JPH0126331B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a sanderch board that can be stamped, and more particularly, it involves laminating and simultaneously polymerizing a metal sheet surface material and an open-cell porous material impregnated with a thermoplastic resin monomer. The present invention relates to a method for manufacturing a molded stamp-formable sandwich board.

As aircraft become larger and vehicles become lighter, the light, strong, and highly rigid Sanderutsch board plays a major role. The main constituent materials of Sanderutsch board are:
It is broadly divided into surface material, core material, and adhesive. Surface materials include metals, non-metals, and plastic materials, depending on the required performance. As the core material, honeycomb core materials, plastic foam, inorganic core materials such as glass wool, and others are used. In many sanderch boards, the surface material and the core material are bonded together with an adhesive, but if the bonding area is large, the work efficiency will be reduced due to the complexity of the adhesive application. For this reason, molding methods that do not use adhesives have been devised. For example, polyurethane foam is injected into the mold of a pre-formed surface material, and the foam is formed and bonded to the surface material at the same time. There is a method in which an FRP surface material impregnated with matrix resin is laminated on a plastic foam core material, and the surface material is molded and bonded to the core material at the same time. That is, the former is bonded by solidifying the polyurethane foam, and the latter is bonded by the solidifying of the impregnated matrix resin.

As such polyurethane foam core materials, closed-cell rigid foams are generally widely used, and sanderch boards made of this and metal or plastic surface materials have high compression resistance and isodynamic strength, and are used as various structural members. ing.

On the other hand, recently, sanderch boards, in which a thermoplastic resin sheet core material such as polypropylene or nylon is interposed between metal sheet surface materials such as iron or aluminum, have been attracting attention as a material that can be stamp-formed to reduce the weight of vehicle exterior panels. There is.

As a result of comparative studies of the various sanderch structures described above, particularly methods for forming sanderch boards that do not use adhesives, the present inventors were able to discover a completely new and efficient method for forming sanderch boards. That is, the present invention impregnates a thermoplastic resin monomer into a flexible, porous, open-cell core material, then laminates a surface material of a metal sheet on at least one surface of the core material, and then laminates such a laminated portion. The present invention relates to a method for manufacturing a sanderch board that can be stamp-formed, characterized in that the monomer is polymerized while being pressed to form an integral mold.

The core material used in the method of the present invention may have any structure as long as it is easily impregnated with resin monomer and easily flows out when pressed. Therefore, flexible, open-celled foams are suitable. Further, it is desirable to have a form that can withstand the molding temperature during stamping molding. Suitable examples include polyurethane foam, polyvinyl chloride foam, polyolefin foam, and phenolic resin foam. Glass wool mats may be used as other core materials.

The laminated portion of the metal sheet and the porous core material impregnated with a thermoplastic resin monomer is pressed from the center in the width direction, and the excess monomer flows out from the side surface of the laminated portion and can be recycled. The method of forming while pressing may be continuous or discontinuous, and is not limited in any way, such as a roll method, a press method, or a method of pressing by pulling a metal plate with magnetic force.

Various types of metal sheets can be used as the metal sheet used in the method of the present invention, but an aluminum plate is preferably selected from the viewpoint of aesthetics, and an iron plate is preferably selected from the viewpoint of strength.
Steel plates lined with various other alloys or thermoplastic resins such as vinyl chloride can also be used. Surfing mat or a nonwoven fabric made of synthetic fibers may be interposed between the metal and the porous core material as long as the thermoplastic resin leaches out.

Examples of the thermoplastic resin monomer to be impregnated into the core material include styrene, acrylonitrile, acrylate, methacrylate, vinyl monomers such as vinyl acetate, mixtures thereof, and ε-caprolactam. A crosslinking agent, an organic or inorganic filler, a soluble polymer, or the like may be added to such monomers.

Example A soft polyurethane foam with a specific gravity of 0.05, 5 mm thick, and 35 cm square was impregnated with 230 g of styrene syrup containing 0.2% benzoyl peroxide (polymer content 20% by prepolymerization) and pretreated with methacryloxysilane. 0.3mm thick, 50cm
Scissors between two pieces of stainless steel on the corner, 1mm
Place thick spacers on the four corners and press, 80~
Polymerize at 120℃.

After preheating this sanderch plate to 120°C, it can be stamped into various shapes using a normal press and mold for iron plates.

Claims (1)

[Scope of Claims] 1. A method for producing a sanderch board comprising a metal sheet surface material and a flexible, porous core material having open cells, in which a thermoplastic resin monomer is contained in the core material. Production of a stamp-formable sanderch board characterized by impregnating the core material, then laminating a metal sheet on at least one side of the core material, and polymerizing the monomer while pressing the laminated portion to integrally mold it with the metal sheet. Method. 2. The manufacturing method according to claim 1, wherein the surface material of the metal sheet is an iron plate or an aluminum plate. 3. The manufacturing method according to claim 1, wherein the flexible, porous, open-cell core material is polyurethane foam. 4 The thermoplastic resin monomer is acrylonitrile,
The manufacturing method according to claim 1, which is one kind or a mixture selected from styrene methacrylate, acrylate, and caprolactam.