JPH10128896A - Fiber reinforced resin laminated molded body - Google Patents
Fiber reinforced resin laminated molded bodyInfo
- Publication number
- JPH10128896A JPH10128896A JP28496996A JP28496996A JPH10128896A JP H10128896 A JPH10128896 A JP H10128896A JP 28496996 A JP28496996 A JP 28496996A JP 28496996 A JP28496996 A JP 28496996A JP H10128896 A JPH10128896 A JP H10128896A
- Authority
- JP
- Japan
- Prior art keywords
- resin
- fiber
- sheet
- porous
- surface layer
- 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.)
- Pending
Links
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、繊維強化した合成
樹脂成形体について、繊維強化熱可塑性樹脂中に連通気
孔を形成した多孔質樹脂基材と、繊維強化した熱硬化性
樹脂の表層部とを積層一体とした樹脂積層成形体に関す
る。[0001] The present invention relates to a fiber-reinforced synthetic resin molded article, comprising a porous resin base material having continuous pores formed in a fiber-reinforced thermoplastic resin, and a surface layer portion of a fiber-reinforced thermosetting resin. The present invention relates to a resin laminated molded article obtained by integrally laminating a resin.
【０００２】[0002]
【従来の技術と課題】繊維補強樹脂による多孔質の樹脂
成形体は既に知られており、熱可塑性樹脂とガラス単繊
維とを均一配合して緻密なシートに加圧成形し、この緻
密なシートの加熱膨張と適当な圧縮成形とを行って多孔
質の樹脂成形体にしたものがある。2. Description of the Related Art A porous resin molded article made of a fiber-reinforced resin is already known. A thermoplastic resin and a single glass fiber are uniformly blended and pressed into a dense sheet. There is a resin molded article obtained by performing heat expansion and appropriate compression molding on the resin molded article.
【０００３】特開昭６０−１７９２３４号公報には、粒
状ないし粉状の熱可塑性樹脂と高弾性率のガラス単繊維
との混合物から緻密な原料シートを形成し、この原料シ
ートを再加熱して多孔質の膨張シートにし、この膨張シ
ートを所望厚みに加圧成形して、連通気孔性の多孔質シ
ート成形体を得る技術が開示されている。この方法は、
この緻密な原料シートを再度加熱することにより、シー
ト中の樹脂を軟化させて、シート中に圧縮屈折したガラ
ス単繊維がその復原力によって伸びる際にシートを押し
広げて膨張させ、内部に多数の気孔を連通状態で形成さ
せるものである。そして、この膨張シートをプレス機等
により所望形状に加熱圧縮成形するが、この際に元の緻
密な原料シート厚みよりも幾らか厚く形成することによ
りその気孔率を制御して連通気孔性とし、このシート成
形体に通気性・通水性を確保し、ガラス繊維により曲げ
強度と耐衝撃強度を高め、多孔質として軽量化を図った
ものである。Japanese Patent Application Laid-Open No. Sho 60-179234 discloses that a dense raw material sheet is formed from a mixture of a granular or powdery thermoplastic resin and a single glass fiber having a high modulus of elasticity, and the raw material sheet is reheated. There is disclosed a technique in which a porous inflatable sheet is formed, and the inflatable sheet is pressure-formed to a desired thickness to obtain a porous sheet molded article having continuous pores. This method
By heating the dense raw material sheet again, the resin in the sheet is softened, and when the glass single fiber compressed and refracted in the sheet expands due to its restoring force, the sheet is expanded by expanding it, and a large number of insides are expanded. The pores are formed in a communicating state. Then, the expansion sheet is heated and compression-molded into a desired shape by a press machine or the like.At this time, the porosity is controlled by forming a somewhat thicker than the original dense raw material sheet thickness to provide continuous pores, The sheet molded body is provided with air permeability and water permeability, the bending strength and the impact resistance are enhanced by glass fibers, and the weight is reduced as a porous body.
【０００４】さらに、特開昭６０−１５８２２７号公報
には、成形用原料となる樹脂シート中にガラス単繊維を
均一に分散させるのを目的として、熱可塑性樹脂の粒体
とチョップドガラス単繊維と水と発泡剤とを混合して発
泡分散液を調製し、この分散液から、紙抄きの方法で、
ネット上にウェッブを抄造し、これから水分を分離して
乾燥させて、通気性シート構造体とする技術が開示され
ている。この通気性シート構造体は、さらに加熱加圧成
形して緻密なシート成形体にするものではあるが、上記
の多孔質シート成形体は、この緻密なシート成形体を原
料シートとして利用したもので、この緻密なシート成形
体を再加熱して得られた多孔質成形体は、再加熱の際の
膨張量が大きく、その強度の高いことが知られている。Further, Japanese Patent Application Laid-Open No. 60-158227 discloses that a thermoplastic resin particle and a chopped glass single fiber are mixed with each other in order to uniformly disperse the glass single fiber in a resin sheet as a raw material for molding. A foaming dispersion is prepared by mixing water and a foaming agent, and from this dispersion, a paper-making method is used.
There is disclosed a technique in which a web is formed on a net, moisture is separated therefrom and dried to obtain a breathable sheet structure. Although this breathable sheet structure is further subjected to heat and pressure molding to form a dense sheet molded body, the porous sheet molded body uses the dense sheet molded body as a raw material sheet. It is known that a porous molded body obtained by reheating this dense sheet molded body has a large expansion amount upon reheating and high strength.
【０００５】このような多孔質シート成形体は、機械的
強度と軽量性とを合わせ持つ点では優れているが、成形
体表面が粗雑であって、ガラス繊維が表面に露出して毛
羽立った状態であるので、そのままでは外装材などとし
ての利用は不適当であった。さらに、ポリオレフィン系
樹脂を使用した成形体は、その表面塗装が困難であり、
その表面性状を平滑で緻密に改善する必要があった。[0005] Such a porous sheet molding is excellent in that it has both mechanical strength and light weight, but the surface of the molding is rough and the glass fibers are exposed on the surface and are fluffy. Therefore, use as it is as an exterior material is inappropriate. Furthermore, the molded body using the polyolefin resin is difficult to surface coat,
It was necessary to improve the surface properties smoothly and precisely.
【０００６】また、この多孔質シート成形体は、多数の
連通気孔による通気性・通水性を有するのが特徴である
が、成形体内部の連通気孔が表面に開口する場合には、
成形体に接した水などの液体が表裏に浸透することにな
り、水槽やその蓋などの用途に対しては、緻密性に欠け
るので、気密的・水密的な使用ができなかった。[0006] Further, this porous sheet molded article is characterized in that it has air permeability and water permeability due to a large number of continuous air holes, but when the continuous air holes inside the molded article are opened to the surface,
Liquids such as water that have come into contact with the molded body penetrate into the front and back, and are not dense enough for water tanks and lids, so that air-tight and water-tight use could not be performed.
【０００７】本発明は、このような繊維強化多孔質樹脂
成形体が有する強度と軽量性の特徴を保持しながら、成
形体の表面性状を改良し、水密的・気密的な用途に特に
適した樹脂積層成形体を提供しようとするものである。[0007] The present invention improves the surface properties of the molded article while maintaining the strength and lightness characteristics of such a fiber-reinforced porous resin molded article, and is particularly suitable for watertight and airtight applications. An object of the present invention is to provide a resin laminate molded article.
【０００８】[0008]
【課題を解決するための手段】本発明の繊維強化樹脂積
層成形体は、単繊維と熱可塑性樹脂とを含む多孔質樹脂
基材の表面に、繊維と熱硬化性樹脂を含む表層部を積層
一体として成ることを特徴とする。According to the present invention, there is provided a fiber-reinforced resin laminate formed by laminating a surface layer containing a fiber and a thermosetting resin on a surface of a porous resin substrate containing a single fiber and a thermoplastic resin. It is characterized by being integrally formed.
【０００９】本発明においては、多孔質熱可塑性樹脂を
基材とし、その基材の表面に熱硬化性樹脂を被覆しかつ
反応硬化させて表層部とした繊維強化樹脂成形体であ
る。表層部は緻密な熱硬化性樹脂であり、その表面は綺
麗な仕上げ面とすることが容易であるので、基材による
強度と軽量性とともに表層部の良好で緻密な表面性状を
具備した積層成形体が可能になる。According to the present invention, there is provided a fiber-reinforced resin molded article comprising a porous thermoplastic resin as a base material, a surface of the base material coated with a thermosetting resin, and cured by reaction to form a surface layer. The surface layer is a dense thermosetting resin, and its surface can be easily finished in a clean finish. Therefore, the laminate molding with good and dense surface properties of the surface layer as well as the strength and lightness of the base material The body becomes possible.
【００１０】上記多孔質樹脂基材には、特に、ポリオレ
フィン系の樹脂にガラス繊維を含む連通気孔性の加熱成
形体が採用され、この場合には、積層する際の熱硬化性
樹脂が基材の表面に開口した気孔内部に含浸充足するの
で、熱硬化性樹脂の硬化後には両者間の接着力を大きく
することができ、熱硬化性樹脂表層部の緻密な面を成形
体の表面とすることができ、これにより、強度と軽量性
とを有し、且つ表面性状が良好で緻密な樹脂積層成形体
とすることができる。[0010] The porous resin substrate is preferably a thermoformed resin having continuous pores containing glass fibers in a polyolefin resin. In this case, the thermosetting resin used for laminating is used as the substrate. Since the inside of the pores opened on the surface of the thermosetting resin is impregnated and filled, the adhesive strength between the two can be increased after the thermosetting resin is cured, and the dense surface of the thermosetting resin surface layer portion is used as the surface of the molded body Thereby, it is possible to obtain a dense resin laminated molded article having strength and lightness, and having good surface properties.
【００１１】さらに、表層部をなす上記熱硬化性樹脂に
は、熱硬化性樹脂に繊維と必要により骨材とを含むシー
トモールディングコンパウンドが採用される。この場合
には、基材とシートモールディングコンパウンドとの両
者を加熱加圧して、基材表面上で熱硬化性樹脂を軟化な
いし溶融させて該表面を被覆し、次いで速やかに樹脂を
熱硬化させることによって、硬化した表層部を形成す
る。そして、熱硬化性樹脂は、熱加圧して積層する際
に、溶融軟化して基材の表面に開口した連通気孔の内部
に含浸して充足するので、熱硬化性樹脂の硬化後には両
者間の接着力が高くなるのである。Further, as the thermosetting resin constituting the surface layer, a sheet molding compound containing fibers and, if necessary, aggregate in the thermosetting resin is employed. In this case, both the base material and the sheet molding compound are heated and pressurized to soften or melt the thermosetting resin on the base material surface, cover the surface, and then heat cure the resin immediately. Thereby, a hardened surface layer portion is formed. When the thermosetting resin is laminated by applying heat and pressure, it is melted and softened and impregnated into the inside of the continuous ventilation hole opened on the surface of the base material to be filled. This increases the adhesive strength.
【００１２】一般に、ポリオレフィン系の樹脂は接着力
が低いのであるが、繊維強化熱硬化性樹脂材料にシート
モールディングコンパウンドを使用すると、これをポリ
オレフィン系樹脂の基材に対して加熱加圧して溶融さ
せ、多孔質樹脂基材の表面に接触充填し直ちに硬化させ
ることにより、基材と表層部との間の接着力を確保する
ことができるのである。Generally, a polyolefin resin has a low adhesive strength. However, when a sheet molding compound is used as a fiber-reinforced thermosetting resin material, the sheet molding compound is melted by applying heat and pressure to a polyolefin resin substrate. By contact-filling and immediately curing the surface of the porous resin substrate, the adhesive force between the substrate and the surface layer can be ensured.
【００１３】[0013]
【発明の実施の形態】本発明の繊維強化樹脂積層成形体
は、その構造を模式的に図１に示すが、繊維強化の多孔
質樹脂の基材１と繊維補強の熱硬化性樹脂表層部２０と
からなるものである。先ず、多孔質樹脂基材１は、熱可
塑性樹脂中に単繊維１３と気孔（不図示）を含有するも
のである。このような多孔質樹脂基材は、好ましくは、
上述のように、特開昭６０−１７９２３４号公報及び特
開昭６０−１５８２２７号公報に開示の技術が適用可能
であり、次のようにして形成したものが利用される。即
ち、熱可塑性樹脂の粉粒体と高弾性率の単繊維と発泡材
と水とを混合した分散液からネット上にシート状に抄い
てウェブとし、これを乾燥し、次いで、薄いシート状に
加圧成形して原料シートに成形する。この原料シートを
加熱して熱可塑性樹脂を軟化させ、ガラス単繊維の反発
により多孔質の膨張シートにし、これを加熱のままプレ
スまたはロールにより多数の気孔を保持でき且つ所望形
状で所望の厚みに圧縮成形して、多孔質樹脂基材にした
ものである。このような基材は、その積層成形体の用途
形状に応じて、シート状、板状、その他の形状、例え
ば、マンホール蓋状にしたものが使用される。DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The structure of a fiber-reinforced resin laminate molded article of the present invention is schematically shown in FIG. 1. A fiber-reinforced porous resin substrate 1 and a fiber-reinforced thermosetting resin surface layer are shown. 20. First, the porous resin substrate 1 contains a single fiber 13 and pores (not shown) in a thermoplastic resin. Such a porous resin substrate is preferably
As described above, the techniques disclosed in JP-A-60-179234 and JP-A-60-158227 are applicable, and those formed as follows are used. That is, a sheet is formed on a net from a dispersion liquid obtained by mixing a granular material of a thermoplastic resin, a single fiber having a high elastic modulus, a foaming material, and water on a net to form a web, which is dried, and then formed into a thin sheet. Press forming to form a raw material sheet. The raw material sheet is heated to soften the thermoplastic resin, and the porous glass expanded into a porous expanded sheet by repulsion of the single glass fiber. The heated expanded sheet can hold a large number of pores by a press or a roll and has a desired shape and a desired thickness. It is compression molded to form a porous resin substrate. Such a substrate may be in the form of a sheet, a plate, or another shape, for example, a manhole cover, depending on the application shape of the laminated molded article.
【００１４】熱可塑性樹脂には、ポリエチレン（ＰＥ）
やポリプロピレン（ＰＰ）などのオレフィン系樹脂、ポ
リエチレンテレフタレート（ＰＥＴ）、ポリブチレンテ
レフタレート（ＰＢＴ）、ポリカーボネート（ＰＣ）、
ナイロン等があり、特に、ポリエチレン（ＰＥ）とポリ
プロピレン（ＰＰ）が好ましく採用される。As the thermoplastic resin, polyethylene (PE)
Olefin resins such as polyethylene and polypropylene (PP), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polycarbonate (PC),
There are nylon and the like, and particularly, polyethylene (PE) and polypropylene (PP) are preferably employed.
【００１５】熱可塑性樹脂に配合される繊維は、基材の
樹脂よりも弾性率の大きい高弾性率のものが使用され、
ガラス繊維、炭素繊維又は金属繊維が使用可能である
が、特にガラス繊維が好ましい。ガラス繊維には、単繊
維の線径５〜２０μｍ、長さ７〜５０ｍｍのものが好適
である。原料シート中にガラス単繊維２０〜６０％（重
量％）程度を配合しておくと、原料シートの加熱によ
り、大きく膨張した多孔性樹脂シートが得られ、その後
やや低温に下げてプレスによる再圧縮成形する過程で、
プレス成形性が良好となり、成形した基材全体に単繊維
と気孔とが均一に分配される。プレスにより成形シート
に補強用リブなどの突起部を構成する場合にも、リブな
ど肉厚の小さい部材中への単繊維の分配が容易になる。
その結果、単繊維による基材の強化と耐衝撃性、耐摩耗
性の改善の効果が積層成形体全体に及ぶようになる。[0015] The fiber to be blended with the thermoplastic resin has a high modulus of elasticity greater than that of the base resin.
Glass fibers, carbon fibers or metal fibers can be used, but glass fibers are particularly preferred. As the glass fiber, a single fiber having a wire diameter of 5 to 20 μm and a length of 7 to 50 mm is preferable. If about 20 to 60% (% by weight) of glass single fiber is blended in the raw material sheet, a porous resin sheet which is greatly expanded by heating the raw material sheet is obtained. During the molding process,
The press formability is improved, and the single fibers and the pores are uniformly distributed throughout the formed base material. Even in the case of forming projections such as reinforcing ribs on a molded sheet by pressing, distribution of single fibers into small-walled members such as ribs is facilitated.
As a result, the effect of reinforcing the base material with a single fiber and improving the impact resistance and abrasion resistance is exerted on the entire laminated molded article.
【００１６】他方、熱硬化性樹脂表層部は、未硬化の熱
硬化性樹脂と繊維とから成る混合物を基材表面に被覆し
て表面形成し且つ該熱硬化性樹脂を硬化させたものであ
る。このような混合物は、液状、ペースト状ないし液泥
状であってもよいが、最も好ましいのは、未硬化熱硬化
性樹脂と繊維と必要により適当な骨材とを混練して固形
状とし、特に、シート状などに予備的に成形されたシー
トモールディングコンパウンド（以下、ＳＭＣとい
う。）である。ＳＭＣは、一定温度以上に加熱すること
によりＳＭＣ中の未硬化樹脂成分が成形可能に軟化ない
し流動化して且つその温度で速やかに反応硬化するもの
が選ばれる。ＳＭＣは、シート状、板状又はブロック状
の形状のものを使用することができる。On the other hand, the surface layer of the thermosetting resin is formed by coating the surface of a base material with a mixture of an uncured thermosetting resin and fibers and forming the surface and curing the thermosetting resin. . Such a mixture may be in the form of a liquid, a paste or a liquid mud, but most preferably, a solid is obtained by kneading an uncured thermosetting resin, fibers and an appropriate aggregate as necessary. Particularly, it is a sheet molding compound (hereinafter, referred to as SMC) preliminarily formed into a sheet or the like. As the SMC, a material is selected in which the uncured resin component in the SMC is softened or fluidized so as to be moldable by heating to a certain temperature or more, and rapidly reacts and cures at that temperature. As the SMC, a sheet-shaped, plate-shaped or block-shaped SMC can be used.
【００１７】ＳＭＣを含めて繊維強化熱硬化性樹脂は、
未硬化熱硬化性樹脂として不飽和ポリエステル樹脂、エ
ポキシ樹脂、フェノール樹脂、ビニルエステル樹脂、ア
クリル樹脂などが選ばれ、これに重合開始剤ないし架橋
剤、硬化剤を含み、強化用の繊維としてガラス繊維、炭
素繊維、アラミド繊維、ポリエステル繊維などが配合さ
れ、必要ならば増粘剤と増量用の充填剤ないし骨材とが
配合されて混合され、予めシート状あるいはマット状に
成形したものが使用される。強化用繊維は、上記種類の
単線維であっもよいが、長繊維の繊維束であってもよ
く、またこの繊維束を織成した織布も使用できる。The fiber-reinforced thermosetting resin including SMC is:
As the uncured thermosetting resin, an unsaturated polyester resin, an epoxy resin, a phenol resin, a vinyl ester resin, an acrylic resin, or the like is selected, which includes a polymerization initiator or a cross-linking agent, a curing agent, and glass fiber as a reinforcing fiber. , Carbon fiber, aramid fiber, polyester fiber, etc. are blended, and if necessary, a thickener and a filler or aggregate for increasing the amount are blended and mixed, and a pre-formed sheet or mat is used. You. The reinforcing fiber may be a single fiber of the type described above, but may also be a fiber bundle of long fibers, or a woven fabric woven from this fiber bundle can be used.
【００１８】繊維強化熱硬化性樹脂シートは、多孔質樹
脂基材の表面に重積して、加熱しながらプレス又はロー
ルなどの加圧成形手段により押圧されて表層部が形成さ
れ、これにより積層体となる。この際の加熱温度は、多
孔質樹脂基材の変形温度（軟化温度）以下であって、表
層部の熱硬化性樹脂の成形温度以上であることが好まし
い。多孔質樹脂基材を軟化温度以上に加熱すると、多孔
質樹脂基材が変形したり、圧縮されて気孔が少なくなり
緻密化したりするのは好ましくない。従って、プレスな
どの加熱成形の際には、多孔質樹脂基材の軟化温度以下
での加熱によって、ＳＭＣなどの熱硬化性樹脂シートが
軟化ないし溶融して、多孔質樹脂基材の表面に密着しそ
のまま重合または架橋反応により硬化して表層部が成形
されるようにする。The fiber-reinforced thermosetting resin sheet is stacked on the surface of the porous resin base material, and is pressed by a press forming means such as a press or a roll while heating to form a surface layer portion. Be a body. The heating temperature at this time is preferably equal to or lower than the deformation temperature (softening temperature) of the porous resin substrate and equal to or higher than the molding temperature of the thermosetting resin in the surface layer. When the porous resin substrate is heated to a temperature higher than the softening temperature, it is not preferable that the porous resin substrate is deformed or compressed to reduce pores and become dense. Therefore, during heat molding such as pressing, the thermosetting resin sheet such as SMC is softened or melted by heating below the softening temperature of the porous resin substrate, and adheres to the surface of the porous resin substrate. Then, it is cured as it is by polymerization or cross-linking reaction to form the surface layer portion.
【００１９】より具体的には、多孔質樹脂基材には、オ
レフィン系樹脂、特にポリプロピレン（ＰＰ）とガラス
繊維の組合せの多孔質シートが好ましく採用できる。こ
の場合、表層部の熱硬化性樹脂シートは、基材のポリプ
ロピレン（ＰＰ）の変形温度以下である６０〜１４０℃
程度の温度範囲で流動性と反応硬化性を有し、この温度
範囲で、１〜１０ｋｇｆ／ｃｍ2 の低い圧力で充分な成
形性能を有するものが好ましい。このような熱硬化性樹
脂シートは、低温低圧ＳＭＣとして入手可能である。More specifically, a porous sheet of an olefin resin, particularly a combination of polypropylene (PP) and glass fiber can be preferably used as the porous resin substrate. In this case, the thermosetting resin sheet of the surface layer portion has a deformation temperature of 60 to 140 ° C. which is lower than the deformation temperature of polypropylene (PP) as the base material.
It is preferable that the material has fluidity and reaction curability in a temperature range of about the same and has sufficient molding performance at a low pressure of 1 to 10 kgf / cm 2 in this temperature range. Such a thermosetting resin sheet is available as a low-temperature low-pressure SMC.
【００２０】低温低圧ＳＭＣとしては、成形温度が６５
〜９５℃で成形圧力２〜１０ｋｇ／ｃｍ2 程度で成形性
良好なものが特に好ましい。このような低温低圧ＳＭＣ
の使用により、熱加圧成形の過程で、多孔質樹脂基材の
変形を招くことなく、熱硬化性樹脂表層部を成形し且つ
硬化させて表面硬化層を形成し、しかも、低圧で多孔質
樹脂基材の表面の気孔中に熱硬化性樹脂を浸入させて硬
化させるのことができる。そこで、多孔質樹脂基材のポ
リエチレン（ＰＥ）やポリプロピレン（ＰＰ）のような
表面被着性の良くない基材樹脂に対しても低温低圧ＳＭ
Ｃの熱硬化性樹脂表層部は溶融接着と気孔へのアンカー
効果によりその接着力を著しく高めることができるので
ある。As the low temperature and low pressure SMC, the molding temperature is 65
Particularly preferred is a material having good molding properties at a molding pressure of about 2 to 10 kg / cm 2 at a temperature of up to 95 ° C. Such low temperature and low pressure SMC
In the process of hot press molding, the surface of the thermosetting resin is molded and cured to form a surface cured layer without causing deformation of the porous resin substrate in the process of hot press molding. The thermosetting resin can be infiltrated into pores on the surface of the resin base material and cured. Therefore, low-temperature and low-pressure SM can be applied to porous resin substrates such as polyethylene (PE) and polypropylene (PP) that have poor surface adhesion.
The thermosetting resin surface layer portion of C can significantly increase the adhesive force due to the fusion bonding and the anchor effect to the pores.
【００２１】積層成形においては、図２に例示するよう
に、加熱加圧可能なプレス成形機３等の金型３１、３２
の間に、多孔質樹脂基材１の表裏に熱硬化性樹脂シート
２、２を配置する。この例で、下側の金型３１には、型
面３１０の周囲に型枠３１１が突設形成されており、上
側の金型３２には、下側の金型３１の型枠３１１内に装
入される型面３２０が、周辺より突設して構成されたも
ので、多孔質樹脂基材１の表裏に熱硬化性樹脂シート
２、２を金型３１、３２間で加熱し加圧しながら昇温し
所定の温度に保持する。金型内で温度上昇とともに熱硬
化性樹脂シート２、２中の樹脂が溶融して流動化し、金
型３１、３２の型面と多孔質樹脂基材１との間で加圧さ
れて、多孔質樹脂基材１の当該表面に密着する。そし
て、該シート２の熱硬化性樹脂の重合反応が進行して硬
化し、図１に示すように（図１には、基材１中の気孔が
省略してある）、表層部２０となり、そのまま冷却し
て、表層部２０の表面に金型の型面３１０、３２０の形
状が賦形された積層成形体１０が得られる。こうして、
積層成形体１０は、多孔質樹脂基材１の芯部は多孔質で
あるが基材１の表面層には熱硬化性樹脂表層部２０が強
固に接着し、この表層部２０の表面２１が綺麗に仕上げ
られた積層成形体１０が得られる。In the lamination molding, as illustrated in FIG. 2, dies 31, 32 such as a press molding machine 3 capable of heating and pressurizing.
In between, the thermosetting resin sheets 2 and 2 are arranged on the front and back of the porous resin substrate 1. In this example, a mold 311 is formed on the lower mold 31 so as to protrude around the mold surface 310, and the upper mold 32 is provided inside the mold 311 of the lower mold 31. The mold surface 320 to be inserted is configured so as to protrude from the periphery, and the thermosetting resin sheets 2 and 2 are heated and pressed between the molds 31 and 32 on the front and back of the porous resin substrate 1. While maintaining the temperature at a predetermined temperature. The resin in the thermosetting resin sheets 2 and 2 is melted and fluidized as the temperature rises in the mold, and is pressed between the mold surfaces of the molds 31 and 32 and the porous resin substrate 1 to form a porous resin. Adhere to the surface of the porous resin substrate 1. Then, the polymerization reaction of the thermosetting resin of the sheet 2 proceeds and cures, and as shown in FIG. 1 (in FIG. 1, the pores in the base material 1 are omitted), the surface layer portion 20 is formed. By cooling as it is, the laminated molded body 10 in which the shapes of the mold surfaces 310 and 320 are formed on the surface of the surface layer portion 20 is obtained. Thus,
In the laminated molded body 10, the core portion of the porous resin substrate 1 is porous, but the thermosetting resin surface layer portion 20 is firmly adhered to the surface layer of the substrate 1, and the surface 21 of the surface layer portion 20 is A neatly finished laminated molded body 10 is obtained.
【００２２】本発明では、多孔質樹脂基材の片面だけで
なく両面にも熱硬化性樹脂表層部の表面を形成すること
ができ、また、積層成形体の縁端部の端面にも同様に熱
硬化性樹脂表層部を形成することも適宜なされる。これ
により、非透水性ないし遮水性を具備した板状の構造
物、パネル、蓋材として利用することができる。According to the present invention, the surface of the thermosetting resin surface layer can be formed not only on one side but also on both sides of the porous resin base material. The formation of the thermosetting resin surface layer is also appropriately performed. Thereby, it can be used as a plate-like structure, a panel, or a lid having impermeable or water-impermeable properties.
【００２３】多孔質樹脂基材の裏面あるいは下面に予め
リブや周辺部の補強部材を一体形成しておき、これに熱
硬化性樹脂表層部を形成して、構造的に強化した積層成
形体とすることもなされる。本発明の積層成形体は、シ
ート、板やパネルとして広い用途に供される。さらに、
多孔質樹脂基材は、その加熱による膨張性を利用した優
れた成形性を有するので、一体にプレスにより、所望の
形状の構造物に成形して、上記の表面層を形成すること
により、例えば、水槽やマンホール用の蓋として、ある
いは、下水処理場その他のピットの蓋として利用でき
る。A rib or a reinforcing member for the peripheral portion is integrally formed on the back or lower surface of the porous resin base material in advance, and a thermosetting resin surface layer portion is formed thereon to form a structurally reinforced laminated molded body. It is also done. The laminated molded article of the present invention is used for a wide range of uses as a sheet, a plate or a panel. further,
Since the porous resin base material has excellent moldability utilizing its expandability due to heating, by integrally pressing, by molding into a structure of a desired shape, and forming the surface layer, for example, It can be used as a lid for water tanks and manholes, or as a lid for sewage treatment plants and other pits.
【００２４】[0024]
【実施例】多孔質樹脂基材の成形のために、ポリプロピ
レンとガラス繊維とを混合した厚み５ｍｍの圧縮成形シ
ート（ケープラシート（株）製造の「ＫＰシート」）
を、２２０℃の温度に加熱して膨張させ、この膨張シー
トを４０〜６０℃の温度でプレスにより圧縮して、厚み
１２ｍｍの板状の多孔質樹脂加熱成形体を得た。EXAMPLE For forming a porous resin substrate, a compression molded sheet having a thickness of 5 mm in which polypropylene and glass fiber were mixed ("KP sheet" manufactured by Cape La Sheet Co., Ltd.)
Was expanded by heating at a temperature of 220 ° C., and the expanded sheet was compressed by a press at a temperature of 40 to 60 ° C. to obtain a plate-shaped porous resin heat molded article having a thickness of 12 mm.
【００２５】この成形体を成形し多孔質樹脂基材（寸法
２５０×２５０ｍｍ）として、その両面に、厚み１．８
ｍｍの低温低圧ＳＭＣシート（武田薬品工業（株）製、
品名「セレクティー Ｒ−１０１」）を挟んで、加熱プ
レス機の片面平滑な上下金型の間に配置し、金型の蒸気
加熱により、８０℃に加熱し、８ｋｇｆ／ｃｍ2 の圧力
で圧下し２５分保持して、厚み１４．６ｍｍの板状の積
層成形した。This molded article was molded to form a porous resin substrate (having a size of 250 × 250 mm).
mm low temperature low pressure SMC sheet (manufactured by Takeda Pharmaceutical Co., Ltd.)
The product is placed between the upper and lower molds on one side of a heating press machine with the product name “Selecty R-101” therebetween, heated to 80 ° C. by steam heating of the mold, and reduced at a pressure of 8 kgf / cm 2. After holding for 25 minutes, a plate-like laminate having a thickness of 14.6 mm was formed.
【００２６】この板状積層成形体から試験片を採取し
て、ＪＩＳ Ａ１４０８に準拠して曲げ強度試験を行っ
た。比較材として、上記多孔質樹脂基材から試験片につ
いても同様の曲げ強度試験を行った。その結果を表１に
示す。A test piece was sampled from the plate-shaped laminate and subjected to a bending strength test according to JIS A1408. As a comparative material, a similar bending strength test was performed on a test piece from the porous resin substrate. Table 1 shows the results.
【００２７】[0027]
【表１】 [Table 1]
【００２８】表１から、本発明の積層体は、比較材に対
して、曲げ強さが大幅に改善されており、また、曲げ弾
性率も僅かながら大きくなっていることが判る。From Table 1, it can be seen that the laminate of the present invention has a significantly improved bending strength and a slightly higher flexural modulus than the comparative material.
【００２９】[0029]
【発明の効果】本発明の繊維強化樹脂積層成形体は、繊
維強化熱可塑性樹脂の多孔質樹脂基材の表面に繊維補強
の熱硬化性樹脂表層部を加熱加圧して表層部を形成した
ので、表層の熱硬化性樹脂が多孔質樹脂基材の気孔内に
含浸充填することができ、積層成形体を強化することが
でき、軽量性と強靭性を兼ね備えた積層体を構成するこ
とができる。According to the fiber-reinforced resin laminate molded article of the present invention, the surface layer is formed by heating and pressing the surface layer of the fiber-reinforced thermosetting resin on the surface of the porous resin substrate of the fiber-reinforced thermoplastic resin. The thermosetting resin of the surface layer can be impregnated and filled into the pores of the porous resin base material, the laminated molded body can be strengthened, and the laminated body having both lightness and toughness can be formed. .
【００３０】また、樹脂積層成形体は、繊維が露出した
多孔質樹脂基材の粗い表面を緻密な表層で被覆して綺麗
な表面とすることができ、また、積層成形体の気密性・
水密性を確保することができ、芯部に多孔質樹脂基材を
使用していながら密封機材としての利用が図れる。Further, the resin laminate molded article can be made to have a clean surface by covering the rough surface of the porous resin base material with the exposed fiber with a dense surface layer.
Water tightness can be ensured, and it can be used as a sealing device while using a porous resin base material for the core.
【００３１】そして上記熱硬化性樹脂表層部に、繊維と
骨材と熱硬化性樹脂を含むシートモールディングコンパ
ウンド（ＳＭＣ）を利用することにより、多孔質樹脂基
材とシート状ないし板状のＳＭＣとを配置して加熱プレ
ス成形することができ、繊維強化樹脂積層成形体が簡便
にかつ量産的に形成できる効果を奏する。さらに、上記
多孔質樹脂基材に接着性の悪いオレフィン系の樹脂を含
む連通気孔性の加熱成形シートを使用する場合にも、シ
ート状のＳＭＣの使用により接着強度の大きい表層部を
形成することができる。By using a sheet molding compound (SMC) containing fibers, an aggregate and a thermosetting resin in the surface layer of the thermosetting resin, a porous resin base material and a sheet or plate-like SMC can be formed. Can be formed by heat press molding, and an effect that a fiber-reinforced resin laminate molded body can be easily and mass-produced. Furthermore, even when using a continuous-pored heat-molded sheet containing an olefin-based resin having poor adhesion to the porous resin base material, a surface layer having a large adhesive strength is formed by using a sheet-like SMC. Can be.
【図１】本発明の繊維強化樹脂積層成形体の概念的な断
面図。FIG. 1 is a conceptual cross-sectional view of a fiber-reinforced resin laminate molded article of the present invention.
【図２】本発明の繊維強化樹脂積層成形体を成形するた
めの金型内配置の断面図。FIG. 2 is a cross-sectional view of an arrangement in a mold for molding the fiber-reinforced resin laminate molded article of the present invention.
１０ 繊維強化樹脂積層成形体 １ 多孔質樹脂基材 ２０ 熱可塑性樹脂表層部 ２ 熱可塑性樹脂シート ３１ 金型 ３２ 金型 DESCRIPTION OF SYMBOLS 10 Fiber-reinforced resin laminated molded article 1 Porous resin base material 20 Thermoplastic resin surface layer part 2 Thermoplastic resin sheet 31 Mold 32 Mold
Claims (5)
脂基材の表面に、繊維と熱硬化性樹脂とを含む表層部を
加熱成形して積層一体とした繊維強化樹脂積層成形体。1. A fiber-reinforced resin laminate formed by laminating and integrally forming a surface layer containing fibers and a thermosetting resin on the surface of a porous resin substrate containing single fibers and a thermoplastic resin.
単繊維と上記熱可塑性樹脂の粉粒体との混合物を加圧成
形したシート状成形体を加熱膨張させて後加圧成形され
て成る連通気孔性の加熱成形体である請求項１記載の繊
維強化樹脂積層成形体。2. A post-press molding method in which the porous resin substrate is heated and expanded to form a sheet-like molded product obtained by press-molding a mixture of the single fiber having a high elastic modulus and the granular material of the thermoplastic resin. The fiber-reinforced resin laminate molded article according to claim 1, which is a heat-molded article having continuous pores formed by said method.
可塑性樹脂がポリオレフィン系樹脂である請求項１又は
２記載の繊維強化樹脂成形体。3. The fiber-reinforced resin molded article according to claim 1, wherein the single fiber is a glass fiber, and the thermoplastic resin is a polyolefin-based resin.
含むシートモールディングコンパウンドから形成されて
成る請求項１記載の繊維強化樹脂積層成形体。4. The fiber-reinforced resin laminate according to claim 1, wherein the surface layer is formed from a sheet molding compound containing fibers and a thermosetting resin.
化温度より低い温度で溶融し且つ硬化するシートモール
ディングコンパウンドから形成されて成る請求項１記載
の繊維強化樹脂積層成形体。5. The fiber-reinforced resin laminate according to claim 1, wherein the surface layer is formed of a sheet molding compound that melts and cures at a temperature lower than the softening temperature of the porous resin substrate.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP28496996A JPH10128896A (en) | 1996-10-28 | 1996-10-28 | Fiber reinforced resin laminated molded body |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP28496996A JPH10128896A (en) | 1996-10-28 | 1996-10-28 | Fiber reinforced resin laminated molded body |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH10128896A true JPH10128896A (en) | 1998-05-19 |
Family
ID=17685433
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP28496996A Pending JPH10128896A (en) | 1996-10-28 | 1996-10-28 | Fiber reinforced resin laminated molded body |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH10128896A (en) |
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| CN114683577A (en) * | 2022-04-02 | 2022-07-01 | 广东汇天航空航天科技有限公司 | Part forming method, protection plate and aerocar |
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