JPH11138565A - Method for decoratively molding fiber-reinforced resin foam - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for decorativelymolding a fiber-reinforced thermoplastic resin foam efficiently and with high quality. SOLUTION: The method for decoratively molding a fiber-reinforced resin foam comprises the steps of decorating one surface of a fiber-reinforced thermoplastic resin sheet having at least one layer obtained by pulling and aligning a continuous fiber made of a plurality of filaments in one direction, laminating a non-molten or high temperature molten synthetic resin film on its decorated surface to form a decorating composite sheet F, shaping the sheet F to a hollow unit T to supply a foamable thermoplastic resin composition H to its interior, shaping the unit T to a desired sectional shape along a restricting member 26 by means of its foaming pressure, and pressure-reducing to adsorb a surface of the sheet to become an inside surface of the unit T in the case of shaping the sheet F to the unit T to dispose it along restricting members 22b to 22d, thereby gradually shaping it to the hollow unit. In this case, the decorated surface is protected by the film. An introducing position to a mold of next stage is ensured by shaping by the pressure reduction adsorption by the restricting members, and a deviation of a design or the like is prevented.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a fiber-reinforced resin foam used for, for example, interior and exterior building materials.

[0002]

2. Description of the Related Art Conventionally, as a method for producing a fiber-reinforced resin molded article having a surface decorated with a color, a pattern, or the like, conventionally, a pulverization using a thermosetting resin has been performed by releasing a mold formed by forming a coating film. A method in which a functional film is drawn into a drawing die together with a fiber base material impregnated with a resin, and simultaneously with molding of a fiber reinforced resin, a coating film is transferred to the surface thereof (Japanese Patent Laid-Open No. Hei 3-184832).
Also, a method in which a surface decorative material such as a film or a sheet is pressed via an adhesive and continuously laminated on the surface of a molded body in a high-temperature state pulled out from a mold after pultrusion molding (JP-A-4-323024). No.) are known.

However, in order to obtain a molded article having a complicated cross-sectional shape, if the former method is used among the above-mentioned conventional methods, the release film is formed along the complicated cross-sectional shape. Not only is it difficult to insert into a mold without wrinkles, but also it is difficult to correctly position the film in a portion requiring painting. Further, even when the latter method is used, it is extremely difficult to laminate a film or sheet-like surface decorative material along the surface of a molded article having a complicated cross-sectional shape without wrinkling.

[0004] In view of this, the present inventor has worked with others to continuously form a fiber-reinforced thermoplastic resin sheet whose surface has been decorated in advance into a hollow body, and to form a foamable thermoplastic resin composition inside the hollow body. A method has been proposed in which the cross-sectional shape is formed into a desired shape by causing the foam to be supplied while being foamed, or foamed after being supplied, and the outer peripheral surface of the hollow body being made to conform to the regulating member by the foaming pressure (JP-A-Hei. No. 8-300373).

According to this method, since the surface of the fiber-reinforced thermoplastic resin layer forming the skin layer of the molded article has been already decorated, even if the molded article has a complicated cross-sectional shape, it is added simultaneously with the molding. Can be decorated. In this proposal, by laminating a protective film on the decorative surface of the fiber-reinforced thermoplastic resin sheet, damage due to the decorative surface coming into contact with the shaping regulating member can be prevented. It also suggests.

[0006]

By the way, when the method proposed in Japanese Patent Application Laid-Open No. Hei 8-300373 is used, the decorated fiber-reinforced thermoplastic resin sheet is distorted in the longitudinal direction at the time of shaping depending on conditions. In some cases, as a result, there is a problem that the form of decoration changes. Also, even if an appropriate protective film is laminated on the decorative surface of the sheet,
In some cases, the film was damaged by heat or shearing force at the time of molding, and the decoration was sometimes damaged.

Further, when the decorated fiber-reinforced thermoplastic resin sheet is shaped into a desired shape through a hollow body, the decoration of the obtained product, such as a pattern, is made in accordance with the circumferential shape of the product. In some cases, slippage occurred.

The present invention has been made in view of such circumstances, and is a development and improvement of the above-mentioned proposal to provide a decorative molding method for a fiber-reinforced resin foam capable of performing more reliable and accurate decoration. It is intended to be provided.

[0009]

In order to achieve the above object, a method for producing a fiber-reinforced resin foam according to the present invention comprises the steps of: providing one or more sheets of a fiber-reinforced thermoplastic resin sheet having a surface decorated; While continuously shaping the hollow body as a whole so that the decorative surface is on the outside, while supplying the expandable thermoplastic resin composition to the inside, the foaming pressure of the hollow body A method of shaping a cross-sectional shape into a desired shape by aligning the outer peripheral surface with a regulating member is characterized by taking the following means.

That is, the fiber-reinforced thermoplastic resin sheet used includes at least one composite layer in which continuous fibers composed of a plurality of filaments are aligned in one direction and integrated with the thermoplastic resin. ,
The decorative surface of the sheet is not thermally fused with the decorative surface,
Further, a composite sheet is formed by laminating synthetic resin films having a melting temperature higher than that of the thermoplastic resin used for the sheet or not melting.

When the composite sheet is formed into a hollow body, the sheet is heated to a plastic state,
A method is employed in which the sheet surface, which is the inner side surface of the hollow body, is depressurized and sucked, while being pressed against the regulating body, and gradually shaped into the hollow body.

The present invention relates to the above-mentioned Japanese Patent Application Laid-Open No. H8-30037.
The present inventors have made intensive studies based on the method proposed in No. 3 and have succeeded in solving some problems arising in the method.

That is, as a fiber-reinforced thermoplastic resin sheet for decoration used in the method of the present invention, at least one composite layer in which continuous fibers are arranged in the longitudinal direction and a reinforcing fiber and a thermoplastic resin are integrated. By using a material that includes a sheet, it is possible to prevent the sheet from being distorted in the longitudinal direction of the continuous fiber (axial direction of the hollow body) due to a tensile stress acting due to heat or shear resistance during molding, and to provide a decorative distortion. Does not occur.

Further, the decorative fiber-reinforced thermoplastic resin sheet does not thermally fuse with the decorative surface, and has a higher melting temperature or a higher melting temperature than the thermoplastic resin used for the sheet. By laminating synthetic resin films that are not used to form a composite sheet, the decorative surface of the sheet is effectively protected from heat and various forces during molding, and distortion and damage to the pattern can be suppressed.

When forming such a composite sheet into a hollow body, the inner surface of the hollow body is depressurized and sucked, pressed against a regulating body, and gradually formed into a hollow body. By adopting the method of shaping, it is possible to shape the hollow body without bringing the decorative surface into contact with the regulating body, and to the regulating member such as a mold for shaping to the desired cross section. Variations in the introduction position of the hollow body are suppressed, introduction into the regulating member is always possible under a fixed positional relationship, and displacement of the picture position in the product circumferential direction can be prevented.

Here, in the present invention, the thermoplastic resin used for the decorative fiber-reinforced thermoplastic resin sheet includes polyethylene, polypropylene, polyvinyl chloride, and the like.
Polystyrene, polyamide, polyethylene terephthalate, polybutylene terephthalate, polycarbonate,
Polyvinylidene fluoride, polyphenylene sulfide,
Examples include polyphenylene oxide, polyether sulfone, polyether ether ketone, polymethyl methacrylate, and the like. Further, a copolymer or graft resin containing such a thermoplastic resin as a main component, or a blend resin, such as chlorinated polyvinyl chloride, ethylene-vinyl chloride copolymer, vinyl acetate-ethylene copolymer, vinyl acetate- Vinyl chloride copolymer, urethane-vinyl chloride copolymer, acrylonitrile-butadiene-styrene copolymer, acrylonitrile-styrene copolymer, silane-modified polyethylene, acrylic acid-modified polypropylene, maleic acid-modified polyethylene, and the like can also be used. In addition, a thermoplastic elastomer or a crosslinked thermoplastic resin can also be used. Of these, considering the molding temperature, 120
Polyethylene, polypropylene, polyvinyl chloride, polystyrene, chlorinated polyvinyl chloride, ethylene-vinyl chloride copolymer, vinyl acetate-ethylene copolymer, vinyl acetate-vinyl chloride copolymer It is preferable to use a polymer, a urethane-vinyl chloride copolymer, an acrylonitrile-butadiene-styrene copolymer, or an acrylonitrile-styrene copolymer.

The thermoplastic resin used in the fiber-reinforced thermoplastic resin sheet of the present invention may be used alone or in combination. As long as the physical properties are not impaired, dibutyltin maleate polymer, dibutyltin bis (monobutyltin) Alkyltin), such as organic tin malate, dibutyltin laurate, and organic tin laurate such as monobutyltin fatty acid salt;
Dioctyltin sulfide, dibutyltin 3 mercaptopropionate and other organic tin mercapto, tribasic lead sulfate, lead group such as basic lead sulfite, calcium stearate, heat stabilizer such as metal soap such as lead stearate,
Lubricants such as fatty acid ester wax, low molecular weight polyethylene wax, metal soap, polyhydric alcohol, aliphatic alcohol and fatty acid amide; processing aids such as acrylic resin and olefin resin; plasticizers such as dibutyl phthalate and dioctyl phthalate; Inhibitors, UV absorbers,
Additives such as modifiers and colorants, and fillers such as talc, mica, calcium carbonate, wood flour, and fiber-reinforced thermosetting resin pulverized powder may be blended.

The fiber-reinforced thermoplastic resin sheet used in the present invention has at least one composite layer in which continuous fibers composed of a plurality of filaments are aligned in one direction and integrated with the thermoplastic resin. Although it has layers, any layers other than such a composite layer can be laminated. The total fiber content in the sheet is 5 to 5.
It is preferably in the range of 80% by weight, especially in the range of 10 to 50% by weight. When the content of the fiber is less than 5% by weight, the reinforcing effect is small, and when the content is more than 80% by weight, the resin binding between the fibers is reduced, so that it is weakened.

As the material of the fiber used in the fiber-reinforced thermoplastic resin sheet, those which do not melt-soften and carbonize by the heat applied in the method of the present invention can be used. Specifically, glass fiber, carbon fiber, silicon fiber and the like can be used. -Titanium-carbon fiber, boron fiber, fine metal fiber, or organic fiber such as aramid fiber, polyester fiber, polyamide fiber, natural fiber such as silk, cotton, hemp, etc. , Glass fiber,
Carbon fibers are preferred. Filament diameter is 1-50
μm, particularly preferably 3 to 30 μm. When the diameter of the filament is smaller than 1 μm, the reinforcing effect by the fiber is reduced. When the diameter is larger than 50 μm, the contact area between the thermoplastic resin and the fiber is smaller than that of the same type and the same amount of fiber. The reinforcing effect of the fibers is undesirably small.

The thickness of the fiber-reinforced thermoplastic resin sheet used in the present invention is preferably 0.1 to 10 mm,
The range of 0.3 to 2 mm is more preferable. 0.1m thick
When the thickness is less than m, the strength is insufficient, and when the thickness is more than 10 mm, it is difficult to form a hollow body.

One example of a method for producing a fiber-reinforced thermoplastic resin sheet having a composite layer in which continuous fibers are aligned in the longitudinal direction and integrated with a thermoplastic resin is as follows. Then, after aligning in one direction, a film made of a thermoplastic resin is overlaid and passed between heating pinch rollers, and the molten thermoplastic resin is infiltrated between filaments to form a sheet.

As another example of the method for producing the sheet, a continuous reinforcing fiber bundle aligned in one direction is drawn into a tank in which a powdery thermoplastic resin is flowing, and the reinforcing fiber bundle is filamentized. The present invention can include a method in which the thermoplastic resin is adhered while being unwoven into paper and then passed between heating pinch rollers to melt the thermoplastic resin and penetrate between the filaments to form a sheet. As a method of decorating the surface of the fiber-reinforced thermoplastic resin sheet used in the method, such as a method of laminating and integrating a thermoplastic resin sheet on which a color or pattern is printed, or printing directly on the sheet surface, particularly Not limited. Also, as the form of decoration, fine irregularities such as embossing,
Includes three-dimensional decorations that provide irregularities such as wood-grained narrow grooves.

In the case of laminating a thermoplastic resin sheet on which a color or a picture or the like is printed, the material is not particularly limited as long as it can be heat-fused with the thermoplastic resin used for the fiber-reinforced thermoplastic resin sheet. . If the thickness is less than 10 μm, a sufficient concealing property of the base cannot be provided, so that the color and the picture are not uniform. 500 μm
With the above, heat, foaming pressure and shearing force during molding,
The thermoplastic resin layer flows, and a pattern shift occurs on the decorative surface.

In the present invention, as the film laminated to protect the decorative surface of the fiber-reinforced thermoplastic resin sheet decorated as described above, the fiber-reinforced thermoplastic resin sheet or the sheet is decorated. It is required that the melting temperature is higher than that of the resin used for the thermoplastic resin layer to be laminated and integrated, or that the resin is not melted by heat, for example, used for a fiber-reinforced thermoplastic resin sheet or a thermoplastic resin layer. For polyvinyl chloride, polypropylene and polyethylene whose resin melts at 200 ° C, 20
Polyethylene terephthalate melting at a temperature higher than 0 ° C.,
In the case of using a film made of polyphenylene lactide, polycarbonate, polyamide, or the like, or a resin that melts at a higher temperature as a sheet or a resin layer, a film that does not melt by crosslinking or vulcanization may be used.

This synthetic resin film has a thickness of 10 μm.
If it is less than the above, breakage due to heat or foaming pressure or shear force at the time of molding, or problems such as difficulty in peeling after molding occur,
If it exceeds 150 μm, the corner of the molded product will not be sharp.

It is desirable that the synthetic resin film has a laminated surface with respect to the decorative surface having a surface roughness Rz = 0.5 to 7 μm. The surface of the film is finely polished by spraying silica sand, etc., sandblasting or mechanical means such as polishing, or etching with chemicals, or directly kneading inorganic fillers etc. into the film itself to form a film. There is no particular limitation such as formation of irregularities.

The surface roughness of this synthetic resin film is Rz =
If the thickness is less than 0.5 μm, the synthetic resin film will not be spontaneously peeled off after lamination, or the interface between the synthetic resin film and the thermoplastic resin layer will be displaced and a picture will not flow. Moreover, the surface roughness is Rz = 7.
If it exceeds μm, a large peeling force is required when the synthetic resin film is peeled off after molding, and in the case of a thin film, there occurs a problem that the film is partially broken.

In the present invention, as a method of shaping a decorated composite sheet comprising a fiber-reinforced thermoplastic resin sheet and the above-mentioned synthetic resin film into a hollow body, there is a method of shaping the hollow sheet into a hollow body. It is only required that the surface of the composite sheet on the inner surface side of the body can be adsorbed to the regulating body, and the method is not limited to the method described in Examples described later.

Here, the hollow body referred to in the present invention is not only a hollow body having a shape in which side edges of a sheet are abutted with each other or are formed such that a gap is formed inside in a state of being overlapped. And a state in which a slight gap is formed between the side edges.

The sheet used for shaping into a hollow body is formed by abutting or overlapping two side edges of one sheet, or by abutting through a slight gap, or using a plurality of sheets. Then, while keeping them parallel to each other, butt these side edges together,
Alternatively, they may be formed into one hollow body as a whole by overlapping or butting through some gaps.

In the present invention, the same thermoplastic resin as that used for the fiber-reinforced thermoplastic resin sheet is used as the thermoplastic resin used in the expandable thermoplastic resin composition supplied into the hollow body. Can be
It is desirable to use a resin that can be thermally fused to the resin used for the fiber-reinforced thermoplastic resin sheet. Specifically, it is preferable to use the same type of thermoplastic resin (a thermoplastic resin polymerized from the same monomer). As a combination when using different kinds of thermoplastic resins, for example, polyethylene and polypropylene, polyethylene and vinyl acetate-ethylene copolymer, polyethylene and chlorinated polyethylene, polystyrene and acrylonitrile-butadiene-styrene copolymer, polystyrene and acrylonitrile -Styrene copolymer, polyvinyl chloride and chlorinated polyvinyl chloride, polyvinyl chloride and ethylene-vinyl chloride copolymer, polyvinyl chloride and vinyl acetate-vinyl chloride copolymer, polyvinyl chloride and urethane-vinyl chloride copolymer Polymer, polyvinyl chloride and polymethyl methacrylate, polyvinyl chloride and acrylonitrile-butadiene
Styrene copolymer, polybutylene terephthalate and polyethylene terephthalate, acrylonitrile-butadiene-styrene copolymer and acrylonitrile-styrene copolymer are exemplified. Further, a combination of a thermoplastic resin and the same type of modified thermoplastic resin can also be used.
Examples thereof include polyethylene and silane-modified polyethylene, polystyrene and acrylic acid-modified polystyrene, and polyethylene and maleic acid-modified polyethylene.

As a foaming agent used in the foamable thermoplastic resin composition, a decomposition-type foaming agent that chemically decomposes by heat to generate a gas and a volatile-type foaming agent that utilizes gasification of a volatile liquid are used. be able to. Alternatively, a gas such as carbon dioxide or nitrogen may be injected under pressure while kneading the thermoplastic resin at a melting temperature or higher, dispersed in the thermoplastic resin, and foamed by releasing the pressure.

Examples of the decomposable foaming agents include azodicarbonamide, azobisisobutyronitrile, N, N'-dinitropentamethylenetetramine, p, p'-oxybisbenzenesulfonylhydrazide, barium azodicarboxylate, and trihydrazino. Triazine, p-toluenesulfonyl hydrazite, sodium bicarbonate, ammonium carbonate and the like.

Examples of the volatile foaming agent include aliphatic hydrocarbons such as propane, butane, pentane, hexane and heptane; carbonized aliphatic hydrocarbons such as methyl chloride and methylene dichloride; and 1,1-dichloro-1-trichloromethane. Fluoroethane,
2,2-dichloro-1,1,1-trifluoroethane,
Freon gas such as 1,1,1,2-tetrafluoroethane and the like can be mentioned.

The amount of the foaming agent to be mixed must be appropriately adjusted since the amount of gas generated varies depending on the type of the foaming agent.
It is preferable to mix in the range of parts by weight. If the blending amount of the foaming agent is too small, a foamed molded article cannot be obtained, and if the blending amount of the foaming agent is too large, cells are broken and a dense cell cannot be obtained. For example, when producing a thermoplastic resin foam having an expansion ratio of 10 using azodicarbonamide, it is appropriate to mix 5-7.5 parts by weight with respect to 100 parts by weight of the resin.

The expansion ratio of the inner foam layer (core layer) of the molded product obtained by foaming the foamable thermoplastic resin composition includes the strength and specific gravity required for the manufactured product, the type of the thermoplastic resin used, and the like. Is appropriately selected according to
A range of 0 times is preferred. When the expansion ratio is less than 1.2, the effect of reducing the weight by foaming is small, and when the expansion ratio exceeds 20 times, the strength becomes very weak.

As a method of supplying the foamable thermoplastic resin composition into the hollow body while foaming the foamed body, a nozzle of the extruder is made to face the inside from an opening part of the hollow body during shaping. A method in which the foamable thermoplastic resin composition is extruded while being foamed can be employed. In this case, in an extruder, a foamable thermoplastic resin composition containing a decomposable foaming agent or a volatile foaming agent is kneaded at a gas generation temperature or higher, and the generated gas is dispersed in the thermoplastic resin to form a foamable thermoplastic resin. It is extruded into a hollow body through a nozzle whose temperature has been adjusted to the melting temperature of the thermoplastic resin composition or higher. Alternatively, while kneading the thermoplastic resin at a melting temperature or higher, a gas such as carbon dioxide or nitrogen is press-fitted to disperse the thermoplastic resin into the hollow resin through a nozzle whose temperature has been adjusted to a temperature higher than the melting temperature of the thermoplastic resin. put out.

As a method of shaping the hollow body by the foaming pressure of the expandable thermoplastic resin composition, the outer surface of the hollow body is inserted into a mold, and the hollow body is formed by the foaming pressure of the expandable thermoplastic resin composition. A method in which the outer surface of the body is pressed against the inner surface of the mold to shape the resin, or a method in which the outer surface of the hollow body is regulated by a roll or shoe while heating from the surroundings to expand the foamable thermoplastic resin composition. Can be mentioned. When shaping in a mold, shaping may be assisted by evacuation or compressed air.

Here, when the hollow body is shaped into a desired cross-sectional shape along the regulating member by the foaming pressure of the foamable thermoplastic resin composition inside, it is generated by the foaming operation of the foamable thermoplastic resin composition. If the foaming pressure alone does not provide enough pressure to press the hollow body against the regulating member, additional pressure may be additionally applied to the inside of the hollow body, and the method of the present invention provides such an auxiliary method. This includes the case where pressure is applied.
When an auxiliary pressure is used, it is preferable to have a structure having a pipe through which gas can be supplied into the hollow body.

When the hollow body is shaped into a desired cross-sectional shape by the internal foaming pressure, the hollow body can be shaped while extending. That is, it is also possible to shape the outer peripheral length of the molded article to be larger than the outer peripheral length of the hollow body. In this case, in consideration of the spreading of the hollow body, the intended decoration is performed after the spreading. Decoration must be applied to obtain a surface.

[0041]

EXAMPLES Examples of the present invention will be described below together with comparative examples.

Example 1 Production of a Composite Sheet for Decoration Table 1 shows the composition of the resin used in the fiber-reinforced thermoplastic resin sheet. This blend was mixed at 100 ° C. with a mixer.

[0043]

[Table 1]

The fibers used in the fiber-reinforced thermoplastic resin sheet are glass fibers (manufactured by Nitto Boseki Co., Ltd., fiber diameter 23
μm, 4400 TEX).

The fiber-reinforced thermoplastic resin sheet was decorated by laminating a colored and patterned thermoplastic resin film on one surface. The material of this film was an acrylic resin (manufactured by Mitsubishi Rayon Co., Ltd., black, 65 μm in thickness).

Further, a synthetic resin film for protecting the decorative surface is made of polyethylene terephthalate (manufactured by Teijin Limited, 2
Axial stretching, thickness 38 μm, single-side sandblasted product, surface roughness Rz = 3.0 μm).

A decorative fiber-reinforced thermoplastic resin sheet was manufactured using the above-mentioned materials and using a manufacturing apparatus as shown in FIG.

That is, the polyvinyl chloride powder A having the composition shown in Table 1 was accommodated in the fluidized tank 1 and was caused to flow by blowing air from the bottom of the fluidized tank 1 through the porous plate 1a. . Sixteen glass fiber bundles B were drawn into the flowing polyvinyl chloride powder A, and a vinyl chloride resin was adhered to each filament in the glass fibers.
The glass fiber bundle B to which the resin powder A has adhered is aligned in the longitudinal direction, guided to the heating roll 2, and pinched at a linear pressure of 12 kg / cm while heating to 210 ° C., whereby the glass fiber and the vinyl chloride resin are integrated. Fiber reinforced thermoplastic resin sheet C was obtained.

Further, the fiber-reinforced thermoplastic resin sheet C thus obtained is successively led to another heating roll 3,
An acrylic film D and a polyethylene terephthalate film E heated to 150 ° C. are laminated at a linear pressure of 2 kg / cm, cooled by a cooling roll 4 and taken up by a take-up roll 5 to obtain a fiber-reinforced thermoplastic resin having a thickness of 0.5 mm. A decorative composite sheet F in which an acrylic resin film D having a thickness of 65 μm and a polyethylene terephthalate film E having a thickness of 38 μm was sequentially laminated on one surface of the sheet C was obtained. Here, the polyethylene terephthalate film E was laminated such that the surface roughened by sandblasting to a surface roughness Rz = 3.0 μm was in contact with the surface of the acrylic resin film D.

This decorative fiber-reinforced thermoplastic resin sheet F
The width of the main body of the fiber-reinforced thermoplastic resin sheet C is 170 mm, and the acrylic resin film D and the polyethylene terephthalate film E are each 160 mm.
As shown in a schematic cross-sectional view in FIG. 2, each of the sheets was laminated on the center portion in the width direction of the fiber-reinforced thermoplastic resin sheet C.

Further, apart from the composite sheet F, a fiber-reinforced thermoplastic resin sheet having a width of 100 mm and only the fiber-reinforced thermoplastic resin layer of the sheet F in which the acrylic resin film D and the polyethylene terephthalate film E are not laminated. G was produced.

Production of Fiber Reinforced Thermoplastic Foam The decorative composite sheet F obtained as described above and the fiber reinforced thermoplastic resin sheet G are used as a skin layer,
Using a foamable thermoplastic resin composition H having the composition shown in the following [Table 2] as the core material layer, a fiber-reinforced thermoplastic resin foam was decoratively molded by an apparatus as shown in FIG.

[0053]

[Table 2]

The apparatus comprises two sheet feeding machines 20, 2
1, a regulating body 22b to 22d having a reduced pressure adsorption function with a heating device 22a, an extruder 23, an extrusion die 24 mounted on the extruder 23, and arranged so as to surround the outer periphery of the extrusion die 24. The outer mold 25, the shaping mold 26, the cooling mold 28, and the product take-up machine 29 are mainly constituted.

The above-described decorative composite sheet F was wound around one sheet feeding machine 20, and the fiber-reinforced thermoplastic resin sheet G was wound around the other sheet feeding machine 21.

The decorative composite sheet F wound around the sheet feeder 20 is heated to a plastic state by a heating device 22a, and is controlled by a regulating body 22 having suction holes for vacuum suction as shown in FIG. It is gradually shaped to a shape as shown in the cross-sectional view at the position XX 'in FIG.

That is, the regulating bodies 22b to 22d are arranged as shown in FIG.
As shown by way of example in FIG. 3, a cross-sectional view of the regulating body 22d at the position XX 'in FIG.
6, a sheet passage 221 for passing the decorative composite sheet F is formed, and an inner surface of a hollow body T described later among the surfaces of the passage 221. , That is, a position corresponding to the surface opposite to the decorative surface, a number of grooves 222 are formed, and each of the grooves 222 communicates with the reduced-pressure suction hole 223. Therefore, the decorating sheet F is heated by the heating device 22a and plasticized in a state where the regulating members 22b to 2b.
By passing through the 2d passage 221, the surface opposite to the decorative surface is adsorbed under reduced pressure to the surface of the passage 222, and
The shape is gradually formed so as to follow the shape of the passage 221 of 2b to 22d, and eventually the cross-sectional shape as shown in FIG.

The decorative composite sheet F thus shaped
Is then inserted between an extrusion die 24 mounted on an extruder 23 and an outer die 25. Extrusion mold 24 and outer mold 25
A gap having a cross-sectional shape substantially equal to the final shape of the sheet F formed by the restrictors 22b to 22d shown in FIG.

The outer mold 25 has an introduction hole 2 for introducing the fiber reinforced thermoplastic resin sheet G into a lower portion thereof.
51 are formed, and the fiber-reinforced thermoplastic resin sheet G introduced from the introduction hole 251 is so formed as to cover the opening of the decorative fiber-reinforced thermoplastic resin sheet F shaped in the shape of FIG. A hollow body T is formed by the two sheets F and G as a whole, as shown in FIG. It is supposed to. Note that the decorative composite sheet F and the fiber-reinforced thermoplastic resin sheet G overlap each other with a width of 5 mm on the folded portions formed on both sides of the opening of the sheet F.
Note that the fiber reinforced thermoplastic resin sheet G is also heated with a hot air heating device (not shown) before the introduction into the introduction hole 251.
To soften by heating.

The extrusion die 24 has a core die part 241 for passing the sheet F in the shape shown in FIG. 4 in cooperation with the outer die 25, and is bent downward at right angles from the core die part 241. 4 has a vertical portion 242 that is connected to the extruder 23 through an opening of the sheet F having the shape shown in FIG. 243 are formed in parallel. Then, the expandable thermoplastic resin composition H supplied from the extruder 23 through the resin flow path 243 can be extruded into the hollow body T.

A shaping die 26 is provided downstream of the extrusion die 24 and the outer die 25. This shaping mold 26
The cross-sectional shape of the outer mold (the extrusion mold 24, the outer mold 25)
8 is the same as the cross-sectional shape of the hollow body T shown in FIG.
The cross-sectional shape of the product at the location indicated by ZZ 'in FIG. 7, that is, the same shape as the final cross-sectional shape of the product, during which the cross-sectional shape gradually changes.

The shaping mold 26 and the above-described outer mold 2
5 is a heater 26 provided on each outer peripheral surface.
a, 25a allows heating to a desired temperature.

A cooling mold 28 is connected to the downstream side of the shaping mold 26 via a heat insulating material 27. This heat insulating material 27
The cross-sectional shape of the cooling mold 28 is the same as the cross-sectional shape at the downstream end of the shaping mold 26. Then, the cooling mold 28
A take-up machine 29 for taking out a molded product is provided downstream of the machine.

In the manufacturing apparatus and the mold described above, the decorative composite sheet F is heated and softened to 100 ° C. by the heating device 22a, and is heated to 720 mmH by the regulating members 22b to 22d.
g, the decorative composite sheet F is regulated by the depressurizing force of g.
22d, and it was shaped into the shape shown in FIG.

Next, while the temperature of the extrusion mold 24 is adjusted to 170 ° C., the extrusion mold 24 is inserted into a gap formed between the extrusion mold 24 and the outer mold 25 and passed therethrough. A fiber-reinforced thermoplastic resin sheet G heated and softened to 100 ° C. by a hot-air heating device was inserted into the hole 251, and the hollow body T shown in FIG.

At the same time, the foamable thermoplastic resin composition H heated and kneaded at 205 ° C. in the extruder 23 was extruded through the resin flow path 243 into the hollow body T. Thereafter, the entirety of the hollow body T and the resin composition H therein are introduced into the shaping mold 26 heated to 180 ° C., and the hollow body T is formed by the foaming pressure of the foamable thermoplastic resin composition H. The outer peripheral surface is gently pressed against the inner peripheral surface of the shaping die 26 while being pulled out by the pulling machine 29 to gradually change the cross section. After shaping into the shape shown in FIG. 8. A cross-sectional irregular shape including a skin layer made of a decorative fiber-reinforced thermoplastic resin layer in which an acrylic film D is arranged in a region indicated by a dashed line in FIG. 8, and a core material layer made of a thermoplastic resin foam. Of a fiber-reinforced thermoplastic resin foam of

The obtained fiber-reinforced thermoplastic resin foam is
A colored acrylic resin D was fused and integrated on one surface thereof, and a polyethylene terephthalate film E was laminated on the acrylic resin surface. The polyethylene terephthalate film E could be easily peeled off. The surface of the molded product after film peeling has a gloss of 8%.
And had a uniform surface without fine vertical streaks and the like during cooling sizing.

<Example 2> In place of the acrylic resin film D used in Example 1, a 150 μm-thick semi-rigid vinyl chloride resin sheet was used, except that a gravure-printed sheet was used on the surface. A fiber-reinforced thermoplastic resin foam was manufactured in the same manner as in Example 1.

The obtained fiber-reinforced thermoplastic resin foam is
As in Example 1, the decorative surface was a uniform surface, and the printed pattern of the grain was almost as it was at the time of printing.

Comparative Example 1 A decorative fiber-reinforced thermoplastic resin sheet was produced based on the same materials and steps as in Example 1 except that the polyethylene terephthalate film was not laminated. Manufactured a fiber-reinforced thermoplastic resin foam using the same materials and steps as in Example 1.

The obtained fiber-reinforced thermoplastic resin foam is
There were portions where the acrylic resin was peeled off, and fine vertical streaks occurred on the surface of the molded product.

<Comparative Example 2> The decorative composite sheet F is shaped by the mold 2 while forming the decorative composite sheet F under reduced pressure by suction using the regulating bodies 22b to 22d.
A fiber-reinforced thermoplastic resin foam was produced in the same manner as in Example 2 except that the mixture was not introduced between 4, 25.

The obtained fiber-reinforced thermoplastic resin foam is
There were spots where the wood grain pattern was entirely distorted and formed.

[0074]

As described above, according to the present invention, a non-melting or high-melting synthetic resin is applied to the decorative surface of a fiber-reinforced thermoplastic resin sheet which has been decorated to form a skin layer of a product. Since the films are laminated, the decorative surface can be protected from heating, foaming pressure, or shearing force during molding, and at the same time, generation of fine vertical streaks during sizing can be eliminated.

The resilience of the synthetic resin film can be adjusted by providing fine irregularities in advance, and the irregularities prevent the fiber-reinforced thermoplastic resin sheet that is the lamination partner from shifting at the interface. And the picture can be reliably protected.
In addition, this synthetic resin film can also be used as a protective film of a molded product.

Further, in shaping the decorative composite sheet into a hollow body as described above, the surface which becomes the inner surface of the hollow body by suction under reduced pressure, that is, the surface opposite to the decorative surface is regulated. Since it is introduced into the extrusion mold or shaping mold while gradually shaping it into a hollow body by bringing it into close contact with the mold, it not only reduces the chance of damaging the decorative surface, but also introduces it into the next stage mold This makes it possible to keep the position constant, and it is possible to eliminate misregistration of a picture or the like.

[Brief description of the drawings]

FIG. 1 is a decorative composite sheet F used in Example 1 of the present invention.
Diagram of manufacturing equipment

FIG. 2 is a schematic cross-sectional view of the decorative composite sheet F manufactured in Example 1 of the present invention.

FIG. 3 is an explanatory diagram of an apparatus for producing a fiber-reinforced thermoplastic resin foam used in Example 1 of the present invention.

FIG. 4 is a cross-sectional view of the decorative composite sheet F at a location indicated by XX ′ in FIG. 3;

FIG. 5 is a sectional view of the restricting body 22d at a location indicated by XX ′ in FIG. 3;

FIG. 6 is a diagram illustrating a restricting body 22 at a location indicated by AA 'in FIG.
Sectional view of d

FIG. 7 shows a hollow body T at a location indicated by YY ′ in FIG.
Cross section of

8 is a cross-sectional view of a molded product at a location indicated by ZZ 'in FIG.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Fluid tank 2,3 Heating roller 4 Cooling roller 20,22 Sheet feeding machine 22a Heating device 22b-22d Regulator 221 Sheet passage 222 Groove 223 Decompression suction hole 23 Extruder 24 Extrusion die 25 Outer die 26 Shaping die 28 Cooling mold 29 Take-off machine C Fiber-reinforced thermoplastic resin sheet D Colored acrylic resin film E Synthetic resin film F Decorating composite sheet G Fiber-reinforced thermoplastic resin sheet H Foamable thermoplastic plastic T Hollow body

Claims (1)

[Claims] 1. One or a plurality of fiber-reinforced thermoplastic resin sheets, the surfaces of which have been decorated, are continuously formed into a hollow body as a whole so that the decoration surface is on the outside. While supplying the foamable thermoplastic resin composition inside,
In the method of shaping the cross-sectional shape into a desired shape by causing the outer peripheral surface of the hollow body to conform to the regulating member by the foaming pressure, the fiber-reinforced thermoplastic resin sheet has a configuration in which a continuous fiber composed of a plurality of filaments is unidirectional. Are aligned with, and
At least one composite layer integrated with a thermoplastic resin
A synthetic resin film that includes a layer and does not thermally fuse with the decorative surface of the sheet and that has a higher melting temperature or does not melt than the thermoplastic resin used for the sheet. When the composite sheet is formed into a hollow body, the sheet is heated to a plastic state, and then the sheet surface serving as the inner side surface of the hollow body is decompressed and sucked. The method for producing a fiber-reinforced resin foam, characterized in that the foam is gradually shaped into a hollow body while being pressed against the regulating body.