JPH079632A - Molded composite and production thereof - Google Patents

Abstract

PURPOSE:To obtain a molded composite having air blocking properties by laminating a skin material to a sheet-like core material shapable by heating and pressure through a thermoplastic resin film specified in its melt index to perform adhesion and shaping by one process. CONSTITUTION:A skin material is laminated to a sheet-like core material shapable by heating and pressure through a thermoplastic resin film with a melt index of 0.5 or more and the obtained laminate is shaped under heating and pressure. For example, the skin material 13 composed of a polyester fiber is bonded to the entire single surface of the core material 11 composed of a nonwoven fabric based on a glass fiber and mixed with a polyester fiber through a linear low density polyethylene film 12 with a melt index of 9.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention has a high adhesive strength between a core material and a skin material, is lightweight, has excellent shapeability, and has excellent ventilation blocking properties, and is an interior material for buildings, ships, vehicles and the like. The present invention relates to a molded composite and a method for producing the same, which are preferably used as the above.

[0002]

2. Description of the Related Art As a ceiling material, for example, Japanese Patent Laid-Open No. 2-57
As described in Japanese Patent No. 333 publication, a hot-melt adhesive layer is adhered over the entire surface of a mat-like material in which inorganic fibers are adhered to each other with a thermoplastic resin to form a plate, and further a skin material is adhered. The sound absorbing material is known.

The hot melt adhesive layer used here is a polyolefin-based, polyamide-based, polyester-based, polyurethane-based, etc., having a pore diameter of 0.2 to 3 mm and an aperture ratio of 0.5 to 20%. Breathable.
To bond the hot-melt adhesive layer and the skin material to the surface of the mat-like material, the mat-like material is heated so that the surface temperature is equal to or higher than the melting point of the thermoplastic resin, and then the hot-melt adhesion is applied to the heated surface. The agent layer and the skin material are bonded together. Alternatively,
The hot melt adhesive and the skin material are heated in advance to bond them.

In order to shape the sound-absorbing material thus formed, it is necessary to heat the mat-like thermoplastic resin and the hot-melt adhesive layer to a temperature not lower than the melting point thereof and press with a relatively low temperature press machine. Done.

[0005]

Since the sound absorbing material described in the above publication has many through holes in order to obtain air permeability,
The mat-like material and the skin material are not completely adhered to each other, and the opening portion of the hot melt adhesive layer is in a non-adhesive state. Then, in the curved surface portion of the molded composite shaped into a predetermined shape, the adhesive layer and the through hole thereof are stretched, and the non-bonded portion is expanded. As a result, the adhesive strength of this portion is remarkably reduced, the mat-like material and the skin material are easily separated from each other, and it may not be possible to cope with severe conditions such as deep press molding and high temperature during use.

When the composite body having a large number of through holes described above is used as a ceiling material for a vehicle, for example, due to an air flow in the vehicle interior during traveling or a change in the indoor air pressure due to opening and closing of a door, the air is absorbed in cigarette smoke and air. There is a problem that the floating fine particles are clogged in the through holes and the dirt on the ceiling material becomes noticeable.

In order to manufacture the above-mentioned sound absorbing material, a step of heating the mat-like material so that the surface temperature thereof is equal to or higher than the melting point of the thermoplastic resin and bonding the hot-melt adhesive layer and the skin material to the surface. And a step of transferring this to a press machine and press-molding it. In such a case, the temperature of the thermoplastic resin falls below the melting point during the transfer to the press machine, so before press molding, the mat-like material and the skin material are bonded again to the melting point of the thermoplastic resin or higher. There is the problem of having to heat up.

The present invention solves the above-mentioned problems of the prior art, firmly and evenly adheres the core material and the skin material so as to withstand deep press molding and harsh conditions, and further has a ventilation blocking property. It is an object of the present invention to provide a molded composite having the above, and a method for producing a molded composite that can perform adhesion and shaping in one step and can maintain ventilation blocking properties.

[0009]

The molded composite of the present invention according to claim 1 comprises a sheet-shaped core material which can be shaped by heating and pressing, and a thermoplastic resin film having a melt index of 0.5 or more. The skin material is laminated via the above and is shaped by heating and pressing.

The molded composite of the present invention according to claim 2 is characterized in that a thermoplastic resin layer is provided on one or both sides of the thermoplastic resin layer surface of the sheet-shaped core material which can be shaped by heating and pressing. A skin material is laminated via a thermoplastic resin film having a melt index of 0.5 or more and shaped by heating and pressing.

The molded composite of the present invention according to claim 3 is the molded composite according to claim 1 or 2, wherein the thermoplastic resin film has a melt index of 0.5 or more (a). ), A heat-resistant resin layer (b) having a melting temperature higher than that of the thermoplastic resin layer (a), and a thermoplastic resin layer (c) are laminated in this order, and the thermoplastic resin layer ( a) is a skin material, a thermoplastic resin layer (c) is laminated in contact with a core material, and is shaped by heating and pressing.

According to a fourth aspect of the present invention, there is provided a method for producing a molded composite, wherein a thermoplastic resin film having a melt index of 0.5 or more is superposed on the surface of a sheet-shaped core material which can be shaped by heating and pressing. Characterized in that the thermoplastic resin film is heated to a temperature higher than its melting temperature and melted, and a skin material is overlaid on the surface of the melted resin to apply pressure, whereby the core material and the skin material are bonded and shaped simultaneously. It is a thing.

According to a fifth aspect of the present invention, in the method for producing a molded composite, the thermoplastic resin is a sheet-shaped core material which is provided with a thermoplastic resin layer on one side or both sides and can be shaped by heating and pressing. By laminating a thermoplastic resin film having a melt index of 0.5 or more on the layer surface, heating and melting the thermoplastic resin film at a temperature not less than its melting temperature, and stacking a skin material on the molten resin surface and applying pressure. The core material and the skin material are bonded and shaped at the same time.

A method for producing the molded composite of the present invention according to claim 6 is the method for producing the molded composite according to claim 4 or 5, wherein the thermoplastic resin film is the thermoplastic resin (a). A thermoplastic resin layer (a) is a composite film in which a heat-resistant resin layer (b) having a higher melting temperature than the thermoplastic resin layer (a) and a thermoplastic resin layer (c) are laminated in this order. It is characterized in that the thermoplastic resin layer (c) is superposed on the skin material so as to be on the core material side.

The present invention will be described in detail below. The core material used in the present invention can be shaped by heating and pressurizing, inorganic fibers or organic fibers, or a non-woven fabric in which these mixed fibers are mutually bonded by a thermoplastic resin, or a knitted fabric of these fibers, Woven cloth is mentioned. Further, it is possible to use, for example, cardboard, corrugated cardboard, chipboard made of pulp, and further a laminate of two or more of these.

The above-mentioned non-woven fabric, knitted fabric, woven fabric (hereinafter referred to as "fabric product")
As the inorganic fiber used for the glass fiber,
Examples include rock fiber, asbestos, carbon fiber, and the like. Organic fibers include natural fibers such as plant fibers and animal fibers, cellulosic fibers,
Examples thereof include polyamide, polyester, polyacrylic, polypropylene, and other synthetic resin fibers.

The inorganic fiber and the organic fiber may be appropriately mixed and made. From the viewpoint of heat distortion resistance and dimensional stability of the molded composite, it is preferable to mainly use inorganic fibers. If the fiber density of these cloth products is too low, the strength is low and they are easily broken. If the fiber density is too high, it becomes difficult to shape. Therefore, the fiber density is preferably 300 to 700 g / m ² . Further, in the case of a non-woven fabric, needle punching may be performed as necessary to increase the strength.

Examples of the thermoplastic resin for adhering the fibers of the non-woven fabric to each other include polyethylene, polypropylene, saturated polyester, polyamide, polystyrene, polyvinyl butyral and the like, and they are used in the form of powder, fiber, emulsion or the like. it can. When a synthetic resin fiber is used for the nonwoven fabric in order to impart bulkiness to the nonwoven fabric or improve shapeability, it is preferable to use one having a lower melting point than the synthetic resin fiber.

In the present invention, in addition to the above, as the core material, a core material having a thermoplastic resin layer on one side or both sides is also used. Even if the thermoplastic resin film (c) of the thermoplastic resin film or the composite film laminated on this surface is melted, impregnation of the molten resin into the core material may be impossible depending on the type of core material, that is, the material and surface condition. Is enough,
Alternatively, since the adhesiveness to the core material may be poor, for example, when the corrugated paper or the chipboard is the core material, it is necessary to make the surface of the core material bondable in advance.

Therefore, in the second and fifth aspects of the invention, the core material having the thermoplastic resin layer on one or both sides is used. As this thermoplastic resin layer,
Polyolefin resins such as polypropylene, polyethylene, ethylene-vinyl acetate copolymer, ethylene-acrylic acid amide copolymer, ethylene-ethyl acrylate copolymer, polyvinyl chloride, polyamide, polystyrene, polyvinyl butyral and the like can be mentioned.

The means for providing the thermoplastic resin layer on the surface of the core material is not particularly limited, and any conventionally known means can be used. For example, a method in which the thermoplastic resin is melted in a mold and extruded into a film on the surface of the core material, and the fibers on the surface of the core material are entangled and cooled to be bonded and laminated,
The thermoplastic resin is once shaped into a film, and a molten resin is supplied between the two while adhering it to the core surface while adhering it,
There is a method of laminating, or a method of sticking the resin shaped into a film on the surface of the core material with an adhesive,
It may be appropriately selected depending on the type of core material and the surface condition.

When the adhesion between the core material and the thermoplastic resin film is poor due to the material and surface condition of the core material, the above thermoplastic resin having good adhesion to the thermoplastic resin film is selected on the surface of the core material. By forming this with a strong adhesive force, the adhesive force between the core material and the thermoplastic resin film can be increased.

Thermoplastic resin layer (a) of a thermoplastic resin film or a composite film for laminating a core material and a skin material
Among those used as hot melt type adhesives, in the present invention, the melt index is 0.5 or more,
Further, those having an upper limit value of 30 or less, preferably 20 or less are used. High density polyethylene, medium low density polyethylene, linear low density polyethylene,
Examples thereof include one or a mixture of two or more polyolefin resins such as polypropylene and ethylene-vinyl acetate copolymer, polyamide, polyvinyl chloride, and acid-modified products of these thermoplastic resins.

The heat-resistant resin layer (b) of the composite film has a higher melting temperature than the thermoplastic resin layer (a),
30 ° C or higher, preferably 50 from the thermoplastic resin layer (a)
Those having a temperature higher than ℃ are preferable. This makes it possible to heat the entire laminate of the core material, the composite film, and the skin material to melt the resin layers other than the heat-resistant resin layer (b).

Examples of the resin for the heat-resistant resin layer (b) include heat-resistant resins such as polybutylene terephthalate, polyethylene terephthalate, polycarbonate, polyamide, and modified products thereof. Further, the resin of the heat-resistant resin layer (b) has a high thermoforming drawing ratio (the thermoforming drawing ratio is higher than the diameter D when the plate-like material is drawn into a cylindrical shape by a vacuum forming machine). The ratio H / D of the height H) is preferably 0.5 or more. When the thermoforming drawing ratio is 0.5 or less, there is a problem in the thermoforming performance of the core material, that is, the shapeability.

With respect to the thermoplastic resin layer (c), any material can be used so long as it can be heat-sealed with the thermoplastic resin on the surface of the core material, and the melt index need not be particularly important. As the resin for the thermoplastic resin layer (c), one or two kinds of polyolefin resins such as high-density polyethylene, medium-low density polyethylene, linear low-density polyethylene, polypropylene, and ethylene-vinyl acetate copolymer are used. A mixture of the above,
Examples thereof include polyamide, polyvinyl chloride, and acid-modified products of these thermoplastic resins.

As the composite film, one having a thermoplastic resin layer (a) and a heat resistant resin layer (b) and an adhesive layer further provided between the heat resistant resin layer (b) and the thermoplastic resin layer (c) is used. You may. The method for producing the composite film is not particularly limited, and a coextrusion method, an extrusion laminating method, a dry laminating method, or the like is applied. Preferably a coextrusion method,
That is, it is a method of producing a multilayer film by an inflation method, a T-die method, or the like with an adhesive resin layer interposed between a thermoplastic resin and a heat-resistant resin layer, and can be produced more economically than other methods.

The skin material used in the present invention is a natural fiber such as a plant fiber or an animal fiber, a cellulose-based material, a polyamide-based material,
Woven or non-woven fabrics made of synthetic resin fibers such as polyester, polyacrylic and polypropylene are preferably used. When a fibrous skin material such as a woven or non-woven fabric is used, the adhesive strength with the core material is increased due to the anchor effect of the thermoplastic resin film melting and penetrating between the fibers.

However, if an anchoring effect with the resin can be obtained, if a foamed sheet having open cells such as polyurethane foam is provided on the surface to be bonded to the core material of woven or non-woven fabric, the core Absorb the unevenness of the material,
It is also possible to enhance the design of the surface of the skin material and impart cushioning properties. A skin material having a thickness of 1 to 2 mm is suitable.

Furthermore, since the thermoplastic resin layer (a) of the thermoplastic resin film and the composite film has a melt index of 0.5 or more, it has good fluidity in the molten state and is easily shaped. Although the shapeability is greatly affected by the hardness and thickness of the core material and the skin material, the dependence of the shaping temperature, etc., even when using a core material or skin material with good shapeability, deep shaping is also possible. Even when the shape is formed, the effect of being able to sufficiently deal with it while keeping the entire surface in a uniform adhesive state is remarkable. A thermoplastic resin film having a melt index of 2 or more has more remarkable effects in terms of maintaining the above-mentioned complete and uniform surface adhesion state, having good fluidity in a molten state, and being easily shaped. .

In the molded composite of the present invention, the thermoplastic resin film (c) and (a) of the thermoplastic resin film or composite film having a melt index of 0.5 or more is melted to form a fiber structure of the core material and the skin material. In the case of biting or having a thermoplastic resin layer provided on the surface of the core material, the thermoplastic resin layer and the melted thermoplastic resin film or thermoplastic resin layer (c) are firmly bonded.

In the method for producing the molded composite of the present invention, the thermoplastic resin layer (c) of the thermoplastic resin film or the composite film is laminated on the core material, and the thermoplastic resin layer (a) of the thermoplastic resin film or the composite film, It is necessary to stack and shape the skin material while (c) remains in the molten state. That is,
Adhesion between the core material and the skin material by melting the thermoplastic resin film or thermoplastic resin layer (c) and the thermoplastic resin (a) by heating and shaping into a desired shape are performed simultaneously, so only one step is required. A shaped composite can be obtained. Further, it is possible to eliminate the waste of heating for bonding and heating during shaping.

Various means such as an infrared heater, a far infrared heater, hot air, and electric heating can be used as the heating means, but the far infrared heater is preferably used.

[0034]

In the molded composite according to claim 1, since the skin material is laminated on the core material via the thermoplastic resin film having a melt index of 0.5 or more, and is shaped by heating and pressing, the core material is formed. And the skin material are completely and uniformly surface-bonded to each other, and the adhesive strength is very excellent even in the concave portion and the convex portion.

In the molded composite according to claim 2, since the thermoplastic resin layer is laminated on one side or both sides of the core material,
Even if the core material has poor adhesion to the thermoplastic resin film, the adhesive strength between the thermoplastic resin layer and the thermoplastic resin film becomes large, and therefore the adhesive strength between the core material and the skin material is excellent.

Further, in the molded composite according to claim 3, in the molded composite according to claim 1 or 2, the thermoplastic resin layer (a) and the thermoplastic resin layer (c) are respectively heated by heat. It is melted and firmly laminated with the core material and the skin material. The intermediate heat-resistant resin layer (b) is firmly laminated with the above-mentioned resin layers (a) and (c) but is not heat-melted, so that the air-permeable blocking property is ensured.

The method for producing a molded composite according to claim 4 is:
A thermoplastic resin film having a melt index of 0.5 or more is superposed on the surface of the core material, the thermoplastic resin film is heated to a temperature equal to or higher than its melting point and melted, and a skin material is superposed on the surface of the melted thermoplastic resin film, and at the same time, press However, when shaped into a desired shape, the thermoplastic resin film is easily shaped because it has good fluidity in the molten state, and follows expansion and contraction due to deformation of the core material or skin material in the curved portion, and at the adhesive surface. The film does not break, digs into the fiber structure of the core material, and maintains a complete and uniform surface adhesion state. Therefore, a molded composite body having a strong adhesive strength between the core material and the skin material can be obtained.

Further, in the method for producing a molded composite according to claim 5, a thermoplastic resin film having a melt index of 0.5 or more is laminated on the surface of the thermoplastic resin layer provided on the surface of the core material, and the thermoplastic resin film is formed. When heated to a temperature equal to or higher than the melting point, melted, and shaped into a desired shape while pressing and overlaying the melted thermoplastic resin film surface, even when the core material has poor adhesiveness with the thermoplastic resin film, Adheres well to the surface of the core material with the thermoplastic resin to maintain a complete and uniform surface-bonding state.

The method for producing a molded composite according to claim 6 is the same as the method for producing a molded composite according to claim 4 or 5, wherein the thermoplastic resin layer (a) and the thermoplastic resin layer (c). Melts due to heat to exhibit fluidity, facilitates shaping, and firmly laminates with the core material and the skin material, respectively. The intermediate heat resistant resin layer (b) is the above resin layer (a)
While being firmly laminated with (c) and (c), they are shaped without being melted by heat while maintaining the ventilation blocking property.

Since the thermoplastic resin layers (a) and (c) of the thermoplastic resin film and the composite film have good fluidity in a molten state, they can be easily shaped, and the expansion and contraction due to the deformation of the core material or the skin material in the curved portion. The film does not break on the adhesive surface, and a perfect and uniform surface adhesive state is maintained. Therefore, a molded composite body having a strong adhesive strength between the core material and the skin material can be obtained. When a composite film is used, the heat resistant resin layer (b) is the thermoplastic resin layer (a),
Since (c) is protected in strength, the blocking property of ventilation is further ensured.

[0041]

Embodiments of the present invention will now be described with reference to the drawings. (Example 1) FIG. 1 is a cross-sectional view showing an example of the molded composite of the present invention according to claim 1, 1 is a molded composite, which is a core made of a non-woven fabric mainly composed of glass fibers and mixed with polyester fibers. A linear low density polyethylene (LLDPE) film 12 having a melt index of 9 on one surface of the material 11.
The skin material 13 made of polyester fiber is
The entire surface is adhered by the LDPE film 12. LL
Since the DPE film 12 is shaped by pressing in a molten state, the core material 11 and the skin material 13 are partially impregnated.

Explaining the core material 11, the glass is used.
Fibers (diameter 20-40 μm, length 20-100 mm) 7
0 parts by weight and polyester fiber (6 denier, length 20 ~
80 mm) 30 parts by weight were mixed and made into a web shape
, Needle punch (density 30 points / m²) Gala
Mainly made of fiber, thickness about 9mm, weight 500g / m
²The felt-like material was used. Emma with emulsion
The felt is passed through the lujon tank and the
Impregnated.

The core material 11 is passed through a sandwich roll to adjust the emulsion amount to a solid content of 30 g / m ² , and the solid material is heated at about 100 ° C. in a hot air dryer to obtain the water content in the emulsion. And a fiber-shaped non-woven fabric in which fibers are partially bound by a thermoplastic resin binder which is impregnated and dispersed in a felt-like material.

FIG. 2 is a sectional view showing the sequence of the method for producing the above-mentioned molded composite. LLDPE (melt index 5 at 150 ° C, melting temperature 125 ° C, thickness 70 μm)
The film 12 is laminated on one surface of the core material 11 to form a laminate 14
And

As shown in FIG. 2A, the core material 11 of the laminate 14 is placed in a lower mold 41 (forming depth 15 mm) heated to 50 ° C. with a far infrared heater (1 KW).
16 on the 12th side of the LLDPE film by 3, 3, ...
The film 12 is melted by heating to 5 ° C., and a non-woven fabric using polyester fiber (fiber density 180 g
/ M ² ), and the upper die 4 was immediately closed as shown in FIG. 2B and heated and pressed at a pressure of 4 kg / cm ² to shape. The pressing time at this time was 20 seconds, and the mold clearance was 5 mm.

As shown in FIG. 2C, in the molded composite 1 obtained by demolding, the core material 11 and the skin material 13 were completely adhered to each other over the entire surface, and the curved surface portion was also subjected to a peeling test under an atmosphere of 85 ° C. ( It had an adhesive strength capable of withstanding 180 ° peeling and a static load of 10 g / mm.

(Example 2) The same core material as used in Example 1 was used, and a copolymerized polyamide film (melt index 7 at 150 ° C, melting temperature 115 ° C, thickness was used) on the upper surface of the core material. 60 μm), and the same mold as that used in Example 1 was heated to 50 ° C. and put, and the polyamide film was heated to 140 ° C. with a far infrared heater (1 KW) to make the film 12 in a molten state. On top of this, a non-woven fabric using polyester fibers (fiber density 180 g / m ² ) was coated with a polyurethane foam (expansion ratio 30 times, thickness 2 mm) on one side with an adhesive, and the mold was immediately overlaid. Was closed and heated and pressed at a pressure of 4 kg / cm ² to shape (not shown). The pressing time at this time was 20 seconds, and the mold clearance was 5 mm.

(Embodiment 3) FIG. 3 is a sectional view showing an embodiment of the molded composite body of the present invention according to claim 2. Reference numeral 2 denotes a molded composite, which is a core material 20 in which a low-density polyethylene resin layer 23 having a thickness of 30 μm is provided on one surface of a corrugated paper board 21 having a thickness of 7 mm by extrusion lamination, and the same skin material 24 as that used in Example 1. And LLDPE film (melt index 10, thickness 70 μm) 22 are bonded and laminated.

The molded composite body 2 of Example 3 was manufactured as follows. The LLDPE film 22 is overlaid on the upper surface of the low-density polyethylene resin layer 23, and this is used in Example 1.
The inside of the same mold as that used in above was heated to 50 ° C. and put in this, and the above LLDP was heated by a far infrared heater (1 KW).
The surface of the E film 22 is heated to 160 ° C.
Was melted, a skin material 24 was placed on the melted state, the mold was immediately closed, and heating and pressurization was applied at a pressure of 4 kg / cm ² to shape (not shown). The pressing time at this time was 20 seconds, and the mold clearance was 5 mm.

In the obtained molded composite body 2, the core material 20 and the skin material 24 are completely adhered over the entire surface, and the curved surface portion is 85.
It had an adhesive strength capable of withstanding a peeling test (180 ° peeling, static load 10 g / mm) in an atmosphere of ° C, and the surface of the skin material 24 did not have fine irregularities.

(Example 4) The same corrugated board used in Example 3 was extruded and laminated on one surface to a thickness of 25.
μm high density polyethylene resin layer (melting temperature 125 ℃)
A low-density polyethylene film (melt index 5 at 150 ° C., thickness 70 μm) as a thermoplastic resin film was overlaid on the surface of the high-density polyethylene resin layer of the core material in which the same gold as used in Example 1 was used. The mold is heated to 50 ° C and put in this, and the low-density polyethylene film is heated to 15 by a far infrared heater (1 kW).
The film was melted by heating to 0 ° C., the same skin material as used in Example 1 was placed on the film, the mold was immediately closed, and the film was heated and pressed at a pressure of 4 kg / cm ² to shape the film. (Not shown). The pressing time at this time was 20 seconds, and the mold clearance was 5 mm.

(Embodiment 5) FIG. 4 is a sectional view showing an embodiment of the molded composite of the present invention according to claim 3. This molded composite 5 is replaced by the LLDPE film 12 used in Embodiment 1. The structure is the same as that of Example 1 except that the composite film 50 shown in FIG. 4 is used.

In the molded composite 5, the LLDPE resin layer 51 is the skin material 13, and the high-density polyethylene resin layer 53 is the core material 11.
Since the LLDPE resin layer 51 is pressure-shaped on the skin material 13 in a melted state, the skin material 13 is partially impregnated.

The composite film 50 is a linear low density polyethylene (LLDPE) having a melt index of 9.
A resin layer 51, a polyamide resin layer 52 having a melting temperature of 225 ° C., and a high-density polyethylene resin layer 53 having a melt index of 1 are laminated in this order by coextrusion molding.

The above-mentioned molded composite 5 is manufactured by using the composite film 5
The LLDPE resin layer 51 of No. 0 is on the skin material 13 side, the high-density polyethylene resin layer 53 is on the core material 11 side, and the layers are shaped by heating and pressing under the same conditions as in Example 1. In the obtained molded composite 5, the core material 11 and the skin material 13 are completely adhered over the entire surface, and the curved surface portion is also subjected to a peeling test in an atmosphere of 85 ° C. (180 ° peeling, static load 10 g / mm).
It has an adhesive strength that can withstand even the air permeability of 0.3
It was cc / cm ² · sec or less, and had a sufficient ventilation blocking property.

(Example 6) FIG. 5 is a cross-sectional view showing another example of the molded composite body according to claim 3, and the same LLDPE resin layer 5 of the composite film 50 as that used in Example 5 is used.
1. The high-density polyethylene resin layer 53 is the same as the one used in Example 1, and the same low-density polyethylene resin layer 23 of the core material 21 used in Example 3 is used in Example 1.
Under the same conditions as described above, they are heated and pressed to bond and laminate, and then shaped.

This molded composite body 6 includes a skin material 13 and a core material 11.
Is completely adhered over the entire surface, and the curved surface is also subjected to a peeling test in an atmosphere of 85 ° C. (180 ° peeling, static load 10
(g / mm), the adhesive strength was sufficient to withstand, and the air permeability was 0.3 cc / cm ² · sec or less, and the air permeability was sufficient.

[0058]

The molded composite of the present invention according to claim 1 is
Since a skin material is laminated on a sheet-shaped core material that can be shaped by heating and pressing through a thermoplastic resin film having a melt index of 0.5 or more, and is shaped by heating and pressing, the core material And the skin material are completely and evenly bonded over the entire surface, and the adhesive strength is very excellent even in the concave portions and the convex portions.

In the molded composite of the present invention as defined in claim 2, wherein a thermoplastic resin layer is laminated on one side or both sides of the core material, a core material having poor adhesion to the thermoplastic resin film is used. However, since the adhesive force between the thermoplastic resin layer and the thermoplastic resin film is increased, the adhesive force between the core material and the skin material is excellent.

Furthermore, the molded composite of the present invention according to claim 3 has the effects of the inventions according to claims 1 and 2, and
Since it has excellent ventilation blocking properties, it is particularly suitable for use as a ceiling material for vehicles and the like because it is less likely to become dirty.

In the method for producing a molded composite of the present invention as set forth in claim 4, a thermoplastic resin film having a melt index of 0.5 or more is superposed on the surface of the core material, and the thermoplastic resin film is heated to its melting temperature or higher. Since the material is heated and melted, and the skin material is pressed on the surface of the molten resin, the core material and the skin material are adhered to each other by melting the thermoplastic resin film by heating, and the desired shape is formed at the same time. Therefore, the molded composite can be obtained in only one step. Therefore, heat and melt the thermoplastic resin film for adhesion,
It is also possible to eliminate the waste of heating again during shaping.

Further, according to the method for producing a molded composite body of the present invention as set forth in claim 5, since the one in which the thermoplastic resin layer is laminated on one surface or both surfaces of the core material is used, the effect of the invention in claim 4 is obtained. In addition, even if the core material has poor adhesiveness to the thermoplastic resin film, the core material is well adhered to the surface of the core material through the thermoplastic resin, so that a complete and uniform surface adhesion state is maintained.

Further, according to the method for producing a molded composite body of the present invention described in claim 6, in addition to the effect of the invention of claim 5, a material excellent in ventilation blocking property can be obtained.

[0064]

[Brief description of drawings]

FIG. 1 is a sectional view showing an embodiment of the molded composite body of the present invention according to claim 1.

FIG. 2 is a cross-sectional view showing one embodiment of the method for producing the molded composite of the present invention in the order of steps.

FIG. 3 is a cross-sectional view showing an example of the molded composite body of the present invention according to claim 2.

FIG. 4 is a sectional view showing an embodiment of the molded composite body of the present invention according to claim 3.

FIG. 5 is a sectional view showing another embodiment of the molded composite body of the present invention according to claim 3;

[Explanation of symbols]

 1, 2, 5, 6: Molded composite 3: Far-infrared heater 11: Core material 12, 22: Linear low density polyethylene film 13, 24: Skin material 14: Laminate 21: Corrugated paper 23: Low density polyethylene resin Layer 4: Upper mold 41: Lower mold 50: Composite film 51: Linear low density polyethylene resin layer 52: Polyamide resin layer 53: High density polyethylene resin layer

Claims (6)

[Claims] 1. A skin material is laminated on a sheet-shaped core material which can be shaped by heating and pressurizing, and a thermoplastic resin film having a melt index of 0.5 or more, which is shaped by heating and pressing. Molded composites. 2. A heat having a melt index of 0.5 or more on the surface of the thermoplastic resin layer of a sheet-shaped core material which is shaped by heating and pressurization and is provided with a thermoplastic resin layer on one side or both sides. A molded composite body in which a skin material is laminated via a plastic resin film and shaped by heating and pressing. 3. The molded composite according to claim 1 or 2, wherein the thermoplastic resin film has a thermoplastic resin layer (a) having a melt index of 0.5 or more, and the thermoplastic resin layer (a). Heat-resistant resin layer (b) having a higher melting temperature than
And a thermoplastic resin layer (c) are laminated in this order, wherein the thermoplastic resin layer (a) is laminated on the skin material and the thermoplastic resin layer (c) is laminated on the core material. A molded composite formed by heating and pressing. 4. A thermoplastic resin film having a melt index of 0.5 or more is superposed on the surface of a sheet-shaped core material that can be shaped by heating and pressing, and the thermoplastic resin film is heated to a temperature above its melting temperature. A method for producing a molded composite, characterized in that the core material and the skin material are adhered and shaped at the same time by melting, melting and superposing the skin material on the surface of the molten resin. 5. A thermoplastic resin layer surface of a sheet-shaped core material which is provided with a thermoplastic resin layer on one side or both sides thereof and which can be shaped by heating and pressing has a melt index of 0.
A thermoplastic resin film of 5 or more is superposed, the thermoplastic resin film is heated to a melting temperature or higher and melted, and a skin material is superposed on the surface of the melted resin to pressurize the core material and the skin material. A method for producing a molded composite, which comprises adhering and shaping at the same time. 6. The method for producing a molded composite according to claim 4 or 5, wherein the thermoplastic resin film has a thermoplastic resin layer (a) and a melting temperature higher than that of the thermoplastic resin layer (a). A heat-resistant resin layer (b) having a high heat resistance and a thermoplastic resin layer (c) are laminated in this order, and the thermoplastic resin layer (a) is used as a skin material and the thermoplastic resin layer (c) is used as a cover material. A method for producing a molded composite, characterized in that the cores are superposed on each other.