TWI690549B - 樹脂成形品及樹脂成形品之製造方法 - Google Patents

樹脂成形品及樹脂成形品之製造方法 Download PDF

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TWI690549B
TWI690549B TW105131467A TW105131467A TWI690549B TW I690549 B TWI690549 B TW I690549B TW 105131467 A TW105131467 A TW 105131467A TW 105131467 A TW105131467 A TW 105131467A TW I690549 B TWI690549 B TW I690549B
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resin
skin material
adhesive layer
molded body
acrylic
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TW105131467A
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TW201730249A (zh
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鈴木正人
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日商天昇電氣工業股份有限公司
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Abstract

本發明提供一種確保纖維混練所產生之強度、剛性、輕量化等特長，並且表面之平滑化、外觀之美觀度等表面性狀優異，同時耐候性、耐紫外線性、耐光性亦優異之樹脂成形品。
該樹脂成形品10之構成為於由碳纖維、玻璃纖維、或該等之複合纖維所構成之纖維基材之成形體1貼合有具有接著層2之樹脂表皮材3，於製造該樹脂成形品時，將混合纖維與樹脂而成之成形體載置於支承治具23後，將具有接著層之樹脂表皮材以使該表皮材之接著層向下之方式配置於該成形體之上方，使成形體及樹脂表皮材之周圍成為負壓狀態，並且加熱樹脂表皮材，使支承治具上升而使成形體密接於已軟化之樹脂表皮材，使支承治具之上方區域成為加壓狀態後，開放支承治具之周圍，取出被覆有樹脂表皮材之成形體。

Description

樹脂成形品及樹脂成形品之製造方法
本發明係關於一種樹脂成形品及樹脂成形品之製造方法以及樹脂成形品之製造裝置。
習知已知有將「混練纖維材料與樹脂材料而成之素材」成形為所期望之形狀而成之成形品，例如，將碳纖維用作纖維材料之纖維強化塑膠為其一例，與金屬製者相比，強度或剛性優異且輕量，腐蝕亦較少，因此用作各種量產構造零件。又，著眼於其量產性，除用於汽車之內裝品或外裝品以外，還用於家電製品、體育用品等多種用途。
又，作為對此種纖維強化塑膠零件實施塗裝而製品化之技術，揭示有專利文獻1所示之塗膜形成方法及塗裝物品，其構成為：以於正發射光方向呈金屬光澤，且於除此以外之方向呈碳纖維強化塑膠之消光之素材感之方式規定光反射性顏料之膜厚及平行光線透過率。
專利文獻2之汽車用外裝品係藉由添加碳黑及塑膠製染料作為著色劑，除使用PC及PBT以外，還使用將丙烯腈-苯乙烯樹脂以數~ 數十重量%之比率混練而聚合物合金化之樹脂材料，從而即便無塗裝亦可獲得深邃感或表面硬度。又，亦揭示有可使汽車之內裝零件簡單地實現發光功能之汽車用功能零件(專利文獻3)、不使用黑色塗料而具備與習知同等之美觀性或耐化學品性等之低亮度色塗裝之汽車車體及汽車零件(專利文獻4)。進而，如專利文獻5~7所示，亦已揭示有使加飾膜或片狀材料覆著於覆著體之真空成形方法及真空成形機。
[先前技術文獻]
[專利文獻]
[專利文獻1]日本特開2012-200681號公報
[專利文獻2]日本特開平11-106518號公報
[專利文獻3]國際公開WO2013/022027號公報
[專利文獻4]日本特開平5-293434號公報
[專利文獻5]日本特開2015-44285號公報
[專利文獻6]日本特開2012-116094公報
[專利文獻7]日本特開2012-96416公報
將纖維混練而成之成形品雖如上所述具有強度或剛性優異、且輕量之優點，但有如下之不良情況：由於纖維質之部分會顯露於表面，因此成形品之表面必定會成為粗面，而成為具有凹凸之表面。因此， 視成形品之用途，必須於後續步驟實施塗裝，或由熟練作業者反覆進行塗裝與表面研磨而進行平滑化。如此一來，習知之纖維強化成形品存在如下問題：後續步驟之表面處理費力而變得高價，並且由於進行塗裝與研磨作業之熟練職人之個人差異而會使表面平滑化之品質產生差異。又，特別於將碳纖維之成形品用於室外之情形時，要求耐候性及耐紫外線性。
本發明之目的在於提供一種確保纖維混練所產生之強度、剛性、輕量化等特長，並且表面之平滑化、外觀之美觀度等表面性狀優異，同時耐候性、耐紫外線性、耐光性亦優異的樹脂成形品。
又，本發明之目的在於提供可實現以纖維素材為基體之成形體之表面處理之容易化、步驟數之削減、表面平滑化等表面性狀之均勻化的樹脂成形品之製造方法及製造裝置。
本發明之樹脂成形品係於由碳纖維、玻璃纖維、或該等之複合纖維所構成之纖維基材之成形體貼合具有接著層之樹脂表皮材而成者。
根據本發明之一形態，其特徵在於：上述成形體係於上述纖維基材成形ABS、聚碳酸酯、丙烯酸、尼龍之至少任一者作為結合劑而成。
又，根據本發明之另一形態，其特徵在於：上述樹脂表皮材於樹脂膜之下側附著有接著層，且於上述成形體之表面形成有加飾層。
根據本發明之進而另一形態，其特徵在於：上述樹脂表皮材於樹脂膜之下側附著有接著層，且於上述樹脂膜與上述接著層之間介隔有加飾層。
根據本發明之進而另一形態，其特徵在於：上述樹脂表皮材 係對上述樹脂膜之下表面進行蝕刻後，附著接著層而成。
根據本發明之進而另一形態，其特徵在於：上述樹脂表皮材為丙烯酸材料、聚碳酸酯材料、ABS材料、PET材料、氯乙烯材料、聚胺酯(polyurethane)材料、及聚丙烯材料之至少任一者。
根據本發明之進而另一形態，其特徵在於：上述樹脂表皮材之厚度為0.1~0.5mm。
本發明之樹脂成形品之製造方法之特徵在於：將由碳纖維、玻璃纖維、或該等之複合纖維所構成之纖維基材之成形體載置於支承治具後，將具有接著層之樹脂表皮材以使該表皮材之上述接著層向下之方式配置於上述成形體之上方，使上述成形體及上述樹脂表皮材之周圍成為負壓狀態，並且對上述樹脂表皮材進行加熱，使上述支承治具上升而使上述成形體密接於已軟化之上述樹脂表皮材，進而，使上述支承治具之上方區域成為加壓狀態後，開放上述支承治具之周圍，取出被覆有樹脂表皮材之成形體。
根據本發明之樹脂成形品之製造方法之一形態，其特徵在於：上述樹脂表皮材於樹脂膜之下側附著有接著層，且於上述成形體之表面形成有加飾層。
根據本發明之樹脂成形品之製造方法之另一形態，其特徵在於：上述樹脂表皮材於樹脂膜之下側附著有接著層，且於上述樹脂膜與上述接著層之間介隔有加飾層。
根據本發明之樹脂成形品之製造方法之進而另一形態，其特徵在於：上述樹脂表皮材係對上述樹脂膜之下表面進行蝕刻後，附著接著 層而成。
根據本發明之樹脂成形品之製造方法之進而另一形態，其特徵在於：上述樹脂表皮材係丙烯酸材料、聚碳酸酯材料、ABS材料、PET材料、氯乙烯材料、聚胺酯材料、聚丙烯材料之至少任一者。
根據本發明之樹脂成形品之製造方法之進而另一形態，其特徵在於：上述樹脂表皮材之厚度為0.1~0.5mm。
根據本發明之樹脂成形品之製造方法之進而另一形態，其特徵在於：上述成形體係於上述纖維基材成形ABS、聚碳酸酯、丙烯酸、尼龍作為結合劑而成。
本發明之樹脂成形品之製造裝置包含：下腔盒，其對於纖維成形體之支承治具以可使其上下移動之方式來收容；上腔盒，其內設加熱器，且可相對於上述下腔盒來進行上下移動；樹脂表皮材，其張設於上述上下腔盒之間；負壓施壓手段，其與上述上下腔盒內連通；空壓施壓手段，其與上述上腔盒內連通；以及上述支承治具之上下移動驅動裝置及上述上腔盒之上下移動驅動裝置；且上述樹脂成形品之製造裝置係以如下方式構成：利用藉由上述下腔盒之上升而實現之上述支承治具上之上述成形體向上述樹脂表皮材的按壓、上述負壓施壓手段及上述空壓施壓手段之施壓、消壓、以及上述加熱器之加熱，來使上述樹脂表皮材覆著於上述成形體。
根據本發明，可獲得確保纖維混練所產生之強度、剛性、輕量化等特長，並且表面之平滑化、外觀之美觀度等表面性狀優異，同時耐候性、耐紫外線性、耐光性亦優異的樹脂成形品。又，可獲得實現以纖維 素材為基體之成形體之表面處理之容易化、步驟數之削減、表面平滑化等表面性狀之均勻化的樹脂成形品之製造方法及製造裝置。
1‧‧‧成形體
2‧‧‧接著層
3、29‧‧‧樹脂表皮膜(透明樹脂膜)
4‧‧‧加飾層
5‧‧‧蝕刻
10‧‧‧樹脂成形品
20‧‧‧樹脂成形品之製造裝置
21‧‧‧下腔盒
22‧‧‧上腔盒
23‧‧‧支承治具
24、31‧‧‧上下移動驅動裝置
26‧‧‧真空罐
27‧‧‧切換閥
28‧‧‧保持框
30‧‧‧加熱器
32‧‧‧壓空罐
33‧‧‧切割器
41‧‧‧乘坐車之保險桿
42‧‧‧側鏡
50‧‧‧高爾夫球桿
圖1係本發明之實施例之樹脂成形品之放大剖視圖。
圖2係本發明之另一實施例之樹脂成形品之放大剖視圖。
圖3係本發明之進而另一實施例之樹脂成形品之放大剖視圖。
圖4係本發明之進而另一實施例之樹脂成形品之放大剖視圖。
圖5係本發明之實施例之樹脂成形品之製造裝置之縱剖視圖。
圖6係表示本發明之實施例之樹脂成形品之製造步驟之前段部分之概略圖。
圖7係表示圖6所示之樹脂成形品之製造步驟之後段部分之概略圖。
圖8係表示本發明之樹脂成形品之使用例之立體圖。
圖9係表示本發明之樹脂成形品之另一使用例之立體圖。
其次，一面參照圖式，一面以各種實施例對本發明進行說明。
圖1~圖4表示本發明之各種實施例之樹脂成形品10，圖1之實施例係如下之例：於將由碳纖維、玻璃纖維、或該等之複合纖維所構成之纖維基材與結合劑混合成形所得之成形體1之上表面，經由接著層2貼合樹脂表皮膜、例如透明樹脂膜3而成為樹脂成形品10。混合有纖維材料之成形體 1雖然其表面由於纖維成分而成為凹凸面，但藉由於該凹凸表面貼合樹脂膜3而獲得平滑之表面，作為汽車之內裝品或保險桿等外裝品，無須進行塗裝或表面研磨即可製成美觀之內外裝品。而且，將纖維素材與樹脂素材混合成形而成之成形體富有強度及剛性，又輕量，且量產性亦優異。
作為纖維基材之成形體之成形方法，可列舉如上述般將纖維基材與用作黏合劑之結合劑混合成形之方法，除此以外，可列舉如下等各種成形方法：將纖維素材進行梭織或編織等而成形；於將纖維素材梭織形成之纖維基材裹繞結合劑而成形；於將纖維素材編織形成之纖維基材裹繞結合劑而成形；進而是，將纖維基材以如上述之各種方法成形後，於表面實施基底塗裝；進而是，將纖維基材以如上述之各種方法成形後，於表面實施基底塗裝，且進一步對表面進行擦光；纖維基材之成形體之成形方法並無限定。又，作為樹脂表皮膜，可列舉可貼合於纖維基材之成形體之各種合成樹脂片材。作為一例之透明樹脂膜3，藉由使用丙烯酸材料，而使耐候性、耐紫外線性良好，又，若為PC材料、ABS材料之膜，則成形性良好從而可實現量產，其等可視用途而適當選擇。作為接著層，較佳為丙烯酸系接著劑。又，含有接著層之樹脂表皮膜(透明樹脂膜3)的適當厚度t為0.1~0.5mm，亦可視成形品之使用場所等用途而任意決定。成形體1、接著層2、樹脂表皮膜3之各構成於以下實施例中亦相同。再者，此處，作為上述樹脂表皮膜，除可採用丙烯酸材料、PC材料、ABS材料以外，PET材料、氯乙烯材料、聚胺酯材料、聚丙烯材料亦為可採用之一例。又，作為結合劑，ABS、聚碳酸酯、丙烯酸、尼龍為可採用之材料之例。然而，樹脂表皮膜之材料質並不限定於該等，只要為於下述貼合步驟中可貼合於成形體之 樹脂片材即可，結合劑並不限定於此，只要為足以成形纖維基材之材料即可。
圖2所示之實施例之樹脂成形品10中，於藉由纖維基材與樹脂材料之混合成形而成之成形體1之表面，藉由印刷手段等而形成文字、圖形等加飾層4，於包含該加飾層4之成形體1之表面附著有接著層2，進而，於接著層2之上表面貼合有透明膜3。藉由以丙烯酸系接著劑構成接著層2，可自透明膜3之外表面目測到成形體之加飾層4。
圖3之實施例之樹脂成形品10中，於成形體1之上表面附著有接著層2，且透明膜3係以於該接著層2與透明膜3之間介隔有加飾層4之形態貼合於下側之接著層2。成形體1之表面之凹凸係藉由透明膜3而被平滑化，且與圖2之實施例同樣可自透明膜3之外表面目視到加飾層4。
圖4所例示之樹脂成形品10中，於樹脂膜之下表面實施有蝕刻5，該實施有蝕刻之面係經由接著層2而貼合於成形體1之上表面。藉由使樹脂膜為透明膜，且以所期望之圖案形成蝕刻，而可自透明膜3之外表面目視到蝕刻作為加飾之面。又，藉由蝕刻而使與接著層2之結合變得更確實，從而成為表面性狀牢固之樹脂成形品10。
其次，參照圖5~圖7對本發明之樹脂成形品之製造裝置及製造方法進行說明。參照圖5，本實施例之樹脂成形品之製造裝置20含有可上下分離之下腔盒21與上腔盒22。於下腔盒21內，可上下移動地配置有載置由上述碳纖維、玻璃纖維、或該等之複合纖維所構成之纖維基材之成形體1(以假想線表示)之支承治具23。具體而言，於下腔盒21之下側設置有上下移動驅動裝置24，該驅動裝置24之動作桿24a插入下腔盒21 內，支承治具23之支持平台25連結於動作桿24a。於下腔盒21連結有進行真空抽吸之裝置、例如真空罐26。真空罐26係經由切換閥27而亦與上腔盒22連通。又，於下腔盒21之上端設置有膜保持框28，於該保持框28可交換地安裝有圖1~圖4所說明之由樹脂膜(透明膜)、接著層、加飾層等所構成之樹脂表皮膜29，於將樹脂表皮膜29安裝於下腔盒21之上端開口部之狀態下，該盒內係保持為密閉狀態。
於相對於下腔盒21上升、下降之上腔盒22內，在其上部部位配置有加熱器30。於上腔盒22之上方位置設置有上下移動驅動裝置31，該動作桿31a係連結於上腔盒22之上表面。又，於上腔盒22，經由切換閥27而連結有用以使該腔盒內成為加壓狀態之加壓裝置、例如壓空罐32。於使上腔盒22下降而與安裝有樹脂表皮膜29之下腔盒21接合之狀態下，上下腔盒22、21內係保持為密閉狀態。
參照圖6、圖7，對藉由成為上述構成之樹脂成形品之製造裝置而製造本發明之樹脂成形品之方法進行說明。首先，如圖6(a)所示，藉由驅動裝置31使上腔盒22上升，而將作為對象製品之將纖維基材混合成形而成之成形體1載置於下腔盒21內之支承治具23上，並且將所期望之樹脂表皮膜29設置於下腔盒上端之樹脂表皮膜之保持框28。於該狀態下，下腔盒21內成為密閉狀態。樹脂表皮膜29係根據對象製品之種類、用途等而選定如圖1~圖4所說明之由透明膜及接著層所構成之表皮膜、由透明膜、加飾層、及接著層所構成之表皮膜、或於下表面實施有蝕刻之由透明膜及接著層所構成之表皮膜。再者，樹脂表皮膜29係以其接著層向下、即與支承治具23上之成形體1相對之朝向設置於保持框28。
其次，如圖6(b)所示，藉由驅動裝置31使上腔盒22下降而使其與下腔盒21接合，並且如圖6(c)所示，操作切換閥27而藉由真空抽吸裝置(真空罐26)對上下腔盒22、21內進行真空抽吸，使其等成為負壓狀態。又，同時對加熱器30賦能而加熱盒內之樹脂表皮膜29，使表皮膜軟化。圖6(c)中樹脂表皮膜29略向支承治具23側下垂係表示表皮膜因該加熱器30之加熱而軟化。
其次，如圖6(d)所示，藉由驅動裝置24而使支承治具23上升，將支承治具23上之成形體1按壓於已軟化之樹脂表皮膜29，將樹脂表皮膜29貼合於成形體1。
其後，於使上腔盒22內之加熱器30運行之狀態下，使上腔盒22內自負壓狀態成為大氣開放或空壓狀態而進一步促進樹脂表皮膜29向成形體表面之貼合。圖6(e)為使上腔盒22內大氣開放之情形，圖6(f)為藉由空壓裝置及壓空罐32而使上腔盒22內成為空壓狀態之情形，可採用任一者作為製造步驟，於視對象製品而需要更強之膜貼合之情形時採用圖6(f)之附加空壓形態。其後，如圖7(a)所示，解除空壓及真空抽吸，並且使上腔盒22上升而自支承治具23取出貼合有表皮膜29之樹脂成形品。於該狀態下，樹脂表皮膜29之周緣部自成形體1略微伸出，因此如圖7(b)所示，進行藉由切割器33而將自成形體1伸出之樹脂表皮膜29之部分切斷之修整加工，從而完成樹脂成形品10。再者，於樹脂成形品之樹脂表皮膜未伸出之情形時，當然亦可省略圖7(b)之修整加工。
本發明之實施例之實施有表面處理之樹脂成形品富有強度、剛性，且輕量，具有耐候性、耐紫外線性、表面凹凸之平滑化及美麗 之外觀性，因此可用於各種場所。圖8係應用於乘坐車之保險桿41及側鏡42之背部保持構件42a之例。可提供如下之汽車零件：藉由對現有之汽車進行簡單之施工便可替換為本實施例之樹脂成形品，而且於強度等方面可充分滿足功能，進而，呈現充分之美觀。此外，亦可應用於車輛之內裝品、例如駕駛席前表面之儀錶板、把手部分等各種汽車零件。又，亦可應用於例如釣竿、高爾夫用具、球技用球拍、登山用具、或作為護理用具之手杖、動力服、步行訓練機材等。圖9係於高爾夫球桿50之部分使用本發明之樹脂成形品10之例，可實現滿足既有之高爾夫球桿所要求之性能並且外觀亦優異之高爾夫球桿。本發明之樹脂成形品不限定於上述2個使用例，可應用於各種日常零件或構造零件，其應用範圍廣泛。
1:成形體
2:接著層
3:樹脂表皮膜(透明樹脂膜)
10:樹脂成形品
t:樹脂表皮膜(透明樹脂膜)之厚度

Claims (7)

  1. 一種樹脂成形品，其係於在由碳纖維、玻璃纖維、或該等之複合纖維所構成之纖維基材成形ABS、聚碳酸酯、丙烯酸、尼龍之至少任一者作為結合劑而成之車輛之內外裝品成形體貼合樹脂表皮材而成；上述樹脂表皮材具有由丙烯酸系接著劑所構成之接著層、及樹脂膜，且係由丙烯酸材料、PC材料或ABS材料之至少任一者所構成，厚度為0.1~0.5mm，且，於樹脂膜之下側附著有接著層，且於上述成形體之表面形成有加飾層。
  2. 一種樹脂成形品，其係於在由碳纖維、玻璃纖維、或該等之複合纖維所構成之纖維基材成形ABS、聚碳酸酯、丙烯酸、尼龍之至少任一者作為結合劑而成之車輛之內外裝品成形體貼合樹脂表皮材而成；上述樹脂表皮材具有由丙烯酸系接著劑所構成之接著層、及樹脂膜，且係由丙烯酸材料、PC材料或ABS材料之至少任一者所構成，厚度為0.1~0.5mm，且，於樹脂膜之下側附著有接著層，且於上述樹脂膜與上述接著層之間介隔有加飾層。
  3. 一種樹脂成形品，其係於在由碳纖維、玻璃纖維、或該等之複合纖維所構成之纖維基材成形ABS、聚碳酸酯、丙烯酸、尼龍之至少任一者作為結合劑而成之車輛之內外裝品成形體貼合樹脂表皮材而成；上述樹脂表皮材具有由丙烯酸系接著劑所構成之接著層、及樹脂膜，且係由丙烯酸材料、PC材料或ABS材料之至少任一者所構成，厚 度為0.1~0.5mm，且，上述樹脂表皮材係對上述樹脂膜之下表面進行蝕刻後，附著接著層而成。
  4. 一種樹脂成形品之製造方法，其係將於由碳纖維、玻璃纖維、或該等之複合纖維所構成之纖維基材成形ABS、聚碳酸酯、丙烯酸、尼龍之至少任一者作為結合劑而成之車輛之內外裝品成形體載置於支承治具後，將樹脂表皮材以使該表皮材之上述接著層向下之方式配置於上述成形體之上方，使上述成形體及上述樹脂表皮材之周圍成為負壓狀態，並且對上述樹脂表皮材進行加熱，使上述支承治具上升而使上述成形體密接於已軟化之上述樹脂表皮材，進而，使上述支承治具之上方區域成為加壓狀態後，開放上述支承治具之周圍，取出被覆有樹脂表皮材之成形體；上述樹脂表皮材具有由丙烯酸系接著劑構成之接著層、及樹脂膜，且由丙烯酸材料、PC材料或ABS材料之至少任一者構成，厚度為0.1~0.5mm。
  5. 如申請專利範圍第4項之樹脂成形品之製造方法，其中，上述樹脂表皮材於樹脂膜之下側附著有接著層，且於上述成形體之表面形成有加飾層。
  6. 如申請專利範圍第4或5項之樹脂成形品之製造方法，其中，上述樹脂表皮材於樹脂膜之下側附著有接著層，且於上述樹脂膜與上述接著層之間介隔有加飾層。
  7. 如申請專利範圍第4或5項之樹脂成形品之製造方法，其中，上述樹 脂表皮材係對上述樹脂膜之下表面進行蝕刻後，附著接著層而成。
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