JPH1120017A - Multilayered molded body having fiber reinforced thermoplastic resin layer and molding method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the lightweight properties, rigidity and dimensional stability of a multilayered formed body by a method wherein a thermoplastic resin sheet having a surface designadness and a fiber reinforced thermoplastic resin sheet are laminated to each other under the condition that the temperature of respective layers are independently controlled to molding temperatures different from each other and, at the same time, the respective layers are differentially molded. SOLUTION: A fiber reinforced thermoplastic resin sheet and a thermoplastic resin sheet having a surface designedness are laminated to each other and then integrally differentially molded. In order to integrally form the laminated sheet at different forming temperatures, the temperatures of the respective layers are independently controlled for forming. Concretely, to a multilayered sheet consisting of an upper sheet 1 made of the thermoplastic resin and a low sheet 2 made of the fiber reinforced thermoplastic resin, the heating object temperature values or the upper and the lower sheets 1 and 2, their conversion percentages, their heating times are set in the inputting means CRT and the surface temperatures of the upper end the lower sheets are detected with a first and a second temperature sensor 9 and 14. The temperature controlling amount of the surface temperatures are calculated with a computer CPU so as to transmit the signals representing the calculated amount through a sequence means SQ to a controlling means SSR in order to control the calorific values of respective heaters.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber-reinforced thermoplastic resin which has strong external design requirements, is lightweight and requires rigidity, such as automobile parts, sanitary members (ceilings, walls, bathtubs), housing of home electric appliances, building materials, etc. The present invention relates to a laminate and a method for forming the same.

[0002]

2. Description of the Related Art A major problem in vacuum forming (differential pressure forming) using a fiber reinforced thermoplastic resin sheet is that if the preheating is performed to a temperature exceeding the melting point or softening point of the fiber reinforced thermoplastic resin, the thermoplastic resin suppresses the problem. The reinforcing fibers that were
As the resin softens, the elastic force is restored, the sheet thickness expands (swells) to about 10 times the thickness before preheating, and air is trapped inside the sheet.
An air pocket remains inside the molded product obtained by molding this at a relatively low pressure, and the appearance is remarkably poor. Regarding this problem, JP-A-7-117114 discloses a thermoplastic resin sheet having a higher melting point or softening point than the thermoplastic resin (a) forming a matrix of the fiber-reinforced resin on both surfaces of the fiber-reinforced thermoplastic resin sheet ( It is disclosed that when b) is laminated and the composite sheet is preheated and molded, the entire periphery is maintained at a temperature equal to or lower than the melting point or softening point of the thermoplastic resin (a). This is intended to cover both sides of the fiber reinforced thermoplastic resin sheet with a resin sheet having a higher melting point, and to keep the peripheral portion at a low temperature to prevent the reinforcing fibers from bulging or entraining air during molding. However, in this prior art, the fiber reinforced thermoplastic resin sheet has a thickness of 1.3 mm, and the thermoplastic resin film laminated on both sides has a thickness of 0.03 to 0.2 mm (30 to 20 mm).
0 μm), which can be formed only in a thin form, especially when the thickness of the surface thermoplastic resin sheet is 0.03 to 0.2 mm
It cannot be used in places where surface hardness is required or surface design (color tone, smoothness) is required. In addition, the surface is apt to be torn, and in design, the glass fiber (GF), which is a reinforcing fiber, is transparent, and irregularities appear. Further, there is a problem that the thermoplastic resin film is required to have a melting point and a softening point higher by 10 ° C. or more than the resin used in the fiber-reinforced thermoplastic resin sheet, for example. Further, in the conventional method, since the fiber-reinforced thermoplastic resin sheet is manufactured by a drying method, the material is difficult to elongate, and the material is liable to be broken or peeled, so that a satisfactory molded product cannot be obtained.

[0003]

When considering a molded article of a fiber-reinforced thermoplastic resin and a thermoplastic resin provided with surface hardness and surface design, the thickness of the thermoplastic resin layer is 1 to 6 mm.
Degree is necessary. The combined total thickness of the fiber-reinforced thermoplastic resin and thermoplastic resin layer is up to about 10 mm, which can be molded simultaneously, and there is a long-awaited demand for a lightweight, high mechanical strength resin multilayer molded product. No molded product has been obtained.

[0004]

In order to solve the above-mentioned problems, the present inventor has studied the temperature conditions of the laminated sheet at the time of molding, and formed a thermoplastic resin layer by differential pressure molding under a specific temperature condition. The present inventors have found that a multilayer molded article free from surface defects and internal defects can be obtained even when the fiber-reinforced thermoplastic resin sheet (A) as a backup material is laminated on a thick sheet (B) having a thickness of 1 to 6 mm. Completed the invention.

According to the present invention, a thermoplastic resin sheet having a surface design and a fiber-reinforced thermoplastic resin sheet are laminated, and each layer is independently controlled at a different molding temperature, and
This is a multi-layer molded body obtained by differential pressure molding of each layer simultaneously.
Further, the fiber-reinforced thermoplastic resin layer is made of a thermoplastic resin 80.
The fiber-reinforced thermoplastic resin sheet containing -35 wt% and reinforcing fibers of 20-65 wt%, is manufactured by a papermaking method in which thermoplastic resin particles and discontinuous fibers are dispersed in water, dewatered, and hot pressed; The matrix resin of the fiber reinforced thermoplastic resin sheet is polyethylene, polypropylene, acrylic, polycarbonate, polystyrene, PVC, AB
It is selected from materials consisting of S, polyamide, polyester, and blends thereof.

Further, the reinforcing fibers of the fiber-reinforced thermoplastic resin sheet may be chopped glass, roving glass,
Aramid fiber, carbon fiber, ceramic fiber, metal fiber and at least one selected from the group consisting of various whiskers, the thermoplastic sheet having the surface design, polyethylene, polypropylene, acrylic,
Carbonate, polystyrene, PVC, acrylic-modified P
It is selected from VC, ABS, polyamide, polyester, and a blend thereof, and further, a heterogeneous multilayer body thereof, and the thickness of the thermoplastic resin sheet is 1.0 to 6 mm.

Further, the present invention provides a method for forming a multilayer molded article, comprising laminating a fiber-reinforced thermoplastic resin sheet and a thermoplastic resin sheet having surface design, clamping the molded article, and integrally molding the sheet using a differential pressure. A method, wherein said integral molding comprises:
This is a method for forming a multilayer molded body in which the temperature of each layer is independently controlled so as to form a laminated sheet at different molding temperatures.

Hereinafter, the present invention will be described in detail.

(1) Fiber-reinforced thermoplastic resin sheet (A) Reinforced fiber The reinforcing fibers used in the fiber-reinforced thermoplastic resin sheet layer of the multilayer molded article of the present invention are glass fibers, carbon fibers, Examples thereof include metal fibers, other inorganic fibers, and organic fibers. Among them, glass fiber is particularly common. It is also possible to use glass fibers as a main component and carbon fibers, aramid fibers, metal fibers, ceramic fibers, and the like as long as they do not depart from the gist of the present invention. It is common to use chopped strands as glass fibers. The chopped strand may be subjected to a surface treatment with an aminosilane coupling agent, an epoxysilane coupling agent, a sizing agent such as polyvinyl alcohol, polyvinyl acetate, polyurethane, or the like, depending on the application.

Thermoplastic resin The resin used for the fiber reinforced thermoplastic resin sheet layer of the present invention is polyethylene, polypropylene, modified P
P, acrylic resin, polystyrene, polyvinyl chloride, A
BS resin, polyester resin (polyethylene terephthalate, polybutylene terephthalate), polycarbonate resin, polyamide, polyacetal, polysulfone,
Polyphenylene sulfide and the like can be mentioned.
These resins can be used not only alone, but also as a mixture or copolymer of two or more kinds. Further, a laminate of these resin sheets may be used. Further, a filler, a weather resistance improver, an additive for improving strength, and the like can be compounded in the resin. Among various resins, polypropylene, polyester, and the like are promising in terms of physical properties such as strength and rigidity, and polypropylene is particularly preferable in consideration of moldability, economy, recyclability, and the like.

The proportion of the thermoplastic resin in the fiber-reinforced thermoplastic resin sheet (A) of the present invention is 80 to 35% by weight (the reinforcing fiber is 20 to 35% by weight).
65% by weight). Preferably, 80 to 60
% By weight (20 to 40% by weight of the reinforcing fiber). When the blending ratio of the thermoplastic resin exceeds 80% by weight, the contribution to the improvement of the rigidity of the obtained molded article becomes small, and when it is less than 20% by weight, a good molded article cannot be obtained.

Thickness of the sheet of the fiber-reinforced thermoplastic resin (A) is 2 to 10
It can be molded in the range of mm. Preferably it is 3-6 mm. If the thickness is less than 2 mm, there is not enough mechanical strength until the thickness of the molded product becomes rigid, and if it is 10 mm or more, it is difficult to perform differential pressure molding.

Production of fiber-reinforced thermoplastic resin sheet (A)
Mixing reinforcing fibers of the thermoplastic resin powder or granular material constant length or different lengths in a law water and water bubbles were dispersed, further heating, under pressure to prepare a web which is an intermediate product by a papermaking method,
A method of forming a fiber-reinforced thermoplastic resin sheet by cooling (wet method). After mixing and dispersing the thermoplastic resin particles and reinforcing fibers,
A method in which the mixture is formed into a web and heated, pressurized, and cooled to obtain a fiber-reinforced thermoplastic resin sheet (dry method). And the like. In the present invention, a fiber-reinforced thermoplastic resin sheet obtained by any manufacturing method may be used, but the reinforcing fiber is more uniformly dispersed, the strength is stable, and the moldability is excellent even at low pressure. It is particularly preferable to use a fiber-reinforced thermoplastic resin sheet that has been subjected to the above.

(2) Thermoplastic resin sheet (B) Thermoplastic resin (B) As the resin used for the thermoplastic resin sheet (B) of the present invention, the above-mentioned fiber-reinforced thermoplastic resin sheet (A) can be used. It can be selected from among the thermoplastic resins (A). Similarly, a material in which a filler, a stabilizer, a coloring agent, a weather resistance improver, and the like are added to a resin can be used. The thickness of these thermoplastic resin sheets (B) is 0.2 mm
It is molded to a size of 10 mm to 10 mm, preferably 0.5 mm to 6 mm. If the thickness exceeds 10 mm, the molding is insufficient and the appearance of the multilayer molded body is poor. If the thickness is less than 0.2 mm, the surface of the GF rises due to thermal expansion due to the elastic recovery of the reinforcing fiber or sometimes the sheet breaks. The melting point or softening point of these thermoplastic resins (B) is 30 times higher than that of the resin used for the fiber-reinforced thermoplastic resin (A).
Even if there is a temperature difference of about 60 ° C. (either high or low), there is no problem in molding by controlling the temperature independently by the method described later.

As an example of the wet method, a surfactant (1 to 5% by weight is added to water, and polypropylene (PP) / GF (chopped strand) is sufficiently stirred in a well-foamed liquid. , To produce a web. Heat this,
The fiber-reinforced thermoplastic resin sheet is manufactured by pressurizing and cooling. When a fiber-reinforced thermoplastic resin sheet (eg, KP sheet under the trade name) manufactured by the papermaking method is formed as the laminated sheet of the present invention, the uniformity of the fiber amount is maintained even in vacuum forming, and about 1 kg / cm ² . Atmospheric pressure or 1-1
It is characterized by be molded with pressure or 10 to 30 kg / cm ² of press pressure of 0 kg / cm ^2. Another feature is that the GF is uniformly dispersed in the deep drawing direction and the shrinkage after molding is small.

Adhesive Layer Between the fiber-reinforced thermoplastic resin sheet (A) and the thermoplastic resin sheet (B) laminated thereon, heat bonding may be performed at the time of molding, or an adhesive layer may be provided. May be. The adhesive layer sandwiches the hot melt adhesive sheet and softens the hot melt during molding to bond the fiber reinforced thermoplastic resin sheet (A) and the thermoplastic resin sheet (B). Polyolefin (polyethylene, polypropylene) resins, vinyl acetate resins, and polyester resins are preferably used for the hot melt. When the matrix resin of the fiber-reinforced thermoplastic resin sheet (A) and the resin of the thermoplastic resin sheet (B) are different and sufficient adhesiveness cannot be obtained only by heat fusion, it is preferable to have an adhesive layer.

According to the present invention, the thermoplastic resin sheet described above is used as a surface material, the fiber reinforced thermoplastic resin sheet is laminated as a backup material, each layer is independently temperature-controlled at different molding temperatures, and each layer is It is a multi-layer molded product obtained by differential pressure molding at the same time (integrally) and has surface design. Here, having the surface design means that even if the thermoplastic resin sheet (B) on the surface is laminated with the fiber-reinforced thermoplastic resin sheet (A) and subjected to differential pressure molding, the single layer is subjected to differential pressure molding within an optimum temperature range. It means that it has the same surface properties as when it was made, and specifically, it means that there is no breakage on the surface and there is substantially no see-through of the reinforcing fibers and no generation of irregularities.

Conventionally, the thermoplastic resin sheet (B) having such surface design and having a surface of 0.2 to 10 mm
It is preferably from 0.5 to 6 mm, and a multi-layer molded article subjected to differential pressure molding in which the fiber-reinforced thermoplastic resin sheet (A) of the backup material has a thickness of 2 to 10 mm, preferably 3 to 6 mm has not been obtained.

That is, when the above-mentioned laminated sheet is subjected to differential pressure molding as a molded article having a molding magnification (development magnification, a ratio of the surface area after molding to the surface area before molding) of 150% or more, preferably 250% or more, A molded article having a surface property substantially equivalent to that of a single-layer molded article and having an Izod impact strength of 20 kgfcm / cm ² or more, preferably 35 kgfcm / cm ² or more, has a light weight and strength not found in conventional products. It is a multilayer molded article having a surface design.

Next, an example of a preferred differential pressure molding of the multilayer molded article of the present invention will be described with reference to the drawings. Heating Device FIG. 1 shows an outline of a heating control device used in one example of a molding method of the present invention. Reference numeral 5 denotes a box-shaped frame 6 in which a number of heater elements 7 having excellent heat generation response are provided. It is a heater placed above. Reference numeral 8 denotes an upper heater temperature sensor for detecting the temperature of the heater element 7, and reference numeral 9 denotes a first temperature sensor of an infrared radiation thermometer for measuring the surface temperature of the upper sheet 1 installed on the upper portion of the frame 6. Similarly, reference numeral 10 denotes a lower heater in which a number of heater elements 12 having excellent heat generation response are arranged on a box-shaped frame 11;
Reference numeral 3 denotes a lower heater temperature sensor that detects the temperature of the heater element 12, and reference numeral 14 denotes a second temperature sensor that measures the surface temperature of the lower sheet 2 installed below the frame 11. 15 is a clamping means for clamping a side edge of a multilayer sheet in which the upper sheet 1 and the lower sheet 2 are vertically stacked, and having an adhesive layer 3 between the upper sheet 1 and the lower sheet 2 if necessary; The multilayer sheet is packed by the clamp means 15 and supplied between the upper heater 5 and the lower heater 10 by a transport means (not shown).

The CRT is for heating the upper sheet 1 and the lower sheet 2
Target temperature value Ts₁, Ts_Two, Upper heater 5 and lower heater
10 to input the ignition rate and the resin sheet heating time t, etc.
Input means. CPU represents a computer,
The heating target temperature value Ts₁, Ts_TwoAnd before heating each sheet
Measured surface temperature T₁, T_TwoWith respect to the deviations a and b
The respective temperature control amounts α and β of the upper heater 5 and the lower heater 10
Various calculation functions such as calculating, the heaters 5, 10
Temperature maximum value TH of each heater based on ignition rate ₁, TH
_TwoFor storing and storing a database for determining
And other functions similar to those of ordinary small computers.
It is something. SSR is upper heater 5 and lower heater 1
It consists of a thyristor etc. for controlling the heating value of 0
The control means and SQ are programmable logic controllers (commonly known as
PLC), and a sequence means such as an I / O station
The upper heater temperature sensor 8 represents the
Temperature sensor 9, lower heater temperature sensor 13 and second
Upon receiving the detection signal from the temperature sensor 14, each control unit S
It has a function of outputting a power supply command to the SR.

Heating method The temperature control using the above-described apparatus is performed on a multilayer sheet in which a thermoplastic resin sheet and a fiber-reinforced thermoplastic resin sheet supplied between an upper heater and a lower heater are vertically stacked.
A method of simultaneously heating from the respective surface sides to control the heating to a temperature suitable for molding, comprising inputting a target heating temperature value of an upper sheet and a lower sheet, an ignition rate of an upper heater and a lower heater, and a sheet heating time. The surface temperature of the upper sheet is detected by the first temperature sensor based on the heating start command, and the surface temperature of the lower sheet is detected by the second temperature sensor based on the heating start command. The computer calculates a temperature control amount of each heater with respect to the deviation amount from each measured value, and transmits a signal of the temperature control amount to the control means via the sequence means, and the control means controls the heat generation amount of each heater. Then, a signal of the actual measured value of the surface temperature of each heated sheet is fed back to the computer to calculate a new temperature control amount, and the corrected amount is calculated. Repeat to control the heating value of the heaters based on the time control amount is controlled so as to approach the upper sheet and the temperature of the lower sheet in each of the heating target temperature.

The respective heating target temperature values of the upper sheet and the lower sheet,
When the ignition rate of the upper heater and the lower heater and the heating time of the resin sheet are inputted by the input means and a heating start command is issued, the surface of the upper sheet and the lower sheet supplied between the upper heater and the lower heater based on the command is issued. The temperature is detected by the first and second temperature sensors, respectively. The computer calculates a deviation between the heating target temperature value and each of the actually measured values, calculates a temperature control amount of each heater corresponding to the deviation amount, and outputs a signal of the temperature control amount to the sequencer. Via the control means. The control means controls the amount of heat generated by each heater to start heating the resin sheet. Heating ends when the actual measured values of the upper sheet and the lower sheet reach the respective heating target temperature values, or when the actual heating time of the sheet reaches the initial set value.

If either the upper sheet or the lower sheet has not reached the heating target temperature value, or if the actual heating time is shorter than the set value, the surface temperature of the sheet is detected again. The signal of the detected measured value is fed back to the computer, and a new temperature control amount is calculated. The heating value of the corresponding heater is automatically controlled based on the corrected temperature control amount so as to approach the initial heating target temperature value.

According to such a heating control method, regardless of the difference in the thickness and the thermal conductivity of the laminated sheets of different materials, the stacked sheets can be quickly brought to a temperature suitable for molding by a simple input operation. To efficiently heat and maintain a stable temperature.

For example, FIG. 4 shows a case where a multi-layer sheet in which a reinforced glass fiber sheet (upper sheet, 2.5 mm in thickness) and an ABS resin sheet (lower sheet, 2.5 mm in thickness) are heated is controlled. 3 is a graph showing a relationship between a temperature, a heater temperature, and a heating time. Here, the upper sheet heating target temperature value Ts ₁ = 120 ° C., the upper heater ignition rate =
8, the lower target heating temperature Ts ₂ = 140 ° C., the lower heater ignition rate = 10, and the sheet heating time t = 180 seconds.

From this graph, it can be seen that the upper and lower sheets are heated to about 100 ° C. in about 50 seconds after the start of heating, and the temperatures of the respective heaters are gradually lowered after about 50 seconds for the upper heater and about 80 seconds for the lower heater. As a result, it was confirmed that each sheet approached the respective heating target temperature in about 150 seconds, and then became stable.

When the multilayer molded article of the present invention is a laminated sheet of the following combination, the molding temperature of the thermoplastic resin sheet and the surface temperature of the fiber-reinforced thermoplastic resin sheet are set to the following temperature ranges, respectively, It is preferable to perform differential pressure molding at this temperature, and at this temperature setting, a multilayer molded article having more excellent surface design can be obtained. In particular, it is preferable when the thermoplastic resin sheet is mainly composed of acrylic resin and the fiber reinforced thermoplastic resin sheet is a matrix mainly composed of polypropylene and contains glass fiber. The temperature of these materials is determined by the inventors of the present invention as the deflection temperature under load (HDT) of the thermoplastic resin + 2.
It has been found that the temperature at which molding is possible is substantially in the range of 0 to 100 ° C, preferably HDT + 70 to 100 ° C. Therefore, a target optimum molding temperature can be easily estimated from the HDT value of each material. The preferred temperature value in the case of laminating a thermoplastic resin sheet having a surface design property and a fiber-reinforced thermoplastic resin sheet according to the method of the present invention and independently controlling the temperature of each layer at a molding temperature and a surface temperature, respectively, is The deflection temperature under load of the thermoplastic resin can be determined as an index. Table 1 shows preferred values for each specific resin.

[0029] Deflection temperature under load (HDT): Measured according to JIS K 6745 , and the softening temperature was determined by tensile strength (kgf / cm ² ). Crosslinked acrylic (methacrylic for sanitary) 107 ° C (71-102 ° C for general cast plate) PP 49-60 ° C (56-82 ° C with talc) PC 121-135 ° C ABS 88-107 ° C PVC 60-77 ° C Acrylic-modified PVC 73-90 ° C

Sheet Clamping In the multilayer vacuum and pressure forming of the fiber-reinforced thermoplastic resin and the thermoplastic resin, it is preferable to clamp and fix both at four sides or at necessary points. The clamp is appropriately used irrespective of the material, such as metal, foam, and rubber.

Forming The fiber-reinforced thermoplastic resin sheet (A) and the thermoplastic resin sheet (B) are formed into a product shape by drawing under vacuum and compressed air while drawing by vacuum and compressed air. The thickness of the molded article is determined when the sheet comes into contact with the mold in the stretching process. That is, the sheet is stretched to the shape of a molded article by uniform vacuum pressure aerodynamics simultaneously with the start of molding. On the other hand, the surface temperature of the sheet in contact with the mold is rapidly cooled, stretching is impossible, and the thickness is fixed. After these processes, the finally stretched sheet comes into contact with the surface of the mold, and upon completion of cooling, a molded product is obtained.

As a specific method: Using a female mold, vacuum form from the mold side and mold. 2. Using a female mold, seal the top and mold with compressed air. 3.1 Method of using both 1 and 2. 4. A method in which a material is stretched once to the vicinity of the mold with an auxiliary plug in the use of a female mold and then evacuated and molded. 5. Using a male mold, vacuum form from the mold side and mold. 6. Use a male mold to seal the top and mold with compressed air. 7.4 Method of using 5 and 5 together. And the present invention is not limited to any method. In these vacuum and pressure forming, 0.3 to 10
kgf / cm ² is preferably carried out by applying a pressure of about 0.5~7kgf / cm ^2.

FIGS. 2 and 3 are cross-sectional views of a vacuum forming machine 16 suitable for forming the molded article of the present invention. FIG. 2 shows a vacuum forming machine 16 having a female mold 17, and FIG. 3 shows a vacuum forming machine 16 having a male mold 20. The upper sheet 1 which is a thermoplastic resin sheet is laminated with the lower sheet 2 which is a fiber-reinforced thermoplastic resin sheet 1 via an adhesive layer 3, and its peripheral portion is clamped by a clamping means 15. The heated laminated sheet is brought into contact with the mold while stretching the sheet with the auxiliary plug 18 as necessary. Immediately before contacting the mold, the laminated sheets and the mold 1 are passed through the molds 17 and 20 and the air holes 19 provided by a vacuum pump or the like.
The air between 7, 20 is discharged.

[0034]

【Example】

(Example 1) An example of forming a fiber-reinforced thermoplastic resin sheet and a thermoplastic resin sheet is shown below. FIG. 1 shows a heating state before molding. A fiber-reinforced thermoplastic resin sheet (KP sheet) 2, an adhesive layer 3, and a (methacrylic sheet for sanitary) 1 as a thermoplastic resin sheet are stacked on a far-infrared furnace or a convection furnace installed near a vacuum forming machine. It is pressed by the clamp means 15 and heated at a desired set temperature shown in Table 1 for a predetermined time. The upper and lower surfaces were controlled to independent set temperatures and heated to obtain a high quality molded product.

After the two sheet materials reached the temperature at which they could be formed, they were sent to the vacuum forming machine 16 shown in FIGS. Next, the sheet is once stretched by the auxiliary plug 18, and at the same time, the female mold 17 is lifted up at the same time, and the sheet 1 + 3 + 2 is passed through the air hole 19 by a vacuum pump or the like immediately before hitting the mold with the material sufficiently stretched.
The atmosphere between the mold 17 and the mold 17 was discharged to complete the mold clamping of the sheets 1 + 3 + 2. Through these steps, a molded product (box molded product, see FIG. 5) of two layers of different materials having different surface designs corresponding to the mold 17 was obtained from the sheet 1 + 3 + 2 molded at the same pressure as the atmospheric pressure. . The elongation was 30%.

(Example 2) Using the male mold 20 shown in FIG. 3, the same pressure molding as in Example 1 was carried out to produce a patterned panel. Separately, as a molding machine, a compressed air molding machine capable of feeding compressed air to form a die of ² to 5 kgf / cm ² ,
Similar molding could be performed using a press having upper and lower dies.

Example 3 The same molding method as in Examples 1 and 2 was used except that the thickness of the methacrylic resin for sanitary was 3 mm.

Example 4 A molding was performed in the same manner as in Examples 1 and 2, except that PP was used instead of the methacrylic resin for sanitary.

Example 5 Molding was performed in the same manner as in Examples 1 and 2, except that PC was used instead of the methacrylic resin for sanitary.

Example 6 A molding was performed in the same manner as in Examples 1 and 2, except that ABS was used instead of the methacrylic resin for sanitary use.

Example 7 A molding was performed in the same manner as in Examples 1 and 2, except that PVC was used instead of the methacrylic resin for sanitary.

Example 8 A molding was performed in the same manner as in Examples 1 and 2, except that a methacrylic modified PVC for sanitary was used instead of the methacrylic resin for sanitary.

(Comparative Example 1) As a vacuum forming machine, a fiber-reinforced thermoplastic resin sheet produced by a method other than the papermaking method was used instead of the KP sheet, in which the temperature control mechanism heated the entire laminated sheet simultaneously. Vacuum forming was performed in the same manner as in Example 1.

(Comparative Example 2) 0.16 m thick as a surface material
m was molded in the same manner as in Example 1 except that a material in which a nylon film of m was previously bonded to a fiber-reinforced thermoplastic resin sheet by a press was used.

* Evaluation The state of molding the box molded product produced in Example 1 and the patterned panel produced in Example 2 was evaluated. Table 2 shows the evaluation results. Further, Examples 3 to 3 differing in the amount of GF and the basis weight
8. Boxes and patterned panels shown in Table 2 were prepared in Comparative Examples 1 and 2, and the moldability was similarly evaluated. Table 2 shows the results.

[0046]

[Table 1]

(Examples 9 to 14) A fiber-reinforced thermoplastic resin sheet (KP sheet) having a different GF amount and a basis weight and a methacrylic resin sheet for sanitary as a surface sheet were molded in the same manner as in Example 1. went.

(Comparative Example 3) The same procedure as in Example 1 was carried out except that only a methacrylic resin sheet for sanitary was formed.

* Evaluation The molding results and physical properties (Izod impact value) of Examples 9 to 14 and Comparative Example 3 were evaluated. The results are shown in Table 3. By molding as a laminate with a fiber reinforced thermoplastic resin sheet, the strength was improved as compared with a single methacrylic resin sheet for sanitary.

[0050] Material: Molding of methacrylic resin for sanitary (thickness: 5 mm) and KP sheet Box: molding ratio 280% ○: Good molding △: Partly defective molding

[0051]

The multilayer molded article comprising the fiber-reinforced thermoplastic resin sheet and the thermoplastic resin sheet of the present invention has a surface design property, is lightweight and rigid, and has excellent dimensional stability. Sanitary parts (bathtubs, ceiling materials, walls),
Extremely useful for home appliance housing.

[Brief description of the drawings]

FIG. 1 is a schematic diagram showing an outline of a suitable heating control device for a molded article of the present invention.

FIG. 2 is a sectional view of a vacuum forming machine.

FIG. 3 is a sectional view of a vacuum forming machine.

FIG. 4 is a graph showing a relationship between a sheet temperature and a heater temperature and a heating time by a heating control device suitable for the present invention.

FIG. 5 is a perspective view showing a box molded product.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Upper sheet 2 Lower sheet 3 Adhesive layer 5 Upper heater 6 Frame 7 Heater element 8 Upper heater temperature sensor 9 First temperature sensor 10 Lower heater 11 Frame 12 Heater element 13 Lower heater temperature sensor 14 Second temperature sensor 15 Clamping means 16 Vacuum forming machine 17 concave type 18 auxiliary plug 19 air hole 20 convex type

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification code FI B29K 105: 08 B29L 9:00

Claims (9)

[Claims] 1. A laminate obtained by laminating a thermoplastic resin sheet having a surface design and a fiber-reinforced thermoplastic resin sheet, independently controlling the temperature of each layer at a different molding temperature, and simultaneously performing differential pressure molding of each layer. Multi-layer molded body. 2. The multilayer molded article according to claim 1, wherein said fiber-reinforced thermoplastic resin layer contains 80 to 35% by weight of a thermoplastic resin and 20 to 65% by weight of a reinforcing fiber. 3. The multilayer according to claim 1, wherein the fiber-reinforced thermoplastic resin sheet is produced by a papermaking method in which thermoplastic resin particles and discontinuous fibers are dispersed in water, dewatered, and hot-pressed. Molded body. 4. The matrix resin of the fiber reinforced thermoplastic resin sheet is polyethylene, polypropylene, acrylic, polycarbonate, polystyrene, PVC, AB
The multilayer molded article according to any one of claims 1 to 3, which is at least one selected from the group consisting of S, polyamide, polyester, and a blend thereof. 5. The reinforcing fiber of the fiber-reinforced thermoplastic resin sheet is at least one selected from the group consisting of chopped glass, roving glass, aramid fiber, carbon fiber, ceramic fiber, metal fiber, and various whiskers. Item 5. The multilayer molded article according to any one of Items 1 to 4. 6. The thermoplastic sheet having a surface design property is made of polyethylene, polypropylene, acrylic, carbonate, polystyrene, PVC, acrylic-modified PVC,
The multilayer molded article according to any one of claims 1 to 5, which is at least one selected from the group consisting of ABS, polyamide, polyester, and a blend thereof. 7. The thermoplastic resin sheet has a thickness of 1.0 to 1.0.
The multilayer molded product according to any one of claims 1 to 6, which is 6 mm. 8. A laminate of a fiber-reinforced thermoplastic resin sheet and a thermoplastic resin sheet having surface design, which is clamped,
A molding method of a multilayer molded body, wherein the molding is performed integrally using a differential pressure. 9. The method according to claim 8, wherein the integral molding is performed by controlling the temperature of each layer independently so that the laminated sheet is molded at different molding temperatures.