JPH05212821A - Foamable laminated board for expansion molding - Google Patents
Foamable laminated board for expansion moldingInfo
- Publication number
- JPH05212821A JPH05212821A JP4017482A JP1748292A JPH05212821A JP H05212821 A JPH05212821 A JP H05212821A JP 4017482 A JP4017482 A JP 4017482A JP 1748292 A JP1748292 A JP 1748292A JP H05212821 A JPH05212821 A JP H05212821A
- Authority
- JP
- Japan
- Prior art keywords
- sheet
- foamable
- thermoplastic resin
- fiber
- reinforced thermoplastic
- 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.)
- Withdrawn
Links
- 238000000465 moulding Methods 0.000 title claims abstract description 14
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 83
- 239000004088 foaming agent Substances 0.000 claims abstract description 30
- 230000001681 protective effect Effects 0.000 claims abstract description 27
- 238000009835 boiling Methods 0.000 claims abstract description 22
- 239000004697 Polyetherimide Substances 0.000 claims abstract description 19
- 229920001601 polyetherimide Polymers 0.000 claims abstract description 18
- 239000006260 foam Substances 0.000 claims description 52
- 239000000835 fiber Substances 0.000 claims description 30
- 239000002667 nucleating agent Substances 0.000 claims description 28
- 238000001704 evaporation Methods 0.000 claims description 18
- 230000008020 evaporation Effects 0.000 claims description 18
- 239000003960 organic solvent Substances 0.000 claims description 16
- 239000004695 Polyether sulfone Substances 0.000 claims description 13
- 229920006393 polyether sulfone Polymers 0.000 claims description 13
- 239000011521 glass Substances 0.000 claims description 7
- 238000010030 laminating Methods 0.000 claims description 7
- 239000004604 Blowing Agent Substances 0.000 claims description 5
- 229920001169 thermoplastic Polymers 0.000 claims description 5
- 239000004416 thermosoftening plastic Substances 0.000 claims description 5
- 239000000843 powder Substances 0.000 claims description 4
- 229920005989 resin Polymers 0.000 abstract description 25
- 239000011347 resin Substances 0.000 abstract description 25
- 238000010097 foam moulding Methods 0.000 description 27
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 21
- 239000000463 material Substances 0.000 description 16
- 238000005187 foaming Methods 0.000 description 13
- 238000004519 manufacturing process Methods 0.000 description 9
- 238000010438 heat treatment Methods 0.000 description 8
- 238000003825 pressing Methods 0.000 description 7
- 239000000047 product Substances 0.000 description 7
- 238000000034 method Methods 0.000 description 6
- -1 polybutylene terephthalate Polymers 0.000 description 6
- 230000007547 defect Effects 0.000 description 5
- 239000003365 glass fiber Substances 0.000 description 5
- 239000011162 core material Substances 0.000 description 4
- 229920003023 plastic Polymers 0.000 description 4
- 239000002759 woven fabric Substances 0.000 description 4
- 229920004738 ULTEM® Polymers 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 238000007731 hot pressing Methods 0.000 description 3
- 239000013067 intermediate product Substances 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 229920001721 polyimide Polymers 0.000 description 3
- 229920001342 Bakelite® Polymers 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 229920004770 ULTEM® 2200 Polymers 0.000 description 2
- 239000004637 bakelite Substances 0.000 description 2
- 239000011256 inorganic filler Substances 0.000 description 2
- 229910003475 inorganic filler Inorganic materials 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000011342 resin composition Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000005979 thermal decomposition reaction Methods 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004696 Poly ether ether ketone Substances 0.000 description 1
- 229930182556 Polyacetal Natural products 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 239000004734 Polyphenylene sulfide Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920003235 aromatic polyamide Polymers 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- RTZKZFJDLAIYFH-UHFFFAOYSA-N ether Substances CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
- 239000002984 plastic foam Substances 0.000 description 1
- 239000000088 plastic resin Substances 0.000 description 1
- 229920006162 poly(etherimide sulfone) Polymers 0.000 description 1
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 229920002530 polyetherether ketone Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 239000004926 polymethyl methacrylate Substances 0.000 description 1
- 229920006324 polyoxymethylene Polymers 0.000 description 1
- 229920001955 polyphenylene ether Polymers 0.000 description 1
- 229920000069 polyphenylene sulfide Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
- B29C44/145—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining the lining being a laminate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/3442—Mixing, kneading or conveying the foamable material
- B29C44/3446—Feeding the blowing agent
- B29C44/3453—Feeding the blowing agent to solid plastic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
- B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
- B32B27/281—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyimides
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2437/00—Clothing
- B32B2437/04—Caps, helmets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/12—Ships
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2201/00—Foams characterised by the foaming process
- C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
- C08J2201/032—Impregnation of a formed object with a gas
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2379/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen, or carbon only, not provided for in groups C08J2361/00 - C08J2377/00
- C08J2379/04—Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
- C08J2379/08—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2381/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen, or carbon only; Polysulfones; Derivatives of such polymers
- C08J2381/06—Polysulfones; Polyethersulfones
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Laminated Bodies (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Molding Of Porous Articles (AREA)
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は、発泡体になる前の発泡
性熱可塑性樹脂シートの両面に表皮材シートを設けた発
泡成形用の発泡性積層板に関する。さらに詳しくは、本
発明は、発泡体をコア材として、表皮材に強度及び剛性
の高い材料を使用したサンドイッチ材、例えば、構造部
材、例えば、自動車、船等のボディーや、プラスチック
製のヘルメット等のサンドイッチ材を発泡成形すること
のできる、未だ発泡していない表皮材シートを設けた発
泡成形用の発泡性積層板に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foamable laminated sheet for foam molding in which a skin material sheet is provided on both sides of a foamable thermoplastic resin sheet before being formed into a foam. More specifically, the present invention relates to a sandwich material using a foam as a core material and a material having high strength and rigidity as a skin material, for example, a structural member such as a body of an automobile or a ship, a plastic helmet, or the like. And a foamable laminated plate for foam molding, which is provided with a skin material sheet which has not been foamed yet, capable of foam-molding the sandwich material.
【０００２】[0002]
【従来の技術】従来、例えば、特開昭６０−１０５５３
１号公報には、表面板と裏面板との間にプラスチックフ
ォームを注入し発泡させること、及びこの発泡された積
層体は断熱材とされることが開示されているが、この積
層体は既に発泡されているものであり、未発泡の発泡性
熱可塑性樹脂シートの両面に表皮材シートを設けた、所
謂、中間製品は開示されていない。2. Description of the Related Art Conventionally, for example, JP-A-60-10553.
Japanese Patent Publication No. 1 discloses that a plastic foam is injected between a front plate and a back plate to foam, and that the foamed laminate is used as a heat insulating material. There is no disclosure of a so-called intermediate product which is foamed and has a skin material sheet provided on both sides of an unfoamed expandable thermoplastic resin sheet.
【０００３】また、特開平１−２２８８１１号公報に
は、三層ラミネート表皮材から作られた所望の閉空間を
有する形状の中に発泡性混合物を注入して一体発泡製品
とすることが開示されているが、未発泡の熱可塑性樹脂
シートの両面に表皮材シートを設けた、中間製品は開示
されていない。Further, Japanese Patent Laid-Open No. 1-228811 discloses that a foamable mixture is injected into a shape having a desired closed space made of a three-layer laminated skin material to form an integrally foamed product. However, an intermediate product in which a skin material sheet is provided on both surfaces of an unfoamed thermoplastic resin sheet is not disclosed.
【０００４】[0004]
【発明が解決しようとする課題】本発明者らは、コア部
分が軽量の発泡体で、表皮が高強度、高剛性の繊維強化
樹脂からなるサンドイッチ材を最終的に製造するため
の、未だ、発泡が行われていない中間製品である発泡性
積層板の製造を試みた。例えば、沸騰蒸発型発泡剤を含
浸した発泡性熱可塑性樹脂シートの両面に表皮材シート
を設けた発泡成形用の発泡性積層板を提供しょうと試み
たが、発泡性熱可塑性樹脂シートを繊維強化熱可塑性樹
脂シートで挟んだ発泡性積層板を発泡成形する際には、
発泡性熱可塑性樹脂シートに含浸されている沸騰蒸発型
発泡剤が繊維強化熱可塑性樹脂シートにも浸透してい
き、繊維強化熱可塑性樹脂シートも発泡されることにな
り、成形された発泡積層成形体の表面に凹凸が生じた。
また、発泡性熱可塑性樹脂シートと繊維強化熱可塑性樹
脂シートとの界面に不良が生じたりしていた。DISCLOSURE OF INVENTION Problems to be Solved by the Invention The present inventors have yet to produce a sandwich material having a lightweight foamed core portion and a fiber-reinforced resin having a high-strength and high-rigidity skin. An attempt was made to produce a foamable laminate, which is an intermediate product that has not been foamed. For example, we tried to provide a foamable laminated sheet for foam molding in which a skin material sheet was provided on both sides of a foamable thermoplastic resin sheet impregnated with a boiling evaporation type foaming agent. When foam-forming a foamable laminate sandwiched between thermoplastic resin sheets,
The boiling evaporation type foaming agent impregnated in the expandable thermoplastic resin sheet also penetrates into the fiber reinforced thermoplastic resin sheet, and the fiber reinforced thermoplastic resin sheet is also expanded, resulting in foamed laminated molding. The surface of the body was uneven.
In addition, a defect occurs at the interface between the foamable thermoplastic resin sheet and the fiber-reinforced thermoplastic resin sheet.
【０００５】そこで、本発明は、コア部分が軽量の発泡
体で、表皮が高強度、高剛性の繊維強化樹脂からなるサ
ンドイッチ材を最終的に製造するための、沸騰蒸発型発
泡剤を含浸した未だ発泡が行われていない発泡性熱可塑
性樹脂シートを内部に有し、その外側の表皮に高強度、
高剛性の繊維強化樹脂シートを有する発泡性積層板にお
いて、この中間成形品である発泡性積層板を用いて発泡
成形したときに、発泡積層成形品の表面に凹凸が生じる
ことなく、また、発泡された発泡シートと高強度、高剛
性の繊維強化樹脂シートとの間に、界面に不良が生じる
ことのない発泡成形用の発泡性積層板を提供することを
目的とする。Therefore, in the present invention, a boiling evaporative foaming agent is impregnated for the final production of a sandwich material having a lightweight core core portion and a high-strength and high-rigidity skin with a fiber-reinforced resin. It has a foamable thermoplastic resin sheet that has not yet been foamed inside, with high strength on the outer skin,
In a foamable laminated plate having a highly rigid fiber-reinforced resin sheet, when the foamable laminated plate as the intermediate molded product is used for foam molding, the surface of the foamed laminated molded product does not become uneven and It is an object of the present invention to provide a foamable laminated plate for foam molding in which no defect occurs at the interface between the foamed sheet and the fiber-reinforced resin sheet having high strength and high rigidity.
【０００６】[0006]
【課題を解決するための手段】図１〜３は本発明の発泡
成形用の発泡性積層板を示す。上記した発明の課題を解
決するための手段を、この図１〜３に基づいて説明す
る。図１及び図２は本発明の１番目及び２番目それぞれ
の発明の発泡成形用の発泡性積層板を示す。本発明の１
番目の発明は、有機溶媒からなる沸騰蒸発型発泡剤を含
浸したポリエーテルイミドシート又はポリエーテルスル
ホンシートからなる発泡性シート１の両面に、繊維強化
熱可塑性樹脂シート２を積層し、さらに、該各々の繊維
強化熱可塑性樹脂シート２の外側に、前記発泡剤を含浸
しにくく且つ該繊維強化熱可塑性樹脂シート２の成形温
度と類似した成形温度を持つ熱可塑性樹脂又は繊維強化
熱可塑性樹脂からなる保護シート３を積層したことを特
徴とする発泡性積層板とするものである。1 to 3 show a foamable laminate for foam molding of the present invention. Means for solving the above-mentioned problems of the invention will be described based on FIGS. 1 and 2 show the foamable laminate for foam molding of the first and second inventions of the present invention. 1 of the present invention
The second invention is to laminate a fiber-reinforced thermoplastic resin sheet 2 on both sides of a foamable sheet 1 made of a polyetherimide sheet or a polyethersulfone sheet impregnated with a boiling evaporation type blowing agent made of an organic solvent, and further, Each of the fiber reinforced thermoplastic resin sheets 2 is made of a thermoplastic resin or a fiber reinforced thermoplastic resin which is hard to be impregnated with the foaming agent and has a molding temperature similar to that of the fiber reinforced thermoplastic resin sheet 2. The foamable laminated plate is characterized in that the protective sheet 3 is laminated.
【０００７】本発明の２番目の発明は、有機溶媒からな
る沸騰蒸発型発泡剤を含浸したポリエーテルイミドシー
ト又はポリエーテルスルホンシートからなる発泡性シー
ト１の両面に、前記発泡剤を含浸しにくい熱可塑性樹脂
又は繊維強化熱可塑性樹脂からなる保護シート３を積層
し、さらに、該各々の保護シート３の外側に該保護シー
ト３の成形温度と類似した成形温度を持つ繊維強化熱可
塑性樹脂シート２を積層したことを特徴とする発泡性積
層板とするものである。The second aspect of the present invention is that it is difficult to impregnate both sides of the foaming sheet 1 made of a polyetherimide sheet or a polyethersulfone sheet impregnated with a boiling evaporation type blowing agent made of an organic solvent. A protective sheet 3 made of a thermoplastic resin or a fiber-reinforced thermoplastic resin is laminated, and further, a fiber-reinforced thermoplastic resin sheet 2 having a molding temperature similar to the molding temperature of the protective sheet 3 is provided on the outer side of each of the protective sheets 3. And a foamable laminated plate.
【０００８】本発明の１番目の発明及び２番目の発明で
保護シート３を用いる理由は、保護シート３が無いと、
発泡性シート１に含まれる有機溶媒からなる沸騰蒸発型
発泡剤が繊維強化熱可塑性樹脂シート２の内部に浸透し
ていき、繊維強化熱可塑性樹脂シート２自体も発泡し、
繊維強化熱可塑性樹脂シート２の表面に凹凸が生じるか
らである。図５に、図１及び図２に示した本発明の発泡
性積層板から保護シート３を除いた構成の発泡性積層板
を示す。図５に示すように発泡性シート１に含まれてい
る有機溶媒からなる沸騰蒸発型発泡剤が繊維強化熱可塑
性樹脂シート２の内部に浸透していく。図５に示す発泡
性積層板を用いて発泡成形をして得た発泡積層体を図６
に示す。７は発泡された発泡シート、８は発泡剤が浸透
して発泡した発泡繊維強化熱可塑性樹脂シートであり、
その発泡繊維強化熱可塑性樹脂シート８の表面には、発
泡により凹凸が生じている。このように、発泡積層体の
表面に凹凸ができると、寸法精度が低下し、その外観も
損なわれる。The reason why the protective sheet 3 is used in the first and second aspects of the present invention is that the protective sheet 3 is not present.
The boiling evaporation type foaming agent composed of an organic solvent contained in the foamable sheet 1 permeates into the inside of the fiber reinforced thermoplastic resin sheet 2, and the fiber reinforced thermoplastic resin sheet 2 itself also foams,
This is because irregularities occur on the surface of the fiber-reinforced thermoplastic resin sheet 2. FIG. 5 shows a foamable laminated plate having a configuration in which the protective sheet 3 is removed from the foamable laminated plate of the present invention shown in FIGS. 1 and 2. As shown in FIG. 5, the boiling evaporation type foaming agent made of an organic solvent contained in the foamable sheet 1 penetrates into the fiber reinforced thermoplastic resin sheet 2. FIG. 6 shows a foam laminate obtained by performing foam molding using the foam laminate shown in FIG.
Shown in. 7 is a foamed foamed sheet, 8 is a foamed fiber reinforced thermoplastic resin sheet in which a foaming agent has penetrated and foamed,
The surface of the foamed fiber reinforced thermoplastic resin sheet 8 has irregularities due to foaming. Thus, if the surface of the foamed laminate has irregularities, the dimensional accuracy is lowered and the appearance thereof is also impaired.
【０００９】このような発泡積層体の表面の不良を防ぐ
ために保護シート３を用いる。この保護シート３には、
発泡性シートの構成樹脂材料であるポリエーテルイミド
又はポリエーテルスルホンの成形温度と近似の成形温度
を持ち、有機溶媒からなる沸騰蒸発型発泡剤に浸されな
い熱可塑性樹脂フィルムが適している。本発明で用いる
保護シート３には、特に、ポリイミドフィルムが有機溶
媒からなる沸騰蒸発型発泡剤の浸透を阻止する機能を有
するので好適に用いることができる。また保護シート３
の他の例として、例えば、ポリイミド、ポリアセター
ル、ポリフェニレンサルファイド、ポリブチレンテレフ
タレート、ポリエーテルエーテルケトン等のフィルムを
使用することができる。A protective sheet 3 is used to prevent such a defective surface of the foam laminate. This protective sheet 3 has
A thermoplastic resin film having a molding temperature close to that of polyetherimide or polyethersulfone, which is a constituent resin material of the foamable sheet, and which is not soaked in a boiling evaporation type foaming agent made of an organic solvent is suitable. In particular, the protective sheet 3 used in the present invention can be preferably used because the polyimide film has a function of preventing permeation of a boiling evaporation type foaming agent made of an organic solvent. Protective sheet 3
As another example, a film of polyimide, polyacetal, polyphenylene sulfide, polybutylene terephthalate, polyether ether ketone, or the like can be used.
【００１０】図３に本発明の３番目の発明である発泡成
形用の発泡性積層板を示す。本発明の３番目の発明は、
有機溶媒からなる沸騰蒸発型発泡剤を含浸し、且つ発泡
核形成剤を含有するポリエーテルイミドシート又はポリ
エーテルスルホンシートからなる発泡性シート４の両面
に、発泡核形成剤を含有する繊維強化熱可塑性樹脂シー
ト５を積層したことを特徴とする発泡性積層板とするも
のである。すなわち、３番目の発明は、発泡状態を改善
することにより、発泡積層体の強度を増加させるもので
ある。この３番目の発明において、発泡核形成剤は、無
機フィラー、好ましくは、ガラスパウダー又はガラス短
繊維が用いられる。このような無機フィラーを発泡核形
成剤として用いると、発泡成形したときに、より緻密で
均一な発泡を行うことができる。FIG. 3 shows a foamable laminate for foam molding, which is the third invention of the present invention. The third invention of the present invention is
Fiber-reinforced heat containing a foam nucleating agent on both sides of a foaming sheet 4 made of a polyetherimide sheet or a polyethersulfone sheet impregnated with a boiling evaporation type foaming agent made of an organic solvent and containing a foam nucleating agent. The foamable laminated plate is characterized by laminating the plastic resin sheets 5. That is, the third invention is to increase the strength of the foam laminate by improving the foamed state. In the third invention, the foam nucleating agent is an inorganic filler, preferably glass powder or glass short fibers. When such an inorganic filler is used as a foam nucleation agent, it is possible to perform more dense and uniform foaming when foam-molding.
【００１１】３番目の発明において、繊維強化熱可塑性
樹脂シート５にも発泡核形成剤を混入させた理由を次に
説明する。図７は繊維強化熱可塑性樹脂シートに発泡核
形成剤を混入せずに、発泡性シートのみに発泡核形成剤
を混入した発泡性積層板を加熱発泡した場合の発泡積層
板を示す。９は緻密で均一に発泡された発泡シート、１
０は、発泡性シートに含まれている発泡剤が浸透してき
て発泡が引き起こされた発泡繊維強化熱可塑性樹脂シー
トを示す。この発泡された発泡繊維強化熱可塑性樹脂シ
ート１０には、発泡核形成剤が含まれていないので、特
に発泡剤が浸透した部分では緻密でない発泡層１１が形
成される。The reason why the foam nucleating agent is also mixed in the fiber reinforced thermoplastic resin sheet 5 in the third invention will be described below. FIG. 7 shows a foam laminated plate in which the foam nucleating agent is not mixed in the fiber reinforced thermoplastic resin sheet, but the foam nucleating agent is mixed only in the foam sheet and the foamed laminated plate is heat-foamed. 9 is a dense and uniformly foamed sheet, 1
0 indicates a foamed fiber reinforced thermoplastic resin sheet in which foaming agent contained in the foamable sheet has penetrated to cause foaming. Since the foamed fiber-reinforced thermoplastic resin sheet 10 thus foamed does not contain a foam nucleating agent, a non-dense foam layer 11 is formed particularly in the portion where the foaming agent has penetrated.
【００１２】このように、緻密で均一に発泡された発泡
シート９と緻密でない発泡層１１との界面では、発泡状
態が異なり、界面に接する部分の発泡体のみが他の部分
の発泡体に比べて発泡倍率が特に大きくなる。そのため
その部分では密度が小さく、気孔が大きくなり強度が低
下する。したがって、３番目の発明においては、繊維強
化熱可塑性樹脂シート５にも発泡核形成剤を混入させる
ことにより、発泡性シート４及び繊維強化熱可塑性樹脂
シート５の両者共に緻密で均一な発泡を行わせる。この
ようにすると、発泡性積層板を発泡成形したときに、成
形されたサンドイッチ材は発泡が均一になることで弾性
率が向上し、また、発泡性シート４と繊維強化熱可塑性
樹脂シート５は共に同じ発泡状態となるので、それらの
界面に不良が発生せず、強度が保たれる。As described above, at the interface between the dense and uniformly foamed foam sheet 9 and the non-dense foam layer 11, the foaming state is different, and only the foam in the portion in contact with the interface is different from the foams in other portions. Therefore, the expansion ratio becomes particularly large. Therefore, in that portion, the density is small, the pores are large, and the strength is reduced. Therefore, in the third invention, both the foamable sheet 4 and the fiber-reinforced thermoplastic resin sheet 5 are densely and uniformly foamed by incorporating the foam nucleating agent into the fiber-reinforced thermoplastic resin sheet 5. Let By doing so, when the foamable laminate is foam-molded, the molded sandwich material has an improved elastic modulus due to uniform foaming, and the foamable sheet 4 and the fiber-reinforced thermoplastic resin sheet 5 are Since they are both in the same foamed state, no defects occur at their interfaces and the strength is maintained.
【００１３】図４に本発明の４番目の発明の発泡成形用
の発泡性積層体を示す。本発明の４番目の発明は、発泡
状態をさらに改善したものであり、３番目の発明を変形
させたものである。すなわち、４番目の発明は、有機溶
媒からなる沸騰蒸発型発泡剤を含浸し、且つ発泡核形成
剤を含有するポリエーテルイミドシート又はポリエーテ
ルスルホンシートからなる発泡性シート４の両面又は片
面に、発泡核形成剤を含有する熱可塑性樹脂シート６を
積層し、さらに、その両外側に繊維強化熱可塑性樹脂シ
ート２を積層したことを特徴とする発泡性積層板とする
ものである。FIG. 4 shows a foamable laminate for foam molding according to a fourth invention of the present invention. A fourth invention of the present invention is to further improve the foaming state and is a modification of the third invention. That is, the fourth aspect of the present invention is, on both sides or one side of a foamable sheet 4 made of a polyetherimide sheet or a polyethersulfone sheet impregnated with a boiling evaporation type foaming agent made of an organic solvent and containing a foam nucleating agent, A thermoplastic resin sheet 6 containing a foam nucleation agent is laminated, and fiber-reinforced thermoplastic resin sheets 2 are further laminated on both outer sides of the thermoplastic resin sheet 6 to provide a foamable laminated plate.
【００１４】４番目の発明においては、発泡核形成剤を
含有する熱可塑性樹脂シート６を発泡性シート４と繊維
強化熱可塑性樹脂シート２との間に設けたので、発泡性
シート４から浸透してくる有機溶媒からなる沸騰蒸発型
発泡剤は主としてこの熱可塑性樹脂シート６に浸透さ
れ、繊維強化熱可塑性樹脂シート２には浸透していかな
い。したがって、４番目の発明の発泡性積層板を発泡成
形した場合、発泡性シート４と熱可塑性樹脂シート６と
の発泡は共に緻密で均一なものとなり、それらの間の界
面において不良は発生しない。また、沸騰蒸発型発泡剤
が繊維強化熱可塑性樹脂シート２まで浸透していかない
ので、繊維強化熱可塑性樹脂シート２の外表面、すなわ
ち、発泡成形体の外表面には、凹凸等の不良は発生しな
い。また、繊維強化熱可塑性樹脂シート２は発泡しない
ので、発泡成形された積層発泡体の強度は十分なものが
得られる。In the fourth invention, since the thermoplastic resin sheet 6 containing the foam nucleating agent is provided between the foam sheet 4 and the fiber-reinforced thermoplastic resin sheet 2, it penetrates from the foam sheet 4. The boiling evaporative foaming agent made of an organic solvent comes into the thermoplastic resin sheet 6 and does not penetrate into the fiber-reinforced thermoplastic resin sheet 2. Therefore, when the foamable laminate of the fourth invention is foam-molded, the foaming of the foamable sheet 4 and the thermoplastic resin sheet 6 are both dense and uniform, and no defects occur at the interface between them. Further, since the boiling evaporation type foaming agent does not penetrate into the fiber reinforced thermoplastic resin sheet 2, defects such as irregularities occur on the outer surface of the fiber reinforced thermoplastic resin sheet 2, that is, the outer surface of the foamed molded product. do not do. In addition, since the fiber-reinforced thermoplastic resin sheet 2 does not foam, a laminated foam that is foam-molded has sufficient strength.
【００１５】４番目の発明において用いられる熱可塑性
樹脂シート６には、発泡性シートと同じ熱可塑性樹脂を
使用したもので、発泡剤を含まず発泡核形成剤を含ん
だ、ポリエーテルイミド、ポリエーテルスルホン等の熱
可塑性樹脂シートが用いられる。本発明の１〜４番目の
発明において発泡性シート１又は４に使用された熱可塑
性樹脂として、ポリエーテルイミド樹脂又はポリエーテ
ルスルホン樹脂を特に用いている。その理由は、それら
の樹脂を用いると比較的均質な発泡が形成でき、また高
い発泡倍率、具体的には３〜２０倍程度の発泡倍率を達
成できるにもかかわらず、その発泡体の圧縮弾性率及び
圧縮強度等の機械的性質が良好であり、強度の高い発泡
成形品を得ることができるからである。具体的には、発
泡倍率によってそれらの機械的性質は異なるが、圧縮弾
性率が２０〜７０Ｎ／ｍｍ2 、圧縮強度が１〜３Ｎ／ｍ
ｍ2 程度のものを得ることができる。例えば、発泡倍率
８倍の場合で、圧縮弾性率が４０Ｎ／ｍｍ2 程度、また
圧縮強度が２Ｎ／ｍｍ2 程度となる。さらに他の理由
は、前記ポリエーテルイミド樹脂又はポリエーテルスル
ホン樹脂以外の樹脂では、局所的に大きすぎる空孔がで
きるなど発泡に問題があるからである。The thermoplastic resin sheet 6 used in the fourth invention is made of the same thermoplastic resin as the expandable sheet, and does not contain a foaming agent but contains a foam nucleating agent. A thermoplastic resin sheet such as ether sulfone is used. As the thermoplastic resin used for the foamable sheet 1 or 4 in the first to fourth inventions of the present invention, a polyetherimide resin or a polyethersulfone resin is particularly used. The reason is that the use of such a resin can form a relatively homogeneous foam, and a high expansion ratio, specifically a foam expansion ratio of about 3 to 20 can be achieved, but the compression elasticity of the foam is high. This is because the mechanical properties such as modulus and compressive strength are good, and a foamed molded product having high strength can be obtained. Specifically, although their mechanical properties differ depending on the expansion ratio, the compressive elastic modulus is 20 to 70 N / mm 2 , and the compressive strength is 1 to 3 N / m.
It is possible to obtain a product having a size of m 2 . For example, when the expansion ratio is 8 times, the compression elastic modulus is about 40 N / mm 2 and the compression strength is about 2 N / mm 2 . Still another reason is that the resin other than the polyetherimide resin or the polyethersulfone resin has a problem in foaming such as locally forming too large pores.
【００１６】また、本発明における発泡性シート１又は
４に用いられる発泡剤には有機溶媒からなる沸騰蒸発型
発泡剤が用いられ、特に、塩化メチレンが好適に用いら
れる。このような沸騰蒸発型発泡剤を用いた理由は、樹
脂シートへの含浸が低温で容易に行われるからである。
さらに、沸騰蒸発型発泡剤を含有した発泡性シートは低
温で軟化し、そのために加熱加圧による表面シートの圧
着も低温で行うことができ、接着性も良好であるからで
ある。これに対して、加熱分解型発泡剤では、樹脂シー
トに含浸することはできず、樹脂を加熱溶解するか又は
樹脂を溶剤で溶かして熱分解型発泡剤を混ぜる必要があ
るからである。さらに、加熱分解型発泡剤を含有させた
発泡性シートは高温で発泡処理せねばならず、そのエネ
ルギー効率的に不利であるからである。A boiling evaporation type foaming agent made of an organic solvent is used as the foaming agent used in the foamable sheet 1 or 4 in the present invention, and methylene chloride is particularly preferably used. The reason why such a boiling evaporation type foaming agent is used is that the impregnation into the resin sheet is easily performed at a low temperature.
Furthermore, the foamable sheet containing the boiling evaporation type foaming agent is softened at a low temperature, so that the surface sheet can be pressure-bonded by heating and pressing at a low temperature, and the adhesiveness is also good. On the other hand, the thermal decomposition type foaming agent cannot impregnate the resin sheet, and it is necessary to melt the resin by heating or dissolve the resin in a solvent to mix the thermal decomposition type foaming agent. Furthermore, the foamable sheet containing the heat-decomposable foaming agent must be foamed at high temperature, which is disadvantageous in terms of energy efficiency.
【００１７】本発明で使用する繊維強化熱可塑性樹脂シ
ート２又は５に用いることのできる繊維として織物又は
マットが使用できる。この繊維強化熱可塑性樹脂シート
２又は５は、例えば、織物シートと樹脂フィルムを重ね
てオートクレーブやホットプレスによって加熱加圧処理
することによって得られる。前記繊維強化熱可塑性樹脂
シート２又は５の織物の材料には、例えば、ガラス、カ
ーボン、アラミド、ポリエチレン、炭化珪素、ボロン、
アルミナ等の繊維から製造したものが用いられる。A woven fabric or a mat can be used as the fiber that can be used in the fiber-reinforced thermoplastic resin sheet 2 or 5 used in the present invention. The fiber reinforced thermoplastic resin sheet 2 or 5 is obtained, for example, by stacking a woven fabric sheet and a resin film and subjecting them to heat and pressure treatment by an autoclave or a hot press. Examples of the material of the woven fabric of the fiber-reinforced thermoplastic resin sheet 2 or 5 include glass, carbon, aramid, polyethylene, silicon carbide, boron,
Those manufactured from fibers such as alumina are used.
【００１８】また、前記繊維強化熱可塑性樹脂シート２
又は５のマトリクス樹脂には、ポリエーテルイミド、ポ
リエーテルスルホン、ポリカーボネート、ポリエチレ
ン、ポリビニルクロライド、ポリプロピレン、ポリスチ
レン、ＡＢＳ樹脂、ポリメチルメタクリレート、ポリア
ミド、ポリフェニレンエーテル、ポリエチレンテレフタ
レート等が用いられ、特にポリエーテルイミド、ポリエ
ーテルスルホンが発泡性シート１又は４に用いた樹脂と
同一なので、接着性等の観点から好適に用いられる。Further, the fiber-reinforced thermoplastic resin sheet 2
Alternatively, as the matrix resin of 5, polyetherimide, polyethersulfone, polycarbonate, polyethylene, polyvinyl chloride, polypropylene, polystyrene, ABS resin, polymethylmethacrylate, polyamide, polyphenylene ether, polyethylene terephthalate, etc. are used, and particularly polyetherimide Since polyethersulfone is the same as the resin used for the foamable sheet 1 or 4, it is preferably used from the viewpoint of adhesiveness and the like.
【００１９】本発明の発泡成形用の発泡性積層板を発泡
成形するには、例えば、加熱加圧の平板プレス板を有す
るプレス成形によりプレスし、その後、減圧することに
より発泡サンドイッチ材を成形する。また、雄型及び／
又は雌型を用いて加熱加圧のプレス成形により、所望の
形状の発泡積層成形品を得る。これらの成形条件は用い
る樹脂の種類や発泡剤の種類、及びそれらの含有量によ
って、かなり巾があるものである。In order to foam-mold the foamable laminated plate for foam-molding of the present invention, for example, pressing is carried out by press molding having a heating and pressing flat plate press plate, and then the foaming sandwich material is molded by depressurizing. .. Also, male and /
Alternatively, a foamed laminated molded article having a desired shape is obtained by heat-pressing with a female die. These molding conditions vary considerably depending on the type of resin used, the type of foaming agent, and their contents.
【００２０】[0020]
【実施例１】本実施例１は、図１に示す発泡成形用の発
泡性積層板の製造例を示す。本実施例１の発泡性積層板
を次のようにして製造する。まず、発泡性シート１の製
造方法を次のようにする。有底の容器中において、ポリ
エーテルイミドであるウルテム（商品名：ＧＥプラスチ
ック社製）を有機溶媒である塩化メチレン中に、ウルテ
ムに対し塩化メチレンを約１対３の割合で完全に溶かし
て溶液とする。この溶液を放置して塩化メチレンの濃度
が約１７％となるまで蒸発させることによって、容器の
底に厚みが約１ｍｍの発泡性シートが生成される。な
お、本発明においてこの発泡性シートの特に好ましい範
囲は０．５〜３ｍｍである。Example 1 This Example 1 shows an example of manufacturing the foamable laminate for foam molding shown in FIG. The expandable laminate of Example 1 is manufactured as follows. First, the method for manufacturing the foamable sheet 1 is as follows. In a container with a bottom, a solution is prepared by completely dissolving the polyetherimide Ultem (trade name: GE Plastics Co., Ltd.) in the organic solvent methylene chloride at a ratio of about 1: 3 of methylene chloride to Ultem. And The solution is left to evaporate until the concentration of methylene chloride is about 17%, producing a foamable sheet at the bottom of the container with a thickness of about 1 mm. In the present invention, the particularly preferable range of this foamable sheet is 0.5 to 3 mm.
【００２１】一方、繊維強化熱可塑性樹脂シート２を次
のように製造する。ガラスファイバー織物にポリエーテ
ルイミド樹脂を含浸させたプリプレグであるＣＥＴＥＸ
ＳＳ３０３（商品名：ＴＥＮ ＣＡＴＥ製）を用意
し、３５０℃のホットプレスで加熱加圧して繊維強化熱
可塑性樹脂シート２とする。なお、ＣＥＴＥＸ ＳＳ３
０３のホットプレスの好ましい温度範囲は２９０℃〜３
８０℃である。厚みは、１枚のプリプレグシートで製造
した場合には０．２５ｍｍとなり、２枚のプリプレグシ
ートで製造した場合には０．５ｍｍとなる。On the other hand, the fiber-reinforced thermoplastic resin sheet 2 is manufactured as follows. CETEX, a prepreg made by impregnating glass fiber fabric with polyetherimide resin
SS303 (trade name: manufactured by TEN CATE) is prepared, and heated and pressed by a hot press at 350 ° C. to obtain the fiber-reinforced thermoplastic resin sheet 2. In addition, CETEX SS3
The preferred temperature range for the 03 hot press is 290 ° C to 3
It is 80 ° C. The thickness is 0.25 mm when manufactured with one prepreg sheet, and 0.5 mm when manufactured with two prepreg sheets.
【００２２】次に、保護シート３としてポリイミドフィ
ルムであるユーピーレックスＲ（商品名：宇部興産製）
を用意し、前記繊維強化熱可塑性樹脂シート２と重ね
て、４００℃、２０気圧のホットプレスで加熱加圧して
積層する。このようにして積層されたシートを２枚使用
して、この積層シートの保護シート３が外側になるよう
に前記発泡性シート１を中間にして挟み、ホットプレス
で加熱加圧して、発泡成形に適した発泡性積層板を製造
する。Next, as a protective sheet 3, a polyimide film, UPLEX R (trade name: manufactured by Ube Industries)
Is prepared, and the fiber-reinforced thermoplastic resin sheet 2 is overlaid, and heated and pressed by a hot press at 400 ° C. and 20 atm to be laminated. Two sheets laminated in this way are used, and the foamable sheet 1 is sandwiched so that the protective sheet 3 of the laminated sheet is on the outside, and heated and pressed by a hot press for foam molding. Produce a suitable foamable laminate.
【００２３】なお、保護シート３と繊維強化熱可塑性樹
脂シート２とをホットプレスで加熱加圧する際の好まし
い温度・圧力の範囲は、５０℃〜５００℃，５〜５０気
圧である。また、積層シートと発泡性シート１をホット
プレスで加熱加圧する際の好ましい温度・圧力の範囲
は、８０℃〜１５０℃，５〜４０気圧である。The preferred temperature / pressure ranges for heating and pressing the protective sheet 3 and the fiber-reinforced thermoplastic resin sheet 2 by hot pressing are 50 ° C. to 500 ° C. and 5 to 50 atm. Further, the preferable temperature and pressure ranges when the laminated sheet and the foamable sheet 1 are heated and pressed by a hot press are 80 ° C. to 150 ° C. and 5 to 40 atm.
【００２４】[0024]
【実施例２】本実施例２は、図２に示す発泡成形用の発
泡性積層板の製造例を示す。保護シート３として、耐薬
品性を向上させたポリエーテルイミドフィルム（塩化メ
チレンを含浸しにくいタイプ）であるスミライトＦＳ１
４５０（商品名：住友ベークライト製）を用意し、該保
護シート３と繊維強化熱可塑性樹脂シート２との積層シ
ートを、この実施例２では、繊維強化熱可塑性樹脂シー
ト２が外側となるようにして、前記実施例１と同一の発
泡性シート１を中間にして挟み、ホットプレスで加熱加
圧して、発泡成形に適した発泡性積層板を製造する。な
お、ホットプレスの好ましい温度・圧力の範囲は実施例
１と同じである。[Embodiment 2] This embodiment 2 shows an example of manufacturing the foamable laminate for foam molding shown in FIG. Sumilite FS1 which is a polyetherimide film with improved chemical resistance (a type that is difficult to be impregnated with methylene chloride) as the protective sheet 3.
450 (trade name: made by Sumitomo Bakelite) is prepared, and a laminated sheet of the protective sheet 3 and the fiber reinforced thermoplastic resin sheet 2 is prepared in this Example 2 so that the fiber reinforced thermoplastic resin sheet 2 is on the outside. Then, the same expandable sheet 1 as in Example 1 is sandwiched in the middle and heated and pressed by a hot press to produce an expandable laminate suitable for foam molding. The preferable temperature and pressure ranges of the hot press are the same as in Example 1.
【００２５】[0025]
【実施例３】本実施例３は、図３に示す発泡成形用の発
泡性積層板の製造例を示す。本実施例３で用いる発泡核
形成剤入りの発泡性シート４を次のようにして製造す
る。有底の容器の中において、ガラスファイバーの短繊
維を含有したポリエーテルイミドであるウルテム２２０
０（商品名：ＧＥプラスチック製）を有機溶媒である塩
化メチレン中に、ウルテム２２００に対し塩化メチレン
を約１対３の割合で完全に溶かして溶液とする。この溶
液を放置して塩化メチレンの濃度が約１７％となるまで
蒸発させることによって、容器の底に厚みが約１ｍｍの
発泡性シートが生成される。なお、本発明においてこの
発泡性シートの特に好ましい範囲は０．５〜３ｍｍであ
る。[Embodiment 3] This embodiment 3 shows an example of manufacturing the foamable laminate for foam molding shown in FIG. The foamable sheet 4 containing the foam nucleating agent used in Example 3 is manufactured as follows. Ultem 220, a polyetherimide containing short glass fibers in a bottomed container
0 (trade name: made by GE Plastics) is completely dissolved in methylene chloride, which is an organic solvent, in a ratio of about 1: 3 with respect to Ultem 2200 to obtain a solution. The solution is left to evaporate until the concentration of methylene chloride is about 17%, producing a foamable sheet at the bottom of the container with a thickness of about 1 mm. In the present invention, the particularly preferable range of this foamable sheet is 0.5 to 3 mm.
【００２６】本実施例３で用いる発泡核形成剤入り繊維
強化熱可塑性樹脂シート５を次のように製造する。発泡
核形成剤としてガラスファイバー及びガラスパウダーが
含有された熱可塑性樹脂組成物であるウルテム２２００
（商品名：ＧＥプラスチック製）を３２０℃で約５気圧
程度のホットプレスにて加熱加圧成形してシート化し、
約０．３ｍｍ程度の膜厚のシートを得る。前記熱可塑性
樹脂組成物中にはガラスファイバーとしては繊維長約１
５０μｍ、繊維径約１０μｍのものが約２０重量％含有
されており、また前記ガラスパウダーは粒子径約５０μ
ｍのものが約２０重量％含有されている。The fiber-reinforced thermoplastic resin sheet 5 containing the foam nucleating agent used in Example 3 is manufactured as follows. Ultem 2200, which is a thermoplastic resin composition containing glass fiber and glass powder as a foam nucleating agent
(Product name: GE plastic) is heated and pressed at 320 ° C with a hot press of about 5 atm to form a sheet,
A sheet having a film thickness of about 0.3 mm is obtained. The glass fiber in the thermoplastic resin composition has a fiber length of about 1
About 20% by weight of 50 μm and fiber diameter of about 10 μm are contained, and the glass powder has a particle size of about 50 μm.
The m content is about 20% by weight.
【００２７】このシートとガラスファイバー織物とを重
ねて３８０℃、２０気圧のホットプレス又はオートクレ
ーブ成形で加熱加圧成形することにより、発泡核形成剤
入り繊維強化熱可塑性樹脂シート５を製造する。なお、
前記ホットプレスは２９０℃〜３８０℃とすることが好
ましい。このようにして得られた発泡核形成剤入り繊維
強化熱可塑性樹脂シート５を２枚用意して、前記発泡性
シート４を中間にして挟み、ホットプレスで加熱加圧し
て、発泡成形に適した発泡性積層板を製造する。The sheet and the glass fiber woven fabric are superposed on each other and heated and pressed by hot pressing or autoclave molding at 380 ° C. and 20 atm to produce a fiber reinforced thermoplastic resin sheet 5 containing a foam nucleating agent. In addition,
The hot press is preferably performed at 290 ° C to 380 ° C. Two pieces of the fiber-reinforced thermoplastic resin sheet 5 containing the foam nucleating agent thus obtained were prepared, sandwiched with the foamable sheet 4 in the middle, and heated and pressed by a hot press to be suitable for foam molding. A foamable laminate is manufactured.
【００２８】なお、発泡性シート４と繊維強化熱可塑性
シートとをホットプレスで加熱・加圧する際の好ましい
温度・圧力の範囲は、８０℃〜１６０℃，５〜４０気圧
である。The preferred temperature and pressure ranges for heating and pressurizing the foamable sheet 4 and the fiber-reinforced thermoplastic sheet with a hot press are 80 ° C. to 160 ° C. and 5 to 40 atm.
【００２９】[0029]
【実施例４】本実施例４は、図４に示す発泡性積層板の
製造例を示す。本実施例４で用いる発泡核形成剤入り熱
可塑性樹脂シート６を前記実施例３と同一の製法で製造
する。このようにして得られた発泡核形成剤入り熱可塑
性樹脂シート６と発泡核形成剤の入っていない繊維強化
熱可塑性シート２とを重ねて２９０℃、２０気圧のホッ
トプレスで加熱加圧して積層する。このようにして得ら
れた積層シートを２枚使用して、繊維強化熱可塑性シー
ト２が外側になるように、実施例３に記載した発泡性シ
ート４を中間にして挟み、ホットプレスで加熱加圧し
て、発泡成形に適した発泡性積層板を製造する。[Embodiment 4] This embodiment 4 shows an example of manufacturing the foamable laminate shown in FIG. The thermoplastic resin sheet 6 containing the foam nucleating agent used in the present Example 4 is manufactured by the same manufacturing method as in the above Example 3. The thermoplastic resin sheet 6 containing a foam nucleating agent thus obtained and the fiber reinforced thermoplastic sheet 2 containing no foam nucleating agent are stacked and laminated by heating and pressing with a hot press at 290 ° C. and 20 atm. To do. Using the two laminated sheets thus obtained, sandwich the foamable sheet 4 described in Example 3 in the middle so that the fiber-reinforced thermoplastic sheet 2 is on the outside, and heat with a hot press. Press to produce a foamable laminate suitable for foam molding.
【００３０】なお、発泡性シート４と繊維強化熱可塑性
シートとをホットプレスで加熱・加圧する際の好ましい
温度・圧力の範囲は、８０℃〜１６０℃，５〜４０気圧
である。The preferable temperature and pressure ranges for heating and pressurizing the foamable sheet 4 and the fiber-reinforced thermoplastic sheet with a hot press are 80 ° C. to 160 ° C. and 5 to 40 atm.
【００３１】[0031]
【発明の効果】以上、詳細に説明したように、本発明の
発泡性積層板を用いて発泡成形すれば、発泡積層成形品
の表面に凹凸が生じることがない。また、本発明の発泡
性積層板を発泡成形すれば、発泡された発泡シートと高
強度、高剛性の繊維強化樹脂シートとの間に、界面の不
良が生じることがない。As described above in detail, when the foamable laminated sheet of the present invention is used for foam molding, the foam laminated molded article does not have irregularities on its surface. Further, when the foamable laminate of the present invention is foam-molded, the interface between the foamed foamed sheet and the high-strength, high-rigidity fiber-reinforced resin sheet does not occur.
【図１】本発明の１番目の発明の発泡成形用の発泡性積
層板を示す。FIG. 1 shows a foamable laminate for foam molding according to the first invention of the present invention.
【図２】本発明の２番目の発明の発泡成形用の発泡性積
層板を示す。FIG. 2 shows a foamable laminate for foam molding according to a second invention of the present invention.
【図３】本発明の３番目の発明の発泡成形用の発泡性積
層板を示す。FIG. 3 shows a foamable laminate for foam molding of a third invention of the present invention.
【図４】本発明の４番目の発明の発泡成形用の発泡性積
層板を示す。FIG. 4 shows a foamable laminate for foam molding according to a fourth invention of the present invention.
【図５】図１及び図２に示した本発明の発泡性積層板か
ら保護シートを除いた構成の発泡性積層板を示す。FIG. 5 shows a foamable laminated plate having a constitution in which the protective sheet is removed from the foamable laminated plate of the present invention shown in FIGS. 1 and 2.
【図６】図５の発泡性積層板を発泡させて得た発泡積層
板を示す。FIG. 6 shows a foamed laminate obtained by foaming the foamable laminate of FIG.
【図７】繊維強化熱可塑性樹脂シートに発泡核形成剤を
混入せずに、発泡性シートのみに発泡核形成剤を混入し
た発泡性積層板を加熱発泡して得た発泡積層板を示す。FIG. 7 shows a foamed laminate obtained by heat-foaming a foamable laminate in which a foam nucleating agent is mixed only in the foamable sheet without mixing the foam nucleating agent in the fiber-reinforced thermoplastic resin sheet.
１，４ 発泡性シート ２，５ 繊維強化熱可塑性樹脂シート ３ 保護シート ６ 熱可塑性樹脂シート ７，９ 発泡シート ８，１０ 発泡繊維強化熱可塑性樹脂シート １１ 緻密でない発泡層 1,4 Foamable sheet 2,5 Fiber reinforced thermoplastic resin sheet 3 Protective sheet 6 Thermoplastic resin sheet 7,9 Foamed sheet 8,10 Foamed fiber reinforced thermoplastic resin sheet 11 Non-dense foam layer
─────────────────────────────────────────────────────
─────────────────────────────────────────────────── ───
【手続補正書】[Procedure amendment]
【提出日】平成４年２月３日[Submission date] February 3, 1992
【手続補正１】[Procedure Amendment 1]
【補正対象書類名】明細書[Document name to be amended] Statement
【補正対象項目名】００２３[Name of item to be corrected] 0023
【補正方法】変更[Correction method] Change
【補正内容】[Correction content]
【００２３】なお、保護シート３と繊維強化熱可塑性樹
脂シート２とをホットプレスで加熱加圧する際の好まし
い温度・圧力の範囲は、５０℃〜５００℃，５〜５０気
圧である。また、積層シートと発泡性シート１をホット
プレスで加熱加圧する際の好ましい温度・圧力の範囲
は、８０℃〜１６０℃，５〜４０気圧である。The preferred temperature / pressure ranges for heating and pressing the protective sheet 3 and the fiber-reinforced thermoplastic resin sheet 2 by hot pressing are 50 ° C. to 500 ° C. and 5 to 50 atm. Further, the preferable temperature and pressure ranges when the laminated sheet and the foamable sheet 1 are heated and pressed by a hot press are 80 ° C. to 160 ° C. and 5 to 40 atm.
【手続補正２】[Procedure Amendment 2]
【補正対象書類名】明細書[Document name to be amended] Statement
【補正対象項目名】００２４[Correction target item name] 0024
【補正方法】変更[Correction method] Change
【補正内容】[Correction content]
【００２４】[0024]
【実施例２】本実施例２は、図２に示す発泡成形用の発
泡性積層板の製造例を示す。保護シート３として、耐薬
品性を向上させたポリエーテルイミドフィルムであるス
ミライトＦＳ１４５０（商品名：住友ベークライト製）
を用意し、該保護シート３と繊維強化熱可塑性樹脂シー
ト２との積層シートを、この実施例２では、繊維強化熱
可塑性樹脂シート２が外側となるようにして、前記実施
例１と同一の発泡性シート１を中間にして挟み、ホット
プレスで加熱加圧して、発泡成形に適した発泡性積層板
を製造する。なお、ホットプレスの好ましい温度・圧力
の範囲は実施例１と同じである。[Embodiment 2] This embodiment 2 shows an example of manufacturing the foamable laminate for foam molding shown in FIG. Sumilite FS1450 (trade name: manufactured by Sumitomo Bakelite), which is a polyetherimide film having improved chemical resistance as the protective sheet 3.
And a laminated sheet of the protective sheet 3 and the fiber-reinforced thermoplastic resin sheet 2 is prepared in the same manner as in Example 1 except that the fiber-reinforced thermoplastic resin sheet 2 is on the outside in this Example 2. The foamable sheet 1 is sandwiched in the middle and heated and pressed by a hot press to manufacture a foamable laminated plate suitable for foam molding. The preferable temperature and pressure ranges of the hot press are the same as in Example 1.
Claims (5)
を含浸したポリエーテルイミドシート又はポリエーテル
スルホンシートからなる発泡性シートの両面に、（２）
繊維強化熱可塑性樹脂シートを積層し、（３）さらに、
該各々の繊維強化熱可塑性樹脂シートの外側に、前記発
泡剤を含浸しにくく、且つ該繊維強化熱可塑性樹脂シー
トの成形温度と類似した成形温度を持つ熱可塑性樹脂又
は繊維強化熱可塑性樹脂からなる保護シートを積層する
ことによって得られた発泡性積層板。(1) Both sides of a foamable sheet made of a polyetherimide sheet or a polyethersulfone sheet impregnated with a boiling evaporation type blowing agent made of an organic solvent, (2)
By laminating fiber reinforced thermoplastic resin sheets, (3)
A thermoplastic resin or a fiber-reinforced thermoplastic resin which is difficult to impregnate the foaming agent on the outside of each fiber-reinforced thermoplastic resin sheet and has a molding temperature similar to the molding temperature of the fiber-reinforced thermoplastic resin sheet. A foamable laminated plate obtained by laminating protective sheets.
を含浸したポリエーテルイミドシート又はポリエーテル
スルホンシートからなる発泡性シートの両面に、（２）
前記発泡剤を含浸しにくい熱可塑性樹脂又は繊維強化熱
可塑性樹脂からなる保護シートを積層し、（３）さら
に、該各々の保護シートの外側に該保護シートの成形温
度と類似した成形温度を持つ繊維強化熱可塑性樹脂シー
トを積層することによって得られた発泡性積層板。2. (1) On both sides of a foamable sheet made of a polyetherimide sheet or a polyethersulfone sheet impregnated with a boiling evaporation type blowing agent made of an organic solvent, (2)
A protective sheet made of a thermoplastic resin or a fiber-reinforced thermoplastic resin that is hard to be impregnated with the foaming agent is laminated, and (3) further, a molding temperature similar to the molding temperature of the protective sheet is provided outside each of the protective sheets. A foamable laminate obtained by laminating fiber-reinforced thermoplastic resin sheets.
を含浸し、且つ発泡核形成剤を含有するポリエーテルイ
ミドシート又はポリエーテルスルホンシートからなる発
泡性シートの両面に、（２）発泡核形成剤を含有する繊
維強化熱可塑性樹脂シートを積層することによって得ら
れた発泡性積層板。(1) Both sides of a foamable sheet made of a polyetherimide sheet or a polyethersulfone sheet impregnated with a boiling evaporation type foaming agent made of an organic solvent and containing a foam nucleating agent, (2) A foamable laminate obtained by laminating fiber-reinforced thermoplastic resin sheets containing a foam nucleating agent.
を含浸し、且つ発泡核形成剤を含有するポリエーテルイ
ミドシート又はポリエーテルスルホンシートからなる発
泡性シートの両面に、（２）発泡核形成剤を含有する熱
可塑性プラスチックシートを積層し、（３）さらに、そ
の両外側に繊維強化熱可塑性樹脂シートを積層すること
によって得られた発泡性積層板。(1) Both sides of a foamable sheet made of a polyetherimide sheet or a polyethersulfone sheet impregnated with a boiling evaporation type blowing agent made of an organic solvent and containing a foam nucleating agent, (2) A foamable laminate obtained by laminating a thermoplastic sheet containing a foam nucleating agent, and (3) further laminating a fiber reinforced thermoplastic resin sheet on both outer sides thereof.
ス短繊維である請求項３又は４記載の発泡性積層板。5. The expandable laminate according to claim 3, wherein the foam nucleating agent is glass powder or glass short fibers.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP4017482A JPH05212821A (en) | 1992-02-03 | 1992-02-03 | Foamable laminated board for expansion molding |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP4017482A JPH05212821A (en) | 1992-02-03 | 1992-02-03 | Foamable laminated board for expansion molding |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH05212821A true JPH05212821A (en) | 1993-08-24 |
Family
ID=11945225
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP4017482A Withdrawn JPH05212821A (en) | 1992-02-03 | 1992-02-03 | Foamable laminated board for expansion molding |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH05212821A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2015174147A1 (en) * | 2014-05-13 | 2015-11-19 | 株式会社日立製作所 | Method for manufacturing composite material structure |
-
1992
- 1992-02-03 JP JP4017482A patent/JPH05212821A/en not_active Withdrawn
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2015174147A1 (en) * | 2014-05-13 | 2015-11-19 | 株式会社日立製作所 | Method for manufacturing composite material structure |
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