appearance of the sheet. The method of laminating a decorative skin on the surface of an expanded heated sheet and press-molding the two at the same time to obtain a laminated molded product is a very effective means for improving the appearance of porous molded products. be.

FIG. 1(a) shows an example of a method for forming a laminate molded product.
It was shown to. A sheet-like molded material 1 is heated in a far-infrared heating furnace 2. The sheet-shaped molded material expands when heated, and more of the reinforcing fibers 3 are exposed. The breathable decorative skin 5 is placed on top of the heated sheet-shaped molding material 4 and inserted into the mold 6, and the two are integrated at the same time as pressure molding is performed under conditions to obtain the desired expansion ratio. A porous laminate molded product 7 is thereby obtained. However, the adhesive strength between the fiber-reinforced thermoplastic resin part of the porous molded article molded by this method and the breathable decorative skin is very weak and is not practical.

[0007] The adhesive strength between the fiber-reinforced thermoplastic resin part of the laminate molded product and the breathable decorative skin is determined by the anchoring effect caused by the thermoplastic resin penetrating into the decorative skin during pressure molding and solidifying and bonding. manifest. However, Figure 1 (
In the method of forming a laminate molded product in a), the reinforcing fibers on the surface of the heating sheet are exposed more, and the flow of the thermoplastic resin inside the expanded sheet is inhibited by the presence of uniformly dispersed reinforcing fibers. This makes it difficult for it to seep out onto the sheet surface during pressure molding. For this reason, the amount of thermoplastic resin that permeates into the skin is extremely small, and a sufficient anchoring effect is not expressed, so that the adhesive strength between the fiber-reinforced thermoplastic resin portion and the skin becomes extremely weak.

[0008]

[Problems to be Solved by the Invention] The present invention provides a porous laminate molded product that has good adhesive strength with a breathable decorative skin, using a sheet-like molded material manufactured by a papermaking method, and a method for molding the same. It is something to do.

[0009]

[Means for Solving the Problems] The present invention provides a fiber-reinforced thermoplastic resin layer with a reinforcing fiber content of 10% by volume or more formed by a paper-making method, and a space between an air-permeable decorative skin and the core. 3
A laminate molded product in which a fiber-reinforced thermoplastic resin layer formed by heating and pressure molding with a thermoplastic resin layer containing ~30 volume% inorganic filler has voids of 5 to 75 volume%, and a paper-making method A fiber-reinforced thermoplastic resin layer with a reinforcing fiber content of 10% by volume or more is used as a core, and when heated, it is expanded using springback due to release of residual stress in the reinforcing fibers, and the air-permeable decorative skin and the core are expanded. heated between 3
A fiber-reinforced thermoplastic resin layer characterized in that the whole is integrated by pressure molding using a mold with a thermoplastic resin layer containing ~30% by volume of inorganic filler interposed therebetween. This is a method for forming a laminate molded product having voids of 5 to 75% by volume.

An example of the method for forming the laminate molded product of the present invention is shown in FIG. 1(b). When the sheet-shaped molded material 8 of the present invention is heated, the fiber-reinforced thermoplastic resin layer 9 having a reinforcing fiber content of 10% by volume or more, which constitutes the core, expands;
The thermoplastic resin layer 10 containing 30% by volume of inorganic filler does not expand, and a large amount of molten thermoplastic resin exists on its surface. Furthermore, thermoplastic resins tend to flow easily even in the presence of inorganic fillers. Therefore, when integrally molded with the breathable decorative skin 5, the thermoplastic resin of the inorganic filler-containing thermoplastic resin layer 10 easily penetrates into the inside of the skin, and the porous laminate molded product 7 has good adhesive strength by being fixed. is obtained.

[0011] In the present invention, in the porous laminate molded product,
The adhesive strength between the fiber-reinforced thermoplastic resin core and the breathable decorative skin was improved by interposing an inorganic filler-containing thermoplastic resin layer between the two and integrally molding them. The content of the inorganic filler in the intermediate layer is such that the melt viscosity increases due to the inclusion of the inorganic filler, which prevents the resin of the intermediate layer from being absorbed into the expanded fiber-reinforced thermoplastic resin layer during heating, and The content is preferably 3% by volume or more, which has the effect of suppressing fibers from being exposed to the sheet surface due to springback, and preferably 30% by volume or less, which allows stable molding of an inorganic filler-containing thermoplastic resin film.

[0012] In the present invention, as inorganic fillers, fine particulate fillers such as calcium carbonate and talc, plate-like fillers such as mica, fibrous fillers such as chopped glass fibers and rock wool fibers, or a mixture of two or more thereof are used. use The surface of the inorganic filler is desirably treated with a silane coupling agent or the like in order to improve adhesiveness with the thermoplastic resin for the purpose of developing strength.

[0013] The thermoplastic resin that is the matrix of the inorganic filler-containing thermoplastic resin layer is generally the same as the fiber-reinforced thermoplastic resin layer to be laminated. For the purpose of improvement, those modified with active groups or mixtures with different resins may be used. The inorganic filler and thermoplastic resin are preferably kneaded using an extruder in order to achieve uniform dispersion, and it is desirable to laminate a film formed using a T-die or the like on the fiber-reinforced thermoplastic resin.

[0014] In the present invention, the fiber content of the fiber-reinforced thermoplastic resin layer of the core is 10% by volume or more at which stable expansion due to springback of the reinforcing fibers occurs, and adhesion between the reinforcing fibers and the thermoplastic resin is possible. It is desirable that the content be 40% by volume or less to sufficiently exhibit strength as a fiber-reinforced thermoplastic resin molded product.

As the reinforcing fibers, in addition to glass fibers, carbon fibers, and metal fibers, inorganic fibers and organic fibers can be used. The shape of the reinforcing fibers is preferably 3 μm φ or more in diameter from the viewpoint of ease of handling and economical aspects, and 30 μm φ or less in order to develop sufficient strength, and the fiber length is 3 mm or more from the viewpoint of developing strength. It is desirable that the thickness be 50 mm or less to enable uniform dispersion. In addition, the reinforcing fibers are made of water-soluble polymers and wetting agents to improve hydrophilicity for the purpose of good dispersion in water, and silane coupling agents to improve adhesion with thermoplastic resins for the purpose of developing strength. It is preferable to perform surface treatment with, etc.

Thermoplastic resins include polyethylene, polypropylene, polystyrene, styrene-butadiene-acrylonitrile copolymer, styrene-acrylonitrile copolymer, polyamide, polycarbonate, polyacetal, polyethylene terephthalate, polybutylene terephthalate, polyphenylene oxide, polysulfone, It is a resin such as polyphenylene sulfide, and these two
It also includes mixtures of different kinds or more, and to which commonly used plasticizers, heat stabilizers, light stabilizers, fillers, dyes and pigments, impact resistance agents, fillers, nucleating agents, processing aids, etc. are added. You can also. As the breathable decorative skin, woven fabrics made of natural or synthetic fibers, needle-punched nonwoven fabrics, raised woven fabrics, knitted fabrics, flocked fabrics, etc. are used.

The porosity of the porous molded product is determined by the expansion ratio during heating of the sheet-like molded material and the pressure molding conditions. In order to take advantage of the lightweight benefits of porous molded products,
Although it is desirable to increase the porosity, it is necessary to sufficiently bond the reinforcing fibers with a thermoplastic resin in order to develop strength, and the porosity of the porous molded product of the present invention is 5 to 7.
5% by volume. Preferably it is 30 to 70% by volume.

FIG. 2 shows an example of the manufacturing process of a sheet-shaped molded material using the papermaking technique. Diameter 3μm φ~30μm
φ, reinforcing fiber 1 such as glass fiber with a length of 3 mm to 50 mm
1 and thermoplastic resin powder 12 are continuously introduced into water in a dispersion tank 13. In the dispersion tank, stirring is performed to uniformly disperse the reinforcing fibers and resin powder, and the dispersion liquid is further supplied by a pump 14 to a head box 16 installed above a mesh belt conveyor 15. The wet box 17 installed at the bottom of the head box is maintained at a negative pressure, and the dispersion inside the head box is continuously sucked and dehydrated to create a composite body in which reinforcing fibers and thermoplastic resin powder are uniformly dispersed. A nonwoven material 18 is produced. This nonwoven material is dried in a hot air dryer 19, and at the same time, part or all of the thermoplastic resin is heated to a temperature higher than its softening point or melting point to melt it, and then cooled to convert the reinforcing fibers into thermoplastic resin. It is a non-woven material bonded with resin. Furthermore, it is heated and pressurized with a double belt conveyor type continuous press 20, further cooled and formed into a sheet shape, and finally reeled up 2
1, or cut with a cutter 22 into a shape according to the dimensions required for hot-press molding to produce a sheet-like molding material 1. The sheet-shaped molding material may be one in which voids are completely removed when a nonwoven material is molded using a double-belt conveyor type continuous press, or one in which voids are present.

The method of laminating the inorganic filler-containing thermoplastic resin layer on the fiber-reinforced thermoplastic resin layer in the present invention is as follows:
This can be easily achieved by laminating a film formed using a T-die or the like of an extruder on a fiber-reinforced thermoplastic resin, heating and pressurizing it with a press molding machine, and further cooling and molding.

As for an industrial method, the lamination process as outlined in FIG. It is efficient to provide The thermoplastic resin 23 and the inorganic filler 24 are kneaded in an extruder 25 to achieve uniform dispersion, and further formed into an inorganic filler-containing thermoplastic resin film 27 in a T-die 26 and supplied to the surface of the nonwoven material 18. be done. The nonwoven material and the inorganic filler-containing thermoplastic resin film are heated and pressed in a double belt conveyor type continuous press 20, and are further cooled to produce the inorganic filler-containing thermoplastic resin laminated sheet-like molded material 8 used in the present invention. . The thickness of the inorganic filler-containing thermoplastic resin film to be laminated is preferably set to the minimum necessary value to ensure good adhesive strength with the breathable decorative skin, in order to place emphasis on the strength of the molded product.

In place of the nonwoven material in the lamination process shown in FIG. 3, it is easy to use a sheet material formed from a nonwoven material using a double belt conveyor type continuous press or the like. In addition, in Figure 3, a thermoplastic resin containing inorganic filler is laminated on one side of the nonwoven material, but the appearance of both sides is required to be improved depending on the application of the molded product, so a breathable decorative skin is laminated on both sides of the sheet-shaped molded material. When molding a laminate molded product, a sheet-like molding material is used in which a thermoplastic resin containing an inorganic filler is laminated on both sides of a nonwoven material.

In the present invention, as shown in FIG. 1(b), a fiber-reinforced thermoplastic resin layer 9 having a reinforcing fiber content of 10% by volume or more and a thermoplastic resin layer 10 containing 3 to 30% by volume of inorganic filler are used. It is desirable to use a sheet-like molded material 8 that has been laminated and molded in advance. When using a fiber-reinforced thermoplastic resin sheet material with a reinforcing fiber content of 10% by volume or more and an inorganic filler-containing thermoplastic resin film in a layered manner during heating, use a sheet-like material that has been laminated and molded in advance. You can get the same effect as when you use it. However, since the process of cutting the two types of molding materials into shapes according to the molded product and overlapping them is increased, it is advantageous in terms of the process to use sheet-like molding materials that have been laminated and molded in advance.

[0023]

[Examples] The present invention will be explained in detail with reference to Examples below. [Example 1] As reinforcing fiber, diameter 10 μm φ, length 1
3mm diameter glass fiber and thermoplastic resin
A spherical pellet of mφ is mechanically crushed, and the crushed product is sieved and classified into 70 mesh (opening diameter 0.212 mm) to 10 mesh (opening diameter 1.7 mm). Using polypropylene resin powder, the glass fiber content is determined by a papermaking method. A nonwoven material having a basis weight of 3000 g/m2 was produced with a composition of 50% by weight (26.0% by volume) and 50% by weight (74.0% by volume) of polypropylene resin.

A talc-containing polypropylene resin film was produced using fine particulate talc with a diameter of 3 μm φ as an inorganic filler and the above polypropylene resin as a thermoplastic resin. The film contains 10% by weight of talc (3.4
(% by volume) and 90% by weight (96.6% by volume) of polypropylene resin were kneaded using an extruder, and the mixture was kneaded using a T-die to a thickness of 0.5% by volume.
It was molded to 4 mm. One sheet of the above-mentioned nonwoven material and one sheet of talc-containing polypropylene resin film were laminated and hot press molded to produce a sheet-like molded material having a thickness of 2.7 mm. The hot press molding conditions were as follows: preheating was carried out at 210° C. for 5 minutes with no load, followed by pressing at a pressure of 20 kgf/cm 2 for 5 minutes, cooling and solidifying to form a sheet.

[Example 2] Using the same talc and polypropylene resin as in Example 1, 20% by weight (7.4% by volume) of talc and 8% by volume of polypropylene resin were prepared in the same manner as in Example 1.
Composition of 0% by weight (92.6% by volume), thickness 0.4mm
A film was formed. One sheet of the nonwoven material of Example 1 and one sheet of this talc-containing polypropylene resin film were laminated to produce a sheet-like molded material having a thickness of 2.7 mm in the same manner as in Example 1.

[Example 3] Using the same talc and polypropylene resin as in Example 1, 30% by weight (12.1% by volume) of talc and 70% by weight (87.9% by volume) of polypropylene resin were prepared in the same manner as in Example 1. Volume %), thickness 0.4m
A film of m was molded. One sheet of the nonwoven material of Example 1 and one sheet of this talc-containing polypropylene resin film were laminated to produce a sheet-like molded material having a thickness of 2.7 mm in the same manner as in Example 1.

[Example 4] Using the same talc and polypropylene resin as in Example 1, 40% by weight (17.6% by volume) of talc and 60% by weight (82.4% by volume) of polypropylene resin were prepared in the same manner as in Example 1. Volume %), thickness 0.4m
A film of m was molded. One sheet of the nonwoven material of Example 1 and one sheet of this talc-containing polypropylene resin film were laminated to produce a sheet-like molded material having a thickness of 2.7 mm in the same manner as in Example 1.

[Example 5] Using the same talc and polypropylene resin as in Example 1, 50% by weight of talc (24.3% by volume) and 50% by weight of polypropylene resin (75.7% by volume) were prepared in the same manner as in Example 1. Volume %), thickness 0.4m
A film of m was molded. One sheet of the nonwoven material of Example 1 and one sheet of this talc-containing polypropylene resin film were laminated to produce a sheet-like molded material having a thickness of 2.7 mm in the same manner as in Example 1.

[Comparative Example 1] Using the same talc and polypropylene resin as in Example 1, 5% by weight (1.7% by volume) of talc and 95% by volume of polypropylene resin were prepared in the same manner as in Example 1.
A film having a thickness of 0.4 mm was molded with a composition of % by weight (98.3% by volume). One sheet of the nonwoven material of Example 1 and one sheet of this talc-containing polypropylene resin film were laminated,
A sheet-shaped molded material having a thickness of 2.7 mm was manufactured in the same manner as in Example 1.

[Comparative Example 2] Using the same polypropylene resin as in Example 1, a thickness of 0.4 m was prepared in the same manner as in Example 1.
A polypropylene resin film of m was molded. Example 1
A sheet-like molded material having a thickness of 2.7 mm was produced in the same manner as in Example 1 by laminating one sheet of the nonwoven material and one sheet of this polypropylene resin film.

[Comparative Example 3] Using the same glass fibers and polypropylene resin as in Example 1, the glass fiber content was 50% by weight (26.0% by volume) and the polypropylene resin was 50% by weight (74.0% by volume) by the papermaking method. %) and a basis weight of 3600 g/m2 was produced. In this case, a sheet-like molded material having a thickness of 2.7 mm was manufactured in the same manner as in Example 1 using one sheet of the above-mentioned nonwoven material without performing film lamination.

Using the sheet-like molding materials of Examples and Comparative Examples, laminate molded products were molded by the method shown in FIG. The sheet-shaped molded material was cut into 15 x 15 cm pieces, heated in a far-infrared heating furnace until the surface temperature of the laminated film side reached 210°C, and then a breathable decorative skin was applied to that surface with a basis weight of 230 g/ m2 of polyester fiber nonwoven fabrics were laminated, inserted into a mold whose temperature was controlled to 40°C, and press-molded at a pressure of 10 kgf/cm2 to form a porous laminate molded product. The expansion ratio of the fiber-reinforced thermoplastic resin part of the molded product (thickness of the fiber-reinforced thermoplastic resin part/thickness of the sheet-shaped molding material) can be doubled by adjusting the mold cavity with a spacer (porosity 50% by volume). I set it to be. The adhesive strength between the fiber-reinforced thermoplastic resin part and the skin of each porous molded product was measured by a 90 degree peel test, and the results are shown in Table 1.

[Table 1]

[0034]

[0035] Good adhesive strength was obtained in the porous laminate molded product of the example. This was because the polypropylene resin had sufficiently penetrated into the skin and became fixed, and in the peel test, the skin was peeled off while being damaged, so much of the skin remained on the peeled surface after the test.

In the sheet-shaped molded material of the example, the talc-containing polypropylene resin layer did not expand and was heated while completely covering the expanded glass fiber reinforced thermoplastic resin layer. Therefore, a large amount of molten polypropylene resin exists in the talc-containing polypropylene resin layer to be adhered to the skin, making it easy to flow even in the presence of talc.As a result, when integrally molded with the breathable decorative skin, polypropylene resin By sufficiently penetrating into the skin and fixing, a porous laminate molded product with good adhesive strength was obtained.

In Comparative Examples 1 and 2, the skin did not adhere to the fiber-reinforced thermoplastic resin portion of the molded product. This is because the polypropylene resin of the laminated film layer is absorbed by the expanded glass fiber-reinforced thermoplastic resin layer, and the exposure of the glass fiber cannot be sufficiently suppressed, resulting in a significant amount of melted polypropylene resin on the surface adhering to the skin. This is because, due to the decreased amount, it hardly penetrated into the epidermis and no anchor effect was expressed. In Comparative Example 3 in which film lamination was not performed, the most exposed reinforcing fibers were observed, and the skin did not adhere to the fiber-reinforced thermoplastic resin portion of the molded product.

[Example 6] Using the sheet-like molding material of Example 3, porous laminate molding of a flat plate was carried out by laminating polyester fiber nonwoven fabric with a basis weight of 230 g/m2 in the same manner as in the above-mentioned Examples and Comparative Examples. The product was molded. The expansion ratio of the fiber-reinforced thermoplastic resin portion of the molded product was set to be 3 times and 4 times. The adhesive strength between the fiber-reinforced thermoplastic resin portion and the skin of each porous molded product was measured by a 90 degree peel test, and the results are shown in Table 2.

[Table 2]

[0040]

As the expansion ratio of the molded product increases,
Although the adhesive strength between the fiber-reinforced thermoplastic resin part and the skin tends to decrease, it was confirmed that the skin was adhered even at an expansion ratio of 4 times (porosity: 75% by volume). The expansion ratio of the laminate molded product was set by changing the thickness of the mold cavity using a spacer. As the expansion ratio increases, the thickness of the cavity increases and the pressure applied to the sheet-shaped molding material decreases, resulting in a decrease in the amount of polypropylene resin that penetrates into the skin and a decrease in adhesive strength.

[Example 7] Inorganic filler with a diameter of 10
μm φ, using chopped glass fibers with a length of 3 mm and the same polypropylene resin as in Example 1, a composition of 20% by weight (8.1% by volume) of chopped glass fibers and 80% by weight (91.9% by volume) of polypropylene resin. were kneaded using an extruder in the same manner as in Example 1, and a chopped glass fiber-containing polypropylene resin film having a thickness of 0.4 mm was formed using a T-die. One sheet of the nonwoven material of Example 1 and one sheet of this chopped glass fiber-containing polypropylene resin film were laminated to produce a sheet-shaped molded material having a thickness of 2.7 mm in the same manner as in Example 1.

[0043] Using this sheet-shaped molded material, the basis weight was 230 g/m2 in the same manner as in the above-mentioned Examples and Comparative Examples.
A porous laminate molded flat plate was formed by laminating polyester fiber nonwoven fabrics. The expansion ratio of the fiber-reinforced thermoplastic resin portion of the molded product was set to double. Furthermore, the adhesive strength between the fiber-reinforced thermoplastic resin part and the skin of the porous molded article was measured by a 90 degree peel test.

Good adhesive strength was also obtained in Example 7. The adhesive strength was 1.4 kgf/cm2, and since the skin was peeled off while being damaged during the peel test, much skin remained on the peeled surface after the test. The chopped glass fibers of the inorganic filler layer were broken down to an average fiber length of about 0.5 mm by kneading with an extruder, and were uniformly dispersed. This layer does not expand when heated, but is heated while completely covering the glass fiber-reinforced thermoplastic resin layer (glass fibers with a fiber length of 13 mm are uniformly dispersed with almost no breakage), which is made using an expanded papermaking method. As a result, the polypropylene resin sufficiently penetrated into the skin and fixed, resulting in good adhesive strength.

[0045]

[Effects of the Invention] The present invention improves the adhesive strength between the fiber-reinforced thermoplastic resin in the core and the breathable decorative skin in a porous laminate molded product using a sheet-like molded material manufactured by a papermaking method. . Although the present invention can be used in general heat and pressure molding, it also provides beneficial results in air pressure molding.

[Brief explanation of drawings]

FIGS. 1(a) and 1(b) are schematic diagrams showing an example of molding processing of a laminated molded product.

FIG. 2 is a schematic diagram showing an example of a manufacturing process of a sheet-like molded material using papermaking technology.

FIG. 3 is a schematic diagram showing an example of a process of laminating an inorganic filler-containing thermoplastic resin onto a fiber-reinforced thermoplastic resin.

[Explanation of symbols]

1 Sheet-shaped molded material 2 Far-infrared heating furnace 3 Exposure due to springback of reinforcing fibers 4
Heated sheet-shaped molded material 5 Breathable decorative skin 6 Molding mold 7 Laminated molded product 8 Sheet-shaped molded material of the present invention 9 Fiber-reinforced thermoplastic resin layer with reinforcing fiber content of 10% by volume or more 10 Inorganic filler-containing thermoplastic Resin layer 11 Reinforcing fiber 12 Thermoplastic resin powder 13 Dispersion tank 14 Pump 15 Mesh belt conveyor 16 Head box 17 Wet box 18 Nonwoven material 19 Hot air dryer 20 Double belt conveyor type continuous press 21 Reel up 22 Cutter 23 Thermoplastic resin 24 Inorganic filler 25 Extruder 26 T-die

Claims (2)

[Claims] Claim 1: The core is a fiber-reinforced thermoplastic resin layer formed by a papermaking method and has a reinforcing fiber content of 10% by volume or more, and 3 to 30% by volume of inorganic filler is present between the breathable decorative skin and the core. A fiber-reinforced thermoplastic resin layer formed by heating and pressure molding with a thermoplastic resin layer containing 5 to 75% by volume
Laminated molded product with voids. [Claim 2] A fiber-reinforced thermoplastic resin layer with a reinforcing fiber content of 10% by volume or more formed by a papermaking method is used as a core, and when heated, the reinforcing fibers are expanded using springback due to release of residual stress to create a breathable decoration. A heated thermoplastic resin layer containing 3 to 30% by volume of inorganic filler is interposed between the skin and the core, and the whole is molded by pressure using a mold. A method for molding a laminate molded product in which a fiber-reinforced thermoplastic resin layer has voids of 5 to 75% by volume, characterized in that the fiber-reinforced thermoplastic resin layer is integrated.