JPH07178859A - Laminate and production thereof - Google Patents
Laminate and production thereofInfo
- Publication number
- JPH07178859A JPH07178859A JP32375093A JP32375093A JPH07178859A JP H07178859 A JPH07178859 A JP H07178859A JP 32375093 A JP32375093 A JP 32375093A JP 32375093 A JP32375093 A JP 32375093A JP H07178859 A JPH07178859 A JP H07178859A
- Authority
- JP
- Japan
- Prior art keywords
- prepreg
- foam
- resin
- laminate
- resin foam
- 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.)
- Granted
Links
Landscapes
- Laminated Bodies (AREA)
Abstract
Description
【0001】[0001]
【産業上の利用分野】本発明は、連続した強化繊維を一
方向に整列させ熱可塑性樹脂を含浸した1枚以上のプリ
プレグの積層体と樹脂発泡体とを多層に組み合せて溶融
一体化して成る成形品及びその製造法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention comprises a laminate of one or more prepregs impregnated with a thermoplastic resin and a resin foam, which are formed by aligning continuous reinforcing fibers in one direction and melt-integrating them. The present invention relates to a molded product and a method for manufacturing the same.
【0002】[0002]
【従来の技術】従来から、樹脂発泡体の上下面に繊維補
強樹脂板を貼り付けることにより、軽量で、面剛性の高
い板が出来ることが知られており一般的にはこのような
板は、不飽和ポリエステル樹脂等の熱硬化性樹脂をマト
リックスとする繊維補強板と熱硬化性のポリウレタン樹
脂を発泡させた硬質ウレタンフォームを一体化すること
により製造される。一体化する方法としては、繊維補強
板のマトリックス樹脂が硬化する前の液状であるうち
に、樹脂発泡体と重ね合わせて、プレス機等で加圧して
液状のマトリックス樹脂を樹脂発泡体の表面から浸透さ
せ、硬化する時に発泡体に浸透した樹脂が固化し発泡体
中に食い込んだ状態で物理的に接合させる場合と、繊維
補強板をあらかじめ成形し、接着剤を使用して発泡体と
接合する場合がある。また、別の方法として繊維強化熱
可塑性樹脂板は熱可塑性樹脂からなる発泡体の上下面に
貼合わせたいたも知られている。2. Description of the Related Art Conventionally, it has been known that a fiber reinforced resin plate is attached to the upper and lower surfaces of a resin foam to make a plate that is lightweight and has high surface rigidity. It is manufactured by integrating a fiber reinforced plate having a thermosetting resin such as an unsaturated polyester resin as a matrix with a hard urethane foam obtained by foaming a thermosetting polyurethane resin. As a method of integrating, while the matrix resin of the fiber reinforced plate is in a liquid state before being cured, it is superposed on the resin foam, and is pressed by a press machine or the like to remove the liquid matrix resin from the surface of the resin foam. When the resin that has penetrated into the foam is solidified when it is allowed to penetrate and harden, and when it is physically joined while it penetrates into the foam, or when the fiber reinforced plate is preformed and the adhesive is used to join with the foam. There are cases. As another method, it is also known that a fiber reinforced thermoplastic resin plate is attached to the upper and lower surfaces of a foam made of a thermoplastic resin.
【0003】[0003]
【発明が解決しようとする課題】しかしながら、上記の
方法で製造された板は上述したように面剛性は高いが、
局部的な曲げ荷重や衝撃荷重が加わった場合に、上下面
の繊維補強樹脂板は破壊しないが、荷重が加わった直下
の発泡体だけが部分的に圧壊し板としての機能が失われ
る現象が頻発し問題である。一方、面全体で荷重を受け
大きな変形を起こした場合に、繊維補強樹脂板と発泡体
との接合面が剥離し易く構造部材として使用するために
は信頼性に乏しい点も指摘されている。また、上記の製
造法では熱硬化性樹脂を取り扱うときの悪臭及び補強繊
維の飛散がが作業環境を悪化させ衛生上の問題が指摘さ
れている。However, although the plate manufactured by the above method has high surface rigidity as described above,
When a local bending load or impact load is applied, the fiber-reinforced resin plates on the upper and lower surfaces are not destroyed, but only the foam directly under the load is partially collapsed and the function as a plate is lost. It is a frequent problem. On the other hand, it has been pointed out that the joint surface between the fiber-reinforced resin plate and the foam is easily peeled off when it is subjected to a large deformation due to the load on the entire surface, and the reliability is poor for use as a structural member. Further, in the above-mentioned manufacturing method, a bad odor when handling the thermosetting resin and the scattering of the reinforcing fibers deteriorate the working environment, and it is pointed out that there is a problem in hygiene.
【0004】さらに繊維補強樹脂板の成形、樹脂発泡体
との接合を行うので、硬化、接着剤の塗布、圧着、養生
等の工程管理が必要であり加工コストが掛かる等の問題
が生じる。また、繊維強化熱可塑性樹脂板は熱可塑性樹
脂からなる発泡体の上下面に貼合わせた板の場合も、適
切な接着剤がないこと、熱融着で接合する場合でも発泡
体の厚さを均一に保持して作業することが困難で性能の
ばらつきが多い等の問題が生じている。そこで、本発明
の目的は、熱可塑性樹脂をマトリックスとする繊維補強
板と熱可塑性樹脂から成る発泡体を使用して、接着剤を
使用せずに繊維補強板と発泡体とが強固に接合された面
剛性が高く、発泡体の厚みが変化しない積層体及びその
製造方法を、衛生的な作業環境で安価に提供することに
ある。Further, since the fiber-reinforced resin plate is molded and joined to the resin foam, there is a problem that process control such as curing, application of adhesive, pressure bonding and curing is required, resulting in high processing cost. Also, in the case of a fiber-reinforced thermoplastic resin plate that is laminated on the upper and lower surfaces of a foam made of a thermoplastic resin, there is no suitable adhesive, and the thickness of the foam does not change even when joining by heat fusion. There are problems that it is difficult to work while holding them uniformly, and there are many variations in performance. Therefore, an object of the present invention is to use a foam made of a thermoplastic resin and a fiber reinforced plate having a thermoplastic resin as a matrix, and to firmly bond the fiber reinforced plate and the foam without using an adhesive. Another object of the present invention is to provide a laminate having a high surface rigidity and a foam that does not change its thickness, and a method for producing the same at low cost in a hygienic work environment.
【0005】[0005]
【課題を解決するための手段】本発明者らは上記目的を
達成するため、鋭意検討を重ねた結果、本発明を完成す
るに至ったものである。すなわち、本発明に係わる積層
体は、連続した強化繊維を一方向に整列させ熱可塑性樹
脂を含浸した1枚以上のプリプレグと樹脂発泡体とを積
層した成形品において、樹脂発泡体とプリプレグとを積
層した組み合せを2層以上重ね合わせて層間を熱接合せ
しめられたことを特徴とする。上記プリプレグは、容積
含有率で30%以上85%以下の強化繊維を含むことが
推奨され、またその強化繊維が一方向に連続な長繊維か
ら成るものであることが推奨される。また、上記強化繊
維がガラス繊維であり、熱可塑性樹脂及び発泡体がポリ
プロピレン系樹脂又はポリスチレン系樹脂であり、更に
荷重が加わる面の表面の近くに存在する発泡体の発泡倍
率の方が、中心層に近い発泡体の発泡倍率より低い様な
場合に対して本発明は好適に適用し得る。The present inventors have completed the present invention as a result of intensive studies to achieve the above object. That is, the laminate according to the present invention is a molded product obtained by laminating one or more prepregs impregnated with a thermoplastic resin and resin foams by aligning continuous reinforcing fibers in one direction and laminating the resin foams and prepregs. It is characterized in that two or more layers of the laminated combination are overlapped and the layers are thermally bonded. It is recommended that the prepreg contains 30% or more and 85% or less by volume content of reinforcing fibers, and that the reinforcing fibers are unidirectionally continuous filaments. Further, the reinforcing fiber is a glass fiber, the thermoplastic resin and the foam is a polypropylene-based resin or polystyrene-based resin, further the expansion ratio of the foam present near the surface of the load is the center, The present invention can be preferably applied to the case where the expansion ratio of the foam close to the layer is lower.
【0006】また、上記の積層成形品を製造するための
本発明に係る製造方法は、連続した強化繊維を一方向に
整列させ熱可塑性樹脂を含浸した1枚以上のプリプレグ
をその熱可塑性樹脂の溶融温度以上に加熱して層間に含
まれる空気の脱気を行うステップと、プリプレグを溶融
温度以上に、樹脂発泡体を溶融温度以下、にお互いが接
触しない状態で同時に加熱するステップと、加熱したプ
リプレグと樹脂発泡体をお互いに重ね合わせて加圧して
熱接合を行うステップと、熱接合された積層品を冷却、
固化して一体化せしめるステップを順次実行することを
特徴とする。上記の製造方法は、その強化繊維が容積含
有率で30%以上85%以下の強化繊維を含み、かつ一
方向に連続な長繊維から成るものであるときに好適に適
用でき、特に、強化繊維がガラス繊維であり、熱可塑性
樹脂及び発泡体がポリプロピレン系樹脂又はポリスチレ
ン系樹脂であり、更に荷重が加わる面の表面の近くに存
在する発泡体の発泡倍率の方が、中心層に近い発泡体の
発泡倍率より低い様な場合に対して本発明は好適に適用
し得る。Further, in the production method according to the present invention for producing the above-mentioned laminated molded article, one or more prepregs in which continuous reinforcing fibers are aligned in one direction and impregnated with the thermoplastic resin are used. Heating to above the melting temperature to degas the air contained in the layers; heating the prepreg above the melting temperature, heating the resin foam below the melting temperature, simultaneously without contacting each other; A step of heat-bonding the prepreg and the resin foam overlaid on each other and applying pressure; cooling the heat-bonded laminate;
It is characterized in that the steps of solidifying and integrating are sequentially executed. The above-mentioned production method can be suitably applied when the reinforcing fiber contains 30% or more and 85% or less by volume content of the reinforcing fiber and is composed of continuous fibers in one direction, and particularly, the reinforcing fiber. Is a glass fiber, the thermoplastic resin and the foam is a polypropylene-based resin or polystyrene-based resin, further the foaming ratio of the foam existing near the surface of the load is closer to the center layer The present invention can be suitably applied to the case where the expansion ratio is lower than the above.
【0007】本発明に使用される、一方向に配列した繊
維に熱可塑性樹脂を含浸させたプリプレグに用いられる
熱可塑性樹脂としては、例えばポリスチレン、ポリプロ
ピレン、ポリエチレン、AS樹脂、ABS樹脂、ASA
樹脂(ポリアクリロニトリル・ポリスチレン・ポリアク
リル酸エステル)、ポリメチルメタクリレート、ナイロ
ン、ポリアセタール、ポリカーボネート、ポリエチレン
テレフタレート、ポリフェニレンオキシド、フッ素樹
脂、ポリフェニレンスルフィド、ポリスルフォン、ポリ
エーテルサルフォン、ポリエーテルケトン、ポリエーテ
ルエーテルケトン、ポリイミド、ポリアリレート等があ
る。The thermoplastic resin used in the prepreg obtained by impregnating the unidirectionally arranged fibers with the thermoplastic resin used in the present invention is, for example, polystyrene, polypropylene, polyethylene, AS resin, ABS resin, ASA.
Resin (polyacrylonitrile / polystyrene / acrylic acid ester), polymethylmethacrylate, nylon, polyacetal, polycarbonate, polyethylene terephthalate, polyphenylene oxide, fluororesin, polyphenylene sulfide, polysulfone, polyethersulfone, polyetherketone, polyetherether Examples include ketones, polyimides, polyarylates and the like.
【0008】一方向に配列した繊維に熱可塑性樹脂を含
浸させたプリプレグに用いられる繊維としては、例えば
ガラス繊維、カーボン繊維、アラミド繊維、炭化ケイ素
繊維等が代表的なものである。一方向に配列した繊維に
熱可塑性樹脂を含浸してなるプリプレグは、通常太さ3
〜25μmのモノフィラメントを200〜12000本
集束したヤーンもしくは、ロービングを、所定本数一方
向に並べたものに熱可塑性樹脂を含浸させたものを用い
る。Typical fibers used in a prepreg in which fibers arranged in one direction are impregnated with a thermoplastic resin are, for example, glass fibers, carbon fibers, aramid fibers and silicon carbide fibers. A prepreg obtained by impregnating fibers arranged in one direction with a thermoplastic resin usually has a thickness of 3
A yarn obtained by bundling 200 to 12000 monofilaments of -25 μm or a roving in which a predetermined number of rovings are arranged in one direction is impregnated with a thermoplastic resin.
【0009】ガラス繊維は通常各種の表面処理を行い、
樹脂との密着性を向上させることが行われる。表面処理
は、集束剤とカップリング剤を組み合わせて行う。モノ
フィラメントを集束するためには、通常集束剤を使用す
る。集束剤は組み合わせる熱可塑性樹脂により選択する
必要がある。一般的には組み合せる樹脂の溶融温度で軟
化して、熱可塑性樹脂が繊維束中に含浸し易いものを選
択する。そのために組み合せる熱可塑性樹脂と同種の樹
脂を主成分とする集束剤を使用する場合が多い。プリプ
レグの繊維として使用するガラス繊維は、シラン系、チ
タネート系、ジルコニウム系のカップリング剤で処理
し、樹脂との密着性を向上させたものを用いる。Glass fiber is usually subjected to various surface treatments,
The adhesion with the resin is improved. The surface treatment is performed by combining a sizing agent and a coupling agent. A sizing agent is usually used to focus the monofilaments. The sizing agent needs to be selected depending on the thermoplastic resin to be combined. Generally, a resin that is softened at the melting temperature of the resins to be combined and easily impregnated with the thermoplastic resin in the fiber bundle is selected. Therefore, a sizing agent whose main component is a resin of the same kind as the thermoplastic resin to be combined is often used. The glass fiber used as the fiber of the prepreg is one that is treated with a silane-based, titanate-based, or zirconium-based coupling agent to improve the adhesion to the resin.
【0010】ガラス繊維の場合のカップリング剤は、組
み合わせる樹脂に応じて最適なものを選ぶ必要があり以
下その具体例を例挙する。ナイロン樹脂であれば、γ−
アミノプロピル−トリメトキシシラン、N−β−(アミ
ノエチル)−γ−アミノプロピル−トリメトキシシラン
等を使用する。ポリカーボネート樹脂であれば、γ−ア
ミノプロピル−トリメトキシシラン、N−β−(アミノ
エチル)−γ−アミノプロピル−トリメトキシシラン等
を使用する。ポリエチレンテレフタレートまたは、ポリ
ブチレンテレフタレート、であれば、β−(3,4−エ
ポキシシクロヘキシル)エチル−トリメトキシシラン、
γ−グリシドキシ−プロピルトリメトキシシラン、γ−
アミノプロピル−トリメトキシシラン等を使用する。ポ
リエチレンまたはポリプロピレンであれば、ビニルトリ
メトキシシラン、ビニル−トリス− (2−メトキシエ
トキシ)シラン、γ−メタクリロキシ−プロピルトリメ
トキシシラン等を使用する。ポリフェニレンオキシド、
ポリフェニレンスルフィド、ポリスルフォン、ポリエー
テルサルフォン、ポリエーテルケトン、ポリエーテルエ
ーテルケトン、ポリイミド、ポリアリレート、フッ素樹
脂であれば、上述したカップリング剤も当然使用出来る
が、その外に、N−(β−アミノエチル)−γ−アミノ
プロピルメチルジメトキシシラン、γ−クロロプロピル
メチルジメトキシシラン、γ−メルカプトプロピルトリ
メトキシシラン、p−アミノフェニルトリエトキシシラ
ン等を使用できる。In the case of glass fiber, it is necessary to select the most suitable coupling agent according to the resin to be combined, and specific examples thereof will be given below. For nylon resin, γ-
Aminopropyl-trimethoxysilane, N-β- (aminoethyl) -γ-aminopropyl-trimethoxysilane and the like are used. If it is a polycarbonate resin, γ-aminopropyl-trimethoxysilane, N-β- (aminoethyl) -γ-aminopropyl-trimethoxysilane and the like are used. If polyethylene terephthalate or polybutylene terephthalate, then β- (3,4-epoxycyclohexyl) ethyl-trimethoxysilane,
γ-glycidoxy-propyltrimethoxysilane, γ-
Aminopropyl-trimethoxysilane or the like is used. If polyethylene or polypropylene is used, vinyltrimethoxysilane, vinyl-tris- (2-methoxyethoxy) silane, γ-methacryloxy-propyltrimethoxysilane, or the like is used. Polyphenylene oxide,
As long as it is polyphenylene sulfide, polysulfone, polyether sulfone, polyether ketone, polyether ether ketone, polyimide, polyarylate, or a fluororesin, the above-mentioned coupling agent can be used, but N- (β -Aminoethyl) -γ-aminopropylmethyldimethoxysilane, γ-chloropropylmethyldimethoxysilane, γ-mercaptopropyltrimethoxysilane, p-aminophenyltriethoxysilane and the like can be used.
【0011】ガラス繊維以外を補強繊維として用いる時
は、アミン硬化型のエポキシ樹脂をカップリング剤とし
て処理する場合が多く、その具体例としてはビスフェノ
ール−A−エピクロルヒドリン樹脂、エポキシノボラッ
ク樹脂、脂環式エポキシ樹脂、脂肪族エポキシ樹脂、グ
リシジルエステル型樹脂を使用することがもあるが、熱
可塑性樹脂は一般的に溶融温度が高いので、通常のカッ
プリング剤は熱分解するので、全くカップリング剤を使
用しない場合もある。When a fiber other than glass fiber is used as the reinforcing fiber, an amine-curing type epoxy resin is often treated as a coupling agent, and specific examples thereof include bisphenol-A-epichlorohydrin resin, epoxy novolac resin and alicyclic compounds. Epoxy resins, aliphatic epoxy resins, and glycidyl ester type resins may be used, but since thermoplastic resins generally have high melting temperatures, ordinary coupling agents undergo thermal decomposition, so no coupling agents are used. It may not be used.
【0012】カップリング剤を繊維表面に施す方法は以
下の通りである。即ち、一つの方法としては、繊維を溶
融してモノフィラメントを引き出す際に集束剤とカップ
リング剤を界面活性剤を添加して水溶液としたものを、
モノフィラメントに噴霧した後、100℃程度の温度で
乾燥して処理する。他の方法として、集束剤を除去した
繊維に、集束剤及びカップリング剤を0.1〜3重量%
溶解した液を、浸漬、噴霧塗布等の手段により完全に含
浸させる。このカップリング剤溶液を含んだ繊維を60
〜120゜Cで乾燥し、カップリング剤を繊維表面に反
応させる。乾燥時間は溶媒が揮散してしまう時間で充分
で15〜20分位である。カップリング剤を溶解する溶
媒は、使用する表面処理剤に応じて、pH2.0〜1
2.0位に調整した水を用いる場合と、エタノール、ト
ルエンアセトン、キシレン等の有機溶剤を単独で、或は
混合して使用する場合とがある。熱可塑性樹脂を一方向
に引き揃えた補強繊維に含浸させてプリプレグとする方
法としては種々の手段があるが、最も一般的な方法は以
下の通りである。一つは、溶剤に可溶な樹脂であれば、
その樹脂を溶液化して補強繊維に含浸させ、その後脱泡
しながら溶媒を除去し、プリプレグとする方法である。The method of applying the coupling agent to the fiber surface is as follows. That is, as one method, when the fiber is melted and the monofilament is pulled out, a sizing agent and a coupling agent are added to the surfactant to prepare an aqueous solution.
After spraying on the monofilament, it is dried and treated at a temperature of about 100 ° C. As another method, 0.1 to 3% by weight of a sizing agent and a coupling agent is added to the fiber from which the sizing agent is removed.
The dissolved liquid is completely impregnated by means such as dipping and spray coating. 60 fibers containing this coupling agent solution
Dry at ~ 120 ° C to allow coupling agent to react with fiber surface. The drying time is sufficient to evaporate the solvent, which is about 15 to 20 minutes. The solvent for dissolving the coupling agent has a pH of 2.0 to 1 depending on the surface treatment agent used.
There are cases where water adjusted to 2.0 is used, and cases where organic solvents such as ethanol, tolueneacetone and xylene are used alone or as a mixture. There are various methods for impregnating the reinforcing fibers unidirectionally aligned with the thermoplastic resin to form the prepreg, but the most general method is as follows. First, if the resin is soluble in the solvent,
This is a method in which the resin is made into a solution and impregnated into reinforcing fibers, and then the solvent is removed while defoaming to obtain a prepreg.
【0013】更に一つは、樹脂を加熱溶融して補強繊維
に含浸し、脱泡し、冷却してプリプレグとする方法であ
る。プリプレグの製造法としては、例えば特公平02−
042168号公報に開示されている方法があげられ
る。この方法により、ガラス繊維の場合は例えば太さ1
3μのモノフィラメントの表面をγ−メタクリロキシ−
プロピルトリメトキシシランで処理し、それを1800
本集束して撚りのないヤーンとし、そのヤーンを80本
均一な張力で引張ながら一方向に整列させて、樹脂をヤ
ーンに絡ませて、その樹脂を熱ロールでしごきながら、
ヤーンに含浸させてプリプレグを製造することが出来
る。この様にして製造したプリプレグは、繊維と熱可塑
性樹脂の密着性に優れ、繊維含有率も30−90重量%
と要求に応じて変えることが出来、厚みも0.1〜1.
0mmで製造することが出来るが、ガラス含有率は30
〜85容量%で、厚さ0.1〜0.6mmのところで使
用するのが望ましい。ガラス繊維含有率が30容量%以
下では繊維量が少ないので強度が低く、また85容量%
以上では繊維に対して樹脂量が少なく繊維と樹脂の密着
性が低下し強度が低くなるので好ましくない。The other is a method of heating and melting a resin to impregnate a reinforcing fiber, defoaming, and cooling to obtain a prepreg. As a method of manufacturing a prepreg, for example, Japanese Patent Publication No. 02-
The method disclosed in Japanese Patent No. 042168 can be mentioned. By this method, for glass fiber, for example, thickness 1
The surface of a 3μ monofilament is γ-methacryloxy-
Treated with propyltrimethoxysilane and treated with 1800
This bundle is made into a twist-free yarn, 80 yarns are aligned in one direction while pulling with a uniform tension, the resin is entangled with the yarn, and the resin is squeezed with a hot roll,
The yarn can be impregnated to produce a prepreg. The prepreg manufactured in this manner has excellent adhesion between the fiber and the thermoplastic resin and has a fiber content of 30-90% by weight.
And it can be changed according to the requirements, and the thickness is 0.1-1.
It can be manufactured with 0 mm, but the glass content is 30
It is desirable to use it in a range of 85% by volume and a thickness of 0.1 to 0.6 mm. When the glass fiber content is 30% by volume or less, the strength is low because the amount of fibers is small, and 85% by volume.
The above is not preferable because the amount of resin with respect to the fiber is small and the adhesion between the fiber and the resin is reduced, resulting in low strength.
【0014】また、本発明で使用する発泡樹脂体として
はポリエチレン発泡体、ポリプロピレン発泡体、ポリス
チレン発泡体又はポリプロピレン発泡体を外層に有する
ポリスチレン発泡体等が挙げられる。また、産業廃棄物
の処理の点からは、樹脂発泡体に用いられる樹脂とプリ
プレグに用いられる樹脂が共に熱可塑性樹脂で構成され
る複合構造体が好ましく、同一の熱可塑性樹脂で構成さ
れる複合構造体がさらに好ましい。発泡体は独立気泡で
も連通気泡から成るものでも良い。独立気泡のものを使
用すると強度は向上する。発泡倍率は100倍以下のも
のが用いられるが、その倍率は軽量化と成型性のバラン
スにより選ばれ、2〜50倍が好ましい。また、発泡体
は架橋体でも無架橋体でもよい。Examples of the foamed resin used in the present invention include polyethylene foam, polypropylene foam, polystyrene foam or polystyrene foam having polypropylene foam as an outer layer. From the viewpoint of processing industrial waste, a composite structure in which the resin used for the resin foam and the resin used for the prepreg are both made of a thermoplastic resin is preferable, and a composite structure made of the same thermoplastic resin is preferable. Structures are more preferred. The foam may be either closed cells or open cells. The strength is improved by using closed cells. A foaming ratio of 100 or less is used, and the ratio is selected from the balance of weight reduction and moldability, and is preferably 2 to 50 times. Further, the foam may be a crosslinked body or a non-crosslinked body.
【0015】本発明に使用される表面材としては、ポリ
プロピレン、ポリスチレンなどの発泡又は非発泡シー
ト、ポリ塩化ビニール等のシート、各種繊維からなる織
布や不織布などがあげられる。このような表面材を適用
することにより、表面の美観を向上させたり、肌触り性
の改善、耐汚染性の向上、他材との剥離性の改良、耐紫
外線性の向上が図れる。Examples of the surface material used in the present invention include foamed or non-foamed sheets such as polypropylene and polystyrene, sheets such as polyvinyl chloride, and woven and non-woven fabrics made of various fibers. By applying such a surface material, it is possible to improve the appearance of the surface, improve the touch, improve the stain resistance, improve the peelability from other materials, and improve the ultraviolet resistance.
【0016】プリプレグと発泡体を熱溶着により一体化
する方法として、積層したプリプレグを溶融温度以上
に、樹脂発泡体を溶融温度未満に同時に加熱し、次いで
プリプレグと発泡体を重ね合わせて、60〜80℃に加
熱されているプレス中で3kg/cm2 以下の圧力で加
圧し冷却すると共に一体化を行い積層体とする。この時
に、プリプレグ積層体のプリプレグ層間に存在する空気
を脱気する必要があり、通常は、プリプレグを構成する
樹脂の融点以上に加熱し3kg/cm2 以下の圧力で加
圧して脱気を行う。この範囲の圧力であれば、樹脂発泡
体が圧壊することもないので、発泡体と一体化する工程
でこの脱気を行うことが出来る。当然のことながら、脱
気をあらかじめ行い冷却し積層板としたものを使用して
も差し支えは無い。プリプレグと発泡体の加熱は、プリ
プレグと発泡体をお互いに接触させずに加熱すること
も、発泡体の上にプリプレグを乗せてお互いが接触した
状態で加熱することも出来る。発泡体の倍率が高い場合
は容易に熱で発泡体が溶けるので溶融したプリプレグが
蓄熱した熱で発泡体の表面が容易に溶けて一体化し得る
ので、プリプレグと発泡体を接触させずに加熱条件を変
えて別々に加熱することが望ましい。一方、発泡倍率が
低い場合は、発泡体に熱が伝導しにくいので溶融プリプ
レグが蓄熱している熱では発泡体表面を溶融出来ないた
めに、プリプレグと発泡体を接触させて、同時に加熱し
発泡体の表面を溶かしながら加熱する方法をとることが
望ましい。As a method of integrating the prepreg and the foam by heat welding, the laminated prepreg is heated to a melting temperature or higher and the resin foam is heated to a temperature lower than the melting temperature at the same time, and then the prepreg and the foam are superposed on each other, and then 60 to 60 In a press heated to 80 ° C., pressure is applied at a pressure of 3 kg / cm 2 or less, cooling is performed, and integration is performed to form a laminated body. At this time, it is necessary to deaerate the air existing between the prepreg layers of the prepreg laminate. Usually, the prepreg is heated by heating it to a temperature higher than the melting point of the resin constituting the prepreg and pressurizing it with a pressure of 3 kg / cm 2 or less. . If the pressure is within this range, the resin foam will not be crushed, so this degassing can be performed in the step of integrating with the foam. As a matter of course, there is no problem in using a laminated plate that is deaerated in advance and cooled. The prepreg and the foam can be heated without contacting the prepreg and the foam with each other, or can be heated with the prepreg placed on the foam and in contact with each other. When the expansion ratio of the foam is high, the foam is easily melted by heat, so the surface of the foam can be easily melted and integrated by the heat accumulated in the molten prepreg, so the heating conditions without contacting the prepreg and the foam It is desirable to change and heat separately. On the other hand, when the expansion ratio is low, the heat is difficult to conduct to the foam, so the surface of the foam cannot be melted by the heat accumulated by the molten prepreg.Therefore, the prepreg and the foam are brought into contact and heated at the same time to foam. It is desirable to take a method of heating while melting the body surface.
【0017】プリプレグと発泡体の一体化は、プリプレ
グが溶融状態にある間に行わなければならないので、加
熱を行うステップから一体化を行うステップへ短時間で
移行する様な装置的な工夫が必要である。そのような装
置の一例として、プリプレグと発泡体を一体化するプレ
ス内に、プレス内に出入り可能なプリプレグと発泡体を
クランプして支持する装置とプレス内に出入り可能なプ
リプレグと発泡体を加熱する熱板を装備した設備があげ
られる。この設備を使用して積層体を成形する手順は、
プレス盤面外にクランプを引きだし、プリプレグと発泡
体を装着した後クランプ装置をプレス盤面内に入れ、次
いで熱板をプレス盤面中に入れプリプレグと発泡体を加
熱し、加熱が終了後プレス盤面外に熱板を引きだし、プ
レスを締めてプリプレグと発泡体を接触させながら溶融
一体化させる。このとき、クランプはプレス盤面に触れ
ると同時に順次材料を離し、プレス盤面外に退避する機
構を供えている必要がある。表面材とプリプレグの一体
化は発泡体とプリプレグの一体化と同様に、プリプレグ
が溶融状態にある間に、一体化することが出来る。Since the prepreg and the foam must be integrated with each other while the prepreg is in a molten state, it is necessary to devise a device so that the step of heating and the step of integrating may be completed in a short time. Is. As an example of such a device, in a press that integrates prepreg and foam, a device that clamps and supports the prepreg and foam that can move in and out of the press, and the prepreg and foam that can move in and out of the press are heated. There is a facility equipped with a hot plate to operate. The procedure for forming a laminate using this equipment is:
After pulling the clamp out of the press platen and mounting the prepreg and foam, put the clamp device in the press platen surface, then put the hot plate in the press platen surface to heat the prepreg and foam, and after heating is completed, press it out of the press platen surface. The hot plate is drawn out, and the press is tightened to bring the prepreg and the foam into contact with each other to melt and integrate them. At this time, it is necessary for the clamp to have a mechanism for sequentially releasing the material while touching the surface of the press platen and retracting the material to the outside of the press platen surface. The integration of the surface material and the prepreg can be performed while the prepreg is in a molten state, like the integration of the foam and the prepreg.
【0018】以下、図面により本発明の実施例について
詳細に説明する。図1は本発明による製造方法により得
られる積層体の外観矢視図である。図2は図1に示した
積層体を製造する装置内にプリプレグ、発泡体が装着さ
れている状態を示す概念図、図3は図2に示した装置か
ら熱源を退避させてプリプレグと発泡体を一体化する第
一段階を示す概略図、図4は図3に示した状態からプリ
プレグ及び発泡体を保持している支持具が外れてプリプ
レグと発泡体をプレスにより冷却一体化を行っている状
態の概念図である。図5及び図6は本発明の別の実施例
を示す概念図である。図7は片面に表面材を貼合わせた
積層体を示す外観矢視図、図8は片面に表面材を貼合わ
せた積層体を成形するために装置内にプリプレグ、発泡
体及び表面材が装着されている状態を示す概念図を示
す。図1に示した1は本発明により得られる積層体を示
す。2、3、4、5、6はプリプレグ積層体を示し、2
〜6が同一の積層構成、板厚さであっても良いし、目的
とする用途に応じて積層構成、板厚さをそれぞれ変えて
もよい。10、11、12、13、14は樹脂発泡体を
示す。10〜14の発泡体は同一の発泡倍率、厚さでも
よいが、目的とする用途に応じて発泡倍率、板厚さをそ
れぞれ変えてもよい。Embodiments of the present invention will be described in detail below with reference to the drawings. FIG. 1 is an external view of a laminate obtained by the manufacturing method according to the present invention. FIG. 2 is a conceptual diagram showing a state in which a prepreg and a foam are installed in the apparatus for manufacturing the laminated body shown in FIG. 1, and FIG. 3 is a system in which the heat source is retracted from the apparatus shown in FIG. FIG. 4 is a schematic view showing a first step of integrating the prepreg and the foam holding the prepreg and the supporting member out of the state shown in FIG. 3, and the prepreg and the foam are cooled and integrated by pressing. It is a conceptual diagram of a state. 5 and 6 are conceptual diagrams showing another embodiment of the present invention. FIG. 7 is an external arrow view showing a laminate in which a surface material is attached to one surface, and FIG. 8 is a prepreg, a foam and a surface material attached to the inside of the apparatus to form a laminate in which the surface material is attached to one surface. The conceptual diagram which shows the state currently being shown is shown. Reference numeral 1 shown in FIG. 1 denotes a laminate obtained by the present invention. 2, 3, 4, 5, and 6 represent prepreg laminates, and 2
6 to 6 may have the same laminated constitution and plate thickness, or may be changed depending on the intended use. Reference numerals 10, 11, 12, 13, and 14 denote resin foams. The foams 10 to 14 may have the same foaming ratio and thickness, but the foaming ratio and the plate thickness may be changed depending on the intended use.
【0019】積層体1に於て、プリプレグ積層体の層間
に存在する空気は、成形時の加熱工程に於て排除され、
かつ、プリプレグ積層体は発泡体の表面を溶融させるの
に十分な熱量が付与され、プリプレグ積層体と発泡体は
強固に接合されている。積層体の表面に近い発泡体10
14の発泡倍率が、中心層の発泡体11、12、13よ
り小さいことが、荷重を受けたときに、発泡体が圧壊し
ないので耐荷重性能を向上させる上で望ましい。全ての
発泡体の発泡倍率を小さくすることは、積層体の重量が
増加するので好ましくない。上述したように、表面層に
近いほど発泡倍率を小さくすることが、耐荷重性能を上
げて、重量増加を防止する上でのポイントである。In the laminated body 1, air existing between the layers of the prepreg laminated body is eliminated in the heating step at the time of molding,
Moreover, the prepreg laminate is provided with a sufficient amount of heat to melt the surface of the foam, and the prepreg laminate and the foam are firmly bonded. Foam 10 close to the surface of the laminate
It is desirable for the expansion ratio of 14 to be smaller than the foams 11, 12, and 13 of the central layer in order to improve the load bearing performance because the foams do not collapse when a load is applied. Reducing the expansion ratio of all foams is not preferable because the weight of the laminate increases. As described above, decreasing the foaming ratio as it gets closer to the surface layer is a point for improving load bearing performance and preventing an increase in weight.
【0020】図2は積層体の成形装置の概略図を示して
いるが、プレスの上下盤面に装着された離型フィルム4
0の間で、プリプレグ積層体及び発泡体を支持するクラ
ンプ20は、加熱されたプリプレグ及び発泡体が垂れ下
がりお互いが接触しない間隔及び張力を調整する機構を
具備しており、成形工程でプレス盤面に触れると盤面外
の33及び34の方向にに退避する機構を備えている。
30は熱板で、プレス盤面内に挿入、プレス盤面外の方
向35に退避が可能な機構を具備している。この熱板に
よりプリプレグ及び発泡体を加熱するが、短時間でプリ
プレグの樹脂が溶融する温度まで上げ、かつ発泡体を溶
融温度近傍まで上げることが必要で、そのためにはプリ
プレグとの間隔の調整機構及び温度制御機構が備わって
いなければならない。FIG. 2 shows a schematic view of the molding apparatus for the laminated body. The release film 4 mounted on the upper and lower surfaces of the press.
Between 0, the clamp 20 supporting the prepreg laminate and the foam has a mechanism for adjusting the interval and the tension at which the heated prepreg and the foam do not hang down and contact each other. A mechanism is provided for retracting in the directions 33 and 34 outside the board when touched.
A hot plate 30 is provided with a mechanism that can be inserted into the press platen surface and retracted in a direction 35 outside the press platen surface. The hot plate heats the prepreg and the foam, but it is necessary to raise the temperature of the resin of the prepreg to melt in a short time and to raise the foam to a temperature near the melting temperature. For that purpose, a mechanism for adjusting the distance from the prepreg. And a temperature control mechanism must be provided.
【0021】プリプレグと発泡体を同時に加熱すると発
泡倍率が高い発泡体の場合は発泡体の樹脂が先に溶融し
てしまうので、プリプレグが溶融状態になってから発泡
体を挿入し、プリプレグと発泡体の加熱時間を変える操
作をすることが望ましい。所定の温度にプリプレグと発
泡体が加熱された後、図3に示すように熱板をプレス盤
面外に退避させ、プレスを作動させて、上盤面が下がる
のに応じて、プリプレグ積層体及び発泡体がクランプか
ら外れプレス盤面外に退避すると同時に、プリプレグ積
層体及び発泡体が接触し、プリプレグに蓄熱された熱で
発泡体の表面が融け、プリプレグと発泡体が溶融一体化
され、次いで図4に示した様に、プレス中で冷却固化さ
れ発泡体を含む積層体が得られる。When the prepreg and the foam are heated at the same time, in the case of a foam having a high expansion ratio, the resin of the foam will be melted first, so the foam is inserted after the prepreg is in a molten state, and the prepreg and the foam are foamed. It is desirable to change the heating time of the body. After the prepreg and the foam are heated to a predetermined temperature, as shown in FIG. 3, the hot plate is evacuated to the outside of the press platen, the press is activated, and the prepreg laminate and the foam are generated in response to the lowering of the upper plate surface. At the same time as the body disengages from the clamp and retreats from the surface of the press board, the prepreg laminate and the foam come into contact with each other, the surface of the foam is melted by the heat accumulated in the prepreg, and the prepreg and the foam are melted and integrated. As shown in, a laminate containing the foam is obtained by cooling and solidifying in a press.
【0022】図5は、積層体を製造する別の方法を示し
たもので、表面層に近い発泡体10の発泡倍率が7倍以
下と低く、中心層の発泡倍率が15倍と高い場合に、同
一の加熱時間の中で発泡倍率の異なる発泡体とプリプレ
グ積層体が同時に所定の温度に加熱されないので、発泡
倍率の低い発泡体10及び14とプリプレグ積層体1と
2、及び5と6を予め重ねてクランプして更に熱板に直
接接触させて加熱する方法を示したものである。(但
し、図5ではクランプを省略した。) 図6は、積層体を製造する別の方法を示したもので、い
ずれか一方の表面層に近い発泡体10の発泡倍率が7倍
以下と低く、他の層の発泡倍率が15倍と高い場合に、
同一の加熱時間の中で発泡倍率の異なる発泡体とプリプ
レグ積層体が同時に所定の温度に加熱されないので、発
泡倍率の低い発泡体10とプリプレグ積層体1と2とを
予め重ねてクランプして更に熱板に直接接触させて加熱
する方法を示したものである。(但し、図6ではクラン
プを省略した。) 更に本発明を具体的な実施例で詳説する。FIG. 5 shows another method for producing a laminate, in the case where the foam 10 near the surface layer has a low expansion ratio of 7 times or less and the center layer has a high expansion ratio of 15 times. Since the foams having different expansion ratios and the prepreg laminates are not simultaneously heated to a predetermined temperature in the same heating time, the foams 10 and 14 having a low expansion ratio and the prepreg laminates 1 and 2 and 5 and 6 are not heated. It shows a method of stacking and clamping in advance and then directly contacting the heating plate for heating. (However, the clamp is omitted in FIG. 5.) FIG. 6 shows another method of manufacturing a laminated body, in which the foaming ratio of the foamed body 10 close to one of the surface layers is as low as 7 times or less. , When the expansion ratio of other layers is as high as 15 times,
Since the foams having different expansion ratios and the prepreg laminate are not simultaneously heated to a predetermined temperature in the same heating time, the foam 10 having a low expansion ratio and the prepreg laminates 1 and 2 are preliminarily overlapped and clamped. It shows a method of heating by directly contacting a hot plate. (However, the clamp is omitted in FIG. 6.) Further, the present invention will be described in detail with reference to specific examples.
【0023】[0023]
【実施例】本実施例で使用するプリプレグは、巾200
mmのものを特公平02−042168号公報に開示さ
れている方法で製造した。ガラス繊維の場合は太さ13
μのモノフィラメントの表面をγ−メタクリロキシ−プ
ロピルトリメトキシシランで処理し、それを1800本
集束して撚りのないヤーンとし、そのヤーンを80本を
均一な張力で引張ながら一方向に整列させて、樹脂をヤ
ーンに絡ませて、その樹脂を熱ロールでしごきながら、
ヤーンに含浸させてプリプレグを製造した。炭素繊維の
場合は、太さ7μのモノフィラメントを集束剤を使用せ
ずに12000本集めたトウを80本を均一な張力で引
張ながら一方向に整列させて、樹脂をヤーンに絡ませ
て、その樹脂を熱ロールでしごきながら、ヤーンに含浸
させてプリプレグを製造した。 この様にして製造した
プリプレグは、繊維と熱可塑性樹脂の密着性に優れ、繊
維含有率も30〜90重量%と要求に応じて変えること
が出来、厚みも0.1〜1.0mmで製造することが出
来るが、ガラス含有率は30−85容量%で、厚さ0.
1〜0.6mmのところで使用するのが望ましい。繊維
の容積含有率が30容量%以下では繊維量が少ないので
強度が低く、また85容量%以上では繊維に対して樹脂
量が少なく繊維と樹脂の密着性が低下し強度が低くなる
ので好ましくない。EXAMPLE The prepreg used in this example has a width of 200
mm was manufactured by the method disclosed in Japanese Patent Publication No. 02-042168. Thickness 13 for glass fiber
The surface of the monofilament of μ was treated with γ-methacryloxy-propyltrimethoxysilane, 1800 filaments were bundled into a twist-free yarn, and the yarn was aligned in one direction while pulling 80 yarns with a uniform tension. Entangling the resin in the yarn and squeezing the resin with a hot roll,
The yarn was impregnated to produce a prepreg. In the case of carbon fibers, without using a sizing agent, 12,000 monofilaments with a thickness of 7μ are gathered in one direction while pulling 80 tows with a uniform tension, and the resin is entangled with the yarn. Was squeezed with a hot roll to impregnate the yarn to produce a prepreg. The prepreg manufactured in this manner has excellent adhesion between the fiber and the thermoplastic resin, and the fiber content can be changed according to the requirement of 30 to 90% by weight, and the thickness is 0.1 to 1.0 mm. However, the glass content is 30-85% by volume and the thickness is 0.
It is desirable to use it at a distance of 1 to 0.6 mm. When the volume content of the fiber is 30% by volume or less, the strength is low because the amount of the fiber is small, and when the volume content of the fiber is 85% by volume or more, the amount of the resin is small with respect to the fiber and the adhesion between the fiber and the resin is reduced, which is not preferable. .
【0024】不飽和ポリエステルとガラス繊維のプリプ
レグは、三井東圧化学株式会社製の不飽和ポリエステル
エスターML1805 100重量部にt−ブチルパー
オキシベンゾエート1重量部、酸化マグネシウム5重量
部を加えた樹脂液を、シートモールディングコンパウン
ド製造機を使用し常法により、一方向に引き揃えたガラ
ス繊維に含浸し、40℃の雰囲気で24時間熟成して製
造した。The prepreg of unsaturated polyester and glass fiber is a resin liquid prepared by adding 1 part by weight of t-butylperoxybenzoate and 5 parts by weight of magnesium oxide to 100 parts by weight of unsaturated polyester ester ML1805 manufactured by Mitsui Toatsu Chemicals, Inc. Was impregnated into glass fibers aligned in one direction by a conventional method using a sheet molding compound manufacturing machine, and aged at 40 ° C. for 24 hours to manufacture.
【0025】表1に本発明の実施例及び比較例で使用す
るために製造したプリプレグの構成を示す。表2に本発
明で使用する樹脂発泡体の性状を示す。Table 1 shows the constitution of prepregs manufactured for use in the examples of the present invention and the comparative examples. Table 2 shows the properties of the resin foam used in the present invention.
【0026】実施例1 プリプレグAをその繊維方向を0度としたときに、上か
ら0度、90度、90度、0度と4枚重ね合わせた50
0mm角の積層体を6組と500mm角の樹脂発泡体P
を5枚準備した。図2に示した装置の1から6に積層体
を、10から14に樹脂発泡体をクランプし装着した。
樹脂発泡体をクランプした状態でプレス盤面外に退避さ
せ、200℃に加熱した熱板30をプレス盤面内に導入
し2分間プリプレグ積層体を加熱後、樹脂発泡体をプレ
ス盤面中に導入し5秒後に、熱板30をプレス盤面外に
退避させ60℃に加熱されたプレス上盤面31とプレス
下盤面32の間でプリプレグと発泡体を0.3kg/c
m2の圧力で加熱しながら冷却し積層体を得た。この積
層体の厚み及び重量を測定し、積層体の表面状態及び外
観を観察した。積層体の重量を(厚み×50×50)で
除して積層体の密度を算出した。また、この積層体を長
さ150mm、巾50mmの短冊状試験片に切りだし、
載荷速度50mm/分で、3点曲げ試験を行い、曲げ強
度及び曲げ弾性率を求めた。支持スパンと板厚みの比は
16:1とした。また、この積層体を長さ300mm、
巾50mmの短冊状試験片に切りだし、載荷速度50m
m/分で、3点曲げ試験を行い、破壊状態の観察を行う
と共に、曲げ強度及び曲げ弾性率を求めた。図9に曲げ
試験を行っている状態を示した。曲げ強度、曲げ弾性率
を密度で除し、比曲げ強度、比曲げ弾性率を算出した。
以上の結果を表3に示した。Example 1 When the fiber direction of the prepreg A was set to 0 degree, four sheets of 0 degree, 90 degree, 90 degree, and 0 degree were laminated from the top 50.
6 sets of 0 mm square laminates and 500 mm square resin foam P
Prepared 5 sheets. The laminated body was clamped to 1 to 6 and the resin foam was clamped to 10 to 14 of the device shown in FIG.
The resin foam is clamped and retracted to the outside of the press board, the hot plate 30 heated to 200 ° C. is introduced into the press board, the prepreg laminate is heated for 2 minutes, and then the resin foam is introduced into the press board. After a few seconds, the hot plate 30 was retracted to the outside of the press platen and 0.3 kg / c of the prepreg and the foam between the press upper platen surface 31 and the press lower platen surface 32 heated to 60 ° C.
A laminate was obtained by cooling while heating at a pressure of m2. The thickness and weight of this laminate were measured, and the surface condition and appearance of the laminate were observed. The weight of the laminate was divided by (thickness × 50 × 50) to calculate the density of the laminate. Further, this laminated body was cut into strip-shaped test pieces having a length of 150 mm and a width of 50 mm,
A three-point bending test was performed at a loading speed of 50 mm / min to determine bending strength and bending elastic modulus. The ratio of support span to plate thickness was 16: 1. In addition, this laminated body has a length of 300 mm,
Cut into 50 mm wide strip-shaped test pieces, loading speed 50 m
A three-point bending test was performed at m / min to observe the fractured state, and the bending strength and bending elastic modulus were obtained. FIG. 9 shows a state where the bending test is being performed. The bending strength and the bending elastic modulus were divided by the density, and the specific bending strength and the specific bending elastic modulus were calculated.
The above results are shown in Table 3.
【0027】実施例2 プリプレグAをその繊維方向を0度としたときに、上か
ら0度、90度、90度、0度と4枚重ね合わせた50
0mm角の積層体を6組と500mm角の樹脂発泡体Q
を2枚、発泡体Pを3枚準備した。図5に示した装置の
1から6に積層体を、10と14に樹脂発泡体Qを、1
1と12と13に樹脂発泡体Pをクランプし装着した。
樹脂発泡体Pをクランプした状態でプレス盤面外に退避
させ、200℃に加熱した熱板30をプレス盤面内に導
入し2分間プリプレグ積層体を加熱後、樹脂発泡体Pを
プレス盤面中に導入し5秒後に、熱板30をプレス盤面
外に退避させ60℃に加熱されたプレス上盤面31とプ
レス下盤面32の間でプリプレグと発泡体を0.3kg
/cm2 の圧力で加熱しながら冷却し積層体を得た。実
施例1と同様にして厚み、重量、表面状態と外観を観察
し、更に曲げ物性を評価した。その結果を表3に示し
た。Example 2 When the fiber direction of the prepreg A was set at 0 degree, four sheets of 0 degree, 90 degree, 90 degree and 0 degree were laminated from the top 50.
6 sets of 0 mm square laminates and 500 mm square resin foam Q
Were prepared, and three foams P were prepared. In the apparatus shown in FIG. 5, 1 to 6 are laminated bodies, and 10 and 14 are resin foam Q, respectively.
The resin foam P was clamped and attached to 1, 12, and 13.
The resin foam P is retracted outside the press board in a clamped state, the hot plate 30 heated to 200 ° C. is introduced into the press board surface, the prepreg laminate is heated for 2 minutes, and then the resin foam P is introduced into the press board surface. Then, after 5 seconds, the hot plate 30 is retracted to the outside of the press platen surface, and 0.3 kg of the prepreg and the foam are pressed between the press upper platen surface 31 and the press lower platen surface 32 heated to 60 ° C.
A laminate was obtained by cooling while heating at a pressure of / cm 2 . In the same manner as in Example 1, the thickness, weight, surface state and appearance were observed, and the bending properties were evaluated. The results are shown in Table 3.
【0028】実施例3 プリプレグAをその繊維方向を0度としたときに、上か
ら0度、90度、90度、0度と4枚重ね合わせた50
0mm角の積層体を6組と500mm角の樹脂発泡体Q
を1枚、発泡体Pを4枚準備した。図6に示した装置の
1から6に積層体を、10に樹脂発泡体Qを、11と1
2と13と14に樹脂発泡体Pをクランプし装着した。
樹脂発泡体Pをクランプした状態でプレス盤面外に退避
させ、200℃に加熱した熱板30をプレス盤面内に導
入し2分間プリプレグ積層体を加熱後、樹脂発泡体Pを
プレス盤面中に導入し5秒後に、熱板30をプレス盤面
外に退避させ60℃に加熱されたプレス上盤面31とプ
レス下盤面32の間でプリプレグと発泡体を0.3kg
/cm2 の圧力で加熱しながら冷却し積層体を得た。実
施例1と同様にして厚み、重量、表面状態と外観を観察
し、更に曲げ物性を評価した。その結果を表3に示し
た。Example 3 When prepreg A has a fiber direction of 0 degree, four sheets of 0 degree, 90 degree, 90 degree and 0 degree are laminated from the top 50.
6 sets of 0 mm square laminates and 500 mm square resin foam Q
1 and 4 foams P were prepared. In the apparatus shown in FIG. 6, 1 to 6 are laminated bodies, 10 is a resin foam Q, and 11 and 1 are the laminated bodies.
The resin foam P was clamped and attached to Nos. 2, 13 and 14.
The resin foam P is retracted outside the press board in a clamped state, the hot plate 30 heated to 200 ° C. is introduced into the press board surface, the prepreg laminate is heated for 2 minutes, and then the resin foam P is introduced into the press board surface. Then, after 5 seconds, the hot plate 30 is retracted to the outside of the press platen surface, and 0.3 kg of the prepreg and the foam are pressed between the press upper platen surface 31 and the press lower platen surface 32 heated to 60 ° C.
A laminate was obtained by cooling while heating at a pressure of / cm 2 . In the same manner as in Example 1, the thickness, weight, surface state and appearance were observed, and the bending properties were evaluated. The results are shown in Table 3.
【0029】実施例4 プリプレグAをその繊維方向を0度としたときに、上か
ら0度、90度、90度、0度と4枚重ね合わせた50
0mm角の積層体を6組と500mm角の樹脂発泡体P
を2枚、発泡体Rを2枚、発泡体Nを1枚準備した。図
5に示した装置の1から6に積層体を、10と14に樹
脂発泡体Rを、11と13に樹脂発泡体Pを、12に樹
脂発泡体Nをクランプし装着した。樹脂発泡体RとNを
クランプした状態でプレス盤面外に退避させ、200℃
に加熱した熱板30をプレス盤面内に導入し2分間プリ
プレグ積層体を加熱後、樹脂発泡体PとNをプレス盤面
中に導入し5秒後に、熱板30をプレス盤面外に退避さ
せ60℃に加熱されたプレス上盤面31とプレス下盤面
32の間でプリプレグと発泡体を0.3kg/cm 2 の
圧力で加熱しながら冷却し積層体を得た。実施例1と同
様にして厚み、重量、表面状態と外観を観察し、更に曲
げ物性を評価した。その結果を表3に示した。Example 4 When the fiber direction of prepreg A was set to 0 degree,
4 layers of 0 degree, 90 degree, 90 degree, 0 degree
6 sets of 0 mm square laminates and 500 mm square resin foam P
Was prepared, two foams R, two foams N, and one foam N were prepared. Figure
Laminates 1 to 6 of the equipment shown in 5 and trees 10 and 14
Resin foam P is used for 11 and 13 and resin foam P is used for 12
The fat foam N was clamped and attached. Resin foam R and N
Retract out of the press board in the clamped state, 200 ℃
The hot plate 30 heated to the inside is introduced into the surface of the press board and pre-treated for 2 minutes.
After heating the prepreg laminate, the resin foams P and N are pressed onto the press surface.
5 seconds after introducing the heat plate, retract the hot plate 30 to the outside of the press platen.
Press upper platen surface 31 and press lower platen surface heated to 60 ° C
0.3kg / cm of prepreg and foam between 32 2of
A laminate was obtained by cooling while heating with pressure. Same as Example 1
Similarly, observe the thickness, weight, surface condition and appearance, and
The physical properties were evaluated. The results are shown in Table 3.
【0030】実施例5 プリプレグAをその繊維方向を0度としたときに、上か
ら0度、90度、90度、0度と4枚重ね合わせた50
0mm角の積層体を6組と500mm角の樹脂発泡体S
を2枚、発泡体Pを3枚準備した。図5に示した装置の
1から6に積層体を、10と14に樹脂発泡体Sを、1
1と12と13に樹脂発泡体Pをクランプし装着した。
樹脂発泡体Pをクランプした状態でプレス盤面外に退避
させ、200℃に加熱した熱板30をプレス盤面内に導
入し2分間プリプレグ積層体を加熱後、樹脂発泡体Pを
プレス盤面中に導入し5秒後に、熱板30をプレス盤面
外に退避させ60℃に加熱されたプレス上盤面31とプ
レス下盤面32の間でプリプレグと発泡体を0.3kg
/cm2 の圧力で加熱しながら冷却し積層体を得た。実
施例1と同様にして厚み、重量、表面状態と外観を観察
し、更に曲げ物性を評価した。その結果を表3に示し
た。Example 5 When prepreg A has a fiber direction of 0 °, four sheets of 0 °, 90 °, 90 °, and 0 ° are laminated from the top 50.
6 sets of 0mm square laminates and 500mm square resin foam S
Were prepared, and three foams P were prepared. In the apparatus shown in FIG. 5, 1 to 6 are laminated bodies, and 10 and 14 are resin foam S.
The resin foam P was clamped and attached to 1, 12, and 13.
The resin foam P is retracted outside the press board in a clamped state, the hot plate 30 heated to 200 ° C. is introduced into the press board surface, the prepreg laminate is heated for 2 minutes, and then the resin foam P is introduced into the press board surface. Then, after 5 seconds, the hot plate 30 is retracted to the outside of the press platen surface, and 0.3 kg of the prepreg and the foam are pressed between the press upper platen surface 31 and the press lower platen surface 32 heated to 60 ° C.
A laminate was obtained by cooling while heating at a pressure of / cm 2 . In the same manner as in Example 1, the thickness, weight, surface state and appearance were observed, and the bending properties were evaluated. The results are shown in Table 3.
【0031】実施例6 プリプレグAの代わりにプリプレグCを使う以外は、実
施例5と同様にして積層体を得た。この積層体を実施例
1と同様にして評価した。評価結果を表3に示した。Example 6 A laminate was obtained in the same manner as in Example 5 except that prepreg C was used instead of prepreg A. This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0032】実施例7 プリプレグAの代わりにプリプレグB、樹脂発泡体Sの
代わりに樹脂発泡体U、樹脂発泡体Pの代わりに樹脂発
泡体Tを使用する以外は実施例5と同様にして積層体を
得た。この積層体を実施例1と同様にして評価した。評
価結果を表3に示した。Example 7 Lamination was performed in the same manner as in Example 5 except that prepreg B was used instead of prepreg A, resin foam U was used instead of resin foam S, and resin foam T was used instead of resin foam P. Got the body This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0033】実施例8 プリプレグAの代わりにプリプレグD、樹脂発泡体Sの
代わりに樹脂発泡体U、樹脂発泡体Pの代わりに樹脂発
泡体Tを使用する以外は実施例5と同様にして積層体を
得た。この積層体を実施例1と同様にして評価した。評
価結果を表3に示した。Example 8 Lamination was performed in the same manner as in Example 5 except that prepreg D was used instead of prepreg A, resin foam U was used instead of resin foam S, and resin foam T was used instead of resin foam P. Got the body This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0034】実施例9 プリプレグAの代わりにプリプレグE、樹脂発泡体Sの
代わりに樹脂発泡体W、樹脂発泡体Pの代わりに樹脂発
泡体Vを使用する以外は実施例5と同様にして積層体を
得た。この積層体を実施例1と同様にして評価した。評
価結果を表3に示した。Example 9 Lamination was performed in the same manner as in Example 5 except that prepreg E was used instead of prepreg A, resin foam W was used instead of resin foam S, and resin foam V was used instead of resin foam P. Got the body This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0035】実施例10 実施例1と同様にして、プリプレグAをその繊維方向を
0度としたときに、上から0度、90度、90度、0度
と4枚重ね合わせた500mm角の積層体を6組と50
0mm角の樹脂発泡体Pを5枚準備した。図8に示した
装置の1から6に積層体を、10から14に樹脂発泡体
をクランプし装着した。更に、2mm厚さの発泡ポリウ
レタンシートで裏打ちされた塩化ビニールレーザー39
を離型フィルム40の上に塩化ビニールレーザーの面が
離型フィルムに接触するようにして静置した。樹脂発泡
体をクランプした状態でプレス盤面外に退避させ、20
0℃に加熱した熱板30をプレス盤面内に導入し2分間
プリプレグ積層体を加熱後、樹脂発泡体をプレス盤面中
に導入し5秒後に、熱板30をプレス盤面外に退避させ
60℃に加熱されたプレス上盤面31とプレス下盤面3
2の間でプリプレグと発泡体を0.3kg/cm2 の圧
力で加熱しながら冷却し積層体を得た。外観良好で、塩
化ビニールレザーの感触の良い積層体が得られた。Example 10 In the same manner as in Example 1, when the fiber direction of the prepreg A was set to 0 degree, four pieces of a 500 mm square, which were 0 degree, 90 degree, 90 degree and 0 degree from the top, were superposed. 6 sets and 50 stacks
Five pieces of 0 mm square resin foam P were prepared. The laminated body was clamped to 1 to 6 and the resin foam was clamped to 10 to 14 of the device shown in FIG. Furthermore, vinyl chloride laser 39 lined with a 2 mm thick polyurethane foam sheet
Was placed on the release film 40 with the surface of the vinyl chloride laser being in contact with the release film. With the resin foam clamped, retract it to the outside of the press board,
The hot plate 30 heated to 0 ° C. is introduced into the press platen surface, the prepreg laminate is heated for 2 minutes, the resin foam is introduced into the press platen surface, and 5 seconds later, the hot plate 30 is evacuated to the outside of the press platen 60 ° C. Pressed upper surface 31 and pressed lower surface 3
Between the two, the prepreg and the foam were cooled while being heated at a pressure of 0.3 kg / cm 2 to obtain a laminate. A laminate having a good appearance and a good feel of vinyl chloride leather was obtained.
【0036】比較例1 プリプレグFをその繊維方向を0度としたときに、上か
ら0度、90度、0度、90度、0度、90度、90
度、0度、90度、0度、90度、0度と12枚重ね合
わせた500mm角の積層体を2組と500mm角の樹
脂発泡体Xを1枚準備した。この積層体と発泡体を上か
ら積層体/発泡体/積層体の順に重ね合わせ、150℃
に加熱した熱板を装着したプレスに投入し、0.3kg
/cm2 の圧力で10分間加熱した後取りだし積層体を
得た。プリプレグFを硬化させるために、150℃の高
温で処理したため、発泡体が圧力で一部破壊し、硬化し
たプリプレグの表面状態も成形圧力不足で悪かった。こ
の積層体を実施例1と同様にして評価した。評価結果を
表3に示した。Comparative Example 1 When the fiber direction of the prepreg F is 0 degree, 0 degree, 90 degree, 0 degree, 90 degree, 0 degree, 90 degree, 90 degrees from the top.
Two sets of 500 mm square laminates were stacked by stacking 12 sheets of 0 °, 90 °, 0 °, 90 °, and 0 °, and one resin foam X of 500 mm square was prepared. This laminated body and the foam are superposed in the order of laminated body / foamed body / laminated body from the top, and the temperature is 150 ° C.
Put into a press equipped with a heating plate heated to 0.3 kg
After being heated at a pressure of / cm 2 for 10 minutes, it was taken out to obtain a laminated body. Since the prepreg F was treated at a high temperature of 150 ° C. to cure it, the foam partly broke under pressure, and the surface condition of the cured prepreg was poor due to insufficient molding pressure. This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0037】比較例2 プリプレグAをその繊維方向を0度としたときに、上か
ら0度、90度、0度、90度、0度、90度、90
度、0度、90度、0度、90度、0度と12枚重ね合
わせた500mm角の積層体を2組と500mm角の樹
脂発泡体Oを1枚準備した。図2に示した装置の1と2
に積層体を、10に樹脂発泡体をクランプし装着した。
(この例の場合、積層体3〜6と発砲体11〜14は装
着されていない。)樹脂発泡体Oクランプした状態でプ
レス盤面外に退避させ、200℃に加熱した熱板30を
プレス盤面内に導入し2分間プリプレグ積層体を加熱
後、樹脂発泡体Oプレス盤面中に導入し5秒後に、熱板
30をプレス盤面外に退避させ60℃に加熱されたプレ
ス上盤面31とプレス下盤面32の間でプリプレグと発
泡体を0.3kg/cm2 の圧力で加熱しながら冷却し
積層体を得た。この積層体を実施例1と同様にして評価
した。評価結果を表3に示した。Comparative Example 2 When the fiber direction of the prepreg A is 0 degree, 0 degree, 90 degree, 0 degree, 90 degree, 0 degree, 90 degree, 90 degrees from the top.
Two sets of 500 mm square laminates, which were a stack of 12 sheets of 0 °, 90 °, 0 °, 90 °, and 0 °, and one resin foam O of 500 mm square were prepared. 1 and 2 of the device shown in FIG.
The laminated body was attached to, and the resin foam was clamped and attached to 10.
(In the case of this example, the laminated bodies 3 to 6 and the foaming bodies 11 to 14 are not attached.) The resin foam O is retracted to the outside of the press board in a clamped state, and the hot plate 30 heated to 200 ° C. is pressed to the press board surface. After heating the prepreg laminate for 2 minutes and introducing it into the resin foam O press board surface, the hot plate 30 is evacuated to the outside of the press board surface 5 seconds later, and the press upper board surface 31 and the press bottom surface heated to 60 ° C. The prepreg and the foam were cooled while being heated at a pressure of 0.3 kg / cm 2 between the board surfaces 32 to obtain a laminate. This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0038】比較例3 プリプレグAの代わりにプリプレグGを使用する以外は
実施例5と同様にして積層体を得た。この積層体を実施
例1と同様にして評価した。評価結果を表3に示した。Comparative Example 3 A laminate was obtained in the same manner as in Example 5 except that prepreg G was used instead of prepreg A. This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0039】比較例4 プリプレグAの代わりにプリプレグHを使用する以外は
実施例5と同様にして積層体を得た。この積層体を実施
例1と同様にして評価した。評価結果を表3に示した。Comparative Example 4 A laminate was obtained in the same manner as in Example 5 except that prepreg H was used instead of prepreg A. This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0040】[0040]
【表1】 [Table 1]
【0041】[0041]
【表2】 [Table 2]
【0042】[0042]
【表3】 [Table 3]
【0043】[0043]
【発明の効果】本発明の方法により、樹脂発泡体と熱可
塑性樹脂プリプレグが強固に一体化された軽量で、高剛
性の積層体を製造することが出来る。According to the method of the present invention, a lightweight and highly rigid laminate in which a resin foam and a thermoplastic resin prepreg are firmly integrated can be manufactured.
【図1】本発明による製造方法により得られる積層体の
外観矢視図である。FIG. 1 is an external view of a laminate obtained by a manufacturing method according to the present invention.
【図2】本発明の積層体を製造する装置内にプリプレ
グ、発泡体が装着されている状態を示す概念図である。FIG. 2 is a conceptual diagram showing a state in which a prepreg and a foam are installed in an apparatus for producing a laminate of the present invention.
【図3】図2に示した装置から熱源を退避させてプリプ
レグと発泡体を一体化する第一段階を示す概略図であ
る。FIG. 3 is a schematic diagram showing a first stage in which the heat source is retracted from the apparatus shown in FIG. 2 to integrate the prepreg and the foam.
【図4】図3に示した状態からプリプレグ及び発泡体を
保持している支持具が外れてプリプレグと発泡体をプレ
スにより冷却一体化を行っている状態の概念図である。FIG. 4 is a conceptual diagram of a state in which the support holding the prepreg and the foam is removed from the state shown in FIG. 3 and the prepreg and the foam are cooled and integrated by a press.
【図5】表面層及び裏面層に近い部分の発泡体の発泡倍
率が中心層にある発泡体の発泡倍率より低い場合の積層
体を成形する時の状態を示す概念図である。FIG. 5 is a conceptual diagram showing a state at the time of molding a laminate in which the foaming ratio of the foam near the front surface layer and the back surface layer is lower than the foaming ratio of the foam in the central layer.
【図6】表面層に近い部分の発泡体の発泡倍率が中心層
にある発泡体の発泡倍率より低い場合の積層体を成形す
る時の状態を示す概念図である。FIG. 6 is a conceptual diagram showing a state at the time of molding a laminate in which the foaming ratio of the foam near the surface layer is lower than the foaming ratio of the foam in the central layer.
【図7】図7は片面に表面材を貼合わせた積層体を示す
外観矢視図を示す。FIG. 7 is an external arrow view showing a laminated body in which a surface material is attached to one surface.
【図8】片面に表面材を貼合わせた積層体を成形するた
めに装置内にプリプレグ、発泡体及び表面材が装着され
ている状態を示す概念図を示す。FIG. 8 is a conceptual diagram showing a state in which a prepreg, a foam, and a surface material are mounted in an apparatus to form a laminate in which a surface material is attached to one surface.
【図9】積層体の曲げ強度を行っている状態を示す。FIG. 9 shows a state in which bending strength of the laminate is being performed.
1・・・・・積層体 2・・・・・プリプレグ積層体 3・・・・・プリプレグ積層体 4・・・・・プリプレグ積層体 5・・・・・プリプレグ積層体 6・・・・・プリプレグ積層体 10・・・・・樹脂発泡体 11・・・・・樹脂発泡体 12・・・・・樹脂発泡体 13・・・・・樹脂発泡体 14・・・・・樹脂発泡体 20・・・・・クランプ 30・・・・・熱板 31・・・・・プレス上盤面 32・・・・・プレス下盤面 33・・・・・右側クランプの退避方向 34・・・・・左側クランプの退避方向 35・・・・・熱板の退避方向 39・・・・・表面材 40・・・・・離型フィルム 1 ... Laminated body 2 ... Prepreg laminated body 3 ... Prepreg laminated body 4 ... Prepreg laminated body 5 ... Prepreg laminated body 6 ... Prepreg laminate 10 ... Resin foam 11 ... Resin foam 12 ... Resin foam 13 ... Resin foam 14 ... Resin foam 20.・ ・ ・ ・ Clamp 30 ・ ・ ・ Hot plate 31 ・ ・ ・ Press upper plate surface 32 ・ ・ ・ Press lower plate surface 33 ・ ・ ・ Right side clamp retracting direction 34 ・ ・ ・ Left side clamp Retracting direction 35 ... Retracting direction of hot plate 39 ... Surface material 40 ... Release film
─────────────────────────────────────────────────────
─────────────────────────────────────────────────── ───
【手続補正書】[Procedure amendment]
【提出日】平成6年2月16日[Submission date] February 16, 1994
【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】発明の詳細な説明[Name of item to be amended] Detailed explanation of the invention
【補正方法】変更[Correction method] Change
【補正内容】[Correction content]
【発明の詳細な説明】Detailed Description of the Invention
【0001】[0001]
【産業上の利用分野】本発明は、連続した強化繊維を一
方向に整列させ熱可塑性樹脂を含浸した1枚以上のプリ
プレグの積層体と樹脂発泡体とを多層に組み合せて溶融
一体化して成る成形品及びその製造法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention comprises a laminate of one or more prepregs impregnated with a thermoplastic resin and a resin foam, which are formed by aligning continuous reinforcing fibers in one direction and melt-integrating them. The present invention relates to a molded product and a method for manufacturing the same.
【0002】[0002]
【従来の技術】従来から、樹脂発泡体の上下面に繊維補
強樹脂板を貼り付けることにより、軽量で、面剛性の高
い板が出来ることが知られており一般的にはこのような
板は、不飽和ポリエステル樹脂等の熱硬化性樹脂をマト
リックスとする繊維補強板と熱硬化性のポリウレタン樹
脂を発泡させた硬質ウレタンフォームを一体化すること
により製造される。一体化する方法としては、繊維補強
板のマトリックス樹脂が硬化する前の液状であるうち
に、樹脂発泡体と重ね合わせて、プレス機等で加圧して
液状のマトリックス樹脂を樹脂発泡体の表面から浸透さ
せ、硬化する時に発泡体に浸透した樹脂が固化し発泡体
中に食い込んだ状態で物理的に接合させる場合と、繊維
補強板をあらかじめ成形し、接着剤を使用して発泡体と
接合する場合がある。また、別の方法として繊維強化熱
可塑性樹脂板は熱可塑性樹脂からなる発泡体の上下面に
貼合わせた板も知られている。2. Description of the Related Art Conventionally, it has been known that a fiber reinforced resin plate is attached to the upper and lower surfaces of a resin foam to make a plate that is lightweight and has high surface rigidity. It is manufactured by integrating a fiber reinforced plate having a thermosetting resin such as an unsaturated polyester resin as a matrix with a hard urethane foam obtained by foaming a thermosetting polyurethane resin. As a method of integrating, while the matrix resin of the fiber reinforced plate is in a liquid state before being cured, it is superposed on the resin foam, and is pressed by a press machine or the like to remove the liquid matrix resin from the surface of the resin foam. When the resin that has penetrated into the foam is solidified when it is allowed to penetrate and harden, and when it is physically joined while it penetrates into the foam, or when the fiber reinforced plate is preformed and the adhesive is used to join with the foam. There are cases. As another method, a plate in which a fiber-reinforced thermoplastic resin plate is laminated on the upper and lower surfaces of a foam made of a thermoplastic resin is also known.
【0003】[0003]
【発明が解決しようとする課題】しかしながら、上記の
方法で製造された板は上述したように面剛性は高いが、
局部的な曲げ荷重や衝撃荷重が加わった場合に、上下面
の繊維補強樹脂板は破壊しないが、荷重が加わった直下
の発泡体だけが部分的に圧壊し板としての機能が失われ
る現象が頻発し問題である。一方、面全体で荷重を受け
大きな変形を起こした場合に、繊維補強樹脂板と発泡体
との接合面が剥離し易く構造部材として使用するために
は信頼性に乏しい点も指摘されている。また、上記の製
造法では熱硬化性樹脂を取り扱うときの悪臭及び補強繊
維の飛散が作業環境を悪化させ衛生上の問題が指摘され
ている。However, although the plate manufactured by the above method has high surface rigidity as described above,
When a local bending load or impact load is applied, the fiber-reinforced resin plates on the upper and lower surfaces are not destroyed, but only the foam directly under the load is partially collapsed and the function as a plate is lost. It is a frequent problem. On the other hand, it has been pointed out that the joint surface between the fiber-reinforced resin plate and the foam is easily peeled off when it is subjected to a large deformation due to the load on the entire surface, and the reliability is poor for use as a structural member. Further, in the above-mentioned manufacturing method, it is pointed out that the bad odor and the scattering of the reinforcing fibers when handling the thermosetting resin deteriorates the working environment and causes a hygiene problem.
【0004】さらに繊維補強樹脂板の成形、樹脂発泡体
との接合を行うので、硬化、接着剤の塗布、圧着、養生
等の工程管理が必要であり加工コストが掛かる等の問題
が生じる。また、繊維強化熱可塑性樹脂板は熱可塑性樹
脂からなる発泡体の上下面に貼合わせた板の場合も、適
切な接着剤がないこと、熱融着で接合する場合でも発泡
体の厚さを均一に保持して作業することが困難で性能の
ばらつきが多い等の問題が生じている。そこで、本発明
の目的は、熱可塑性樹脂をマトリックスとする繊維補強
板と熱可塑性樹脂から成る発泡体を使用して、接着剤を
使用せずに繊維補強板と発泡体とが強固に接合された面
剛性が高く、発泡体の厚みが変化しない積層体及びその
製造方法を、衛生的な作業環境で安価に提供することに
ある。Further, since the fiber-reinforced resin plate is molded and joined to the resin foam, there is a problem that process control such as curing, application of adhesive, pressure bonding and curing is required, resulting in high processing cost. Also, in the case of a fiber-reinforced thermoplastic resin plate that is laminated on the upper and lower surfaces of a foam made of a thermoplastic resin, there is no suitable adhesive, and the thickness of the foam does not change even when joining by heat fusion. There are problems that it is difficult to work while holding them uniformly, and there are many variations in performance. Therefore, an object of the present invention is to use a foam made of a thermoplastic resin and a fiber reinforced plate having a thermoplastic resin as a matrix, and to firmly bond the fiber reinforced plate and the foam without using an adhesive. Another object of the present invention is to provide a laminate having a high surface rigidity and a foam that does not change its thickness, and a method for producing the same at low cost in a hygienic work environment.
【0005】[0005]
【課題を解決するための手段】本発明者らは上記目的を
達成するため、鋭意検討を重ねた結果、本発明を完成す
るに至ったものである。すなわち、本発明に係わる積層
体は、連続した強化繊維を一方向に整列させ熱可塑性樹
脂を含浸した1枚以上のプリプレグと樹脂発泡体とを積
層した成形品において、樹脂発泡体とプリプレグとを積
層した組み合せを2層以上重ね合わせて層間を熱接合せ
しめられたことを特徴とする。上記プリプレグは、容積
含有率で30%以上85%以下の強化繊維を含むことが
推奨され、またその強化繊維が一方向に連続な長繊維か
ら成るものであることが推奨される。また、上記強化繊
維がガラス繊維であり、熱可塑性樹脂及び発泡体がポリ
プロピレン系樹脂又はポリスチレン系樹脂であり、更に
荷重が加わる面の表面の近くに存在する発泡体の発泡倍
率の方が、中心層に近い発泡体の発泡倍率より低い様な
場合に対して本発明は好適に適用し得る。The present inventors have completed the present invention as a result of intensive studies to achieve the above object. That is, the laminate according to the present invention is a molded product obtained by laminating one or more prepregs impregnated with a thermoplastic resin and resin foams by aligning continuous reinforcing fibers in one direction and laminating the resin foams and prepregs. It is characterized in that two or more layers of the laminated combination are overlapped and the layers are thermally bonded. It is recommended that the prepreg contains 30% or more and 85% or less by volume content of reinforcing fibers, and that the reinforcing fibers are unidirectionally continuous filaments. Further, the reinforcing fiber is a glass fiber, the thermoplastic resin and the foam is a polypropylene-based resin or polystyrene-based resin, further the expansion ratio of the foam present near the surface of the load is the center, The present invention can be preferably applied to the case where the expansion ratio of the foam close to the layer is lower.
【0006】また、上記の積層成形品を製造するための
本発明に係る製造方法は、連続した強化繊維を一方向に
整列させ熱可塑性樹脂を含浸した1枚以上のプリプレグ
をその熱可塑性樹脂の溶融温度以上に加熱して層間に含
まれる空気の脱気を行うステップと、プリプレグを溶融
温度以上に、樹脂発泡体を溶融温度以下、にお互いが接
触しない状態で同時に加熱するステップと、加熱したプ
リプレグと樹脂発泡体をお互いに重ね合わせて加圧して
熱接合を行うステップと、熱接合された積層品を冷却、
固化して一体化せしめるステップを順次実行することを
特徴とする。上記の製造方法は、その強化繊維が容積含
有率で30%以上85%以下の強化繊維を含み、かつ一
方向に連続な長繊維から成るものであるときに好適に適
用でき、特に、強化繊維がガラス繊維であり、熱可塑性
樹脂及び発泡体がポリプロピレン系樹脂又はポリスチレ
ン系樹脂であり、更に荷重が加わる面の表面の近くに存
在する発泡体の発泡倍率の方が、中心層に近い発泡体の
発泡倍率より低い様な場合に対して本発明は好適に適用
し得る。Further, in the production method according to the present invention for producing the above-mentioned laminated molded article, one or more prepregs in which continuous reinforcing fibers are aligned in one direction and impregnated with the thermoplastic resin are used. Heating to above the melting temperature to degas the air contained in the layers; heating the prepreg above the melting temperature, heating the resin foam below the melting temperature, simultaneously without contacting each other; A step of heat-bonding the prepreg and the resin foam overlaid on each other and applying pressure; cooling the heat-bonded laminate;
It is characterized in that the steps of solidifying and integrating are sequentially executed. The above-mentioned production method can be suitably applied when the reinforcing fiber contains 30% or more and 85% or less by volume content of the reinforcing fiber and is composed of continuous fibers in one direction, and particularly, the reinforcing fiber. Is a glass fiber, the thermoplastic resin and the foam is a polypropylene-based resin or polystyrene-based resin, further the foaming ratio of the foam existing near the surface of the load is closer to the center layer The present invention can be suitably applied to the case where the expansion ratio is lower than the above.
【0007】本発明に使用される、一方向に配列した繊
維に熱可塑性樹脂を含浸させたプリプレグに用いられる
熱可塑性樹脂としては、例えばポリスチレン、ポリプロ
ピレン、ポリエチレン、AS樹脂、ABS樹脂、ASA
樹脂(ポリアクリロニトリル・ポリスチレン・ポリアク
リル酸エステル)、ポリメチルメタクリレート、ナイロ
ン、ポリアセタール、ポリカーボネート、ポリエチレン
テレフタレート、ポリフェニレンオキシド、フッ素樹
脂、ポリフェニレンスルフィド、ポリスルフォン、ポリ
エーテルサルフォン、ポリエーテルケトン、ポリエーテ
ルエーテルケトン、ポリイミド、ポリアリレート等があ
る。The thermoplastic resin used in the prepreg obtained by impregnating the unidirectionally arranged fibers with the thermoplastic resin used in the present invention is, for example, polystyrene, polypropylene, polyethylene, AS resin, ABS resin, ASA.
Resin (polyacrylonitrile / polystyrene / acrylic acid ester), polymethylmethacrylate, nylon, polyacetal, polycarbonate, polyethylene terephthalate, polyphenylene oxide, fluororesin, polyphenylene sulfide, polysulfone, polyethersulfone, polyetherketone, polyetherether Examples include ketones, polyimides, polyarylates and the like.
【0008】一方向に配列した繊維に熱可塑性樹脂を含
浸させたプリプレグに用いられる繊維としては、例えば
ガラス繊維、カーボン繊維、アラミド繊維、炭化ケイ素
繊維等が代表的なものである。一方向に配列した繊維に
熱可塑性樹脂を含浸してなるプリプレグは、通常太さ3
〜25μmのモノフィラメントを200〜12000本
集束したヤーンもしくは、ロービングを、所定本数一方
向に並べたものに熱可塑性樹脂を含浸させたものを用い
る。Typical fibers used in a prepreg in which fibers arranged in one direction are impregnated with a thermoplastic resin are, for example, glass fibers, carbon fibers, aramid fibers and silicon carbide fibers. A prepreg obtained by impregnating fibers arranged in one direction with a thermoplastic resin usually has a thickness of 3
A yarn obtained by bundling 200 to 12000 monofilaments of -25 μm or a roving in which a predetermined number of rovings are arranged in one direction is impregnated with a thermoplastic resin.
【0009】ガラス繊維は通常各種の表面処理を行い、
樹脂との密着性を向上させることが行われる。表面処理
は、集束剤とカップリング剤を組み合わせて行う。モノ
フィラメントを集束するためには、通常集束剤を使用す
る。集束剤は組み合わせる熱可塑性樹脂により選択する
必要がある。一般的には組み合せる樹脂の溶融温度で軟
化して、熱可塑性樹脂が繊維束中に含浸し易いものを選
択する。そのために組み合せる熱可塑性樹脂と同種の樹
脂を主成分とする集束剤を使用する場合が多い。プリプ
レグの繊維として使用するガラス繊維は、シラン系、チ
タネート系、ジルコニウム系のカップリング剤で処理
し、樹脂との密着性を向上させたものを用いる。Glass fiber is usually subjected to various surface treatments,
The adhesion with the resin is improved. The surface treatment is performed by combining a sizing agent and a coupling agent. A sizing agent is usually used to focus the monofilaments. The sizing agent needs to be selected depending on the thermoplastic resin to be combined. Generally, a resin that is softened at the melting temperature of the resins to be combined and easily impregnated with the thermoplastic resin in the fiber bundle is selected. Therefore, a sizing agent whose main component is a resin of the same kind as the thermoplastic resin to be combined is often used. The glass fiber used as the fiber of the prepreg is one that is treated with a silane-based, titanate-based, or zirconium-based coupling agent to improve the adhesion to the resin.
【0010】ガラス繊維の場合のカップリング剤は、組
み合わせる樹脂に応じて最適なものを選ぶ必要があり以
下その具体例を例挙する。ナイロン樹脂であれば、γ−
アミノプロピル−トリメトキシシラン、N−β−(アミ
ノエチル)−γ−アミノプロピル−トリメトキシシラン
等を使用する。ポリカーボネート樹脂であれば、γ−ア
ミノプロピル−トリメトキシシラン、N−β−(アミノ
エチル)−γ−アミノプロピル−トリメトキシシラン等
を使用する。ポリエチレンテレフタレートまたは、ポリ
ブチレンテレフタレート、であれば、β−(3,4−エ
ポキシシクロヘキシル)エチル−トリメトキシシラン、
γ−グリシドキシ−プロピルトリメトキシシラン、γ−
アミノプロピル−トリメトキシシラン等を使用する。ポ
リエチレンまたはポリプロピレンであれば、ビニルトリ
メトキシシラン、ビニル−トリス− (2−メトキシエ
トキシ)シラン、γ−メタクリロキシ−プロピルトリメ
トキシシラン等を使用する。ポリフェニレンオキシド、
ポリフェニレンスルフィド、ポリスルフォン、ポリエー
テルサルフォン、ポリエーテルケトン、ポリエーテルエ
ーテルケトン、ポリイミド、ポリアリレート、フッ素樹
脂であれば、上述したカップリング剤も当然使用出来る
が、その外に、N−(β−アミノエチル)−γ−アミノ
プロピルメチルジメトキシシラン、γ−クロロプロピル
メチルジメトキシシラン、γ−メルカプトプロピルトリ
メトキシシラン、p−アミノフェニルトリエトキシシラ
ン等を使用できる。In the case of glass fiber, it is necessary to select the most suitable coupling agent according to the resin to be combined, and specific examples thereof will be given below. For nylon resin, γ-
Aminopropyl-trimethoxysilane, N-β- (aminoethyl) -γ-aminopropyl-trimethoxysilane and the like are used. If it is a polycarbonate resin, γ-aminopropyl-trimethoxysilane, N-β- (aminoethyl) -γ-aminopropyl-trimethoxysilane and the like are used. If polyethylene terephthalate or polybutylene terephthalate, then β- (3,4-epoxycyclohexyl) ethyl-trimethoxysilane,
γ-glycidoxy-propyltrimethoxysilane, γ-
Aminopropyl-trimethoxysilane or the like is used. If polyethylene or polypropylene is used, vinyltrimethoxysilane, vinyl-tris- (2-methoxyethoxy) silane, γ-methacryloxy-propyltrimethoxysilane, or the like is used. Polyphenylene oxide,
As long as it is polyphenylene sulfide, polysulfone, polyether sulfone, polyether ketone, polyether ether ketone, polyimide, polyarylate, or a fluororesin, the above-mentioned coupling agent can be used, but N- (β -Aminoethyl) -γ-aminopropylmethyldimethoxysilane, γ-chloropropylmethyldimethoxysilane, γ-mercaptopropyltrimethoxysilane, p-aminophenyltriethoxysilane and the like can be used.
【0011】ガラス繊維以外を補強繊維として用いる時
は、アミン硬化型のエポキシ樹脂をカップリング剤とし
て処理する場合が多く、その具体例としてはビスフェノ
ール−A−エピクロルヒドリン樹脂、エポキシノボラッ
ク樹脂、脂環式エポキシ樹脂、脂肪族エポキシ樹脂、グ
リシジルエステル型樹脂を使用することがもあるが、熱
可塑性樹脂は一般的に溶融温度が高いので、通常のカッ
プリング剤は熱分解するので、全くカップリング剤を使
用しない場合もある。When a fiber other than glass fiber is used as the reinforcing fiber, an amine-curing type epoxy resin is often treated as a coupling agent, and specific examples thereof include bisphenol-A-epichlorohydrin resin, epoxy novolac resin and alicyclic compounds. Epoxy resins, aliphatic epoxy resins, and glycidyl ester type resins may be used, but since thermoplastic resins generally have high melting temperatures, ordinary coupling agents undergo thermal decomposition, so no coupling agents are used. It may not be used.
【0012】カップリング剤を繊維表面に施す方法は以
下の通りである。即ち、一つの方法としては、繊維を溶
融してモノフィラメントを引き出す際に集束剤とカップ
リング剤を界面活性剤を添加して水溶液としたものを、
モノフィラメントに噴霧した後、100℃程度の温度で
乾燥して処理する。他の方法として、集束剤を除去した
繊維に、集束剤及びカップリング剤を0.1〜3重量%
溶解した液を、浸漬、噴霧塗布等の手段により完全に含
浸させる。このカップリング剤溶液を含んだ繊維を60
〜120゜Cで乾燥し、カップリング剤を繊維表面に反
応させる。乾燥時間は溶媒が揮散してしまう時間で充分
で15〜20分位である。カップリング剤を溶解する溶
媒は、使用する表面処理剤に応じて、pH2.0〜1
2.0位に調整した水を用いる場合と、エタノール、ト
ルエンアセトン、キシレン等の有機溶剤を単独で、或は
混合して使用する場合とがある。熱可塑性樹脂を一方向
に引き揃えた補強繊維に含浸させてプリプレグとする方
法としては種々の手段があるが、最も一般的な方法は以
下の通りである。一つは、溶剤に可溶な樹脂であれば、
その樹脂を溶液化して補強繊維に含浸させ、その後脱泡
しながら溶媒を除去し、プリプレグとする方法である。The method of applying the coupling agent to the fiber surface is as follows. That is, as one method, when the fiber is melted and the monofilament is pulled out, a sizing agent and a coupling agent are added to the surfactant to prepare an aqueous solution.
After spraying on the monofilament, it is dried and treated at a temperature of about 100 ° C. As another method, 0.1 to 3% by weight of a sizing agent and a coupling agent is added to the fiber from which the sizing agent is removed.
The dissolved liquid is completely impregnated by means such as dipping and spray coating. 60 fibers containing this coupling agent solution
Dry at ~ 120 ° C to allow coupling agent to react with fiber surface. The drying time is sufficient to evaporate the solvent, which is about 15 to 20 minutes. The solvent for dissolving the coupling agent has a pH of 2.0 to 1 depending on the surface treatment agent used.
There are cases where water adjusted to 2.0 is used, and cases where organic solvents such as ethanol, tolueneacetone and xylene are used alone or as a mixture. There are various methods for impregnating the reinforcing fibers unidirectionally aligned with the thermoplastic resin to form the prepreg, but the most general method is as follows. First, if the resin is soluble in the solvent,
This is a method in which the resin is made into a solution and impregnated into reinforcing fibers, and then the solvent is removed while defoaming to obtain a prepreg.
【0013】更に一つは、樹脂を加熱溶融して補強繊維
に含浸し、脱泡し、冷却してプリプレグとする方法であ
る。プリプレグの製造法としては、例えば特公平02−
042168号公報に開示されている方法があげられ
る。この方法により、ガラス繊維の場合は例えば太さ1
3μのモノフィラメントの表面をγ−メタクリロキシ−
プロピルトリメトキシシランで処理し、それを1800
本集束して撚りのないヤーンとし、そのヤーンを80本
均一な張力で引張ながら一方向に整列させて、樹脂をヤ
ーンに絡ませて、その樹脂を熱ロールでしごきながら、
ヤーンに含浸させてプリプレグを製造することが出来
る。この様にして製造したプリプレグは、繊維と熱可塑
性樹脂の密着性に優れ、繊維含有率も30−90重量%
と要求に応じて変えることが出来、厚みも0.1〜1.
0mmで製造することが出来るが、ガラス含有率は30
〜85容量%で、厚さ0.1〜0.6mmのところで使
用するのが望ましい。ガラス繊維含有率が30容量%以
下では繊維量が少ないので強度が低く、また85容量%
以上では繊維に対して樹脂量が少なく繊維と樹脂の密着
性が低下し強度が低くなるので好ましくない。The other is a method of heating and melting a resin to impregnate a reinforcing fiber, defoaming, and cooling to obtain a prepreg. As a method of manufacturing a prepreg, for example, Japanese Patent Publication No. 02-
The method disclosed in Japanese Patent No. 042168 can be mentioned. By this method, for glass fiber, for example, thickness 1
The surface of a 3μ monofilament is γ-methacryloxy-
Treated with propyltrimethoxysilane and treated with 1800
This bundle is made into a twist-free yarn, 80 yarns are aligned in one direction while pulling with a uniform tension, the resin is entangled with the yarn, and the resin is squeezed with a hot roll,
The yarn can be impregnated to produce a prepreg. The prepreg manufactured in this manner has excellent adhesion between the fiber and the thermoplastic resin and has a fiber content of 30-90% by weight.
And it can be changed according to the requirements, and the thickness is 0.1-1.
It can be manufactured with 0 mm, but the glass content is 30
It is desirable to use it in a range of 85% by volume and a thickness of 0.1 to 0.6 mm. When the glass fiber content is 30% by volume or less, the strength is low because the amount of fibers is small, and 85% by volume.
The above is not preferable because the amount of resin with respect to the fiber is small and the adhesion between the fiber and the resin is reduced, resulting in low strength.
【0014】また、本発明で使用する発泡樹脂体として
はポリエチレン発泡体、ポリプロピレン発泡体、ポリス
チレン発泡体又はポリプロピレン発泡体を外層に有する
ポリスチレン発泡体等が挙げられる。また、産業廃棄物
の処理の点からは、樹脂発泡体に用いられる樹脂とプリ
プレグに用いられる樹脂が共に熱可塑性樹脂で構成され
る複合構造体が好ましく、同一の熱可塑性樹脂で構成さ
れる複合構造体がさらに好ましい。発泡体は独立気泡で
も連通気泡から成るものでも良い。独立気泡のものを使
用すると強度は向上する。発泡倍率は100倍以下のも
のが用いられるが、その倍率は軽量化と成型性のバラン
スにより選ばれ、2〜50倍が好ましい。また、発泡体
は架橋体でも無架橋体でもよい。Examples of the foamed resin used in the present invention include polyethylene foam, polypropylene foam, polystyrene foam or polystyrene foam having polypropylene foam as an outer layer. From the viewpoint of processing industrial waste, a composite structure in which the resin used for the resin foam and the resin used for the prepreg are both made of a thermoplastic resin is preferable, and a composite structure made of the same thermoplastic resin is preferable. Structures are more preferred. The foam may be either closed cells or open cells. The strength is improved by using closed cells. A foaming ratio of 100 or less is used, and the ratio is selected from the balance of weight reduction and moldability, and is preferably 2 to 50 times. Further, the foam may be a crosslinked body or a non-crosslinked body.
【0015】本発明に使用される表面材としては、ポリ
プロピレン、ポリスチレンなどの発泡又は非発泡シー
ト、ポリ塩化ビニール等のシート、各種繊維からなる織
布や不織布などがあげられる。このような表面材を適用
することにより、表面の美観を向上させたり、肌触り性
の改善、耐汚染性の向上、他材との剥離性の改良、耐紫
外線性の向上が図れる。Examples of the surface material used in the present invention include foamed or non-foamed sheets such as polypropylene and polystyrene, sheets such as polyvinyl chloride, and woven and non-woven fabrics made of various fibers. By applying such a surface material, it is possible to improve the appearance of the surface, improve the touch, improve the stain resistance, improve the peelability from other materials, and improve the ultraviolet resistance.
【0016】プリプレグと発泡体を熱溶着により一体化
する方法として、積層したプリプレグを溶融温度以上
に、樹脂発泡体を溶融温度未満に同時に加熱し、次いで
プリプレグと発泡体を重ね合わせて、60〜80℃に加
熱されているプレス中で3kg/cm2 以下の圧力で加
圧し冷却すると共に一体化を行い積層体とする。この時
に、プリプレグ積層体のプリプレグ層間に存在する空気
を脱気する必要があり、通常は、プリプレグを構成する
樹脂の融点以上に加熱し3kg/cm2 以下の圧力で加
圧して脱気を行う。この範囲の圧力であれば、樹脂発泡
体が圧壊することもないので、発泡体と一体化する工程
でこの脱気を行うことが出来る。当然のことながら、脱
気をあらかじめ行い冷却し積層板としたものを使用して
も差し支えは無い。プリプレグと発泡体の加熱は、プリ
プレグと発泡体をお互いに接触させずに加熱すること
も、発泡体の上にプリプレグを乗せてお互いが接触した
状態で加熱することも出来る。発泡体の倍率が高い場合
は容易に熱で発泡体が溶けるので溶融したプリプレグが
蓄熱した熱で発泡体の表面が容易に溶けて一体化し得る
ので、プリプレグと発泡体を接触させずに加熱条件を変
えて別々に加熱することが望ましい。一方、発泡倍率が
低い場合は、発泡体に熱が伝導しにくいので溶融プリプ
レグが蓄熱している熱では発泡体表面を溶融出来ないた
めに、プリプレグと発泡体を接触させて、同時に加熱し
発泡体の表面を溶かしながら加熱する方法をとることが
望ましい。As a method of integrating the prepreg and the foam by heat welding, the laminated prepreg is heated to a melting temperature or higher and the resin foam is heated to a temperature lower than the melting temperature at the same time, and then the prepreg and the foam are superposed on each other, and then 60 to 60 In a press heated to 80 ° C., pressure is applied at a pressure of 3 kg / cm 2 or less, cooling is performed, and integration is performed to form a laminated body. At this time, it is necessary to deaerate the air existing between the prepreg layers of the prepreg laminate. Usually, the prepreg is heated by heating it to a temperature higher than the melting point of the resin constituting the prepreg and pressurizing it with a pressure of 3 kg / cm 2 or less. . If the pressure is within this range, the resin foam will not be crushed, so this degassing can be performed in the step of integrating with the foam. As a matter of course, there is no problem in using a laminated plate that is deaerated in advance and cooled. The prepreg and the foam can be heated without contacting the prepreg and the foam with each other, or can be heated with the prepreg placed on the foam and in contact with each other. When the expansion ratio of the foam is high, the foam is easily melted by heat, so the surface of the foam can be easily melted and integrated by the heat accumulated in the molten prepreg, so the heating conditions without contacting the prepreg and the foam It is desirable to change and heat separately. On the other hand, when the expansion ratio is low, the heat is difficult to conduct to the foam, so the surface of the foam cannot be melted by the heat accumulated by the molten prepreg.Therefore, the prepreg and the foam are brought into contact and heated at the same time to foam. It is desirable to take a method of heating while melting the body surface.
【0017】プリプレグと発泡体の一体化は、プリプレ
グが溶融状態にある間に行わなければならないので、加
熱を行うステップから一体化を行うステップへ短時間で
移行する様な装置的な工夫が必要である。そのような装
置の一例として、プリプレグと発泡体を一体化するプレ
ス内に、プレス内に出入り可能なプリプレグと発泡体を
クランプして支持する装置とプレス内に出入り可能なプ
リプレグと発泡体を加熱する熱板を装備した設備があげ
られる。この設備を使用して積層体を成形する手順は、
プレス盤面外にクランプを引きだし、プリプレグと発泡
体を装着した後クランプ装置をプレス盤面内に入れ、次
いで熱板をプレス盤面中に入れプリプレグと発泡体を加
熱し、加熱が終了後プレス盤面外に熱板を引きだし、プ
レスを締めてプリプレグと発泡体を接触させながら溶融
一体化させる。このとき、クランプはプレス盤面に触れ
ると同時に順次材料を離し、プレス盤面外に退避する機
構を供えている必要がある。表面材とプリプレグの一体
化は発泡体とプリプレグの一体化と同様に、プリプレグ
が溶融状態にある間に、一体化することが出来る。Since the prepreg and the foam must be integrated with each other while the prepreg is in a molten state, it is necessary to devise a device so that the step of heating and the step of integrating may be completed in a short time. Is. As an example of such a device, in a press that integrates prepreg and foam, a device that clamps and supports the prepreg and foam that can move in and out of the press, and the prepreg and foam that can move in and out of the press are heated. There is a facility equipped with a hot plate to operate. The procedure for forming a laminate using this equipment is:
After pulling the clamp out of the press platen and mounting the prepreg and foam, put the clamp device in the press platen surface, then put the hot plate in the press platen surface to heat the prepreg and foam, and after heating is completed, press it out of the press platen surface. The hot plate is drawn out, and the press is tightened to bring the prepreg and the foam into contact with each other to melt and integrate them. At this time, it is necessary for the clamp to have a mechanism for sequentially releasing the material while touching the surface of the press platen and retracting the material to the outside of the press platen surface. The integration of the surface material and the prepreg can be performed while the prepreg is in a molten state, like the integration of the foam and the prepreg.
【0018】以下、図面により本発明の実施例について
詳細に説明する。図1は本発明による製造方法により得
られる積層体の外観矢視図である。図2は図1に示した
積層体を製造する装置内にプリプレグ、発泡体が装着さ
れている状態を示す概念図、図3は図2に示した装置か
ら熱源を退避させてプリプレグと発泡体を一体化する第
一段階を示す概略図、図4は図3に示した状態からプリ
プレグ及び発泡体を保持している支持具が外れてプリプ
レグと発泡体をプレスにより冷却一体化を行っている状
態の概念図である。図5及び図6は本発明の別の実施例
を示す概念図である。図7は片面に表面材を貼合わせた
積層体を示す外観矢視図、図8は片面に表面材を貼合わ
せた積層体を成形するために装置内にプリプレグ、発泡
体及び表面材が装着されている状態を示す概念図を示
す。図10は、プレス熱板が加熱及び冷却機構を備えて
いる、冷却プレスである場合の積層体を製造する方法を
示した概念ずである。図1に示した1は本発明により得
られる積層体を示す。2、3、4、5、6はプリプレグ
積層体を示し、2〜6が同一の積層構成、板厚さであっ
ても良いし、目的とする用途に応じて積層構成、板厚さ
をそれぞれ変えてもよい。10、11、12、13、1
4は樹脂発泡体を示す。10〜14の発泡体は同一の発
泡倍率、厚さでもよいが、目的とする用途に応じて発泡
倍率、板厚さをそれぞれ変えてもよい。Embodiments of the present invention will be described in detail below with reference to the drawings. FIG. 1 is an external view of a laminate obtained by the manufacturing method according to the present invention. FIG. 2 is a conceptual diagram showing a state in which a prepreg and a foam are installed in the apparatus for manufacturing the laminated body shown in FIG. 1, and FIG. 3 is a system in which the heat source is retracted from the apparatus shown in FIG. FIG. 4 is a schematic view showing a first step of integrating the prepreg and the foam holding the prepreg and the supporting member out of the state shown in FIG. 3, and the prepreg and the foam are cooled and integrated by pressing. It is a conceptual diagram of a state. 5 and 6 are conceptual diagrams showing another embodiment of the present invention. FIG. 7 is an external arrow view showing a laminate in which a surface material is attached to one surface, and FIG. 8 is a prepreg, a foam and a surface material attached to the inside of the apparatus to form a laminate in which the surface material is attached to one surface. The conceptual diagram which shows the state currently being shown is shown. FIG. 10 is a conceptual diagram showing a method for producing a laminated body in the case where the press hot plate is equipped with a heating and cooling mechanism and is a cooling press. Reference numeral 1 shown in FIG. 1 denotes a laminate obtained by the present invention. Reference numerals 2, 3, 4, 5, and 6 represent prepreg laminated bodies, and 2 to 6 may have the same laminated constitution and plate thickness, or the laminated constitution and plate thickness may be changed depending on the intended use. You can change it. 10, 11, 12, 13, 1
Reference numeral 4 represents a resin foam. The foams 10 to 14 may have the same foaming ratio and thickness, but the foaming ratio and the plate thickness may be changed depending on the intended use.
【0019】積層体1に於て、プリプレグ積層体の層間
に存在する空気は、成形時の加熱工程に於て排除され、
かつ、プリプレグ積層体は発泡体の表面を溶融させるの
に十分な熱量が付与され、プリプレグ積層体と発泡体は
強固に接合されている。積層体の表面に近い発泡体1
0、14の発泡倍率が、中心層の発泡体11、12、1
3より小さいことが、荷重を受けたときに、発泡体が圧
壊しないので耐荷重性能を向上させる上で望ましい。全
ての発泡体の発泡倍率を小さくすることは、積層体の重
量が増加するので好ましくない。上述したように、表面
層に近いほど発泡倍率を小さくすることが、耐荷重性能
を上げて、重量増加を防止する上でのポイントである。In the laminated body 1, air existing between the layers of the prepreg laminated body is eliminated in the heating step at the time of molding,
Moreover, the prepreg laminate is provided with a sufficient amount of heat to melt the surface of the foam, and the prepreg laminate and the foam are firmly bonded. Foam 1 close to the surface of the laminate
The expansion ratios of 0 and 14 are the same as those of the central layer foams 11, 12, and 1.
A value less than 3 is desirable from the viewpoint of improving load bearing performance because the foam does not collapse when a load is applied. Reducing the expansion ratio of all foams is not preferable because the weight of the laminate increases. As described above, decreasing the foaming ratio as it gets closer to the surface layer is a point for improving load bearing performance and preventing an increase in weight.
【0020】図2は積層体の成形装置の概略図を示して
いるが、プレスの上下盤面に装着された離型フィルム4
0の間で、プリプレグ積層体及び発泡体を支持するクラ
ンプ20は、加熱されたプリプレグ及び発泡体が垂れ下
がりお互いが接触しない間隔及び張力を調整する機構を
具備しており、成形工程でプレス盤面に触れると盤面外
の33及び34の方向にに退避する機構を備えている。
30は熱板で、プレス盤面内に挿入、プレス盤面外の方
向35に退避が可能な機構を具備している。この熱板に
よりプリプレグ及び発泡体を加熱するが、短時間でプリ
プレグの樹脂が溶融する温度まで上げ、かつ発泡体を溶
融温度近傍まで上げることが必要で、そのためにはプリ
プレグとの間隔の調整機構及び温度制御機構が備わって
いなければならない。FIG. 2 shows a schematic view of the molding apparatus for the laminated body. The release film 4 mounted on the upper and lower surfaces of the press.
Between 0, the clamp 20 supporting the prepreg laminate and the foam has a mechanism for adjusting the interval and the tension at which the heated prepreg and the foam do not hang down and contact each other. A mechanism is provided for retracting in the directions 33 and 34 outside the board when touched.
A hot plate 30 is provided with a mechanism that can be inserted into the press platen surface and retracted in a direction 35 outside the press platen surface. The hot plate heats the prepreg and the foam, but it is necessary to raise the temperature of the resin of the prepreg to melt in a short time and to raise the foam to a temperature near the melting temperature. For that purpose, a mechanism for adjusting the distance from the prepreg. And a temperature control mechanism must be provided.
【0021】プリプレグと発泡体を同時に加熱すると発
泡倍率が高い発泡体の場合は発泡体の樹脂が先に溶融し
てしまうので、プリプレグが溶融状態になってから発泡
体を挿入し、プリプレグと発泡体の加熱時間を変える操
作をすることが望ましい。所定の温度にプリプレグと発
泡体が加熱された後、図3に示すように熱板をプレス盤
面外に退避させ、プレスを作動させて、上盤面が下がる
のに応じて、プリプレグ積層体及び発泡体がクランプか
ら外れプレス盤面外に退避すると同時に、プリプレグ積
層体及び発泡体が接触し、プリプレグに蓄熱された熱で
発泡体の表面が融け、プリプレグと発泡体が溶融一体化
され、次いで図4に示した様に、プレス中で冷却固化さ
れ発泡体を含む積層体が得られる。When the prepreg and the foam are heated at the same time, in the case of a foam having a high expansion ratio, the resin of the foam will be melted first, so the foam is inserted after the prepreg is in a molten state, and the prepreg and the foam are foamed. It is desirable to change the heating time of the body. After the prepreg and the foam are heated to a predetermined temperature, as shown in FIG. 3, the hot plate is evacuated to the outside of the press platen, the press is activated, and the prepreg laminate and the foam are generated in response to the lowering of the upper plate surface. At the same time as the body disengages from the clamp and retreats from the surface of the press board, the prepreg laminate and the foam come into contact with each other, the surface of the foam is melted by the heat accumulated in the prepreg, and the prepreg and the foam are melted and integrated. As shown in, a laminate containing the foam is obtained by cooling and solidifying in a press.
【0022】図5は、積層体を製造する別の方法を示し
たもので、表面層に近い発泡体10の発泡倍率が7倍以
下と低く、中心層の発泡倍率が15倍と高い場合に、同
一の加熱時間の中で発泡倍率の異なる発泡体とプリプレ
グ積層体が同時に所定の温度に加熱されないので、発泡
倍率の低い発泡体10及び14とプリプレグ積層体1と
2、及び5と6を予め重ねてクランプして更に熱板に直
接接触させて加熱する方法を示したものである。(但
し、図5ではクランプを省略した。) 図6は、積層体を製造する別の方法を示したもので、い
ずれか一方の表面層に近い発泡体10の発泡倍率が7倍
以下と低く、他の層の発泡倍率が15倍と高い場合に、
同一の加熱時間の中で発泡倍率の異なる発泡体とプリプ
レグ積層体が同時に所定の温度に加熱されないので、発
泡倍率の低い発泡体10とプリプレグ積層体1と2とを
予め重ねてクランプして更に熱板に直接接触させて加熱
する方法を示したものである。(但し、図6ではクラン
プを省略した。) 図10は熱冷プレスを使用する積層体の製造方法であ
る。積層体及び樹脂発泡体が熱融着する温度でまず、図
10−1に示す様に、樹脂発泡体10の上、下面に積層
体1、2を融着一体化後、プレスと積層体が冷えないう
ちに下熱板上に耐熱体を置き、その上に熱融着した積層
体の上側面の離型フィルムを取り除き、新たな樹脂発泡
体11と積層体3を積み重ね、熱圧して融着一体化を行
なう。次いで、プレス圧を解除後、上側の離型フィルム
を取り除き、新たな樹脂発泡体12と積層体4を積み重
ね、熱圧して融着一体化を行なう。この工程を所定数の
発泡体を積み上げるまで繰り返す。最後の工程で、プレ
ス圧を解除せずに冷媒42を通して冷却後、プレス圧を
解除して積層体を取り出すものである。断熱材41はこ
の工程が終了する時、積層体1及び樹脂発泡体2の温度
をその溶融温度以上に上昇させない断熱性能及び厚みを
持つとともに、積層体と樹脂発泡体を一体化させる時の
成形圧力に耐える性能が必要である。その様な材質とし
ては、石こうボード、アスベスト板、合板などがあげら
れる。更に本発明を具体的な実施例で詳説する。FIG. 5 shows another method for producing a laminate, in the case where the foam 10 near the surface layer has a low expansion ratio of 7 times or less and the center layer has a high expansion ratio of 15 times. Since the foams having different expansion ratios and the prepreg laminates are not simultaneously heated to a predetermined temperature in the same heating time, the foams 10 and 14 having a low expansion ratio and the prepreg laminates 1 and 2 and 5 and 6 are not heated. It shows a method of stacking and clamping in advance and then directly contacting the heating plate for heating. (However, the clamp is omitted in FIG. 5.) FIG. 6 shows another method of manufacturing a laminated body, in which the foaming ratio of the foamed body 10 close to one of the surface layers is as low as 7 times or less. , When the expansion ratio of other layers is as high as 15 times,
Since the foams having different expansion ratios and the prepreg laminate are not simultaneously heated to a predetermined temperature in the same heating time, the foam 10 having a low expansion ratio and the prepreg laminates 1 and 2 are preliminarily overlapped and clamped. It shows a method of heating by directly contacting a hot plate. (However, the clamp is omitted in FIG. 6.) FIG. 10 shows a method for manufacturing a laminated body using a hot-cold press. At a temperature at which the laminate and the resin foam are heat-sealed, first, as shown in FIG. 10-1, the laminates 1 and 2 are fused and integrated on the upper and lower surfaces of the resin foam 10, and then the press and the laminate are joined together. Place a heat-resistant body on the lower hot plate while it is not cooled, remove the release film on the upper side of the laminated body that is heat-sealed thereon, stack a new resin foam 11 and laminated body 3 and heat and melt them. Wear and integrate. Next, after releasing the press pressure, the upper release film is removed, and a new resin foam 12 and the laminated body 4 are stacked and hot pressed to perform fusion and integration. This process is repeated until a predetermined number of foams are stacked. In the last step, after cooling the refrigerant 42 without cooling the press pressure, the press pressure is released and the laminate is taken out. When this step is completed, the heat insulating material 41 has a heat insulating property and a thickness that prevent the temperature of the laminated body 1 and the resin foam 2 from rising above their melting temperature, and molding for integrating the laminated body and the resin foam. It must have the ability to withstand pressure. Such materials include gypsum board, asbestos board, plywood and the like. Further, the present invention will be described in detail with reference to specific examples.
【0023】[0023]
【実施例】本実施例で使用するプリプレグは、巾200
mmのものを特公平02−042168号公報に開示さ
れている方法で製造した。ガラス繊維の場合は太さ13
μのモノフィラメントの表面をγ−メタクリロキシ−プ
ロピルトリメトキシシランで処理し、それを1800本
集束して撚りのないヤーンとし、そのヤーンを80本を
均一な張力で引張ながら一方向に整列させて、樹脂をヤ
ーンに絡ませて、その樹脂を熱ロールでしごきながら、
ヤーンに含浸させてプリプレグを製造した。炭素繊維の
場合は、太さ7μのモノフィラメントを集束剤を使用せ
ずに12000本集めたトウを80本を均一な張力で引
張ながら一方向に整列させて、樹脂をヤーンに絡ませ
て、その樹脂を熱ロールでしごきながら、ヤーンに含浸
させてプリプレグを製造した。 この様にして製造した
プリプレグは、繊維と熱可塑性樹脂の密着性に優れ、繊
維含有率も30〜90重量%と要求に応じて変えること
が出来、厚みも0.1〜1.0mmで製造することが出
来るが、ガラス含有率は30−85容量%で、厚さ0.
1〜0.6mmのところで使用するのが望ましい。繊維
の容積含有率が30容量%以下では繊維量が少ないので
強度が低く、また85容量%以上では繊維に対して樹脂
量が少なく繊維と樹脂の密着性が低下し強度が低くなる
ので好ましくない。EXAMPLE The prepreg used in this example has a width of 200
mm was manufactured by the method disclosed in Japanese Patent Publication No. 02-042168. Thickness 13 for glass fiber
The surface of the monofilament of μ was treated with γ-methacryloxy-propyltrimethoxysilane, 1800 filaments were bundled into a twist-free yarn, and the yarn was aligned in one direction while pulling 80 yarns with a uniform tension. Entangling the resin in the yarn and squeezing the resin with a hot roll,
The yarn was impregnated to produce a prepreg. In the case of carbon fibers, without using a sizing agent, 12,000 monofilaments with a thickness of 7μ are gathered in one direction while pulling 80 tows with a uniform tension, and the resin is entangled with the yarn. Was squeezed with a hot roll to impregnate the yarn to produce a prepreg. The prepreg manufactured in this manner has excellent adhesion between the fiber and the thermoplastic resin, and the fiber content can be changed according to the requirement of 30 to 90% by weight, and the thickness is 0.1 to 1.0 mm. However, the glass content is 30-85% by volume and the thickness is 0.
It is desirable to use it at a distance of 1 to 0.6 mm. When the volume content of the fiber is 30% by volume or less, the strength is low because the amount of the fiber is small, and when the volume content of the fiber is 85% by volume or more, the amount of the resin is small with respect to the fiber and the adhesion between the fiber and the resin is reduced, which is not preferable. .
【0024】不飽和ポリエステルとガラス繊維のプリプ
レグは、三井東圧化学株式会社製の不飽和ポリエステル
エスターML1805 100重量部にt−ブチルパー
オキシベンゾエート1重量部、酸化マグネシウム5重量
部を加えた樹脂液を、シートモールディングコンパウン
ド製造機を使用し常法により、一方向に引き揃えたガラ
ス繊維に含浸し、40℃の雰囲気で24時間熟成して製
造した。The prepreg of unsaturated polyester and glass fiber is a resin liquid prepared by adding 1 part by weight of t-butylperoxybenzoate and 5 parts by weight of magnesium oxide to 100 parts by weight of unsaturated polyester ester ML1805 manufactured by Mitsui Toatsu Chemicals, Inc. Was impregnated into glass fibers aligned in one direction by a conventional method using a sheet molding compound manufacturing machine, and aged at 40 ° C. for 24 hours to manufacture.
【0025】表1に本発明の実施例及び比較例で使用す
るために製造したプリプレグの構成を示す。表2に本発
明で使用する樹脂発泡体の性状を示す。Table 1 shows the constitution of prepregs manufactured for use in the examples of the present invention and the comparative examples. Table 2 shows the properties of the resin foam used in the present invention.
【0026】実施例1 プリプレグAをその繊維方向を0度としたときに、上か
ら0度、90度、90度、0度と4枚重ね合わせた50
0mm角の積層体を6組と500mm角の樹脂発泡体P
を5枚準備した。図2に示した装置の1から6に積層体
を、10から14に樹脂発泡体をクランプし装着した。
樹脂発泡体をクランプした状態でプレス盤面外に退避さ
せ、200℃に加熱した熱板30をプレス盤面内に導入
し2分間プリプレグ積層体を加熱後、樹脂発泡体をプレ
ス盤面中に導入し5秒後に、熱板30をプレス盤面外に
退避させ60℃に加熱されたプレス上盤面31とプレス
下盤面32の間でプリプレグと発泡体を0.3kg/c
m2の圧力で加熱しながら冷却し積層体を得た。この積
層体の厚み及び重量を測定し、積層体の表面状態及び外
観を観察した。積層体の重量を(厚み×50×50)で
除して積層体の密度を算出した。また、この積層体を長
さ150mm、巾50mmの短冊状試験片に切りだし、
載荷速度50mm/分で、3点曲げ試験を行い、曲げ強
度及び曲げ弾性率を求めた。支持スパンと板厚みの比は
16:1とした。また、この積層体を長さ300mm、
巾50mmの短冊状試験片に切りだし、載荷速度50m
m/分で、3点曲げ試験を行い、破壊状態の観察を行う
と共に、曲げ強度及び曲げ弾性率を求めた。図9に曲げ
試験を行っている状態を示した。曲げ強度、曲げ弾性率
を密度で除し、比曲げ強度、比曲げ弾性率を算出した。
以上の結果を表3に示した。Example 1 When the fiber direction of the prepreg A was set to 0 degree, four sheets of 0 degree, 90 degree, 90 degree, and 0 degree were laminated from the top 50.
6 sets of 0 mm square laminates and 500 mm square resin foam P
Prepared 5 sheets. The laminated body was clamped to 1 to 6 and the resin foam was clamped to 10 to 14 of the device shown in FIG.
The resin foam is clamped and retracted to the outside of the press board, the hot plate 30 heated to 200 ° C. is introduced into the press board, the prepreg laminate is heated for 2 minutes, and then the resin foam is introduced into the press board. After a few seconds, the hot plate 30 was retracted to the outside of the press platen and 0.3 kg / c of the prepreg and the foam between the press upper platen surface 31 and the press lower platen surface 32 heated to 60 ° C.
A laminate was obtained by cooling while heating at a pressure of m2. The thickness and weight of this laminate were measured, and the surface condition and appearance of the laminate were observed. The weight of the laminate was divided by (thickness × 50 × 50) to calculate the density of the laminate. Further, this laminated body was cut into strip-shaped test pieces having a length of 150 mm and a width of 50 mm,
A three-point bending test was performed at a loading speed of 50 mm / min to determine bending strength and bending elastic modulus. The ratio of support span to plate thickness was 16: 1. In addition, this laminated body has a length of 300 mm,
Cut into 50 mm wide strip-shaped test pieces, loading speed 50 m
A three-point bending test was performed at m / min to observe the fractured state, and the bending strength and bending elastic modulus were obtained. FIG. 9 shows a state where the bending test is being performed. The bending strength and the bending elastic modulus were divided by the density, and the specific bending strength and the specific bending elastic modulus were calculated.
The above results are shown in Table 3.
【0027】実施例2 プリプレグAをその繊維方向を0度としたときに、上か
ら0度、90度、90度、0度と4枚重ね合わせた50
0mm角の積層体を6組と500mm角の樹脂発泡体Q
を2枚、発泡体Pを3枚準備した。図5に示した装置の
1から6に積層体を、10と14に樹脂発泡体Qを、1
1と12と13に樹脂発泡体Pをクランプし装着した。
樹脂発泡体Pをクランプした状態でプレス盤面外に退避
させ、200℃に加熱した熱板30をプレス盤面内に導
入し2分間プリプレグ積層体を加熱後、樹脂発泡体Pを
プレス盤面中に導入し5秒後に、熱板30をプレス盤面
外に退避させ60℃に加熱されたプレス上盤面31とプ
レス下盤面32の間でプリプレグと発泡体を0.3kg
/cm2 の圧力で加熱しながら冷却し積層体を得た。実
施例1と同様にして厚み、重量、表面状態と外観を観察
し、更に曲げ物性を評価した。その結果を表3に示し
た。Example 2 When the fiber direction of the prepreg A was set at 0 degree, four sheets of 0 degree, 90 degree, 90 degree and 0 degree were laminated from the top 50.
6 sets of 0 mm square laminates and 500 mm square resin foam Q
Were prepared, and three foams P were prepared. In the apparatus shown in FIG. 5, 1 to 6 are laminated bodies, and 10 and 14 are resin foam Q, respectively.
The resin foam P was clamped and attached to 1, 12, and 13.
The resin foam P is retracted outside the press board in a clamped state, the hot plate 30 heated to 200 ° C. is introduced into the press board surface, the prepreg laminate is heated for 2 minutes, and then the resin foam P is introduced into the press board surface. Then, after 5 seconds, the hot plate 30 is retracted to the outside of the press platen surface, and 0.3 kg of the prepreg and the foam are pressed between the press upper platen surface 31 and the press lower platen surface 32 heated to 60 ° C.
A laminate was obtained by cooling while heating at a pressure of / cm 2 . In the same manner as in Example 1, the thickness, weight, surface state and appearance were observed, and the bending properties were evaluated. The results are shown in Table 3.
【0028】実施例3 プリプレグAをその繊維方向を0度としたときに、上か
ら0度、90度、90度、0度と4枚重ね合わせた50
0mm角の積層体を6組と500mm角の樹脂発泡体Q
を1枚、発泡体Pを4枚準備した。図6に示した装置の
1から6に積層体を、10に樹脂発泡体Qを、11と1
2と13と14に樹脂発泡体Pをクランプし装着した。
樹脂発泡体Pをクランプした状態でプレス盤面外に退避
させ、200℃に加熱した熱板30をプレス盤面内に導
入し2分間プリプレグ積層体を加熱後、樹脂発泡体Pを
プレス盤面中に導入し5秒後に、熱板30をプレス盤面
外に退避させ60℃に加熱されたプレス上盤面31とプ
レス下盤面32の間でプリプレグと発泡体を0.3kg
/cm2 の圧力で加熱しながら冷却し積層体を得た。実
施例1と同様にして厚み、重量、表面状態と外観を観察
し、更に曲げ物性を評価した。その結果を表3に示し
た。Example 3 When prepreg A has a fiber direction of 0 degree, four sheets of 0 degree, 90 degree, 90 degree and 0 degree are laminated from the top 50.
6 sets of 0 mm square laminates and 500 mm square resin foam Q
1 and 4 foams P were prepared. In the apparatus shown in FIG. 6, 1 to 6 are laminated bodies, 10 is a resin foam Q, and 11 and 1 are the laminated bodies.
The resin foam P was clamped and attached to Nos. 2, 13 and 14.
The resin foam P is retracted outside the press board in a clamped state, the hot plate 30 heated to 200 ° C. is introduced into the press board surface, the prepreg laminate is heated for 2 minutes, and then the resin foam P is introduced into the press board surface. Then, after 5 seconds, the hot plate 30 is retracted to the outside of the press platen surface, and 0.3 kg of the prepreg and the foam are pressed between the press upper platen surface 31 and the press lower platen surface 32 heated to 60 ° C.
A laminate was obtained by cooling while heating at a pressure of / cm 2 . In the same manner as in Example 1, the thickness, weight, surface state and appearance were observed, and the bending properties were evaluated. The results are shown in Table 3.
【0029】実施例4 プリプレグAをその繊維方向を0度としたときに、上か
ら0度、90度、90度、0度と4枚重ね合わせた50
0mm角の積層体を6組と500mm角の樹脂発泡体P
を2枚、発泡体Rを2枚、発泡体Nを1枚準備した。図
5に示した装置の1から6に積層体を、10と14に樹
脂発泡体Rを、11と13に樹脂発泡体Pを、12に樹
脂発泡体Nをクランプし装着した。樹脂発泡体RとNを
クランプした状態でプレス盤面外に退避させ、200℃
に加熱した熱板30をプレス盤面内に導入し2分間プリ
プレグ積層体を加熱後、樹脂発泡体PとNをプレス盤面
中に導入し5秒後に、熱板30をプレス盤面外に退避さ
せ60℃に加熱されたプレス上盤面31とプレス下盤面
32の間でプリプレグと発泡体を0.3kg/cm 2 の
圧力で加熱しながら冷却し積層体を得た。実施例1と同
様にして厚み、重量、表面状態と外観を観察し、更に曲
げ物性を評価した。その結果を表3に示した。Example 4 When the fiber direction of prepreg A was set to 0 degree,
4 layers of 0 degree, 90 degree, 90 degree, 0 degree
6 sets of 0 mm square laminates and 500 mm square resin foam P
Was prepared, two foams R, two foams N, and one foam N were prepared. Figure
Laminates 1 to 6 of the equipment shown in 5 and trees 10 and 14
Resin foam P is used for 11 and 13 and resin foam P is used for 12
The fat foam N was clamped and attached. Resin foam R and N
Retract out of the press board in the clamped state, 200 ℃
The hot plate 30 heated to the inside is introduced into the surface of the press board and pre-treated for 2 minutes.
After heating the prepreg laminate, the resin foams P and N are pressed onto the press surface.
5 seconds after introducing the heat plate, retract the hot plate 30 to the outside of the press platen.
Press upper platen surface 31 and press lower platen surface heated to 60 ° C
0.3kg / cm of prepreg and foam between 32 2of
A laminate was obtained by cooling while heating with pressure. Same as Example 1
Similarly, observe the thickness, weight, surface condition and appearance, and
The physical properties were evaluated. The results are shown in Table 3.
【0030】実施例5 プリプレグAをその繊維方向を0度としたときに、上か
ら0度、90度、90度、0度と4枚重ね合わせた50
0mm角の積層体を6組と500mm角の樹脂発泡体S
を2枚、発泡体Pを3枚準備した。図5に示した装置の
1から6に積層体を、10と14に樹脂発泡体Sを、1
1と12と13に樹脂発泡体Pをクランプし装着した。
樹脂発泡体Pをクランプした状態でプレス盤面外に退避
させ、200℃に加熱した熱板30をプレス盤面内に導
入し2分間プリプレグ積層体を加熱後、樹脂発泡体Pを
プレス盤面中に導入し5秒後に、熱板30をプレス盤面
外に退避させ60℃に加熱されたプレス上盤面31とプ
レス下盤面32の間でプリプレグと発泡体を0.3kg
/cm2 の圧力で加熱しながら冷却し積層体を得た。実
施例1と同様にして厚み、重量、表面状態と外観を観察
し、更に曲げ物性を評価した。その結果を表3に示し
た。Example 5 When prepreg A has a fiber direction of 0 °, four sheets of 0 °, 90 °, 90 °, and 0 ° are laminated from the top 50.
6 sets of 0mm square laminates and 500mm square resin foam S
Were prepared, and three foams P were prepared. In the apparatus shown in FIG. 5, 1 to 6 are laminated bodies, and 10 and 14 are resin foam S.
The resin foam P was clamped and attached to 1, 12, and 13.
The resin foam P is retracted outside the press board in a clamped state, the hot plate 30 heated to 200 ° C. is introduced into the press board surface, the prepreg laminate is heated for 2 minutes, and then the resin foam P is introduced into the press board surface. Then, after 5 seconds, the hot plate 30 is retracted to the outside of the press platen surface, and 0.3 kg of the prepreg and the foam are pressed between the press upper platen surface 31 and the press lower platen surface 32 heated to 60 ° C.
A laminate was obtained by cooling while heating at a pressure of / cm 2 . In the same manner as in Example 1, the thickness, weight, surface state and appearance were observed, and the bending properties were evaluated. The results are shown in Table 3.
【0031】実施例6 プリプレグAの代わりにプリプレグCを使う以外は、実
施例5と同様にして積層体を得た。この積層体を実施例
1と同様にして評価した。評価結果を表3に示した。Example 6 A laminate was obtained in the same manner as in Example 5 except that prepreg C was used instead of prepreg A. This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0032】実施例7 プリプレグAの代わりにプリプレグB、樹脂発泡体Sの
代わりに樹脂発泡体U、樹脂発泡体Pの代わりに樹脂発
泡体Tを使用する以外は実施例5と同様にして積層体を
得た。この積層体を実施例1と同様にして評価した。評
価結果を表3に示した。Example 7 Lamination was performed in the same manner as in Example 5 except that prepreg B was used instead of prepreg A, resin foam U was used instead of resin foam S, and resin foam T was used instead of resin foam P. Got the body This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0033】実施例8 プリプレグAの代わりにプリプレグD、樹脂発泡体Sの
代わりに樹脂発泡体U、樹脂発泡体Pの代わりに樹脂発
泡体Tを使用する以外は実施例5と同様にして積層体を
得た。この積層体を実施例1と同様にして評価した。評
価結果を表3に示した。Example 8 Lamination was performed in the same manner as in Example 5 except that prepreg D was used instead of prepreg A, resin foam U was used instead of resin foam S, and resin foam T was used instead of resin foam P. Got the body This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0034】実施例9 プリプレグAの代わりにプリプレグE、樹脂発泡体Sの
代わりに樹脂発泡体W、樹脂発泡体Pの代わりに樹脂発
泡体Vを使用する以外は実施例5と同様にして積層体を
得た。この積層体を実施例1と同様にして評価した。評
価結果を表3に示した。Example 9 Lamination was performed in the same manner as in Example 5 except that prepreg E was used instead of prepreg A, resin foam W was used instead of resin foam S, and resin foam V was used instead of resin foam P. Got the body This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0035】実施例10 実施例1と同様にして、プリプレグAをその繊維方向を
0度としたときに、上から0度、90度、90度、0度
と4枚重ね合わせた500mm角の積層体を6組と50
0mm角の樹脂発泡体Pを5枚準備した。図8に示した
装置の1から6に積層体を、10から14に樹脂発泡体
をクランプし装着した。更に、2mm厚さの発泡ポリウ
レタンシートで裏打ちされた塩化ビニールレーザー39
を離型フィルム40の上に塩化ビニールレーザーの面が
離型フィルムに接触するようにして静置した。樹脂発泡
体をクランプした状態でプレス盤面外に退避させ、20
0℃に加熱した熱板30をプレス盤面内に導入し2分間
プリプレグ積層体を加熱後、樹脂発泡体をプレス盤面中
に導入し5秒後に、熱板30をプレス盤面外に退避させ
60℃に加熱されたプレス上盤面31とプレス下盤面3
2の間でプリプレグと発泡体を0.3kg/cm2 の圧
力で加熱しながら冷却し積層体を得た。外観良好で、塩
化ビニールレザーの感触の良い積層体が得られた。Example 10 In the same manner as in Example 1, when the fiber direction of the prepreg A was set to 0 degree, four pieces of a 500 mm square, which were 0 degree, 90 degree, 90 degree and 0 degree from the top, were superposed. 6 sets and 50 stacks
Five pieces of 0 mm square resin foam P were prepared. The laminated body was clamped to 1 to 6 and the resin foam was clamped to 10 to 14 of the device shown in FIG. Furthermore, vinyl chloride laser 39 lined with a 2 mm thick polyurethane foam sheet
Was placed on the release film 40 with the surface of the vinyl chloride laser being in contact with the release film. With the resin foam clamped, retract it to the outside of the press board,
The hot plate 30 heated to 0 ° C. is introduced into the press platen surface, the prepreg laminate is heated for 2 minutes, the resin foam is introduced into the press platen surface, and 5 seconds later, the hot plate 30 is evacuated to the outside of the press platen 60 ° C. Pressed upper surface 31 and pressed lower surface 3
Between the two, the prepreg and the foam were cooled while being heated at a pressure of 0.3 kg / cm 2 to obtain a laminate. A laminate having a good appearance and a good feel of vinyl chloride leather was obtained.
【0036】実施例11 プリプレグAをその繊維方向を0度としたときに、上か
ら0度、90度、90度、0度と4枚重ね合わせた50
0mm角の積層体を6組と500mm角の樹脂発泡体P
を5枚準備した。図10−1に示した様にプレス熱板を
180℃に加熱し、発泡体10の上下面に積層体1と2
を重ねたものを離型フィルムにはさみプレス熱板中に投
入し、0.3Kg/cm2の圧力で1分間加圧し熱融着
させる。次いでプレス圧力を解放し、図10−2に示す
様に、下熱板32の上に断熱板41を乗せ、さらに熱融
着した積層体をその上に乗せ、上側の離型フィルムを取
り除き、新たな発泡体11と積層体3を重ね、離型フィ
ルムを介して0.3Kg/cm2の圧力で1分間加圧
し、熱融着を行なう。次いで、図10−3に示す様に、
プレス圧を解除後、上側の離型フィルムを取り除き、新
たな樹脂発泡体12と積層体4を重ねて、0.3Kg/
cm2の圧力で1分間加圧し熱融着を行なう。この工程
をさらに2回繰り返した。最後の工程で、0.3Kg/
cm2の圧力で1分間加圧後、プレス圧力を保持した状
態で、図10−4に示した様に上、下熱板内に冷媒42
を通し、室温まで冷却後、プレス圧を解除して積層体を
得た実施例1と同様にして厚み、重量、表面状態を観察
し、更に曲げ物性を評価した。その結果を表3に示し
た。Example 11 When the fiber direction of the prepreg A was set to 0 degree, four sheets of 0 degree, 90 degree, 90 degree, and 0 degree were laminated from the top 50.
6 sets of 0 mm square laminates and 500 mm square resin foam P
Prepared 5 sheets. As shown in FIG. 10-1, the press hot plate is heated to 180 ° C., and the laminates 1 and 2 are formed on the upper and lower surfaces of the foam 10.
The layered product is sandwiched by a release film, put into a hot press plate, and heated at a pressure of 0.3 Kg / cm 2 for 1 minute for heat fusion. Next, the press pressure is released, and as shown in FIG. 10-2, the heat insulating plate 41 is placed on the lower heating plate 32, the heat-sealed laminate is further placed thereon, and the upper release film is removed. The new foam 11 and the laminated body 3 are superposed, and heat fusion is carried out by applying a pressure of 0.3 Kg / cm 2 through the release film for 1 minute. Then, as shown in FIG.
After releasing the pressing pressure, the upper release film is removed, a new resin foam 12 and a layered product 4 are overlaid, and 0.3 kg /
Heat fusion is performed by applying a pressure of 1 cm 2 for 1 minute. This process was repeated twice more. In the last step, 0.3 kg /
After pressurizing with a pressure of cm 2 for 1 minute, while maintaining the press pressure, the refrigerant 42 is placed in the upper and lower heating plates as shown in FIG. 10-4.
Then, after cooling to room temperature, the press pressure was released to obtain a laminate, and the thickness, weight and surface condition were observed in the same manner as in Example 1, and the bending properties were evaluated. The results are shown in Table 3.
【0037】比較例1 プリプレグFをその繊維方向を0度としたときに、上か
ら0度、90度、0度、90度、0度、90度、90
度、0度、90度、0度、90度、0度と12枚重ね合
わせた500mm角の積層体を2組と500mm角の樹
脂発泡体Xを1枚準備した。この積層体と発泡体を上か
ら積層体/発泡体/積層体の順に重ね合わせ、150℃
に加熱した熱板を装着したプレスに投入し、0.3kg
/cm2 の圧力で10分間加熱した後取りだし積層体を
得た。プリプレグFを硬化させるために、150℃の高
温で処理したため、発泡体が圧力で一部破壊し、硬化し
たプリプレグの表面状態も成形圧力不足で悪かった。こ
の積層体を実施例1と同様にして評価した。評価結果を
表3に示した。Comparative Example 1 When the fiber direction of the prepreg F is 0 degree, 0 degree, 90 degree, 0 degree, 90 degree, 0 degree, 90 degree, 90 degrees from the top.
Two sets of 500 mm square laminates were stacked by stacking 12 sheets of 0 °, 90 °, 0 °, 90 °, and 0 °, and one resin foam X of 500 mm square was prepared. This laminated body and the foam are superposed in the order of laminated body / foamed body / laminated body from the top, and the temperature is 150 °
Put into a press equipped with a heating plate heated to 0.3 kg
After being heated at a pressure of / cm 2 for 10 minutes, it was taken out to obtain a laminated body. Since the prepreg F was treated at a high temperature of 150 ° C. to cure it, the foam partly broke under pressure, and the surface condition of the cured prepreg was poor due to insufficient molding pressure. This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0038】比較例2 プリプレグAをその繊維方向を0度としたときに、上か
ら0度、90度、0度、90度、0度、90度、90
度、0度、90度、0度、90度、0度と12枚重ね合
わせた500mm角の積層体を2組と500mm角の樹
脂発泡体Oを1枚準備した。図2に示した装置の1と2
に積層体を、10に樹脂発泡体をクランプし装着した。
(この例の場合、積層体3〜6と発砲体11〜14は装
着されていない。)樹脂発泡体Oクランプした状態でプ
レス盤面外に退避させ、200℃に加熱した熱板30を
プレス盤面内に導入し2分間プリプレグ積層体を加熱
後、樹脂発泡体Oプレス盤面中に導入し5秒後に、熱板
30をプレス盤面外に退避させ60℃に加熱されたプレ
ス上盤面31とプレス下盤面32の間でプリプレグと発
泡体を0.3kg/cm2 の圧力で加熱しながら冷却し
積層体を得た。この積層体を実施例1と同様にして評価
した。評価結果を表3に示した。Comparative Example 2 When the fiber direction of the prepreg A is 0 degree, 0 degree, 90 degree, 0 degree, 90 degree, 0 degree, 90 degree, 90 degrees from the top.
Two sets of 500 mm square laminates, which were a stack of 12 sheets of 0 °, 90 °, 0 °, 90 °, and 0 °, and one resin foam O of 500 mm square were prepared. 1 and 2 of the device shown in FIG.
The laminated body was attached to, and the resin foam was clamped and attached to 10.
(In the case of this example, the laminated bodies 3 to 6 and the foaming bodies 11 to 14 are not attached.) The resin foam O is retracted to the outside of the press board in a clamped state, and the hot plate 30 heated to 200 ° C. is pressed to the press board surface. After heating the prepreg laminate for 2 minutes and introducing it into the resin foam O press board surface, the hot plate 30 is evacuated to the outside of the press board surface 5 seconds later, and the press upper board surface 31 and the press bottom surface heated to 60 ° C. The prepreg and the foam were cooled while being heated at a pressure of 0.3 kg / cm 2 between the board surfaces 32 to obtain a laminate. This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0039】比較例3 プリプレグAの代わりにプリプレグGを使用する以外は
実施例5と同様にして積層体を得た。この積層体を実施
例1と同様にして評価した。評価結果を表3に示した。Comparative Example 3 A laminate was obtained in the same manner as in Example 5 except that prepreg G was used instead of prepreg A. This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0040】比較例4 プリプレグAの代わりにプリプレグHを使用する以外は
実施例5と同様にして積層体を得た。この積層体を実施
例1と同様にして評価した。評価結果を表3に示した。Comparative Example 4 A laminate was obtained in the same manner as in Example 5 except that prepreg H was used instead of prepreg A. This laminate was evaluated in the same manner as in Example 1. The evaluation results are shown in Table 3.
【0041】[0041]
【表1】 [Table 1]
【0042】[0042]
【表2】 [Table 2]
【0043】[0043]
【表3】 [Table 3]
【0044】[0044]
【発明の効果】本発明の方法により、樹脂発泡体と熱可
塑性樹脂プリプレグが強固に一体化された軽量で、高剛
性の積層体を製造することが出来る。According to the method of the present invention, a lightweight and highly rigid laminate in which a resin foam and a thermoplastic resin prepreg are firmly integrated can be manufactured.
【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】図面の簡単な説明[Name of item to be corrected] Brief description of the drawing
【補正方法】変更[Correction method] Change
【補正内容】[Correction content]
【図面の簡単な説明】[Brief description of drawings]
【図1】本発明による製造方法により得られる積層体の
外観矢視図である。FIG. 1 is an external view of a laminate obtained by a manufacturing method according to the present invention.
【図2】本発明の積層体を製造する装置内にプリプレ
グ、発泡体が装着されている状態を示す概念図である。FIG. 2 is a conceptual diagram showing a state in which a prepreg and a foam are installed in an apparatus for producing a laminate of the present invention.
【図3】図2に示した装置から熱源を退避させてプリプ
レグと発泡体を一体化する第一段階を示す概略図であ
る。FIG. 3 is a schematic diagram showing a first stage in which the heat source is retracted from the apparatus shown in FIG. 2 to integrate the prepreg and the foam.
【図4】図3に示した状態からプリプレグ及び発泡体を
保持している支持具が外れてプリプレグと発泡体をプレ
スにより冷却一体化を行っている状態の概念図である。FIG. 4 is a conceptual diagram of a state in which the support holding the prepreg and the foam is removed from the state shown in FIG. 3 and the prepreg and the foam are cooled and integrated by a press.
【図5】表面層及び裏面層に近い部分の発泡体の発泡倍
率が中心層にある発泡体の発泡倍率より低い場合の積層
体を成形する時の状態を示す概念図である。FIG. 5 is a conceptual diagram showing a state at the time of molding a laminate in which the foaming ratio of the foam near the front surface layer and the back surface layer is lower than the foaming ratio of the foam in the central layer.
【図6】表面層に近い部分の発泡体の発泡倍率が中心層
にある発泡体の発泡倍率より低い場合の積層体を成形す
る時の状態を示す概念図である。FIG. 6 is a conceptual diagram showing a state at the time of molding a laminate in which the foaming ratio of the foam near the surface layer is lower than the foaming ratio of the foam in the central layer.
【図7】図7は片面に表面材を貼合わせた積層体を示す
外観矢視図を示す。FIG. 7 is an external arrow view showing a laminated body in which a surface material is attached to one surface.
【図8】片面に表面材を貼合わせた積層体を成形するた
めに装置内にプリプレグ、発泡体及び表面材が装着され
ている状態を示す概念図を示す。FIG. 8 is a conceptual diagram showing a state in which a prepreg, a foam, and a surface material are mounted in an apparatus to form a laminate in which a surface material is attached to one surface.
【図9】積層体の曲げ強度を行っている状態を示す。FIG. 9 shows a state in which bending strength of the laminate is being performed.
【図10】熱冷ブレスを使用して、積層体を成形する方
法を示す概念図FIG. 10 is a conceptual diagram showing a method for forming a laminate by using a heat-cooled breath.
【符号の説明】 1・・・・・積層体 2・・・・・プリプレグ積層体 3・・・・・プリプレグ積層体 4・・・・・プリプレグ積層体 5・・・・・プリプレグ積層体 6・・・・・プリプレグ積層体 10・・・・・樹脂発泡体 11・・・・・樹脂発泡体 12・・・・・樹脂発泡体 13・・・・・樹脂発泡体 14・・・・・樹脂発泡体 20・・・・・クランプ 30・・・・・熱板 31・・・・・プレス上盤面 32・・・・・プレス下盤面 33・・・・・右側クランプの退避方向 34・・・・・左側クランプの退避方向 35・・・・・熱板の退避方向 39・・・・・表面材 40・・・・・離型フィルム 41・・・・・断熱材 42・・・・・冷媒が通る方向[Explanation of reference numerals] 1 ... Laminated body 2 ... Prepreg laminated body 3 ... Prepreg laminated body 4 ... Prepreg laminated body 5 ... Prepreg laminated body 6 ... prepreg laminate 10 ... resin foam 11 ... resin foam 12 ... resin foam 13 ... resin foam 14 ... Resin foam 20 ... Clamp 30 ... Hot plate 31 ... Press upper surface 32 ... Press lower surface 33 ... Right side clamp retracting direction 34 ...・ ・ ・ Retracting direction of left clamp 35 ・ ・ ・ Retracting direction of hot plate 39 ・ ・ ・ Surface material 40 ・ ・ ・ Release film 41 ・ ・ ・ Insulation material 42 ・ ・ ・ ・ ・Direction of refrigerant flow
【手続補正3】[Procedure 3]
【補正対象書類名】図面[Document name to be corrected] Drawing
【補正対象項目名】全図[Correction target item name] All drawings
【補正方法】変更[Correction method] Change
【補正内容】[Correction content]
【図1】 [Figure 1]
【図2】 [Fig. 2]
【図4】 [Figure 4]
【図3】 [Figure 3]
【図5】 [Figure 5]
【図6】 [Figure 6]
【図7】 [Figure 7]
【図8】 [Figure 8]
【図9】 [Figure 9]
【図10】 [Figure 10]
───────────────────────────────────────────────────── フロントページの続き (72)発明者 田邉 浩史 神奈川県横浜市栄区笠間町1190番地 三井 東圧化学株式会社内 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Hiroshi Tanabe 1190 Kasama-cho, Sakae-ku, Yokohama-shi, Kanagawa Mitsui Toatsu Chemical Co., Ltd.
Claims (21)
可塑性樹脂を含浸した1枚以上のプリプレグと樹脂発泡
体とを積層した成形品において、樹脂発泡体とプリプレ
グとを積層した組み合せを2層以上重ね合わせて層間を
熱接合したことを特徴とする積層体。1. A molded article obtained by laminating one or more sheets of prepreg impregnated with a thermoplastic resin and a resin foam, in which continuous reinforcing fibers are aligned in one direction, and a combination of the resin foam and the prepreg is laminated in two. A laminated body, characterized in that at least one layer is overlaid and the layers are thermally bonded.
を特徴とする請求項1に記載の積層体。2. The laminate according to claim 1, wherein a surface material is attached to one side or both sides.
85%以下の強化繊維を含む請求項1に記載の積層体。3. The laminate according to claim 1, wherein the prepreg contains reinforcing fibers in a volume content of 30% or more and 85% or less.
り、熱可塑性樹脂がポリプロピレン系樹脂である請求項
1に記載の積層体。4. The laminate according to claim 1, wherein the reinforcing fiber of the prepreg is a glass fiber and the thermoplastic resin is a polypropylene resin.
り、熱可塑性樹脂がポリスチレン系樹脂である請求項1
に記載の積層体。5. The reinforcing fiber of the prepreg is a glass fiber and the thermoplastic resin is a polystyrene resin.
The laminated body according to.
束が一方向に引き揃えられているプリプレグである請求
項1乃至4のうちいずれか1項に記載の積層体。6. The laminate according to claim 1, which is a prepreg in which continuous fibers are bundled and each bundle is aligned in one direction.
脂が同種類である請求項1に記載の積層体。7. The laminate according to claim 1, wherein the resin constituting the prepreg and the resin of the foam are of the same type.
以下である請求項1に記載の積層体。8. The laminate according to claim 1, wherein the expansion ratio of the resin foam is 2 times or more and 50 times or less.
一方の面に近い樹脂発泡体の発泡倍率が、中央層に近い
樹脂発泡体より低いことを特徴とする請求項1に記載の
積層体。9. The laminate according to claim 1, wherein the foaming ratio of the resin foam near both the front surface and the back surface or one of the surfaces is lower than that of the resin foam near the central layer. .
接合面積1cm2 当り3kg以下の圧力で層間を熱接合
する請求項1に記載の積層体。10. The laminate according to claim 1, wherein the layers are thermally bonded together under a pressure of 3 kg or less per 1 cm 2 of the bonding area between the pair of prepregs and the resin foam.
なる織布又は不織布である請求項2に記載の積層体。11. The laminate according to claim 2, wherein the surface material is a woven or non-woven fabric made of a resin film and a fibrous material.
熱可塑性樹脂を含浸した1枚以上のプリプレグをその熱
可塑性樹脂の溶融温度以上に加熱して層間に含まれる空
気の脱気を行うステップと、プリプレグを溶融温度以上
に、樹脂発泡体を溶融温度以下、にお互いが接触しない
状態で同時に加熱するステップと、加熱したプリプレグ
と樹脂発泡体をお互いに重ね合わせて加圧して熱接合を
行うステップと、熱接合された積層品を冷却、固化して
一体化せしめるステップを順次実行することを特徴とす
る積層体の製造方法。12. A step of degassing air contained in layers by heating one or more prepregs in which continuous reinforcing fibers are aligned in one direction and impregnated with a thermoplastic resin to a temperature equal to or higher than a melting temperature of the thermoplastic resin. And heating the prepreg to a melting temperature or higher and the resin foam to a melting temperature or lower at the same time in a state where they do not contact each other, and heating the prepreg and the resin foam are overlapped with each other and pressure applied to perform thermal bonding. A method for manufacturing a laminated body, comprising sequentially performing a step and a step of cooling and solidifying the thermally bonded laminated body to integrate them.
%以上85%以下の強化繊維を含む請求項10に記載の
積層体の製造方法。13. The prepreg has a volume content of 30.
The method for producing a laminate according to claim 10, wherein the reinforcing fibers are contained in an amount of not less than 85% and not more than 85%.
あり、熱可塑性樹脂がポリプロピレン系樹脂である請求
項10に記載の積層体の製造方法。14. The method for producing a laminate according to claim 10, wherein the reinforcing fibers of the prepreg are glass fibers and the thermoplastic resin is a polypropylene resin.
あり、熱可塑性樹脂がポリスチレン系樹脂である請求項
10に記載の積層体の製造方法。15. The method for producing a laminate according to claim 10, wherein the reinforcing fiber of the prepreg is glass fiber, and the thermoplastic resin is polystyrene resin.
の束が一方向に引き揃えられているプリプレグである請
求項10乃至13のうちいずれか1項に記載の積層体の
製造方法。16. The method for producing a laminated body according to claim 10, wherein the continuous fibers are bundled, and each bundle is a prepreg aligned in one direction.
樹脂が同種類である請求項10に記載の積層体の製造方
法。17. The method for producing a laminate according to claim 10, wherein the resin constituting the prepreg and the resin of the foam are the same type.
倍以下である請求項10に記載の積層体の製造方法。18. The foaming ratio of the resin foam is 2 times or more 50.
The method for producing a laminate according to claim 10, wherein the number of times is not more than double.
か一方の面に近い樹脂発泡体の発泡倍率が、中央層に近
い樹脂発泡体より低いことを特徴とする請求項10に記
載の積層体の製造方法。19. The laminate according to claim 10, wherein the foaming ratio of the resin foam near both the front surface and the back surface or one of the surfaces is lower than that of the resin foam near the central layer. Manufacturing method.
か一方の面に近い樹脂発泡体の発泡倍率が2倍以上7倍
以下の場合は、プリプレグと発泡体を重ね合わせて更に
熱板に直接接触させて加熱することを特徴とする請求項
10に記載の積層体の製造方法。20. When the expansion ratio of the resin foam on both the front surface and the back surface or on one of the two surfaces is 2 times or more and 7 times or less, the prepreg and the foam are superposed and further directly applied to the hot plate. The method for producing a layered product according to claim 10, wherein heating is performed by bringing them into contact with each other.
接合面積1cm2 当り3kg以下の圧力で層間を熱接合
する請求項10に記載の積層体の製造方法。21. The method for producing a laminate according to claim 10, wherein the layers are thermally bonded together under a pressure of 3 kg or less per 1 cm 2 of the bonding area between the pair of prepregs and the resin foam.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP32375093A JP3272519B2 (en) | 1993-12-22 | 1993-12-22 | Laminated body and method for producing the same |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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JP32375093A JP3272519B2 (en) | 1993-12-22 | 1993-12-22 | Laminated body and method for producing the same |
Publications (2)
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JPH07178859A true JPH07178859A (en) | 1995-07-18 |
JP3272519B2 JP3272519B2 (en) | 2002-04-08 |
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JP32375093A Expired - Fee Related JP3272519B2 (en) | 1993-12-22 | 1993-12-22 | Laminated body and method for producing the same |
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WO2007088892A1 (en) * | 2006-02-02 | 2007-08-09 | Mitsui Chemicals, Inc. | Backside protective substrate for solar cell module, solar cell module and electric power generator |
JP2010002289A (en) * | 2008-06-20 | 2010-01-07 | Society Of Japanese Aerospace Co Inc | Evaluation testing method of peeling in multilayer structure |
JP2011194796A (en) * | 2010-03-23 | 2011-10-06 | Ube Industries Ltd | Production process for laminate of polyimide foam and thermoplastic resin sheet, and laminate |
JP2011218779A (en) * | 2010-03-23 | 2011-11-04 | Ube Industries Ltd | Method for manufacturing laminate of polyimide foam and thermoplastic resin sheet, and laminate |
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WO2020202754A1 (en) | 2019-04-01 | 2020-10-08 | 三井化学株式会社 | Laminate, three-dimensional molded laminate, and method for producing three-dimensional molded laminate |
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1993
- 1993-12-22 JP JP32375093A patent/JP3272519B2/en not_active Expired - Fee Related
Cited By (13)
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JP2012076464A (en) * | 2004-03-29 | 2012-04-19 | Toray Ind Inc | Method of manufacturing fiber-reinforced resin-made sandwich panel |
WO2007088892A1 (en) * | 2006-02-02 | 2007-08-09 | Mitsui Chemicals, Inc. | Backside protective substrate for solar cell module, solar cell module and electric power generator |
JP4809374B2 (en) * | 2006-02-02 | 2011-11-09 | 三井化学株式会社 | Back surface protection substrate for solar cell module, solar cell module and power generator |
JP2014024337A (en) * | 2007-09-26 | 2014-02-06 | Fiberforge Corp | System and method for rapid, automated manufacture of advanced composite tailored blanks |
JP2010002289A (en) * | 2008-06-20 | 2010-01-07 | Society Of Japanese Aerospace Co Inc | Evaluation testing method of peeling in multilayer structure |
JP2011218779A (en) * | 2010-03-23 | 2011-11-04 | Ube Industries Ltd | Method for manufacturing laminate of polyimide foam and thermoplastic resin sheet, and laminate |
JP2011194796A (en) * | 2010-03-23 | 2011-10-06 | Ube Industries Ltd | Production process for laminate of polyimide foam and thermoplastic resin sheet, and laminate |
JP2012002028A (en) * | 2010-06-21 | 2012-01-05 | Mitsubishi Plastics Inc | Cut-off door |
JP2014208419A (en) * | 2013-03-29 | 2014-11-06 | 積水化成品工業株式会社 | Method for producing fiber reinforced composite and fiber reinforced composite |
JP2015226997A (en) * | 2014-05-30 | 2015-12-17 | 積水化成品工業株式会社 | Production method of fiber-reinforced composite body and fiber-reinforced composite body |
WO2020202754A1 (en) | 2019-04-01 | 2020-10-08 | 三井化学株式会社 | Laminate, three-dimensional molded laminate, and method for producing three-dimensional molded laminate |
CN115243880A (en) * | 2020-03-18 | 2022-10-25 | 东丽株式会社 | Laminate and welded body using same |
CN115243880B (en) * | 2020-03-18 | 2024-02-02 | 东丽株式会社 | Laminate and welded body using same |
Also Published As
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---|---|
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