JPH1044281A - Composite board and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent deformation and obtain plate rigidity and smooth surface by bonding and integrating a stiffening plate with a paper sheet connected to both the surfaces of a fiber reinforced thermoplastic resin sheet having continuous fiber blended at a specific ratio on one surface or both the surfaces of an intermediate layer consisting of a core material placed within a frame body. SOLUTION: A stiffening plate 5 with a paper sheet 4 connected to both the surfaces of a fiber reinforced thermoplastic resin sheet 3 made of prepreg having one-way arranged continuous long fiber at a weight content of 40-80% is integrated on one surface or both the surfaces of an intermediate layer consisting a core material 2 placed within a frame body 1 via an adhesive layer 6. In this instance, the fiber reinforced thermoplastic resin sheet 3 is heated, and then a paper sheet 4 is superimposed on its both surfaces to subsequently be cooled while compressing by press rollers or the like, thereby obtain a stiffening plate 5. Wood, resin, and metal are used for such a frame body. A paper honeycomb and resin foamed body are preferable used for such a core material 2. For such a continuous fiber, glass fiber is used suitably. The adhesive is made of each kind of resin, rubber adhesive, etc.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite board used for architectural purposes such as walls, ceilings and floors of fittings, doors, assembled houses and the like, and for general industrial use, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, as for composite boards used for fittings, doors, etc., an intermediate layer in which a lightweight core material such as paper honeycomb is filled in the space of a framed frame is bonded to both sides of an intermediate layer with an adhesive. A plywood made of a material or the like is stuck. It is well known that the surface of the plywood and the side surfaces of the frame are decorated with a skin material such as paper, vinyl chloride or the like, and are widely used for construction and general industry. However, while this composite board has excellent properties such as smooth appearance, finishing, and lightness, the veneer board and the frame expand and contract with changes in temperature and humidity. As a result, there is a problem that the plywood is warped and the appearance of the composite board is impaired. In addition, the veneer plate has a problem that it is relatively heavy and easily bends in spite of its thin thickness, so that it is difficult to work at the time of manufacturing and assembling the composite plate. In applications where a concentrated load acts on the veneer surface, there has been a problem that breakage is likely to occur. Further, in recent years, when the price of the raw material used as the material of the plywood has greatly fluctuated, the price of the composite plate has also risen, causing a problem in cost. There is a demand for a composite board made of a material with less price fluctuations, replacing the plywood board. Therefore, in the case of a composite plate in which the frame and the face material are made of a metal material and the above-mentioned problems can be solved,
While it has high strength and rigidity, it can suppress warpage and bending,
Due to the drawbacks of increased weight and poor design appearance, only a few applications, such as entrance doors, at the expense of lightness and design are widespread.

[0003] For example, Japanese Patent Application Laid-Open No. 7-96569 discloses a method in which a paper and a resin sheet are laminated in five layers on both sides of a metal foil on both sides of an intermediate layer composed of a frame and a honeycomb core. A composite board is disclosed. However, in this composite plate, when a load acts locally, there is a problem that the strength of the face material is not sufficient, so that a hole is formed or a crack is caused to cause deformation, and the waterproof function is lost.

[0004] As a method for solving the strength and water resistance, Japanese Patent Application Laid-Open No. Hei 7-233630 discloses a concrete board in which a fiber-reinforced thermoplastic resin sheet is bonded on both sides to an intermediate layer composed of a frame and a core material of a honeycomb core. It is disclosed for moldwork. However, a special surface treatment or an adhesive is required for bonding to the thermoplastic resin sheet, and there is a disadvantage that processing cost is increased. In addition, fiber reinforced thermoplastic resin sheets manufactured by the lamination fusing method or the papermaking method become thicker and heavier because the strength and rigidity as face materials decrease when the thickness for a sheet where fibers are not aligned is reduced. There are drawbacks. JP-A-6-134913 discloses a composite plate in which a unidirectional fiber-reinforced thermoplastic resin sheet is bonded to both sides of an intermediate layer made of a resin foam core material. JP-A-7-88988 discloses a composite plate in which a unidirectional fiber reinforced thermoplastic resin sheet is bonded to both surfaces of an intermediate layer made of a core material of a honeycomb core. In any case, a composite plate can be obtained by a heat lamination method in which a fiber-reinforced thermoplastic resin sheet is heated and melted without using an adhesive, laminated with a core material, cooled and solidified, and integrated. Japanese Patent Application Laid-Open No. 7-32397 discloses a method and apparatus capable of producing a low-cost, high-quality composite board by continuously laminating a fiber-reinforced thermoplastic resin sheet to a core material.

However, if the fiber-reinforced thermoplastic resin sheet is integrated with the intermediate layer composed of the frame and the core material by the above-described thermal lamination method, there is a problem that a step appears at the boundary between the frame and the core material. . Further, there is a problem that unevenness due to the distribution and thickness unevenness of the glass fibers of the fiber reinforced thermoplastic resin sheet appears on the surface.

[0006]

SUMMARY OF THE INVENTION The present invention has been made in order to solve the above-mentioned problems, and an object of the present invention is to make it possible to reduce the weight and cost and to make the deformation due to humidity and temperature changes. It is an object of the present invention to provide a high-quality composite board having excellent durability, excellent flat plate rigidity and impact strength, and a smooth surface.

[0007]

SUMMARY OF THE INVENTION A first object of the present invention is to provide:
Paper sheets (4) on both sides of a fiber-reinforced thermoplastic resin sheet (3) composed of a prepreg containing a continuous filament aligned in one direction and having a weight content of 40% or more and 80% or less.
A bonding plate (5) is provided on one or both sides of an intermediate layer composed of a frame (1) and a core material (2) filled in the space inside the frame (1) by bonding a reinforcing plate (5) to which This is achieved by an integrated composite plate.

Further, a fiber-reinforced thermoplastic resin sheet (3)
But it is desirable in which the thermal expansion coefficient of the fiber direction are laminated 2-4 sheets of 10 ^{@ 5} / ° C. or less of the prepreg at any angle alone or orientation angle 0 to 90 °. Preferably, the fibers of the prepreg forming the fiber reinforced thermoplastic resin sheet (3) are glass fibers, and the thermoplastic resin is a polyolefin resin. The paper sheet (4) in contact with the adhesive layer (6) is a paper sheet layer (4a) impregnated with a thermoplastic resin and a paper sheet layer (4b) impregnated with an adhesive.
And at least two layers.

It is desirable that a skin material (7) is integrated with at least one surface of the composite plate via an adhesive layer (6). In one preferred embodiment, the core (2) is a paper honeycomb or resin foam. The thickness of the fiber-reinforced thermoplastic sheet (3) is in the range of 0.05 mm to 1 mm, and the thickness of the paper sheet (4) is 0.5 mm.
It is desirable that the thickness is in the range of not less than 02 mm and not more than 0.5 mm, and the thickness of the reinforcing plate (5) is in the range of not less than 0.2 mm and not more than 2 mm.

[0010] A second object of the present invention is to heat (a) the fiber-reinforced thermoplastic resin sheet (3) to a temperature higher than the melting temperature of the thermoplastic resin and, in a state where the thermoplastic resin is molten, to form a paper sheet (3). 4) is laminated on both sides of the fiber-reinforced thermoplastic resin sheet (3) and then cooled and solidified to produce a reinforcing plate (5), and (b) a surface of the reinforcing plate (5) An application step of applying an adhesive;
(C) an assembling step of forming an intermediate layer in which the core material (2) is inserted into the space inside the frame body (1); and (d) a reinforcing plate with an adhesive (5) is laminated on both sides of this plate to form an adhesive layer. (6) There is provided a composite plate manufacturing method in which a reinforcing plate bonding step of integrating through a step (6) is sequentially performed. In the reinforcing plate bonding step (d), the thermoplastic resin forming the fiber-reinforced thermoplastic resin sheet (3) is softened. This is achieved by a method of manufacturing a composite board that solidifies the adhesive below the temperature.

(A) a heat laminating step, (b) a coating step, (c) an assembling step, (d) a reinforcing plate bonding step, and (e) a bonding layer ( There is a composite plate manufacturing method in which a skin material bonding step of integrating the skin material (8) through 7) is sequentially performed. In the reinforcing plate bonding step (d) and the skin material bonding step (e), fiber-reinforced thermoplastic resin is used. This is achieved by a method of manufacturing a composite board in which the adhesive is solidified at a temperature lower than the softening temperature of the thermoplastic resin forming the resin sheet (3).

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the drawings. FIG. 1 is a perspective view showing one embodiment of the composite plate according to the present invention, FIG. 2 is a cross-sectional view showing the structure of the composite plate shown in FIG. 1, and FIG. 3 shows one embodiment of the composite plate according to the present invention. FIG. 4 is a perspective view, FIG. 4 is a sectional view showing the configuration of the composite plate shown in FIG. 3,
FIG. 5 is a cross-sectional view showing a configuration of a composite plate having a skin material on the surface according to the present invention, FIG. 6 is a cross-sectional view showing one embodiment having a skin material on the surface, and FIG. 7 is an embodiment different from the above. FIG. 8 is a sectional view showing a fiber-reinforced thermoplastic resin sheet (3) on the surface of an intermediate layer composed of a frame (1) and a core material (2) filled in a space inside the frame (1). FIG. 9 is a partially enlarged cross-sectional view showing a state in which a reinforcing plate (5) having paper sheets (4) bonded to both sides thereof is bonded via an adhesive layer (6). FIG. 9 is an adhesive layer (6) shown in FIG. FIG. 10 is a partially enlarged sectional view showing a state in which a paper sheet (4) in contact with a paper sheet layer (4a) impregnated with a thermoplastic resin and a paper sheet layer (4b) impregnated with an adhesive. FIG. 11 is an explanatory view schematically showing an apparatus for manufacturing a composite plate according to the present invention, and FIG. 11 is a view showing a device used in a drop weight impact test of the composite plate according to the present invention. It is an explanatory diagram showing a schematic. In these figures, in order to show the cross-sectional structure in detail, the thickness is emphasized in comparison with the surface dimensions.

FIGS. 1 and 2 show a composite panel having a lightweight panel air-core structure (flash structure) suitably used for furniture, fittings and the like, and a frame (1) composed of a pier (1a) and a burial (1b). ) And a core (2) made of paper honeycomb filled in the space inside the frame (1), and a reinforcing plate (5) is integrated via an adhesive layer (6) on both front and back surfaces of an intermediate layer. Things.

The reinforcing plate (5) aligns continuous long fibers in one direction by aligning them and impregnating them with a thermoplastic resin so that the compounding ratio of the fibers is 40% or more and 80% or less by weight. A prepreg to be made, that is, a sheet in which paper sheets (4) are bonded to both sides of a fiber-reinforced thermoplastic resin sheet (3), which is a single sheet or preferably two to four sheets, and is laminated by changing the direction of fibers. is there.

FIGS. 3 and 4 show a composite panel having a lightweight panel air-core structure (flash structure) which is suitably used for furniture, fittings and the like for applications requiring heat insulation and water resistance.
a) and a frame (1b) made of embedded wood (1b), and a core material (2) made of a resin foam filled in the space inside the frame (1). The plate (5) is integrated via an adhesive layer (6).

FIG. 5 shows a composite panel having a lightweight panel air core structure suitably used for furniture, fittings, etc., and a frame (1) comprising a plurality of piers (1a) and buried trees (1b), A reinforcing plate (5) is integrated via an adhesive layer (6) on both front and back surfaces of an intermediate layer composed of a core material (2) made of a resin foam filled in the space inside the frame (1). is there. Further, a skin material (7) covering the frame (1) and the reinforcing plate (5) is integrated via an adhesive layer (6).

FIG. 6 shows a composite panel having a lightweight panel air-core structure suitably used for floor materials, floor heating, and the like, and a frame (1) comprising a plurality of piers (1a) and buried trees (1b). And a natural wood decorative plywood as a surface plate is adhered to the surface of an intermediate layer composed of a core material (2) made of a resin foam filled in the space in the frame (1), and a reinforcing plate is provided on the back side of the intermediate layer. (5)
Are integrated via an adhesive layer (6).

FIG. 7 shows a composite panel having a lightweight panel air core structure suitably used for furniture, fittings and the like having a curved structure at the end. The frame (1) is composed of a crosspiece (1a) and a buried tree (1b). )
And a frame (1) in which both front and back surfaces and the outside of a middle layer composed of a core material (2) made of a resin foam filled in a space in the frame (1) are processed into a curved surface, and a reinforcing plate ( 5) is integrated via an adhesive layer (6). Further, a skin material (7) covering the reinforcing plate (5) is integrated via an adhesive layer (6). Hereinafter, the material constituting each part will be described.

As the frame (1), wood, veneer plywood,
Wooden frames processed from woody materials such as softwood plywood, glulam, LVL (laminate laminated), particle board, fiber board, or rigid such as hard or semi-hard urethane foam, polystyrene foam, phenolic resin foam, etc. Or foaming resin having a low expansion ratio of 5 times or less of semi-rigid, fiber-reinforced thermoplastic resin, fiber-reinforced thermosetting resin,
A resin frame made of a thermoplastic resin, a thermosetting resin, or the like, or an aluminum extruded material, a metal frame formed by hollowing a metal such as steel, or the like can be used. Frame (1)
Is composed of a crosspiece (1a) forming an outer peripheral portion and a padding (1b) arranged so as to cross the core material (2) filled in the space in the crosspiece frame. Furthermore, when the crosspiece (1a) is provided around the outer edge, the thickness and width are 10 mm or more and 200 mm or more.
If the thickness is less than 10 mm, the joining strength is weakened, and the strength as a composite plate is reduced. If the thickness exceeds 200 mm, the weight increases and the lightness is lost. In addition, two or more crosspieces (1a) are
By cutting the space between a), the shape of the composite plate can be easily changed without cutting the frame (1).

Further, in order to further increase the strength of the composite board and to fix instruments such as handles and shelves on the surface of the composite board, a padding (1b) is disposed at an appropriate place in the frame of the crosspiece (1a). If it is possible, and reinforcement is not required, the embedded tree (1b) may be omitted. The thickness and width of the embedded wood (1b) are preferably in the range of 10 mm or more and 200 mm or less in the same manner as the crosspiece (1a) from the viewpoint of strength and weight. Filled wood (1b) and pier (1
The materials of a) may be the same or different. The arrangement of the buried trees (1b) is not particularly limited, but an arrangement of a grid, an oblique shape, a ladder or the like is preferable because it can be easily manufactured and the strength of the composite board can be improved. The thickness and width of the frame need not be the same, but the thickness needs to be the same for both the burial and the pier.

As the core material (2), any known lightweight material can be used as a lightweight material that can be filled in the space in the frame (1). For example, a foamed material such as expanded polystyrene or urethane foam or A honeycomb core is preferable, and a paper honeycomb or a resin foam having a specific gravity of 0.1 or less is more preferable in terms of price, workability, weight, and strength. By setting the thickness of the core material to be the same as the thickness of the frame, a flat composite plate can be obtained.

The plate-shaped honeycomb core is a plate-shaped member in which countless cylindrical portions are formed adjacent to each other in the outer peripheral direction, and a cross section parallel to the plate surface is formed in a honeycomb shape. It is not limited to the case where the front and back are closed. The honeycomb core used for the core material is not limited to a cross section in which ordinary hexagons are collected, and includes a cross section in which circles are collected, a cross section in which triangles are collected, and the like. These honeycomb cores only need to have a cylindrical surface perpendicular to the reinforcing plate (5) attached to one or both sides, and it is not necessarily required that each cylindrical portion has a cylindrical shape. It is not necessary that they adhere to each other, and they may be present separately or in blocks.
Further, the size and shape of the cylindrical portion may be different, or a simply bent band may be bonded at any point on the band surface, but a high strength composite plate In order to obtain, the size and shape of each cylindrical part are equal,
Further, it is preferable that they are closely attached. Furthermore, each cylindrical part may be fine,
Although it may be large, in order to increase the strength of the composite plate and improve the adhesion to the reinforcing plate (5) or the surface plate, the bottom area of each cylindrical portion is reduced, and It is preferable to increase the thickness of the material forming the portion.
The material of the honeycomb core may be any of aluminum, paper, and thermoplastic resin such as polypropylene, polystyrene, and polyvinyl chloride. The material is not particularly limited as long as the core material (2) of the composite board can exhibit sufficient strength. It is preferable to use the honeycomb core (paper honeycomb) because it is inexpensive, lightweight and has sufficient compressive strength.

As the resin used for the foam, polyethylene, polypropylene, polystyrene, vinyl chloride resin, polyurethane, phenol resin, urea resin, epoxy resin, silicon resin and the like can be used. A resin foam having a fine foam structure can be obtained by an appropriate treatment, for example, a method of foaming by mechanical stirring, a method of utilizing a reaction product gas, a method of using a foaming agent, and the like. . The expansion ratio is 10 to 50 times, the heat insulating material,
Suitable as sound absorbing material and shock absorbing material.

The reinforcing plate (5) used in the composite board of the present invention is a prepreg containing a continuous filament aligned in one direction in a weight content of 40% to 80%, alone or at an orientation angle. It is manufactured by bonding paper sheets (4) to both surfaces of two to four fiber-reinforced thermoplastic resin sheets (3) laminated at an arbitrary angle of 0 to 90 °.

The thermoplastic resin of the prepreg forming the fiber-reinforced thermoplastic resin sheet (3) is not particularly limited.
For example, polystyrene and its copolymer resin, polyvinyl chloride, linear low-density polyethylene, low-density polyethylene, high-density polyethylene, polypropylene, polycarbonate, polybutylene terephthalate, polyethylene terephthalate, polyethersulfone, polysulfone, polyetherimide ( Trademark: ULTEM), polyether ether ketone, polyphenylene sulfide, etc. can be used, but from the viewpoints of strength, abrasion resistance, price and ease of recycling when it becomes waste, polyethylene or polyethylene is the most desirable resin. General-purpose polyolefin resins such as polypropylene are recommended.

Examples of continuous continuous fibers to be mixed with the prepreg forming the fiber-reinforced thermoplastic resin sheet (3) include synthetic resin fibers such as aramid fibers (registered trademark “Kepler”), natural organic fibers, titanium, boron, and the like. Examples include metal fibers such as stainless steel, and inorganic fibers such as glass, carbon, and silicon carbide. However, the material is not necessarily limited to these, and any material having sufficient strength, inexpensive and available in large quantities may be used, and glass fiber is particularly preferable. The material of the glass fiber is not particularly limited, and may be any of alkali-containing glass, low-alkali glass, non-alkali glass, and the like, and various glass fibers conventionally used as glass fibers such as E glass, C glass, and A glass are used. be able to.

The continuous filament used has a diameter of 5 μm.
It is preferable that the thickness be in the range of at least 36 μm. If the diameter of the continuous continuous fiber is less than 5 μm, the fiber is liable to be cut and a prepreg for forming a fiber reinforced thermoplastic resin sheet cannot be obtained. If the diameter exceeds 36 μm, the fiber becomes rigid and the thermoplastic resin is inserted into the fiber gap. And the effect of reinforcing the fiber is not exhibited. In particular, in the case of glass fiber, it is more preferably 10 μm or more and 25 μm or less in terms of cost, workability and strength.

The prepreg for forming the fiber reinforced thermoplastic resin sheet (3) can be produced by the method disclosed in Japanese Patent Publication No. 4-42168. That is, a monofilament of a reinforcing glass fiber was treated with a coupling agent, for example, γ-methacryloxy-propyltrimethoxysilane, and a large number of converged yarns were aligned and melted while being pulled under uniform tension. By contacting the thermoplastic resin and impregnating the resin at a constant speed while squeezing with a hot roll, a prepreg is obtained in which continuous filaments aligned in one direction are blended at a fixed ratio with respect to the thermoplastic resin. .

The mixing ratio of the continuous long fibers of the prepreg is in the range of 40% to 80% by weight. Mixing ratio is 40%
If it is less than 1, when a paper sheet is heat-sealed on both sides of a fiber-reinforced thermoplastic resin sheet, the flowability of the resin becomes high, so that continuous long fibers move and a reinforcing plate in which the fibers are not aligned in one direction is not preferable. With such a reinforcing plate,
Since the required rigidity is reduced and the thermal expansion coefficient in the fiber direction is increased, the impact strength of the surface of the composite plate is reduced, and warpage is more likely to occur. On the other hand, if the compounding ratio exceeds 80%, the adhesion to the paper sheet is reduced, so that it is difficult to laminate the reinforcing plate.

Even when the prepreg has a large thermal expansion coefficient in the fiber direction, the composite board is warped, so that the thermal expansion coefficient is 10 ^-5 / ° C.
It is desirable to make the following. It is recommended to use two or more layers of this prepreg, but especially when bonding a reinforcing plate to only one side of the composite board, if the fiber reinforced thermoplastic resin sheet is too thick, A warping phenomenon is seen.

Therefore, the thickness of the prepreg single layer is 50 μm.
As described above, it is preferable that the thickness be 600 μm or less, and the thickness of the fiber-reinforced thermoplastic resin sheet obtained by laminating two or more and four or less prepregs be 1 mm or less from the viewpoint of low weight and prevention of warpage. That is, if the thickness of the fiber-reinforced thermoplastic resin sheet exceeds 1 mm, the weight increases, while
If it is less than mm, no reinforcing effect is exhibited. It is also recommended that the continuous filaments of the fiber reinforced thermoplastic resin sheet be aligned and aligned in a certain direction, usually a direction that receives bending stress during use, and used.

A fiber-reinforced thermoplastic resin sheet (3) comprising continuous filaments and a thermoplastic resin is heated to a temperature not lower than the melting temperature of the thermoplastic resin, and the paper sheets (4) are superimposed on both front and back surfaces thereof. By cooling while pressurizing, for example, a paper sheet layer (4a) impregnated with a thermoplastic resin is formed to obtain a reinforcing plate (5). If necessary, a surface material whose surface side is desired, in particular, decorative paper may be used.

The paper used for the paper sheet is not particularly limited, and includes, for example, high-quality paper, medium-quality paper, paper-up, paper-up, gravure paper, printed paper, cotton paper, bond paper, and the like.
Printing and writing drawing paper such as art paper, coated paper, lightweight coated paper, kraft paper for heavy bags, unbleached kraft paper, semi-bleached kraft paper, bleached kraft paper, pure white kraft paper, pure white roll paper, S roll paper, piece Packaging paper such as glossy kraft paper and thin imitation paper, corrugated cardboard base paper such as liner paper and middle shin base paper, white paperboard, yellow paperboard, chipboard, paper tube raw paper, and building material raw paper can be used.

The thickness of the fiber reinforced thermoplastic resin sheet is
When the one having a range of 0.05 mm to 1 mm is used, a concave portion having a maximum depth of about 1 mm is formed on the surface of the resin sheet,
The width is up to about 2 mm at the maximum, while the step between the frame and the core material has a gap of about 1 to 3 mm and a step of about 1 mm in depth in order to ensure assembling and workability.

Also, in a reinforcing plate in which a paper sheet of less than 0.01 mm is laminated on both sides of a fiber-reinforced thermoplastic resin sheet, the thermoplastic resin is impregnated into the paper sheet and the resin is covered up to the bonding surface, so that adhesion is difficult. Is not preferred. The thickness of the paper sheet capable of forming an adhesive layer stably over the unevenness due to the distribution and thickness unevenness of the reinforcing fibers of the fiber-reinforced thermoplastic resin sheet and the boundary between the frame and the core material is 0.0
2 mm or more is required. Further, in the case of a composite plate obtained by integrating a skin material with an adhesive layer interposed therebetween, a reinforcing plate is required which has an intermediate layer having a defect such as unevenness or a step and an uneven thickness to have a smooth surface. Defects and uneven thickness can be completely eliminated if the thickness of the paper sheet is at least 0.1 mm or more.

Further, when the paper sheet exceeds 0.5 mm or more, the heat insulating property is increased and the generated steam is increased, so that it becomes difficult to heat laminate with the fiber reinforced thermoplastic resin sheet, and the paper sheet becomes heavy and practically used. Do not follow. From the viewpoint of weight and cost, the thickness of the paper sheet is preferably 0.3 mm or less. That is,
The thickness of the paper sheet is preferably in the range of 0.02 mm to 0.5 mm, more preferably in the range of 0.02 mm to 0.3 mm.
A range of 0.5 mm is preferred. Kamitsubo amount of this range, depending on paper varieties do not but 20g / m ² ~300g / m ² is used as being limited thereto. Desirably, the paper sheet is as thin and light as possible, and has a basis weight of 30 g / m ^2.
To 150 g / m ² is good, further be said if 60 g / m ² to 12
0 g / m ² is good for smoothness, and 30 g / m ^{2 to} 100 g / m ² is good from the viewpoint of adhesive strength to the frame, the core material and the surface material.
From the above, the thickness can be selected from the thickness of the fiber reinforced thermoplastic resin sheet in the range of 0.05 mm to 1 mm and the paper sheet in the range of 0.02 mm to 0.5 mm, and the thickness of the reinforcing plate is 0.2 mm or more. It is desirable that the distance be 2 mm or less. That is, the thickness of the reinforcing plate is 0.2 mm
If it is less than 10 mm, strength and rigidity are insufficient, a step is formed at the boundary between the frame and the core material, and the surface property is deteriorated. If it is 2 mm or more, the weight of the reinforcing plate becomes heavy and the lightness is lost, so that it is inappropriate.

The material constituting the skin material may be a foamed or non-foamed sheet of polypropylene, polystyrene, or the like;
VC and PZT sheets and other thermoplastic resin products, metal plates and metal foils such as aluminum and steel plates, inorganic plates with excellent fire resistance such as gypsum boards and lightweight cement plates, thin paper and titanium paper, with a wood grain pattern printed mainly on wood grain Examples include paper, woven fabric and nonwoven fabric made of various fibers. When the above-mentioned thermoplastic resin product or metal foil is used as the material of the skin material, it is desirable to use a paper sheet as the backing material of the skin material. As the adhesive for forming the adhesive layer (6), it is necessary to select an adhesive suitable for the materials of the paper sheet (4) and the core material (2) and the frame (1) of the intermediate layer. As the adhesive, epoxy resin,
Polyester, silicone resin, urea resin, melamine resin, urea melamine resin, phenol resin, phenolic epoxy resin, resorcin resin, phenol resorcin resin, alicyclic epoxy resin, epoxy asphalt, polyester polyisocyanate, furan resin, polyethylene imine, polyisocyanate, etc. Urethane resin adhesives such as thermosetting resin adhesives, moisture-curable polyurethane adhesives, two-component curable polyurethane adhesives, cellulose acetate, cellulose acetate butyrate, cellulose carboxylate, nitrocellulose, methylcellulose, ethylcellulose, and hydroxyethylcellulose , Polyvinyl acetate, vinyl acetate vinyl chloride copolymer, polyvinyl chloride (including modified), post-chlorinated vinyl resin (including modified) Polyol, polyvinyl butyral, polyvinyl alcohol, polyvinyl ether, vinyl acetate ethylene copolymer, acrylic resin, carboxyl-containing acrylic resin, methacrylic resin, monomer-containing methacrylic resin, cyanoacrylate, vinyl acetate acrylate copolymer, polystyrene, polyamide resin, Thermoplastic resin adhesives such as thermoplastic polyesters and polyethers, composite adhesives such as polyvinylfomar phenolic, polyvinyl butyral phenolic, nitrile phenolic, neoprene phenolic, and nylon epoxy, natural rubber, chloride rubber, recycled rubber, styrene butadiene rubber, Nitrile rubber, neoprene rubber, butyl rubber, polyisobutylene rubber, polyisobutylene rubber, polyurethane rubber, polysulfide rubber, silicon rubber Rubber-based adhesives, can be used wax, asphalt, soluble silicates, enamels, ceramics and the like.

Hereinafter, the adhesion between the intermediate layer composed of the frame (1) and the core material (2) and the reinforcing plate (5) will be described.
The paper sheet is a paper sheet layer (4) impregnated with a thermoplastic resin.
By forming at least two layers of a) and the paper sheet layer (4b) impregnated with the adhesive, the reinforcing effect of the reinforcing plate can be exhibited. The thickness of the paper sheet layer impregnated with the thermoplastic resin and the thickness of the paper sheet layer impregnated with the adhesive are preferably in the range of 10 to 90% with respect to the thickness of the paper sheet. The ratio at which the adhesive strength is obtained is when the respective thickness ratios are 50% and 50%, that is, when the intermediate layer of the paper sheet alone is 0%.

Hereinafter, the ratio and size of the composite plate and the materials constituting the composite plate will be described. The size of the composite board is not particularly limited, but the height and width are 300 mm or more and 4000 or more.
It is a flat plate having a size of not more than 10 mm, and a standard size generally used is 610 mm × 1810 mm, 910 mm.
mm × 1820mm, 910mm × 2420mm, 12
10mm × 2420mm, 1210mm × 2730mm
However, there is also a 910 mm x 6000 mm long size for siding material for residential use and field board use, that is, the size can be freely selected. Further, the frame and the core material constituting the composite plate are preferably 10 mm or more and 200 mm or less, and therefore, although not particularly limited, a composite plate having a range of 10 to 200 mm is preferable. Further, the volume ratio of the core material to the intermediate layer composed of the frame and the core material is preferably 50% to 99%. When the volume ratio of the core material is less than 50%, the weight of the composite
If it exceeds 9%, the surface rigidity of the composite plate supported by the frame decreases, which is not preferable. For composite board applications requiring both lightness and surface rigidity, the volume ratio of the core material is more preferably in the range of 60% to 95%.

Hereinafter, the method for producing a composite plate of the present invention will be described. This can be achieved by a lightweight panel air core structure obtained by bonding a plywood to both surfaces of a core material made of general wood or paper, that is, a manufacturing facility according to a manufacturing process of a flash plywood. Since the reinforcing plate can be handled in the same manner as the plywood, the existing flash plywood manufacturing process can be used. Since no new manufacturing equipment is required, it is very preferable in terms of manufacturing equipment cost.

As a method for assuring the bonding between the intermediate layer composed of the frame and the core material and the reinforcing plate more quickly, the reinforcing plate coated with the adhesive and the intermediate layer are overlapped and heated and pressed. When the heating temperature is equal to or higher than the softening temperature of the thermoplastic resin used for the reinforcing plate, the reinforcing plate itself is thermally deformed due to a pressure difference generated between the frame and the core material, resulting in a step. When the temperature at the time of bonding the intermediate layer to the reinforcing plate and the reinforcing plate to the surface material is lower than the softening temperature of the thermoplastic resin used for the reinforcing plate, and the adhesive is solidified, the space between the frame and the core material It does not deform due to the pressure difference generated in. By this manufacturing method, the composite plate of the present invention is completed.

[0042]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments embodying a composite plate according to the present invention will be described with reference to the drawings, in comparison with comparative examples. 1. Production of Composite Board Composite boards of Examples and Comparative Examples were prepared using the following (a) frame, (b) core material, (c) reinforcing plate, and the adhesive. (A) Frame In the test, LVL (single-plate laminated material) was used as a wooden frame, a low-foam resin of polystyrene was used as a resin frame, or a hollow aluminum extruded material was used as a metal frame. Table 1 shows the properties of the frame used. (B) Core Material In the test, a polystyrene resin foam, a polyurethane resin foam, or a paper honeycomb was used as the core material (2). Table 2 shows the properties of the core material used. (C) Reinforcement plate The prepregs used in this example were all manufactured by the method disclosed in the above-mentioned Japanese Patent Publication No. 4-42168.

In the case of glass fibers, the surface of a monofilament having a thickness of 13 μm is treated with γ-methacryloxy-propyltrimethoxysilane, and 1,800 of them are bundled into a twist-free yarn, and the yarn is stretched under uniform tension. After arranging in one direction, the resin was entangled with the yarn, and impregnated into the yarn while squeezing the resin with a hot roll to produce a prepreg.

The prepreg thus produced has excellent adhesion between the fiber and the thermoplastic resin, and the fiber content is 40 to 8%.
0% by weight and can be changed as required.
It can be manufactured in the range of 0.5 to 0.60 mm. These prepregs are used alone or in two to four layers, and laminated by changing the fiber direction by 90 degrees to form a fiber-reinforced thermoplastic resin sheet. Further, a paper sheet is simultaneously laminated on both front and back surfaces, and is heated and cooled by press rollers. By forming a paper sheet layer (4a) impregnated with a plastic resin, a reinforcing plate (5) comprising a fiber-reinforced thermoplastic resin sheet (3) and a paper sheet (4) is obtained. FIG. 10 shows a reinforcing plate manufacturing facility.

Table 3 shows the structure of the reinforcing plate (5) manufactured for use in Examples and Comparative Examples of the composite plate according to the present invention. The reinforcing plates A to E in Table 3 have a fiber mixing ratio of 40 to 80% by volume and a thickness of the paper sheet (4) of 0.1 to 0.5 mm, that is, according to the present invention. In F, the composition ratio of the fibers was out of the above range, and in G, the thickness of the paper sheet was outside the above range, that is, as a comparative example.

Example 1 A 30 mm × 30 mm square LVL (wooden frame) was used for the frame.
A paper honeycomb core (core material PH) having an outer dimension of 900 mm x 1800 mm square and assembled with a column having a thickness of 30 mm and having a diameter of 8 mm connected between the frames was used as a core material to form an intermediate layer. . 900mm length x 18 width
A rectangular reinforcing plate (reinforcement A) of 00 mm was cut out as a set of two sheets, and a vinyl acetate emulsion adhesive (aqueous vinegar) was applied to one surface of each of the two sheets at a rate of 100 g / m ² .
The upper and lower layers are superimposed on the intermediate layer, and the pressure is applied to the frame with a pressing jig at 2 kg / cm2 (the pressure for the core material is 0 kg / cm2) and left at 30 ° C (room temperature) for 60 minutes to bond. The agent was impregnated into reinforced kraft paper and solidified to obtain a composite plate. Table 4 shows the contents and characteristics of the adhesive used in the test.

For the production of the composite plate, (a) shown in FIG.
A heat laminating step of manufacturing a reinforcing plate, (b) an applying step of applying an adhesive to the surface of the reinforcing plate, (c) a step of incorporating a core material into a frame, (d) a jig for bonding the reinforcing plate, and a hot press. And the like.

When a general hot press is used, the press temperature is in the range of 80 ° C. to 120 ° C., and the pressure is 1 to 3 kg / cm.
^{In two} ranges, the pressurization time ranged from 30 seconds to 3 minutes. In addition, in the case of a pressing jig or cold press, it is hardened at room temperature,
The pressing time is 30 minutes to 10 hours, which is longer than that of the hot press.

Example 2 A double-foamed polystyrene (frame PS) was used for the frame, a 30-fold polystyrene (core PS) was used for the core, and an epoxy resin was used as the adhesive for the reinforcing plate. And modified polyamine mixed type adhesive (EP), and the pressing time is 6
A composite plate was produced in the same manner as in Example 1 except that the time was set to 0 minutes.

Example 3 A 2 mm thick aluminum extruded material (frame AL) was used for the frame.
A hot melt type ethylene / vinyl acetate copolymer type adhesive (EVA) was used as the adhesive for the reinforcing plate, the bonding temperature was set to 120 ° C. and the pressing time was set to 2 minutes to obtain a composite plate. Mold adhesive (water-based vinegar)
After applying 100 g / m ² on a reinforcing plate, one sheet of decorative paper printed with woodgrain on thin paper is laminated as a surface material, and pressed with a pressing jig at a pressure of 2 kg / cm 2 at 30 ° C. (room temperature) for 60 minutes. A composite board was produced in the same manner as in Example 1 except that the adhesive was impregnated and solidified into the reinforced kraft paper and decorative paper by leaving to stand.

Example 4 A 30-fold polyurethane foam (core material PU) was used as the core material, and a reinforcing plate (reinforcement A) and a 4.2 mm thick natural wood decorative plywood (decorative plywood) were mixed with a vinyl emulsion. A composite board was produced in the same manner as in Example 1 except that an isocyanate-mixed adhesive (VU) was used.

Example 5 A 30-fold polyurethane foam (core material PU) was used as a core material, and a vinyl emulsion and an isocyanate mixed type adhesive (VU) were used as an adhesive for a reinforcing plate. C. and a pressing time of 2 minutes to obtain a composite board. Further, a vinyl acetate emulsion adhesive (aqueous vinyl acetate) was applied at 100 g / m ² on a reinforcing plate, and then a woodgrain-printed makeup was applied to thin paper. Laminate paper on the front and back as a surface material, hot melt film type (30μm thick) ethylene
A composite board was prepared in the same manner as in Example 1 except that the adhesive temperature was set to 120 ° C., the pressing time was set to 2 minutes, and an iron-type pressing jig was used, and a vinyl acetate copolymer adhesive (EVA) was used. did.

Example 6 A 2 mm thick aluminum extruded material (frame AL) was used for the frame,
A composite plate was produced in the same manner as in Example 1 except that a metal-less aluminum frame was adhered to the reinforcing plate adhesive using a solventless two-liquid mixed polyurethane type adhesive (PU).

Examples 7 and 8 A composite plate was produced in the same manner as in Example 2 except that the frame and / or the reinforcing plate were changed as shown in Table 5. Examples 9 and 10 A composite plate was produced in the same manner as in Example 3 except that the frame and / or the reinforcing plate were changed as shown in Table 5. Example 11 A composite plate was produced in the same manner as in Example 4, except that the reinforcing plate was changed as shown in Table 5.

Comparative Example 1 A composite plate was produced under the same conditions as in Example 1 except that a reinforcing plate having a low fiber content of 33% was used. Comparative Example 2 A composite plate was manufactured under the same conditions as in Example 1 except that a 3 mm-thick Rawan plywood was used without using the reinforcing plate according to the present invention. Comparative Example 3 A composite plate was produced under the same conditions as in Example 3 except that a thin reinforcing plate having a thickness of 0.11 mm was used.

Comparative Example 4 The temperature conditions for solidifying the adhesive were 140 ° C., except that the softening temperature of the thermoplastic resin of the reinforcing plate (reinforcement A) used, ie, polypropylene, was 135 ° C. The composite plate was manufactured under the same conditions as in Example 3 of Example 1.

Comparative Example 5 A 0.4 mm thick DAP-impregnated paper obtained by impregnating a diallyl phthalate resin into a paper sheet and then curing it with a high-temperature radical catalyst was used without using the reinforcing plate according to the present invention. A composite plate was produced under the same conditions as in Example 4 except for the above.

COMPARATIVE EXAMPLE 6 The temperature conditions for solidifying the adhesive were 140 ° C., except that the softening temperature of the thermoplastic resin of the used reinforcing plate (reinforcement A), ie, polypropylene, was 135 ° C. The composite plate was manufactured under the same conditions as in Example 5 of Example 1. For these comparative samples, rectangular composite plates having the same dimensions as those of the above-mentioned working samples, that is, 900 mm × 1800 mm square were produced, tested in the same manner as in the working examples, and their performances were evaluated.

Table 5 shows the structures of the composite plates of the examples and comparative examples. 2. Performance evaluation of composite board The contents of the tests performed are as follows. Surface water absorption test: According to the surface water absorption test of JIS A1414, a test frame is horizontally mounted on a 25 cm × 20 cm square surface of the composite plate so as to always have a water depth of 2 cm, and the surface water absorption after 48 hours (g / g) cm ² ) and the presence or absence of water permeation on the back surface were measured.

Deformation test by temperature and humidity: JIS
The temperature test was 900 mm x 1800 according to A1414.
The amount of displacement of the surface side (one side) of the test piece of mm square was heated by radiation of 900 kcal / m ² h for 8 hours, and the humidity test was also performed by keeping the humidity on one side at 90% and the humidity on the other side at 40%. The amount of warpage displacement (mm) after time was measured.

Dropping weight impact test: A 150 mm × 150 mm square test piece was cut out from a portion consisting of an intermediate layer consisting of only a core material and a reinforcing plate, and placed on a pedestal (inner diameter 44.3 mm, outer diameter 50 mm), and a load ( 0.5kg or 1kg)
Was dropped from different heights (maximum 100 cm), and the product of the weight and the height (maximum 100 kg · cm) that penetrated the test piece was measured.

Surface properties: Observation of the surface,
The mark indicates that a smooth surface was formed, and the cross indicates that irregularities or steps appeared on the surface. Weight: Weight of composite board of 900 mm x 1800 mm square (k
g) was measured. Table 6 shows the results of the performance test of the composite plate. Examples 1 to 11
In each case, a lightweight composite board was obtained which did not absorb water from the surface, did not undergo any deformation due to temperature and humidity, had extremely high falling weight impact capacity, and had excellent surface smoothness.

On the other hand, in Comparative Example 1, the reinforcing plate (reinforcement F) with a low fiber content of 33% had a large amount of PP resin, so that the glass fibers could not be aligned in one direction, meandered, and had a coefficient of thermal expansion of 2 × 10 3. ^-5 / ° C. Therefore, the amount of deformation due to temperature and humidity was increased, and the impact resistance was also reduced. In Comparative Example 3, the reinforcing effect (reinforcement G) was reduced due to the use of a thin reinforcing plate (reinforcement G) having a thickness of 0.11 mm.

The Lauan plywood-type composite board of Comparative Example 2 and the DAP-impregnated paper-type composite board of Comparative Example 5, which are widely used in the past, are disadvantageous in that the deformation is large and the impact resistance is low. In the first and fourth embodiments using the reinforcing plate according to the present invention, the disadvantage can be solved by the reinforcing plate (reinforcement A) manufactured under thin and light conditions.

Further, as can be seen from Comparative Examples 4 and 6, the conditions for solidifying the adhesive at a temperature lower than the softening temperature of the thermoplastic resin used for the reinforcing plate are different from those of the method for producing a composite plate having excellent surface properties. Can be.

[0066]

[Table 1]

[0067]

[Table 2]

[0068]

[Table 3]

[0069]

[Table 4]

[0070]

[Table 5]

[0071]

[Table 6]

[0072]

The composite board of the present invention is lighter than conventional flash plywood, is excellent in workability such as transportation, installation and cutting on site, and requires only a small amount of raw materials. It is an earth-friendly panel that can greatly contribute to energy saving. Furthermore, in the composite plate reinforced by the low elongation and high strength reinforcing plate, a prepreg laminate made of a fiber-reinforced synthetic resin having extremely high rigidity and tensile strength is formed on both front and back surfaces or one surface thereof. If it is very rigid as a whole, a very rigid structure can be constructed in use. In addition, the present invention makes it possible to complete a dream panel that does not warp at all due to a large change due to the environment, by using a composite plate composed of a reinforcing plate in which continuous filaments arranged in one direction are effectively arranged. It can be widely used as a building material for applications such as floors, outer walls, and roofs even in areas with large temperature differences. Also, since it has excellent surface smoothness, it can be used for interior composite boards to which a surface material is attached.

The composite board of the present invention has a feature that it can be easily manufactured by a widely used flash plywood manufacturing facility, and a conventional fiber reinforced resin board flash board which requires a special adhesive and manufacturing equipment. It can be manufactured at much lower cost and energy saving. That is, according to the composite plate of the present invention and the method for producing the same, high strength, water resistance, rich in corrosion resistance,
It is possible to supply inexpensively large quantities of high-quality and ultra-light flash panels with high strength and surface smoothness without dimensional change due to moisture absorption.

[Brief description of the drawings]

FIG. 1 is a perspective view showing one embodiment of a composite plate according to the present invention.

FIG. 2 is a cross-sectional view showing a configuration of the composite board shown in FIG.

FIG. 3 is a perspective view showing an embodiment different from that shown in FIG. 1;

FIG. 4 is a cross-sectional view showing a configuration of the composite plate shown in FIG.

FIG. 5 is a cross-sectional view showing a configuration of a composite plate having a skin material on a surface according to the present invention.

FIG. 6 is a cross-sectional view showing one embodiment having a skin material on the surface.

FIG. 7 is a cross-sectional view showing one embodiment having a skin material on the surface.

FIG. 8 is a partially enlarged cross-sectional view showing a state in which a reinforcing plate is joined to a surface of an intermediate layer composed of a frame and a core material via an adhesive layer.

9 is a partial view showing a state in which the paper sheet of the reinforcing plate shown in FIG. 8 is composed of a paper sheet layer (4a) impregnated with a thermoplastic resin and a paper sheet layer (4b) impregnated with an adhesive; It is an expanded sectional view.

FIG. 10 is an explanatory view schematically showing an apparatus for manufacturing a composite plate according to the present invention.

FIG. 11 is an explanatory view schematically showing an apparatus used for a falling weight impact test of a composite plate according to the present invention.

[Explanation of symbols]

 1 ... frame 1a ... pier 1b ... filled wood 2 ... core material 3 ... fiber reinforced thermoplastic resin sheet 4 ... paper Sheet 4a ... Paper sheet layer impregnated with thermoplastic resin 4b ... Paper sheet layer impregnated with adhesive 5 ... Reinforcing plate 6 ... Adhesive layer 7 ... ··· Skin material 8 ··· Plywood 9 ··· Veneer (natural wood thin plate) (a) ··· Thermal lamination process (b) ··· Coating process (c) ····· Incorporation process (d) ···· Reinforcement plate bonding process 10 ··· Heating roll 11 ··· Cooling roll 12 ···· Adhesive 13 ···· Weight 14 ... Shooting type 15 ... Cradle

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification number Agency reference number FI Technical display location B32B 17/04 B32B 27/32 Z 27/32 B29C 67/14 G

Claims (9)

[Claims] 1. A paper sheet (4) on both sides of a fiber reinforced thermoplastic resin sheet (3) comprising a prepreg containing a continuous filament aligned in one direction and having a weight content of 40% or more and 80% or less. A bonding plate (5) is provided on one or both sides of an intermediate layer composed of a frame (1) and a core material (2) filled in the space inside the frame (1) by bonding a reinforcing plate (5) to which Composite board integrated. 2. A fiber-reinforced thermoplastic resin sheet (3) comprising:
Composite plate according to claim 1, characterized in that the thermal expansion coefficient of the fiber direction are laminated 2-4 sheets of 10 ^{@ 5} / ° C. or less of the prepreg at any angle alone or orientation angle 0 to 90 ° . 3. The composite according to claim 1, wherein the fibers of the prepreg forming the fiber-reinforced thermoplastic resin sheet (3) are glass fibers, and the thermoplastic resin is a polyolefin-based resin. Board. 4. A paper sheet (4) in contact with an adhesive layer (6).
The composite board according to claim 1, wherein the composite board comprises at least two layers of a paper sheet layer (4a) impregnated with a thermoplastic resin and a paper sheet layer (4b) impregnated with an adhesive. 5. The composite board according to claim 1, wherein a skin material is integrally formed on at least one surface of the composite board via an adhesive layer. 6. The composite board according to claim 1, wherein the core material (2) is a paper honeycomb or a resin foam. 7. The fiber reinforced thermoplastic sheet (3) has a thickness of 0.05 mm or more and 1 mm or less, and the paper sheet (4) has a thickness of 0.02 mm or more and 0.5 mm or less. The thickness of the plate (5) is 0.2 m
The composite board according to claim 1, wherein the thickness is in a range from m to 2 mm. 8. The fiber-reinforced thermoplastic resin sheet (3) is heated to a temperature not lower than the melting temperature of the thermoplastic resin, and the paper sheet (4) is melted in a state where the thermoplastic resin is melted. A heat laminating step (a) for producing a reinforcing plate (5) which is superposed on both sides of the substrate and then cooled and solidified;
An application step (b) of applying an adhesive to the surface of the reinforcing plate (5), and an incorporation step (c) of forming an intermediate layer in which a core material (2) is inserted into a space within the frame (1). An adhesive layer (6) obtained by laminating a reinforcing plate (5) with an adhesive on both surfaces of the intermediate layer and solidifying the adhesive at a temperature lower than the softening temperature of the thermoplastic resin forming the fiber-reinforced thermoplastic resin sheet (3) is obtained. A method for producing a composite plate, in which a reinforcing plate bonding step (d) for integrating through a step is sequentially performed. 9. The method for manufacturing a composite board according to claim 8, wherein
Further, a skin material (7) is provided on the surface of the reinforcing plate (5) via an adhesive layer (6) in which the adhesive is solidified at a temperature lower than the softening temperature of the thermoplastic resin forming the fiber-reinforced thermoplastic resin sheet (3). A method for producing a composite plate, which performs a skin material bonding step (e) for integrating the above.