KR20240060349A - Molded body - Google Patents

Abstract

The purpose of this application is to provide a plate-shaped molded body, a manufacturing method thereof, and a use of the plate-shaped molded body. The main purpose of this application is to provide a plate-shaped body containing a resin component and a filler component and having pores formed therein, a method for manufacturing the plate-shaped body, and a use for the plate-shaped body. In addition, another purpose of the present application is to provide a plate-shaped molded body in which the rigidity obtained through a specific equation is at a level similar to the actual rigidity.

Description

Molded body

This application relates to molded bodies, methods for manufacturing the same, and uses of the molded bodies.

Materials containing pores can be used for various purposes.

For example, the above materials can be used as materials to process heat generated from products. As described above, the importance of technology for processing heat generated from products is increasing.

It is necessary to process heat in products composed of elements that generate heat (heating elements). For example, a battery module or battery pack includes a plurality of battery cells or a plurality of battery modules, which are located relatively adjacent to each other. Therefore, heat generated from one battery cell or battery module affects other adjacent devices, and in some cases, may cause problems such as chain ignition or chain explosion.

Therefore, in these products, it is necessary to ensure that heat, explosion, or fire generated from one element does not affect other adjacent elements.

The purpose of this application is to provide a plate-shaped molded body, a manufacturing method thereof, and a use of the plate-shaped molded body. The main purpose of this application is to provide a plate-shaped body containing a resin component and a filler component and having pores formed therein, a method for manufacturing the plate-shaped body, and a use for the plate-shaped body. In addition, another purpose of the present application is to provide a plate-shaped molded body in which the rigidity obtained through a specific equation is at a level similar to the actual rigidity.

This application relates to molded bodies. The molded body may be manufactured to have a desired shape using plastic such as thermoplastic resin as a raw material. In one example, the molded body may be a plate-shaped molded body.

The molded body may contain at least a resin component and a filler component.

The molded body includes pores formed inside. These pores may be formed at least at the interface between the resin component and the filler component inside the molded body. The molded body of the present application is manufactured through a molding step of forming an uneven shape by applying pressure to a fabric containing a resin component and a filler component, as described later. At this time, pores can be formed inside the molded body by controlling the type of filler component contained in the fabric and/or the conditions of the molding step, and in particular, the pores can be formed at the interface between the resin component and the filler component. . This method is different from the existing method of forming pores through a foaming process, etc.

The porosity of the above molded body can be adjusted to an appropriate range depending on the purpose. For example, the lower limit of the porosity of the molded body may be about 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, or 50%, and the upper limit is 90%, It may be 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20% or 15%. The porosity is above or above any one of the above-described lower limits, below or below any one of the above-described upper limits, or above or above any one of the above-described lower limits while also being above. It may be within a range that is below or below any of the upper limits described. The porosity can be obtained by the method in the examples described later. However, in order to secure a molded body with appropriate rigidity and excellent heat conduction properties, the upper limit of the porosity is 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20% or 15%. It may be to some extent.

The stiffness (G) of the molded body measured according to ASTM D638 may satisfy the relationship of Equation 1 below. Stiffness in this specification may be referred to as stiffness or modulus.

[Equation 1]

p × G _Y ≤ G ≤ q × G _Y

In equation 1, p and q are constants, p is 0.8 or 0.9, and q is 1.1 or 1.2. When p is 0.8, q may be 1.1 or 1.2, and when p is 0.9, q may be 1.1 or 1.2.

In Equation 1, G _Y can be expressed as Equation 2 below.

[Equation 2]

_{G Y = G} ^​

In Equation 2, M _Y is the intrinsic stiffness value measured according to ASTM D638 for the resin component, and M _X is 2.3 GPa. The intrinsic stiffness value in this specification refers to the stiffness measured at 25°C according to ASTM D638 in a sample containing 100% of the corresponding resin component. In addition, stiffness in this specification refers to the elastic modulus (k) value when measured according to ASTM D638 and follows Hook's law. The stiffness of the molded body or resin component can be measured as specifically described in the Examples.

Additionally, M _Y /M _X in Equation 2 may be referred to herein as the stiffness ratio. The _M The M _Y can be a known value for each resin component. In this case, it can be known using SEM images and data stored in an analysis tool (Geodict software, Math2Market).

In Equation 2, _G

[Equation 3]

_G

In Equation 3, a is an arbitrary number in the range of 0.15 to 0.5, b is an arbitrary number in the range of -1 to 2, and F refers to the content volume ratio (vol%) of the filler component to the total volume.

In Equation 2, N can be expressed as Equation 4 below. Additionally, N may be referred to herein as the index of stiffness ratio.

[Equation 4]

N = c × F + d

In Equation 4, c is an arbitrary number in the range of -0.1 to 0.1, d is an arbitrary number in the range of -1 to 1, and F refers to the content volume ratio (vol%) of the filler component compared to the total volume. . Additionally, in Equation 4, c may be in the range of -0.1 to 0 or in the range of -0.05 to -0.01. Additionally, in Equation 4, d may be 0 or more and may be in the range of 0.5 or more to 0.8.

When F in Equation 3 is 1 vol% or more and less than 15 vol%, a in Equation 3 may be in the range of 0.35 or more to 0.36 or less, and b may be any number in the range of 1 to 1.5.

When F in Equation 3 is 15 vol% or more and less than 25 vol%, a in Equation 3 may be in the range of 0.33 or more to 0.345 or less, and b may be any number in the range of 0.5 to 0.9.

When F in Equation 3 is 25 vol% or more and less than 35 vol%, a in Equation 3 may be in the range of 0.3 or more to 0.33 or less, and b may be any number in the range of 0.1 to 0.45.

When F in Equation 3 is 35 vol% or more and less than 45 vol%, a in Equation 3 may be in the range of 0.27 or more to less than 0.3, and b may be any number in the range of less than 0 to -0.2 or more.

When F in Equation 3 is 45% by volume or more and less than 55% by volume, a in Equation 3 may be in the range of 0.2 or more to less than 0.27, and b may be any number in the range of less than -0.2 to -0.5 or more.

There is no particular limitation on the type of resin component included in the molded body. For example, the required type may be appropriately selected and used from among resin components known to be moldable. For example, the resin component may include a thermoplastic polymer. Types of thermoplastic polymers applicable in this process include various crystalline or amorphous polymers, examples of which include polyolefin-based polymers such as PP (polypropylene) or PE (polyethylene), mPPO (Modified PPO (Polyethylene oxide)), etc. Polyalkylene oxide-based polymers, polyamide-based polymers such as PA (polyamide), acetal-based polymers such as POM (polyoxymethylene), PC (polycarbonate), PBT (polybutylene terephthalate), or PET (polyethylene terephthalate). Examples may include polyester-based polymers, acrylic-based polymers such as PMMA (poly(methyl methacrylate)), and polystyrene-based polymers such as PS (polystyrene) or ABS (Acrylonitrile butadiene styrene), but are not limited thereto.

Resin components may have a unique glass transition temperature (Tg) depending on the type. Although not particularly limited, the lower limit of the glass transition temperature of the resin component applied in the present application is 50°C, 55°C, 60°C, 65°C, 70°C, 75°C, 80°C, 85°C, 90°C, 95°C. It may be around ℃, 100℃, 105℃, 110℃, 115℃, 120℃, 125℃, 130℃, 135℃, 140℃ or 145℃, and the upper limit is 500℃, 450℃, 400℃, 350℃. , it may be around 300°C, 250°C, 200°C, or 150°C. The glass transition temperature of the resin component is above or above any one of the above-described lower limits, below or below any of the above-described upper limits, or above any one of the above-described lower limits, or It may be within a range that is both above and below or below any of the above-described upper limits.

There is no particular limitation on the ratio of the resin components in the molded body, and it can be adjusted to an appropriate ratio depending on the purpose. For example, the lower limit of the ratio of the resin component in the molded body is 50% by weight, 55% by weight, 60% by weight, 65% by weight, 70% by weight, 75% by weight, 80% by weight, 85% by weight, 90% by weight. % or 95% by weight, and the upper limit is 100% by weight, 95% by weight, 90% by weight, 85% by weight, 80% by weight, 75% by weight, 70% by weight, 65% by weight, 60% by weight, or 55% by weight. It may be about weight percent. The ratio of the resin component is above or above any one of the above-described lower limits, below or below any one of the above-described upper limits, or above or above any one of the above-described lower limits. At the same time, it may be within a range that is below or below any of the upper limits described above.

The molded body may contain a filler component as an additional component. These filler components may be included, for example, as reinforcing materials.

There is no particular limitation on examples of filler components that can be applied, and for example, organic or inorganic fillers or organic/inorganic fillers such as glass filler, carbon filler, and/or silica filler can be applied.

There is no particular limitation on the shape of the filler. For example, the filler may be a particulate filler (spherical, square, irregular, or other shaped particulate filler), a plate-shaped filler, or a fibrous filler.

The lower limit of the size of the above filler may be, for example, 1 μm, 5 μm, or 10 μm, and the upper limit is 100 μm, 95 μm, 90 μm, 85 μm, 80 μm, 75 μm, 70 μm, It may be about 65 μm, 60 μm, 55 μm, 50 μm, 45 μm, 40 μm, 35 μm, 30 μm, 25 μm, 20 μm, or 15 μm. The size of the filler is above or above any one of the above-described lower limits, below or below any one of the above-described upper limits, or above or above any one of the above-described lower limits. At the same time, it may be within a range that is below or below any of the upper limits described above.

The size of the filler may be the average diameter of the filler (median diameter in D50 particle size) when the filler is in the form of particles, and when the filler is in the form of a plate, the thickness of the filler or the long side in the direction perpendicular to the thickness direction of the filler. Alternatively, it may be a short side, and in the case of a fibrous shape, it may be the diameter of the cross section of the filler.

In one example, the filler may be a fibrous filler. When applying a fibrous filler, pores can be formed more efficiently in the molding process described later depending on the aspect ratio of the filler. In addition, through the aspect ratio, the fibrous filler exhibits orientation during the manufacturing process of the molded body and can effectively form pores of an appropriate shape according to the pressure applied accordingly.

In the case of fibrous filler, the lower limit of the aspect ratio of the filler may be about 3, 5, 7, 9, 10, 12, 14, 16, 18, 20, 22 or 24, and the upper limit is about 60, It could be around 55, 50, 45, 40, 35, 30 or 25. The aspect ratio is above or above any one of the above-described lower limits, below or below any one of the above-described upper limits, or above or above any one of the above-described lower limits while also being above. It may be within a range that is below or below any of the upper limits described. The aspect ratio of a fibrous filler is the length of the filler divided by the diameter of the cross-section of the filler.

In the case of fibrous fillers, the lower limit of the cross-sectional diameter of the filler may be, for example, 1 μm, 5 μm, or 10 μm, and the upper limit is 100 μm, 95 μm, 90 μm, 85 μm, 80 μm, 75 μm. , 70 μm, 65 μm, 60 μm, 55 μm, 50 μm, 45 μm, 40 μm, 35 μm, 30 μm, 25 μm, 20 μm, or 15 μm. The cross-sectional diameter of the fibrous filler is greater than or greater than any one of the above-described lower limits, is less than or below any of the above-described upper limits, or is greater than or equal to any one of the above-described lower limits. or it may be within a range that is both above and below or below any one of the above-described upper limits.

The lower limit of the weight ratio of the filler component to 100 parts by weight of the resin component in the molded body may be about 1 part by weight, 5 parts by weight, 10 parts by weight, 15 parts by weight, 20 parts by weight, or 25 parts by weight, and the upper limit is , 100 parts by weight, 95 parts by weight, 90 parts by weight, 85 parts by weight, 80 parts by weight, 75 parts by weight, 70 parts by weight, 65 parts by weight, 60 parts by weight, 55 parts by weight, 50 parts by weight, 45 parts by weight, 40 It may be about 35 parts by weight, 30 parts by weight, or 25 parts by weight. The weight ratio of the filler component is above or above any one of the above-described lower limits, below or below any one of the above-described upper limits, or above any one of the above-described lower limits, or It may be within a range that is both above and below or below any of the above-described upper limits. Additionally, considering the desired physical properties, the weight ratio of the filler component may be changed within or outside the range described above.

The molded body of the present application containing the above components may be a plate-shaped molded body, or may also be a molded body having a concavo-convex shape formed including embossed portions and engraved portions.

There is no particular limitation on the specific form of the concavo-convex shape, for example, the depth, height, area, shape and/or number of the engraved or embossed shape, and an appropriate form of concavo-convex shape can be applied considering the purpose to which the molded body is applied. there is.

Representative examples of existing molding methods for producing molded bodies with concavo-convex shapes and containing filler components include injection molding. In these existing methods, the manufacturing conditions of the molded body are controlled to prevent internal pores from occurring as much as possible during the molding process. This is because when pores are generated inside during the molding process, the mechanical properties of the molded body deteriorate, and when pores are formed unevenly, the mechanical properties of the molded body also appear uneven in each part.

However, in the present application, conditions are adjusted so that pores can be actively formed in the molding process described later. In addition, by controlling the molding conditions during the process, the molded body can be made to exhibit uniform and stable mechanical properties as a whole.

For example, when the plate-shaped molded body of the present application has sides formed in the first direction, the tensile breaking strength of each of the upper, middle, and lower ends obtained by dividing the molded body into three parts in a direction perpendicular to the side in the first direction is The standard deviation can be controlled below a certain level.

The first direction is a direction parallel to an arbitrary side of the plate-shaped molded body observed when the plate-shaped molded body is observed along the thickness direction of the molded body. For example, referring to FIG. 1, if the molded body has a rectangular shape as shown in FIG. 1, the direction of the horizontal side 100 or the vertical side 200 of the rectangle may be the first direction. In FIG. 1, the molded body is divided into three parts in a direction perpendicular to the side of the first direction with the vertical side 200 as the first direction, and an upper end (U), a middle part (M), and a lower end (L) are defined. The results are shown in dotted lines. In some cases, when the side of the molded body is not in the form of a straight line, the direction of a virtual straight line connecting both end points of the side (2001, 2002 in the case of FIG. 1) may be set as the first direction.

In the above, dividing the molded body into three parts along the first direction may mean dividing the molded body so that the upper end (U), middle part (M), and lower end (L) have equal areas.

On the other hand _, the standard deviation _is {[(S _U -A ₎ ² + ( This value is calculated as S _M -A) ² +(S _L -A) ² ]/3} ^0.5 .

In a suitable example, the upper limit of the standard deviation of the tensile breaking strength of each of the top, middle and bottom portions is 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, It may be around 30, 25, 20, 15 or 10, and the lower limit may be around 0, 2, 4, 6, 8, 10, 12 or 14. The standard deviation is within a range that is below or below any one of the above-described upper limits, or is above or above any one of the above-described lower limits and is also below or below any one of the above-described upper limits. There may be.

The method of measuring the tensile breaking strength referred to in this specification is summarized in the Examples. The tensile breaking strength can be measured at room temperature (about 25°C) using UTM (Universal Testing Machine) equipment on a specimen cut to have a horizontal length of about 45 mm and a vertical length of about 12.5 mm. .

The horizontal direction of the specimen may be parallel to the MD (Machine Direction) or TD (Transverse Direction) of the fabric. In the above, MD and TD refer to the MD and TD directions of the fabric, which will be described later, and this refers to the MD and TD directions during the extrusion process of manufacturing the fabric.

Fix both ends of the specimen in the transverse direction to the equipment at a time of about 8 mm, measure the strength at the point when the specimen breaks while stretching the specimen in the transverse direction at a speed of approximately 50 mm/sec, and measure the strength. It is based on tensile breaking strength.

The molded body of the present application can also be manufactured to have physical properties at a certain ratio or higher compared to the physical properties of the fabric. In the above, the fabric refers to a material in the form of a film or sheet applied to manufacture the molded body having the concavo-convex shape. In other words, the process of manufacturing the molded body of the present application includes a molding step of manufacturing a plate (sheet or film) by applying a material containing the resin component and the filler component to an extrusion process and forming an uneven portion on the plate. can do. If pores are generated at the interface between the resin component and the filler component inside the plate due to the pressure applied during the molding process, the physical properties of the final molded body may be different from those of the previous plate. In this case, the physical properties of the fabric and the molded body may be different. It is best to keep the deviation as small as possible. When the method of the present application is applied, changes in the physical properties of the fabric can be controlled to an appropriate level.

For example, the molded body may have a change ratio of tensile breaking strength compared to the fabric within a predetermined range or more. In the above, the ratio of _change in tensile breaking strength compared to the fabric is _{a value} calculated as ₁₀₀ The unit is %. In addition, the tensile breaking strength S _S of the molded body may be the tensile breaking strength of the concave portion or the embossed portion of the molded body, or may be the arithmetic average of the tensile breaking strengths of the concave portion and the embossed portion.

The lower limit of the change rate of the tensile breaking strength in the molded body is 20%, 22%, 24%, 26%, 28%, 30%, 32%, 34%, 36%, 38%, 40%, 42%, 44%, 46%, 48%, 50%, 52%, 54%, 56%, 58%, 60%, 62%, 64%, 66%, 68%, 70%, 72%, 74%, 76% , 78%, 80%, 82%, 84%, 86%, 88%, 90%, 92%, 94%, 96%, or 98%, and the upper limit is 100%, 98%, 96%, 94%, 92%, 90%, 88%, 86%, 84%, 82%, 80%, 78%, 76%, 74%, 72%, 70%, 98%, 66%, 64%, 62% , 60%, 58%, 56%, 54%, 52%, 50%, 48%, 46%, 44%, 42%, 40%, 38%, 36%, 34%, 32%, 30%, 28 %, 26%, 24% or 22%. The rate of change in the tensile breaking strength is greater than or greater than any one of the above-described lower limits, or greater than or greater than any one of the above-described lower limits and less than any one of the above-described upper limits. Or it may be within the following range.

The thickness of the molded body can be adjusted to an appropriate level depending on the purpose, and is not greatly limited. For example, the lower limit of the thickness of the molded body may be about 100 μm, 500 μm, 1,000 μm, 1,500 μm, or 2,000 μm, and the upper limit is 100 mm, 95 mm, 90 mm, 85 mm, 80 mm, 75 mm. mm, 70 mm, 65 mm, 60 mm, 55 mm, 50 mm, 45 mm, 40 mm, 35 mm, 30 mm, 25 mm, 20 mm, 15 mm, 10 mm, 8 mm, 6 mm, 4 mm or It may be around 2 mm. The thickness is above or above any one of the above-described lower limits, below or below any one of the above-described upper limits, or above or above any one of the above-described lower limits while simultaneously being above or above any one of the above-described lower limits. It may be within a range that is below or below any of the upper limits described.

In the molded body, the engraved portion or the anode portion may have a certain level of tensile breaking strength.

For example, the lower limit of the tensile breaking strength of the concave or embossed portion of the molded body is 50 MPa, 52 MPa, 54 MPa, 56 MPa, 58 MPa, 60 MPa, 62 MPa, 64 MPa, 66 MPa, 68 MPa. , 70 MPa, 72 MPa, 74 MPa, 76 MPa, 78 MPa, 80 MPa, 82 MPa or 84 MPa, and the upper limit is 1,000 MPa, 950 MPa, 900 MPa, 850 MPa, 800 MPa, 750 MPa, 700 MPa. MPa, 650 MPa, 600 MPa, 550 MPa, 500 MPa, 450 MPa, 400 MPa, 350 MPa, 300 MPa, 250 MPa, 200 MPa, 150 MPa, 100 MPa or 90 MPa. The tensile breaking strength is in a range that is above or above any one of the above-described lower limits, or is above or above any one of the above-described lower limits and is below or below any one of the above-described upper limits. It may be within.

The molded body can be used for various purposes, examples of which include insulators. An insulating material is a material that can block the spread of heat or flame generated from one point or part to another point or part. The molded body includes pores formed inside, has stable and uniform mechanical properties, and can be stably used as an insulating material.

The insulating material may include at least the plate-shaped molded body described above. The insulation material may be composed of only the plate-shaped molded body, or may include the plate-shaped molded body and other necessary materials.

Information about the plate-shaped molded body included in the insulation material, for example, information about the resin component and filler component, the absolute value of the difference in tensile breaking strength between the engraved portion and the embossed portion, the ratio of change in tensile breaking strength compared to the fabric, The standard deviation of the tensile breaking strength of each of the upper, middle and lower parts obtained by dividing into three parts and the thickness of the plate-shaped molded body can be equally applied to the above-mentioned contents.

The present application also relates to a method of manufacturing the said molded body.

The manufacturing method of the present application may include the step of molding a sheet or film containing the resin component and the filler component to manufacture a molded body having a concavo-convex shape including the intaglio portion and the anode portion.

Pores may be created inside the molded body (particularly at the interface between the resin component and the filler component) by the pressure applied to form the concavo-convex shape.

The sheet or film containing the resin component and filler component may be the fabric described above. Such a fabric can be manufactured by applying a material containing the resin component and filler component to a known molding process, such as an extrusion process. The specific types and mixing ratios of the resin component and filler component used in manufacturing the fabric are the same as those described in the molded article.

This fabric may be in the form of a sheet or film as described above.

In this case, the thickness of the fabric can be adjusted to an appropriate level depending on the purpose, and this is not greatly limited. For example, the lower limit of the thickness of the fabric may be about 100 μm, 500 μm, 1,000 μm, 1,500 μm, or 2,000 μm, and the upper limit is 100 mm, 95 mm, 90 mm, 85 mm, 80 mm, 75 mm. mm, 70 mm, 65 mm, 60 mm, 55 mm, 50 mm, 45 mm, 40 mm, 35 mm, 30 mm, 25 mm, 20 mm, 15 mm, 10 mm, 8 mm, 6 mm, 4 mm or It may be around 2 mm. The thickness is above or above any one of the above-described lower limits, below or below any one of the above-described upper limits, or above or above any one of the above-described lower limits while simultaneously being above or above any one of the above-described lower limits. It may be within a range that is below or below any of the upper limits described.

In this application, a molding step of forming the concavo-convex shape is performed using the fabric.

In the forming step, as shown in FIG. 2, a mold 3000 having an engraving corresponding to the desired concave-convex shape is used. The concave shape of the mold may be determined according to the concavo-convex shape.

In the molding step, the step of placing the fabric 1000 on the upper part of the mold 3000 and applying a suction force (applying a suction force in the L direction in FIG. 2) to the fabric from the lower part of the mold 3000 is performed. You can.

In the forming step, pressure can be applied from the top of the fabric at the same time as applying the suction force as described above (direction U in FIG. 2). The pressure from the top may or may not be applied to the fabric in the molding step, but it is appropriate from the viewpoint of maintaining uniform physical properties of the molded body.

There is no particular limitation on the method of applying force from the top of the fabric 1000.

For example, as shown in FIGS. 3 and 4, the application of pressure from the top can be performed using an additional mold 4000 (hereinafter referred to as a second mold). That is, prepare a second mold 4000 having a positive shape corresponding to the negative engraving of a mold having a negative engraving corresponding to the above-described concavo-convex shape, and as shown in FIGS. 3 and 4, the second mold 4000 The pressure can be applied by moving toward the fabric 1000 and pressing the fabric 1000.

In another example, the application of pressure from the top may be performed by spraying gas from the top of the fabric.

An example of this is shown in Figure 5. As shown in Figure 5, after forming a closed space by covering the cover 5000, etc., the pressure can be applied by gas (U) such as air from the top.

In the molding step, the temperature of the fabric, for example, the surface temperature of the fabric, can be adjusted. Specifically, the temperature of the fabric can be adjusted so that the absolute value of ΔT according to Equation 5 below is within a predetermined range. .

[Equation 5]

△T = 100 × (Ts - Tg)/Tg

In Equation 5, Ts is the surface temperature of the fabric in the molding step, and Tg is the glass transition temperature of the resin component.

For example, the upper limits of the absolute value of △T are 50%, 48%, 46%, 44%, 42%, 40%, 38%, 36%, 34%, 32%, 30%, 28%, 26. %, 24%, or 22%, and the lower limit may be 0%, 5%, 10%, 15%, 20%, 25%, or 30%. ΔT in Equation 5 is greater than or greater than any one of the above-described lower limits, less than or below any of the above-described upper limits, or greater than or equal to any one of the above-described lower limits, or It may be within a range that is both above and below or below any of the above-described upper limits.

The surface temperature (Ts) of the fabric may be higher or lower than the glass transition temperature of the resin component as long as it satisfies the range of the absolute value of ΔT in Equation 5 above.

There is no particular limitation on the method of controlling the surface temperature of the fabric, and for example, it can be adjusted using a known heater such as a ceramic heater or coil heater.

Additionally, when force is applied from the top, the relationship between the suction force applied from the bottom of the fabric and the pressure applied from the top of the fabric can be adjusted in the process.

For example, the suction from the lower part and the application of pressure from the upper part can be controlled so that the absolute value of ΔP according to Equation 6 below is within a predetermined range.

[Equation 6]

△P = 100 Х(P _U - P _L )/P _L

In Equation 6, P _U is the pressure applied to the fabric by the pressure applied from the upper part of the fabric in the forming step, and P _L is the pressure applied to the fabric by suction from the lower part of the fabric.

For example, the upper limit of the absolute value of ΔP in Equation 6 is 100%, 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, It can be around 45%, 40%, 35%, 30%, 25%, 20%, 15% or 5%, with the lower limit being 0%, 5%, 10%, 15%, 20%, 25%, 30%. It could be %, 35%, 40%, 45%, 50%, 55% or 60%. ΔP in Equation 6 is above or above any one of the above-described lower limits, below or below any of the above-described upper limits, or above any one of the above-described lower limits, or It may be within a range that is both above and below or below any of the above-described upper limits.

The pressure P _U in Equation 6 means the net load applied to the fabric when only the suction force is applied, and P _L means the instantaneous load applied to the fabric when only the pressure is applied.

ΔP in Equation 6 may be positive or negative as long as its absolute value satisfies the above range.

In the above, the lower limit of the pressure (P _L in Equation 6) applied to the fabric by suction from the lower part of the fabric is 100 kgf/m ² , 150 kgf/m ² , 200 kgf/m ² , 250 kgf/m ² , 300 kgf/m ² , 350 kgf/m ² , 400 kgf/m ² , 450 kgf/m ² , 500 kgf/m ² , 550 kgf/m ² , 600 kgf/m ² or 650 kgf/m ² There is, and the upper limits are 2,000 kgf/m ² , 1,900 kgf/m ² , 1,800 kgf/m ² , 1,700 kgf/m ² , 1,600 kgf/m ² , 1,500 kgf/m ² , 1,400 kgf/m ² , 1,300 kgf/ m ² , 1,200 kgf/m ² , 1,100 kgf/m ² , 1,000 kgf/m ² , 950 kgf/m ² , 900 kgf/m ² , 850 kgf/m ² , 800 kgf/m ² , 750 kgf/m ² Or it may be around 700 kgf/m ² . is above or above any one of the above-described lower limits, is below or below any one of the above-described upper limits, or is above or above any one of the above-described lower limits while simultaneously being above the above-described upper limit. It may be within a range that is below or below any one of the upper limits.

Through the above process, the molded body of the present application can be manufactured.

In other words, it is possible to manufacture a molded body in which the above-described pores are formed through the above process, and if the above-described fibrous filler is applied in this process, it is possible to manufacture a molded body in which the desired pores are formed more appropriately.

The method of the present application may further include any steps necessary in addition to the above process. For example, in the method, a step of fixing the molded shape through a cooling process or the like may be additionally performed after the forming step.

This application can provide a plate-shaped molded body, a manufacturing method thereof, and a use of the plate-shaped molded body. In this application, it is possible to provide a plate-shaped body containing a resin component and a filler component and having pores formed therein, a method of manufacturing the plate-shaped body, and a use of the plate-shaped body. Additionally, in the present application, it is possible to provide a plate-shaped molded body in which the rigidity obtained through a specific equation is at a level similar to the actual rigidity.

Figure 1 is a diagram for explaining a method of dividing a molded body into three parts.
2 to 5 are diagrams for explaining the manufacturing method of the molded body of the present application.
Figure 6 is a photograph of the molded body manufactured in the manufacturing example.
Figure 7 is a graph showing data on stiffness by porosity according to the content of the filler component according to Experimental Example 1.
Figure 8 is a graph showing N data according to the content of filler components according to Experimental Example 2.

The present application will be described in detail through examples below, but the scope of the present application is not limited by the examples below.

Manufacturing Example 1.

As shown in FIG. 6, a molded body having a concavo-convex shape having an engraved shape 100 and an embossed shape 200 was manufactured. In addition, the pores of the molded body were controlled by maintaining different temperatures on the surface of the fabric using heaters as described below.

The molded body in FIG. 6 is in the form of a rectangular plate, with a horizontal length of about 608 mm, a vertical length of about 308 mm, and a thickness of about 2 mm.

정도이고 고유 강성 값은 약 2.3 GPa이며, 상기 유리 섬유는, 단면의 직경이 약 12.5μm 정도이고, 종횡비가 24 정도였다.First, the fabric was manufactured. The fabric is made by extruding a material in which mPPO (Modified PPO (Polyethylene oxide)), a resin component, and glass fiber (glass fiber), a filler component, are mixed at a weight ratio of 8:2 (mPPO: filler component). It was manufactured to a thickness of about mm. The resin component, mPPO, has a glass transition temperature of about 145

The intrinsic stiffness value was about 2.3 GPa, the cross-sectional diameter of the glass fiber was about 12.5 μm, and the aspect ratio was about 24.

The molded body of Figure 6 was manufactured using the above fabric in the following manner. As shown in FIG. 3, the fabric 1000 was placed on the first mold 3000 in which an intaglio corresponding to the concavo-convex shape of the molded body was formed. Additionally, a second mold 4000 in which an embossed shape corresponding to the concavo-convex shape was formed was placed on the fabric 1000.

Then, the temperature of the surface of the fabric was maintained at an appropriate level using a ceramic heater. The ceramic heater was located inside the temperature increasing equipment, and the temperature was raised to the desired temperature through temperature control of a PLC (Programmable Logic Controller) system while the ceramic heater was placed on top of the fabric. Whether the surface temperature of the fabric was controlled to the desired temperature was confirmed using a non-contact infrared thermometer.

Thereafter, while maintaining the temperature, suction (L) is performed at the lower part of the first mold 3000 as shown in FIG. 3, and at the same time, the second mold 4000 is moved to the lower part to form a mold as shown in FIG. 4. Pressure was applied to the fabric in the form of

In the above process, suction (L) was performed with the gauge of the equipment open to 100%. In this case, based on the rate, the vacuum flow is about 1 atmosphere, and in this case, the instantaneous load applied to the fabric is about 690.2 gf/cm ² (applied load about 1,000 kg). In addition, the pressing force of the second mold 4000 was applied to the fabric at a level of approximately 274.4 gf/cm ² (applied load level of approximately 500 kg).

까지 감온하여 냉각 공정을 수행하였다.The state of the first mold 3000 and the second mold 4000 as shown in FIG. 4 is maintained for about 10 seconds, and the temperature of the molded body (fabric) 1000 is maintained at about 40.

The cooling process was performed by reducing the temperature to .

After the cooling process, the first and second molds 3000 and 4000 were separated, and the molded body was recovered.

Manufacturing example 2.

A molded body having the same shape as that manufactured in Preparation Example 1 was manufactured using the same fabric as Preparation Example 1 in the following manner.

As shown in Figure 5, the fabric 1000 was placed on the first mold 3000 in which an engraving corresponding to the engraved shape of the desired molded body was formed, and a cover 5000 was covered to form a closed space.

Then, the temperature of the surface of the fabric was maintained at an appropriate level using a coil heater. The heater was located inside the temperature increasing equipment, and the temperature was raised to the desired temperature through temperature control of a PLC (Programmable Logic Controller) system while the heater was placed on top of the fabric. Whether the surface temperature of the fabric was controlled to the desired temperature was confirmed using a non-contact infrared thermometer.

Subsequently, suction was performed on the lower part of the first mold 3000, and air pressure was applied on the upper part of the fabric 1000. The suction was performed in the same manner as in Example 1, and the pneumatic pressure was such that the load applied to the fabric was about 548.7 gf/cm ² (applied load about 1,000 kg).

미만까지 감온하여 냉각 공정을 수행하여 성형체를 제조하였다.After maintaining the stage where suction force and pneumatic pressure are applied for about 10 seconds, the temperature is raised to about 40 degrees Celsius.

A molded body was manufactured by reducing the temperature to below and performing a cooling process.

Molded bodies with porosity of 10%, 20%, 30%, 40%, 50%, 60%, 70%, and 80% were manufactured according to Preparation Example 1 or Preparation Example 2, respectively. In this case, where the weight ratio of the resin component and the filler component included in the fabric is 8:2 (resin component: filler component), the filler component accounts for approximately 13% by volume of the total volume of the molded body. At this time, the volume ratio of the filler component can be confirmed using SEM images and an analysis tool (Geodict software, Math2Market).

In addition, in Preparation Example 1 or Preparation Example 2, the weight ratio of the resin component and filler component included in the fabric was changed from 8:2 (resin component:filler component) to 9:1 to increase the porosity to 10 as described above. %, 20%, 30%, 40%, 50%, 60%, 70%, and 80% molded bodies were manufactured, respectively. In this case, where the weight ratio of the resin component and filler component included in the fabric is 9:1 (resin component: filler component), the filler component accounts for approximately 6.5% by volume relative to the total volume of the molded body. At this time, the volume ratio of the filler component can be confirmed using SEM images and an analysis tool (Geodict software, Math2Market).

In addition, in Preparation Example 1 or Preparation Example 2, the weight ratio of the resin component and filler component included in the fabric was changed from 8:2 (resin component:filler component) to 7:3 to increase the porosity to 10 as described above. %, 20%, 30%, 40%, 50%, 60%, 70%, and 80% molded bodies were manufactured, respectively. In this case, where the weight ratio of the resin component and the filler component included in the fabric is 7:3 (resin component: filler component), the filler component accounts for approximately 19% by volume of the total volume of the molded body. At this time, the volume ratio of the filler component can be confirmed using SEM images and an analysis tool (Geodict software, Math2Market).

Measurement Example 1: Porosity

The porosity of the molded body was confirmed using the SEM image obtained in Test Example 1 and an analysis tool (Geodict software, Math2Market). The analysis tool (Geodict software) is software that can identify material properties through multi-scale 2D and 3D image processing, material modeling, visualization, and property analysis. After processing the image, porosity was calculated based on it.

Specifically, the obtained SEM image was input into the analysis tool, and firstly, an appropriate correction filter (Non-local Means Filter) was applied, and secondly, pores, resin components, and filler components were distinguished based on the gray value difference. There are various types of image filters in the Geodict system, including the Non-Local Means Filter applied in the current analysis, Median Filter, Mean Filter, Gauss Filter, Sharpen Filter, Morphological Filter, and H-Minima Transform Filter. There are various filters such as Compute Gradient Filter, Watershed Filter, and User Defined Filter.

In the case of the image filter, the most appropriate filter is applied to the SEM image to clearly determine the division of the image, thereby helping to distinguish components. The Non-Local Means Filter is a filter that is easy to remove noise from SEM images, and is especially easy to distinguish components because it can smoothly blur rough surfaces.

Afterwards, the boundary of the Gray Value value is set to distinguish Matrix (resin component), Pore (pores), and Fiber (filler component). When the SEM image is adjusted with the gray values available in the software, the overall gray value has a value within the range of 0 to 255, and the gray value of the components in the material within the above range is divided.

There may be differences in the resolution of the SEM image and the appropriate Gray Value value for each component, but the results for each applied material are similar. For example, in the case of the molded body manufactured above, the Gray Value of the pore is in the range of about 0 to less than 31, and the Gray Value of the matrix (resin component) is in the range of about 31 to less than 95, The Gray Value of fiber (filler component) is in the range of about 95 or more to 255 or less.

The distribution and porosity of pores can be confirmed through the method described above. Additionally, the distribution and volume ratio of fibers (filler component) can also be confirmed in the same manner as above.

Measurement Example 2: Stiffness

Stiffness was measured at 25°C using a sample of the manufactured molded body or resin component through a stress-strain test method by tension according to the method specified in ASTM D638. The sample was manufactured by cutting the molded body or resin component into a dog bone type with a length of about 7 cm and a width of about 1 cm. When cutting the sample, the molded body was cut so that the MD (Machine Direction) direction was horizontal. The MD direction is a direction based on the extrusion process for manufacturing the fabric. After fixing both ends of the sample with a jig, the rigidity is measured according to ASTM D638. Here, stiffness refers to the elastic modulus (k) value when following Hook's law.

<Measurement conditions for rigidity>

Measuring instrument: UTM (Universal Testing Machine)

Equipment Model: Zwick Roell Z010, Instron (made)

Measuring conditions:

Load cell: 3,000 N

Tensile speed: 50 mm/sec

Experimental Example 1.

The stiffness (G, stiffness) of the molded body manufactured above was measured at 25°C. A graph was created with the vertical axis being the measured stiffness and the horizontal axis being the volume ratio (%) of the filler component to the total volume of the molded body (horizontal axis unit: volume %, vertical axis unit: GPa), and the results shown by porosity are shown in Figure 7 Same as

In Figure 7, when the vertical axis is called the y-axis and the horizontal axis is the x-axis, the trend line of the linear function is drawn as y = 0.2652x-04218 for a molded body with a porosity of 50%. Also, referring to Figure 7, for a molded body with a porosity of 40%, a trend line of a linear function was created as y=0.2982x-0.0985. Also, referring to Figure 7, for a molded body with a porosity of 30%, a trend line of a linear function was created as y=0.3189x+0.4021. Additionally, referring to Figure 7, for a molded body with a porosity of 20%, a trend line of a linear function was created as y=0.3447x+0.8257. Also, referring to Figure 7, for a molded body with a porosity of 10%, a trend line of a linear function was created as y=0.3556x+1.3443.

Experimental Example 2.

The stiffness ratio index at 25°C for the molded body manufactured above was derived using SEM images and an analysis tool (Geodict software, Math2Market), and the results are shown in Figure 8. Referring to FIG. 8, the graph for calculating the index of the stiffness ratio was created as a linear function trend line (horizontal axis unit: volume % of filler component, vertical axis unit: none), and the equation was shown as y=-0.0176x+0.6657.

Example 1.

The target product was manufactured in the same manner as in Preparation Example 1, except that PET (polyethylene terephthalate, intrinsic stiffness value: about 2.95 GPa) was used as the resin component instead of mPPO and the porosity was controlled to be about 30% (filler Ingredients: approximately 13% by volume) to prepare a molded body.

In the graph of FIG. 7 obtained in the above-described Experimental Example 1, the first-order function with a porosity of 30% is selected, the content ratio of the filler component in this function is 13% by volume, and the stiffness when mPPO is selected as the resin component was obtained. Specifically, referring to FIG. 7, the first-order function with a porosity of 30% is y = 0.3189x + 0.4021, and by substituting 13 volume% for the x value, a stiffness of 4.5478 GPa was obtained as the y value. That is, in Equation 3 below, a is 0.3189, b is 0.4021, and G _X according to Equation 3 is 4.5478.

[Equation 3]

_G

From the function shown in the graph of FIG. 8 obtained in Experimental Example 2 described above, the value of the constant N when the content ratio of the filler component was 13% by volume was obtained. Specifically, referring to FIG. 8, the function is y=-0.0176x+0.6657, and by substituting 13 volume% for the x value, the y value of about 0.4369 was obtained. That is, in Equation 4 below, c is -0.0176, d is 0.6657, and N according to Equation 4 is 0.4369.

[Equation 4]

N = c × F + d

In Equation 2 below, _{G In} addition, _M Accordingly, the calculated G _Y is about 5.070 GPa.

[Equation 2]

_{G Y = G} ^​

The stiffness of the molded body manufactured by applying PET as the resin component was found to be within about 10% of the difference when compared to the stiffness obtained according to Equation 2 above.

Example 2.

The target product was prepared in the same manner as in Preparation Example 1, except that PET (polyethylene terephthalate, intrinsic stiffness value: about 2.95 GPa) was used as the resin component instead of mPPO and the porosity was controlled to be about 10% (filler Ingredients: approximately 13% by volume) to prepare a molded body.

In the graph of FIG. 7 obtained in the above-described Experimental Example 1, the first-order function with a porosity of 10% is selected, and the content ratio of the filler component in this function is 13% by volume, and the stiffness when mPPO is selected as the resin component was obtained. Specifically, referring to FIG. 7, the first-order function with a porosity of 10% is y = 0.3556x + 0.13443, and by substituting 13 volume% for the x value, a stiffness of 4.7572 GPa was obtained as the y value. That is, in Equation 3 below, a is 0.3556, b is 1.3443, and G _X according to Equation 3 is 4.7572.

[Equation 3]

_G

From the function shown in the graph of FIG. 8 obtained in Experimental Example 2 described above, the value of the constant N when the content ratio of the filler component was 13% by volume was obtained. Specifically, referring to FIG. 8, the function is y=-0.0176x+0.6657, and by substituting 13 volume% for the x value, the y value of about 0.4369 was obtained. That is, in Equation 4 below, c is -0.0176, d is 0.6657, and N according to Equation 4 is 0.4369.

[Equation 4]

N = c × F + d

In Equation 2 below, _{G In} addition, _M Accordingly, the calculated G _Y is about 5.304 GPa.

[Equation 2]

_{G Y = G} ^​

The stiffness of the molded body manufactured by applying PET as the resin component was found to be within about 10% of the difference when compared to the stiffness obtained according to Equation 2 above.

Example 3.

The target product was manufactured in the same manner as in Preparation Example 1, except that PET (polyethylene terephthalate, intrinsic stiffness value: about 2.95 GPa) was used as the resin component instead of mPPO and the porosity was controlled to be about 50% (filler Ingredients: approximately 13% by volume) to prepare a molded body.

In the graph of FIG. 7 obtained in the above-described Experimental Example 1, the first-order function with a porosity of 50% is selected, the content ratio of the filler component in this function is 13% by volume, and the stiffness when mPPO is selected as the resin component was obtained. Specifically, referring to FIG. 7, the first-order function with a porosity of 50% is y=0.2652x-0.4218, and by substituting 13 volume% for the x value, a stiffness of 3.0258 GPa was obtained as the y value. That is, in Equation 3 below, a is 0.2652, b is -0.4218, and G _X according to Equation 3 is 3.0258.

[Equation 3]

_G

From the function shown in the graph of FIG. 8 obtained in the above-described Experimental Example 2, the value of the constant N when the content ratio of the filler component was 13% by volume was obtained. Specifically, referring to FIG. 8, the function is y=-0.0176x+0.6657, and by substituting 13 volume% for the x value, the y value of about 0.4369 was obtained. That is, in Equation 4 below, c is -0.0176, d is 0.6657, and N according to Equation 4 is 0.4369.

[Equation 4]

N = c × F + d

In Equation 2 below, _{G In} addition, _M Accordingly, the calculated G _Y is approximately 3.3734 GPa.

[Equation 2]

_{G Y = G} ^​

The stiffness of the molded body manufactured by applying PET as the resin component was found to be within about 10% of the difference when compared to the stiffness obtained according to Equation 2 above.

Example 4.

For the target product, in Preparation Example 1, PET (polyethylene terephthalate, intrinsic stiffness value: about 2.95 GPa) was used as the resin component instead of mPPO, the porosity was controlled to be about 30%, and the weight ratio of the resin component and the filler component was 9: A molded body was manufactured in the same manner as Preparation Example 1 (filler component: about 6.5% by volume) except that it was changed to 1 (resin component: filler component).

In the graph of FIG. 7 obtained in the above-described Experimental Example 1, the first-order function with a porosity of 30% is selected, and the content ratio of the filler component in this function is 6.5% by volume, and the stiffness when mPPO is selected as the resin component was obtained. Specifically, referring to FIG. 7, the first-order function with a porosity of 30% is y = 0.3189x + 0.4021, and by substituting 6.5 volume% for the x value, a stiffness of 2.4750 GPa was obtained as the y value. That is, in Equation 3 below, a is 0.3189, b is 0.4021, and G _X according to Equation 3 is 2.4750.

[Equation 3]

_G

From the function shown in the graph of FIG. 8 obtained in Experimental Example 2 described above, the value of the constant N when the content ratio of the filler component was 6.5% by volume was obtained. Specifically, referring to FIG. 8, the function is y=-0.0176x+0.6657, and by substituting 6.5 volume% for the x value, the y value of about 0.7801 was obtained. That is, in Equation 4 below, c is -0.0176, d is 0.6657, and N according to Equation 4 is 0.7801.

[Equation 4]

N = c × F + d

In Equation 2 below, _{G In} addition, _M Accordingly, the calculated G _Y is approximately 3.005 GPa.

[Equation 2]

_{G Y = G} ^​

The stiffness of the molded body manufactured by applying PET as the resin component was found to be within about 10% of the difference when compared to the stiffness obtained according to Equation 2 above.

Example 5.

For the target product, in Preparation Example 1, PET (polyethylene terephthalate, intrinsic stiffness value: about 2.95 GPa) was used as the resin component instead of mPPO, the porosity was controlled to be about 30%, and the weight ratio of the resin component and the filler component was 7: A molded body was manufactured in the same manner as Preparation Example 1 (filler component: about 19% by volume) except for the change to 3 (resin component: filler component).

In the graph of FIG. 7 obtained in the above-described Experimental Example 1, the first-order function with a porosity of 30% is selected, and the content ratio of the filler component in this function is 19% by volume, and the stiffness when mPPO is selected as the resin component was obtained. Specifically, referring to FIG. 7, the first-order function with a porosity of 30% is y=0.3189x+0.4021, and by substituting 19 volume% for the x value, a stiffness of 6.4612 GPa was obtained as the y value. That is, in Equation 3 below, a is 0.3189, b is 0.4021, and G _X according to Equation 3 is 6.4612.

[Equation 3]

_G

From the function shown in the graph of FIG. 8 obtained in Experimental Example 2 described above, the value of the constant N when the content ratio of the filler component was 19% by volume was obtained. Specifically, referring to FIG. 8, the function is y=-0.0176x+0.6657, and by substituting 19 volume% for the x value, the y value of about 0.3313 was obtained. That is, in Equation 4 below, c is -0.0176, d is 0.6657, and N according to Equation 4 is 0.3313.

[Equation 4]

N = c × F + d

In Equation 2 below, _{G In} addition, _M Accordingly, the calculated G _Y is about 7.0165 GPa.

[Equation 2]

_{G Y = G} ^​

The stiffness of the molded body manufactured by applying PET as the resin component was found to be within about 10% of the difference when compared to the stiffness obtained according to Equation 2 above.

Example 6.

The target product was manufactured in the same manner as Preparation Example 1 (filler Ingredients: approximately 13% by volume) to prepare a molded body.

G _Y in Equation 2 calculated in the same manner as Example 1 for the manufactured molded body is about 4.956 GPa. The stiffness of the molded body manufactured by applying PA6 as the resin component was found to be within about 10% of the difference when compared to the stiffness obtained according to Equation 2 above.

Example 7.

The target product was prepared in the same manner as Preparation Example 1 (filler component) except that PI (polyimide, intrinsic stiffness value: about 2.43 GPa) was used instead of mPPO as the resin component in Example 1 and the porosity was controlled to be about 30%. : Approximately 13% by volume) to produce a molded body.

G _Y in Equation 2 calculated in the same manner as in Example 1 for the manufactured molded body is about 4.658 GPa. The stiffness of the molded body manufactured by applying PI as the resin component was found to be within about 10% of the difference when compared to the stiffness obtained according to Equation 2 above.

Example 8.

The target product was prepared in the same manner as Preparation Example 1 (filler component) except that PC (polycarbonate, intrinsic stiffness value: about 2.3 GPa) was used instead of mPPO as the resin component in Example 1 and the porosity was controlled to be about 30%. : Approximately 13% by volume) to produce a molded body.

G _Y in Equation 2 calculated in the same manner as Example 1 for the manufactured molded body is about 4.548 GPa. When compared to the rigidity obtained according to Equation 2 above, the difference in rigidity of the molded body manufactured by applying PC as the resin component was found to be within about 10%.

Example 9.

The target product was prepared in the same manner as Preparation Example 1 except that PP (polypropylene, intrinsic stiffness value: about 1.95 GPa) was used instead of mPPO as the resin component in Example 1 and the porosity was controlled to be about 30% (filler component) : Approximately 13% by volume) to produce a molded body.

G _Y in Equation 2 calculated in the same manner as Example 1 for the manufactured molded body is about 4.231 GPa. The stiffness of the molded body manufactured by applying PP as the resin component was found to be within about 10% of the difference when compared to the stiffness obtained according to Equation 2 above.

Example 10.

The target product was produced in the same manner as Preparation Example 1, except that ABS (acrylonitrile butadiene styrene copolymer, intrinsic stiffness value: about 1.22 GPa) was used as the resin component instead of mPPO and the porosity was controlled to be about 30%. A molded body was manufactured with (filler ingredient: about 13% by volume).

G _Y in Equation 2 calculated in the same manner as Example 1 for the manufactured molded body is about 3.447 GPa. When compared to the rigidity obtained according to Equation 2 above, the difference in rigidity of the molded body manufactured by applying ABS as the resin component was found to be within about 10%.

Claims (20)

Contains resin ingredients and filler ingredients
Pores are formed inside,
A plate-shaped molded body whose stiffness (G) measured according to ASTM D638 satisfies the relationship of Equation 1 below:
[Equation 1]
0.8×G _Y ≤ G ≤ 1.2×G _Y
In Equation 1, G _Y is expressed as Equation 2 below,
[Equation 2]
_{G Y = G} ^​
_In Equation 2 _{, G}
[Equation 3]
_G
In Equation 3, a is an arbitrary number in the range of 0.15 to 0.5, b is an arbitrary number in the range of -1 to 2, and F refers to the content volume ratio (vol%) of the filler component compared to the total volume,
[Equation 4]
N = c × F + d
In Equation 4, c is an arbitrary number in the range of -0.1 to 0.1, d is an arbitrary number in the range of -1 to 1, and F refers to the content volume ratio (vol%) of the filler component compared to the total volume. . The plate-shaped molded body according to claim 1, wherein an uneven shape including an embossed portion and an engraved portion is formed. The plate-shaped molded body according to claim 1, wherein the pores are formed at the interface between the resin component and the filler component. The plate-shaped molded body according to claim 1, wherein the porosity of the plate-shaped molded body is in the range of 10% to 60%. The plate-shaped molded body according to claim 2, wherein the absolute value of the difference between the tensile breaking strength of the embossed portion and the tensile breaking strength of the engraved portion is 10% or less. The plate-shaped molded body according to claim 2, wherein the rate of change in tensile breaking strength of the embossed portion or the engraved portion is 80% or more. The method of claim 1, having sides formed in a first direction,
A plate-shaped molded body having a standard deviation of tensile strength at break of 100 or less for each of the upper, middle, and lower ends obtained by dividing it into three parts in the direction perpendicular to the side in the one direction. The plate-shaped molded body according to claim 1, wherein the resin component is a thermoplastic polymer. The plate-shaped molded body according to claim 1, wherein the filler component includes a fibrous filler. The plate-shaped molded body according to claim 9, wherein the fibrous filler has an aspect ratio in the range of 3 to 60. The plate-shaped molded body according to claim 10, wherein the fibrous filler has a cross-sectional diameter in the range of 1 ㎛ to 100 ㎛. The plate-shaped molded body according to claim 1, wherein the plate-shaped molded body contains a filler component in the range of 1 to 100 parts by weight based on 100 parts by weight of the resin component. The plate-shaped molded body according to claim 1, wherein the plate-shaped molded body has a thickness in the range of 100 ㎛ to 100 mm. A method of manufacturing a plate-shaped molded body by molding a fabric containing a resin component and a filler component and forming pores inside,
The plate-shaped molded body is a method of manufacturing a plate-shaped molded body whose stiffness (G) measured according to ASTM D638 satisfies the relationship of Equation 1 below:
[Equation 1]
0.8×G _Y ≤ G ≤ 1.2×G _Y
In Equation 1, G _Y is expressed as Equation 2 below,
[Equation 2]
_{G Y = G} ^​
_In Equation 2 _{, G}
[Equation 3]
_G
In Equation 3, a is an arbitrary number in the range of 0.15 to 0.5, b is an arbitrary number in the range of -1 to 2, and F refers to the content volume ratio (vol%) of the filler component compared to the total volume,
[Equation 4]
N = c × F + d
In Equation 4, c is an arbitrary number in the range of -0.1 to 0.1, d is an arbitrary number in the range of -1 to 1, and F refers to the content volume ratio (vol%) of the filler component compared to the total volume. . According to clause 14,
A molding step of manufacturing a plate-shaped molded body having a concavo-convex shape including embossed portions and engraved portions, placing the fabric on the intaglio of a mold having a concavo-convex shape corresponding to the concave-convex shape, and suctioning the fabric from the lower part of the mold. A method of manufacturing a plate-shaped molded body comprising. The method of claim 15, wherein pressure is applied from the top of the fabric while sucking the fabric from the bottom of the mold. The method of claim 16, wherein the pressure is applied by spraying gas from the top of the fabric. The method of claim 16, wherein the application of pressure is performed by pressing the fabric into the embossed shape of a second mold (male tool) having an embossed shape corresponding to the intaglio of the mold. The method of claim 15, wherein in the molding step, the temperature of the fabric is maintained such that the absolute value of △T according to Equation 5 below is 5% or more:
[Equation 5]
△T = 100 × (Ts-Tg)/Tg
In Equation 5, Ts is the surface temperature of the fabric in the molding step, and Tg is the glass transition temperature of the resin component. The method of claim 15, wherein the suction from the bottom and the application of pressure from the top are performed so that the absolute value of ΔP according to Equation 6 below is 5% or less,
Method for producing a plate-shaped molded body in which the pressure applied to the fabric by the suction force applied from the lower part of the fabric is in the range of 100 gf/cm ² to 2,000 gf/cm ² :
[Equation 6]
△P = 100 × (P _U -P _L )/P _L
In Equation 6, P _U is the pressure applied to the fabric by the pressure applied from the upper part of the fabric in the forming step, and P _L is the pressure applied to the fabric by suction from the lower part of the fabric.