JPS635913A - Manufacture of composite material employing synthetic resin as base material - Google Patents

Abstract

PURPOSE:To make it possible to surely and uniformly bond powdered matters on the surface of synthetic resin by a method wherein the powdered matters such as metal, ceramic or the like are coated on the surface of a synthetic resin form and the resultant foam coated with the powdered matters is compression molded in a mold under heat. CONSTITUTION:Powdered matters 2 are coated on the surface of a synthetic resin foam 1. Because the foam 1 has recesses 1' formed on its surface and bubbles 1'' formed in is interior, the powdered matters 2 enter in the recesses 1'. Metal such as zinc, tin, aluminum or the like, ceramic or the like is selected as the powdered matters in accordance with the object. The foam 1 is seated to molds 3 so as to be compression molded under heat. First of all, the recesses 1' and the bubbles 1'' are collapsed and the powdered matters 2, which have entered in the recesses 1', are wrapped in the interior of the foam. Further, the powdered matters 2 excluding those in the recesses 1' bond with the foam, which is heated and brought into molten state, so as to foam an integral body. In addition, by coating the powdered matters 2 on both the sides of the foam 1 and at the same time employing the powdered matters 2 consisting of different material from each other on the respective sides of the foam, a composite material having the characteristics of the respective materials can also be manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a method for manufacturing a composite material, which is formed by using a synthetic resin as a base material and integrally bonding a thin layer of metal, ceramics, etc. to the surface thereof.

[Prior Art] Conventionally, there are many types of composite materials made of synthetic resins, metals, and the like. For example, there is a method in which a metal plate is attached to the surface of a synthetic resin with an adhesive, or a method in which a composite material is manufactured by mixing metal powder during injection molding of a synthetic resin.

[Problems to be Solved by the Invention] In the prior art, when an adhesive is used, there is a risk that the metal plate will peel off after long-term use.

In addition, when injection molding is performed while mixing metal powder, it is difficult to concentrate the metal on the surface of the molded product and form a uniform layer over the entire surface, which is especially difficult when the shape of the molded product is complex. It is.

[Means for Solving the Problems] Therefore, in the present invention, a powder 2 of metal, ceramic, etc. is applied to the surface of a synthetic resin foam 1, and this is compressed while being heated in a mold 3. In this manner, a composite material 4 made of synthetic resin as a base material is manufactured.

[Function] When the powder 2 is applied to the surface of the foam 1, the powder 2 enters the concave portions on the surface of the foam 1. When the foam 1 is pressed while being heated in this state, the four-part pipe is crushed while holding the powder 2 in its mouth, and the powder 2 is wrapped in the recessed part.

Furthermore, the powdered material 2 that is not wrapped in the recessed portion B is integrally bonded by the synthetic resin being melted by heating.

[Example] Figures (A) to (B) are schematic diagrams illustrating details of the present invention.

Figure (a) shows a state in which powder 2 is applied to the surface of a synthetic resin foam 1. As is well known, 1 foam 1
Since the four parts L' and air bubbles 1' are formed on the surface and inside of the powder, the powder 2 coated on the surface enters the four parts L' (see enlarged part (a) in the figure). The powder 2 is selected from metals such as zinc, tin, aluminum, ceramics, etc. depending on the purpose. For example, when the composite material 4 obtained according to the present invention is used as an electromagnetic shielding material, metal powders such as zinc, tin, aluminum, etc. are used, and when used as a horizontal material for construction that similarly requires durability. Ceramic powder is used for this purpose.

The first possible method for applying the powder 2 is to apply a thermal spraying technique, but it may also be applied by spraying with an airbrush or the like.

Next, as shown in FIG. 1(B), the foam 1 is placed on a mold 3, and while the foam 1 is heated, it is press-molded as shown in FIG. 1(A). As a result, first of all, the four parts l' and the air bubbles 1" are crushed. At this time, the powder 2 that has entered the recess
is enclosed inside the concave portion B by crushing (see enlarged portion (b) in the figure). Furthermore, the powdered material 2 located outside the four-part plastic is combined and integrated with the foamed material 1 in a heated and melted state.

In this example, the powder 2 was applied only to one side of the foam 1, but the invention is of course not limited to this, and the powder 2 was applied to both sides of the foam 1, and different materials were used. It is also possible to use the powder 2 to produce a composite material that has the characteristics of each material.

According to the present invention, as described in "Effects of the Invention" 2, powder can be reliably bonded to the surface of a synthetic resin.

In addition, since the powder is applied to the surface of the foam in advance and then molded into any desired shape, a layer of metal, etc. is uniformly applied to the entire surface, no matter how complex the shape. It is something that can be formed.

[Brief explanation of drawings]

The drawings are schematic diagrams illustrating the steps of the invention. l...Foam, 2...Powder, 3...Mold, 4...Composite material. =4- Procedural amendment (to 9) September 2, 1988 Commissioner of the Patent Office Kuro 1) Akio Tono 2, Name of invention Method for manufacturing composite material based on synthetic resin 3, Case of person making amendment Relationship with Patent applicant Name Yoshio Arata Oka 4, Agent 5 Date of amendment order August 26, 1985 6 explanation"
(1) In the specification, the word "Figure" on page 3, line 2, line 4, and line 20 of page 3 is amended to read "Figure 1." (2) In the specification, in the first line of page 4, the phrase ``Figure 1 (a)'' is amended to ``Figure 1 (c)''. (3) In the specification, on page 5, line 3, the phrase "The drawings show..." should be replaced with "The drawings show one embodiment of the present invention."
FIGS. 1(a) to 1(c) are schematic views showing the steps of the present invention, and FIGS. 1(a) and 1(b) are enlarged views of the main parts. ” he corrected. (4) Amend the drawing as shown in the attached sheet. that's all

Claims (1)

[Claims] A synthetic resin-based composite material characterized by applying powdered materials such as metals or ceramics to the surface of a synthetic resin foam and press-molding it while heating it in a mold. Production method.