JPH0593352A - Thermoformable core material and method for producing the same - Google Patents

Abstract

PURPOSE:To obtain a thermoformable core material suitable as a substrate for formed ceiling and formed inner trim substrate for door of automobile, etc., by producing a sandwich laminate from inorganic resin and thermoplastic resin fiber and heat-treating the laminate under specific condition. CONSTITUTION:Both surfaces of a mat produced by using an inorganic fiber and a thermoplastic resin fiber are laminated with thermoplastic resin sheets (a) and (b). At least one surface of the obtained sandwiched laminate is laminated with a sheet made of a heat-resistant rigid resin (d) having a melting point higher than that of the thermoplastic resin fiber and the thermoplastic resin. The objective thermoformable core material is obtained by heating the laminated sheet at a temperature below the melting temperature of the heat- resistant rigid resin to melt the thermoplastic resin fiber and the thermoplastic resin and pressing the sheet to impregnate the thermoplastic resins (a) and (b) into the mat and bond the inorganic fibers with each other without impregnating the heat-resistant rigid resin (d) into the mat.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a thermoformed composite material,
In particular, the present invention relates to a thermoformable core material used as a base material for a molded ceiling of a vehicle such as an automobile and a molded interior base material for a door, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, a thermoformable core material used as a base material for an interior of a vehicle such as an automobile, especially a thermoformed ceiling, is lightweight,
Excellent performance such as rigidity, heat resistance, and heat shaping property is required. As this kind of material, for example, JP-A-60-
In Japanese Patent No. 83832, a base material is formed by laminating a synthetic resin layer such as polyethylene on both surfaces of an inorganic fiber layer such as glass fiber, and a skin material is provided on the surface of the resin layer of the base material via a foam layer. A thermoformable composite material formed by laminating is disclosed.
However, such a thermoformable material has particularly low sound absorbing property and insufficient bending strength, and is insufficient for use as a core material for an automobile ceiling material, for example.

In order to eliminate such a drawback, the present inventors have already disclosed in Japanese Patent Laid-Open Nos. 1-56562 and 2-539.
No. 48, the inorganic fibers are partially bound by a binder,
A fiber molded body or a laminated body, which is a molded body having a large number of voids throughout and in which a large number of pores communicating from both surfaces to internal voids is formed, has been proposed. These fiber moldings and laminates have the advantages of excellent heat resistance, heat shaping properties, sound absorption properties, and the like.

[0004]

However, this type of laminate has a large number of pores and voids because the inorganic fibers are partially bound by a binder made of a thermoplastic resin. However, it has air permeability and its mechanical strength, that is, its rigidity, is limited.

Therefore, when this type of laminated body is used as a base material for a molded ceiling of an automobile, for example, the skin material laminated thereon is, for example, a knit skin, a knit urethane skin or a non-woven fabric skin. When a material having air permeability is used, there is a problem in that the surface of the skin material is contaminated by the air generated due to temperature changes.

For this reason, conventionally, the skin material is limited to a non-breathable material such as vinyl chloride leather, non-breathable sheets are added to the skin material, or the ceiling does not vent due to the body structure. However, there are drawbacks such as an increase in automobile interior cost, a narrow selection range of skin materials, and a decrease in productivity.

In order to solve such a defect, Japanese Patent Laid-Open No. Sho 64-64
Japanese Patent Laid-Open No. 63113 discloses a method for manufacturing a composite molded body. However, since the composite molded body obtained by this method does not melt the heat-resistant resin sheet to be laminated, the bonding strength between the inorganic fiber portion and the heat-resistant resin sheet is small, and peeling occurs during the subsequent secondary processing or over time. May occur. Further, the secondary processing is accompanied by hot drawing, but wrinkles often occur in the heat resistant resin sheet due to hot drawing.

It is an object of the present invention to have a complete air-blocking property even after the core material itself is heated and shaped without impairing the lightness, the heat resistance, the heat shaping property, and the sound absorbing property, and the core material. Another object of the present invention is to provide a thermoformable core material with improved mechanical strength (rigidity) of the core material after shaping and a method for producing the same.

As a result of earnest studies, the inventors of the present invention intervene a thermoplastic resin layer between a heat-resistant and rigid resin layer and a mat-like material mainly composed of inorganic fibers and thermoplastic resin fibers and heat it. It was found that the above object can be achieved by melting and compressing, and the present invention has been completed based on the findings.

[0010]

That is, according to the present invention, a heat-resistant and rigid resin having a melting temperature higher than that of the thermoplastic resin is provided on at least one surface of the mat-like material in which the inorganic fibers are bound by the thermoplastic resin. There is provided a thermoformable core material, characterized in that the sheet-like material consisting of d) is laminated and the inorganic fibers are expanded in the thickness direction.

According to the present invention, the thermoplastic resin sheet materials (a) and (b) are laminated on both surfaces of the mat-like material formed of inorganic fibers and thermoplastic resin fibers as main materials to obtain a mat-shaped material. A laminated sheet, in which a sheet material made of a heat-resistant and rigid resin (d) having a higher melting temperature than the thermoplastic resin fiber and the thermoplastic resin is laminated on at least one surface of the sandwich laminate, By heating at the following temperature, the thermoplastic resin fiber and the thermoplastic resin are respectively melted and compressed, the thermoplastic resin (a) (b) is impregnated in the mat-like material There is provided a method for producing a thermoformable core material, which comprises binding the inorganic fibers to each other, while not impregnating the heat-resistant and rigid resin (d) into the mat-like material.

The present invention will be described in detail below.

The mat-like material used in the present invention is mainly composed of inorganic fibers and thermoplastic resin fibers. Examples of the inorganic fibers include glass fibers and rock wool. The length of the inorganic fiber is preferably from 5 to 250 mm, more preferably from 50 to 50, from the viewpoint of forming the mat-like material.
The one having a diameter of 150 mm has a distribution of 70% by weight or more. Further, the thickness of the inorganic fiber is preferably 5 to 20 μm, more preferably 7 to 13 μm from the viewpoint of bending strength and thickness recovery of the thermoformed core material obtained.

The thermoplastic resin fiber is preferably a resin that is easily melted and bound to the glass fiber, and examples thereof include fibers made of a resin such as polyethylene, polypropylene and polystyrene. The length and thickness of the thermoplastic resin fiber are preferably such that the above-mentioned inorganic fiber can be easily mixed to form a mat-like material. Specifically, the length is 5
~ 200 mm is preferred, more preferably 20-100 mm
Is. The thickness is preferably 5 to 70 μm, more preferably 15 to 40 μm. As the thermoplastic resin fiber,
It may have a core material and a hot-melt type exterior.

Regarding the blending ratio of the inorganic fibers and the thermoplastic resin fibers, if the proportion of the inorganic fibers is small, the heat resistance of the obtained thermoformable core material is lowered, and if the proportion is large, the joint portion between the inorganic fibers is lowered and the mechanical fibers are mechanical It is preferable to set the weight ratio of the inorganic fiber and the thermoplastic resin to be in the range of 5: 1 to 1: 5 because the mechanical strength, that is, the rigidity is lowered.

Any method may be used for producing the mat-like material. Generally, the above-mentioned inorganic fiber and thermoplastic fiber are supplied to a card machine, defibrated and needle punched to produce the mat-like material. .. Needle punch is 1 cm ^{2 in} order to improve the mechanical strength of the mat-like material and the resulting thermoformable core material.
The number of hits is preferably 2 to 100, and more preferably 10 to 50.

The density of the mat-like material is preferably 0.01 to 0.2 g / cm ³ because the mat-like material becomes heavier as the mat-like material becomes heavier and the mechanical strength as the mat-like material decreases as the mat-like material becomes smaller.
The weight of the mat is 200 to obtain the mechanical strength.
~ 1500 g / m ² is preferred, more preferably 300
~ 800 g / m ² is good.

The thermoplastic resin used in the present invention is easily impregnated in the mat-like material in a molten state and is easily bound to the glass fiber. Examples of such a thermoplastic resin include thermoplastic resins such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer, saturated polyester and modified products thereof (for example, maleic anhydride-modified polyethylene).

The heat-resistant and rigid resin used in the present invention has a melting temperature higher than that of the thermoplastic resin fiber and the thermoplastic resin, and is 30 ° C. or more, preferably 50 ° C. or more higher than the melting temperature of the thermoplastic resin. It is a thing. As a result, the entire laminated sheet can be heated to melt the resin other than the heat-resistant and rigid resin. Examples of such heat-resistant and rigid resins include heat-resistant and rigid resins such as polybutylene terephthalate, saturated polyester, polycarbonate, and modified products thereof.

In addition, the heat-resistant and rigid resin used in the present invention has a strong and complete resin layer laminated on the surface of the inorganic fiber layer to completely block air permeability and improve the rigidity of the core material. And flexural modulus of 15000 kg /
It is preferably cm ² or more. More preferably 20000
It is a heat-resistant and rigid resin with a weight of more than kg / cm ² . Flexural modulus is 1
When it is 5000 kg / cm ² or less, the air permeability of the core material can be completely cut off, but it becomes difficult to contribute to the improvement of rigidity.

The heat-resistant and rigid resin used in the present invention has a thermoforming drawing ratio (the thermoforming drawing ratio is the diameter when a plate-like material is drawn into a cylindrical shape by a vacuum forming machine). It is preferable that the ratio H / D of D to height H) is 0.5 or more. When the thermoforming drawing ratio is 0.5 or less, there is a problem in the thermoforming performance of the core material, that is, the shapeability.

Next, a method for obtaining a laminated sheet structure in the present invention will be described.

First, the first method is to apply the
Thermoplastic resin sheets (a) and (b) are laminated, and the heat-resistant and rigid resin is laminated on at least one side of the resulting sandwich laminate.
It is a method of obtaining a laminated sheet by laminating sheet-like materials comprising (d).

The thermoplastic resin sheet material melts and contributes to the joining of the mat-like material and the heat-resistant and rigid resin (for example, polybutylene terephthalate) sheet-like material and the impregnation of the mat-like material. Further, if the mat-like material is already sufficiently impregnated with the thermoplastic resin, the thermoplastic resin sheet-like material should mainly contribute to the joining of the mat-like material and the heat-resistant and rigid resin sheet-like material. May be.

In the second method, a multilayer sheet material [(d) / (c)] comprising a heat-resistant and rigid resin layer (d) and a thermoplastic resin layer (c) is formed on at least one surface of the sandwich laminate. (c)
It is a method of obtaining a laminated sheet by laminating the sheet so that it is on the outside.

In the third method, the thermoplastic resin sheet material (a) is laminated on one surface of the mat-like material, and the heat-resistant and rigid resin layer (d) is sandwiched between the thermoplastic resin sheet material (a) and the other surface of the mat-like material. Multi-layer sheet material [(b) / consisting of plastic resin layers (b) and (c)]
(d) / (c)] is laminated so that the layer (c) is on the outer side to obtain a laminated sheet.

A fourth method is a multilayer sheet material [(b) / (consisting of a heat-resistant and rigid resin layer (d) and thermoplastic resin layers (b) and (c) sandwiching the same on both surfaces of the mat-like material. d) / (c)
] Is laminated so that the layer (c) is on the outside to obtain a laminated sheet.

In the present invention, in the above laminated structure, if the thermoplastic resin layer and the heat-resistant and rigid resin layer are not firmly adhered to each other, the heat-resistant and rigid resin layer (sheet-like material) may be peeled from the obtained thermoformable core material. Therefore, in order to increase the adhesive strength, it is preferable to provide an adhesive resin layer on at least one surface of the heat-resistant and rigid resin layer (d). That is, the adhesive strength can be increased by interposing an adhesive resin between the thermoplastic resin layer (a), (b) or (c) and the heat-resistant and rigid resin layer (d). The adhesive strength (peel strength) between the thermoplastic resin (a) or (b) and the heat-resistant and rigid resin layer (sheet-like material) is preferably 100 g / 15 mm or more, more preferably 150 g / 15 mm or more. And more preferably 200 g / 15 mm or more. If the adhesive strength is 100 g / 15 mm or less, there is a problem of peeling when manufacturing the core material, when heating the ceiling of an automobile or the like, and when used as a ceiling.

Further, the thermoplastic resin layers ((a), (b), (c)
), The heat-resistant and rigid resin layer (d), and the adhesive (resin) layer are not particularly limited in thickness. Specifically, the thermoplastic resin layers ((a) and (b)) are sufficiently melt-impregnated in the mat-like material to have a thickness necessary to sufficiently bind the inorganic fibers together with the thermoplastic resin fibers in the mat-like material. Then, 25 to 40% of the weight of the thermoformable core material to be obtained is desirable, and generally 50 to 150 μm is preferable. The thermoplastic resin layer (c) is 5
˜20 μm is preferred. In addition, the heat-resistant and rigid resin layer (d) has a thickness such that it does not follow the elongation during thermoforming and is not partially cut, and high rigidity is obtained.
50 μm, preferably 5 to 40 μm, more preferably 1
It is 0 to 25 μm. If the thickness is 5 μm or less, it is difficult to completely block the air permeability, and it is not preferable to increase the thickness to 50 μm or more from the viewpoint of an increase in weight of the core material and an economical viewpoint. The adhesive (resin) layer is used in the production of a thermoformable core material, the heat history when the core material is heated and shaped, the mechanical stress (compression, thickness expansion, stretching, etc.) history and the use as an automobile ceiling material , A thickness that provides sufficient adhesive strength, generally 5 to
20 μm is desirable.

In the present invention, the thermoplastic resin, the heat-resistant and rigid resin and the adhesive resin may be appropriately mixed with an antioxidant or a slip agent, if necessary.

In the present invention, the method for producing the laminated sheet structure is not particularly limited, and the coextrusion method,
An extrusion laminating method, a dry laminating method, etc. are mentioned. A preferred method is a co-extrusion method, that is, a method in which an adhesive resin is interposed between a thermoplastic resin and a heat-resistant and rigid resin, co-extrusion, and a laminated sheet is produced by a conventional method such as T-die. Target.

In the present invention, the laminated sheet obtained by the first to fourth methods is heated at a temperature below the melting temperature of the heat-resistant rigid resin, and compressed while being kept at this heating temperature. The compression pressure is 2 to 20 kg / cm, and the compression time is 2 to
A range of 10 seconds is preferred.

After this compression, the thickness of the entire laminated sheet (mat-like material and sheet-like material) is increased. The increase in thickness is
It may be recovered by the elasticity of the inorganic fibers, but it is forced by vacuum suction on both surfaces of the Teflon coated steel sheet or glass cloth sheet to facilitate the release of the sheet-like material on the outside of the laminated sheet at room temperature. You may go to When the thermoplastic resin layer (c) is provided on the outside of the heat-resistant and rigid resin layer (d), the thermoplastic resin (c) on the outside is melted, so that the adhesion with the steel plate or the glass cloth sheet does not occur. Good and stable thickness can be expanded.

In this heat compression step, the thermoplastic resin
(a) and (b) are melted and impregnated in the mat-like material, and together with the thermoplastic resin fiber which is also melted, the inorganic fibers and the inorganic fibers are bound to each other. On the other hand, the heat-resistant and rigid resin (d) does not melt and does not impregnate into the mat-like material. Also,
The thermoplastic resin (c) outside the heat-resistant and rigid resin (d) is melted, but not impregnated into the mat-like material.

[0035]

EXAMPLES The present invention will be specifically described below with reference to examples, but the present invention is not limited thereto.

[Example 1] Length 40 to 75 mm, diameter 9
Glass fiber of μm and high-density polyethylene fiber of 6 denier and 50 mm cut were blended at a weight ratio of 2: 1 and supplied to a card machine to be defibrated and mixed to obtain a cotton-like material. .. Next, the cotton-like material was needle punched at a density of 20 points / cm ² to obtain a mat-like material having a basis weight of about 500 g / m ² .

Next, a high-density polyethylene resin (melting point = 135 ° C., MFR = 7.0; J
Sheet-like materials having a thickness of about 100 μm formed by IS K 6870) were laminated. Furthermore, on one side of this laminate, polybutylene terephthalate resin (melting point = 2
20 ° C., hot drawing rate H / D = 1.5, flexural modulus = 2
2000 kg / cm ² ), maleic anhydride-modified polyethylene resin (MFR = 0.91) and high-density polyethylene resin (melting point = 135 ° C., MFR = 2.0), layer thickness 3
Sheets (H / D = 1.5) coextruded at 0 μm / 20 μm / 30 μm are laminated so that the polybutylene terephthalate resin is on the outside, and the thickness is about 7 mm and the weight is about 80.
A 0 g / m ² laminated sheet was prepared.

The peel strength (adhesive strength) between the polyethylene resin layer and the polybutylene terephthalate resin layer of this laminated sheet was measured and found to be 360 g / 15 mm.

The laminated sheet thus prepared was sandwiched from both sides with a Teflon-coated glass cloth sheet, and 2
It is supplied to a hot air heating furnace at 00 ° C and left for 5 minutes, then 20
It was transferred to a flat plate press heated to 0 ° C., compressed so that the thickness of the laminated sheet was 0.9 mm, and held for 5 seconds. Next, the flat plate press is spread out so that the interval is about 7 mm, and while the laminated sheet is sandwiched by the glass cloth sheets, it is moved to a flat plate vacuum expansion device, and the glass sheets are moved from both sides by 0.5 mm.
Suction was performed at a speed of / sec, the suction plate interval was expanded to 6 mm, the suction was released, the product was taken out and air-cooled for 3 minutes. next,
The glass cloth sheet was peeled off to obtain a flat thermoformable core material having a thickness of about 5.5 mm and a weight of about 800 g / m ² .

When the surface of the obtained thermoformable core material was observed with a magnifying glass, a large number of pores of 0.3 mm or less were recognized on the surface on which only the high-density polyethylene resin sheet was laminated.
No pores were observed on the opposite surface. Further, by cutting a part of the obtained thermoformable core material and observing the cross section, the polybutylene terephthalate resin layer is closely adhered to the glass fiber layer of the mat-like material, but the other resin layers are glass. The fiber layer is melt-impregnated, and is bonded to the glass fiber together with the melted polyethylene fiber, and is also bonded to the intersections of the glass fibers. As it turned, the amount of resin melt-impregnated decreased and the space increased. Further, as a result of measuring the air permeability and the mechanical strength (flexural elastic modulus) of the thermoformable core material piece, as shown in Table 1, ventilation was blocked and the rigidity was excellent.

Next, the thermoformed core material obtained was set in a frame whose peripheral portion can be fixed, with the surface in which pores were observed (the surface on which only the high-density polyethylene resin sheet material was laminated) facing up.
When supplied to a far-infrared furnace, the surface temperature of the thermoformable core material is about 17
Heated to 0 ° C. Then, with the thermoformable core material fixed to the frame, a pair of upper and lower molds (temperature 40 ° C.) having a shaping surface with a maximum drawing depth of 200 mm and a minimum curvature radius of 5 mm.
It was pressurized for 1 minute to obtain a concave shaped body.

The obtained shaped body had almost the same shape as the shape of the mold. When the surface of this shaped body was observed in detail, innumerable pores were recognized on the concave side, but on the opposite side. No pores were found. Further, as a result of measuring a physical property value by taking a sample piece from this shaped body, as shown in Table 1, the air permeability and mechanical strength were excellent, and the shapeability was also good.

Example 2 The polybutylene terephthalate resin used in Example 1 was replaced by a polycarbonate resin (melting start temperature = 210 ° C., MFR = 3.0, H / D = 2.
A laminated sheet was prepared in the same manner as in Example 1 except that the flexural modulus was 0, and the flexural modulus was 20000 kg / cm ² .

The peel strength between the polyethylene resin layer and the polycarbonate resin layer of this laminated sheet was measured and found to be 40 g / 15 mm.

From the laminated sheet thus prepared, a flat thermoformable core material having a thickness of about 6 mm and a weight of about 800 g / m ² was obtained in the same manner as in Example 1.

When the surface of the obtained thermoformable core material is observed with a magnifying glass, as in the case of Example 1, the surface on which only the high-density polyethylene resin sheet-like material is arranged has pores of about 0.3 mm. Were observed, and no pores were observed on the opposite surface. Further, when a part of the obtained thermoformable core material was cut out and the cross section was observed, the polyethylene terephthalate resin layer was closely adhered to the glass fiber layer of the mat-like material as in Example 1. , The other resin layers are melt-impregnated into the glass fiber layer, and are bonded to the glass fibers together with the melted polyethylene fibers, and are also bonded to the intersections of the glass fibers, and further, the mat-like shape. From both sides of the product, the amount of resin that had been melt-impregnated decreased and the space increased as it went toward the center. Further, as a result of measuring the air permeability and the mechanical strength (flexural elastic modulus) of the thermoformable core material piece, as shown in Table 1, ventilation was blocked and the rigidity was excellent.

Then, a shaped body was obtained in the same manner as in Example 1 and was observed in the same manner as in Example 1. As a result, the situation was almost the same as in Example 1. In addition, as a result of measuring the air permeability and mechanical strength of the shaped sample piece, as shown in Table 1, it was as good as the result of Example 1.

[Example 3] On one surface of the same mat-like material as used in Example 1, a thickness of a maleic anhydride-modified high-density polyethylene resin (melting point = 135 ° C, MFR = 7.0) was about 10. Sheets having a thickness of 130 μm were laminated. On the other hand, on the other side of the mat-like material, maleic anhydride-modified high-density polyethylene resin (melting point = 135 ° C., MFR = 5.0),
Adhesive polyethylene resin (melting point = 105 ° C, MFR =
4.0) and polybutylene terephthalate resin (melting point =
220 ° C., hot drawing rate H / D = 1.5, flexural modulus =
22000 kg / cm ² ), adhesive polyethylene resin (melting point = 105 ° C., MFR = 4.0), maleic anhydride modified high density polyethylene resin (melting point = 135 ° C., MFR =
5.0) and the layer thickness 90 μm / 10 μm / 20 μm /
Sheets (H / D) coextruded at 10 μm / 10 μm
= 1.5) is laminated so that the polyethylene resin with a thickness of 10 μm is on the outside, and the thickness is about 7 mm and the weight is about 800 g / m.
A laminated sheet of ² was created.

With respect to this laminated sheet, the peel strength (adhesive strength) between the polyethylene resin layer (thickness 90 μm) and the polybutylene terephthalate resin layer was measured, and the result was 360.
It was g / 15 mm.

From the laminated sheet thus prepared, a flat thermoformable core material having a thickness of about 5.5 mm and a weight of about 800 g / m ² was obtained in the same manner as in Example 1.

When the surface of the obtained thermoformable core material was observed with a magnifying glass, a large number of pores of 0.3 mm or less were recognized on the surface on which only the high-density polyethylene resin sheet was laminated.
No pores were observed on the opposite surface. Further, when a part of the obtained thermoformable core material is cut out and the cross section is observed, the polybutylene terephthalate resin layer is closely adhered to the glass fiber layer of the mat-like material, and the resin layer inside (90 μm / 10 μm) ) Is melt-impregnated into the glass fiber layer, and is bonded to the glass fiber together with the melted polyethylene fiber, and is also bonded to the intersections of the glass fibers. As it went to the center, the amount of the resin melt-impregnated decreased and the space increased. Further, as a result of measuring the air permeability and the mechanical strength (flexural elastic modulus) of the thermoformable core material piece, as shown in Table 1, ventilation was blocked and the rigidity was excellent.

Then, a concave shaped body was obtained in the same manner as in Example 1 and observed in the same manner as in Example 1.
It was almost the same situation as. In addition, as a result of measuring the air permeability and mechanical strength of the shaped sample piece, as shown in Table 1, it was as good as the result of Example 1.

Comparative Example The same maleic anhydride-modified high-density polyethylene resin as used in Example 3 (melting point = 135 ° C., MF, MF)
R = 7.0) sheets having a thickness of about 130 μm were laminated to prepare a laminated sheet having a thickness of about 7 mm and a weight of about 800 g / m ² .

From the laminated sheet thus prepared, a flat thermoformable core material having a thickness of about 5.9 mm and a weight of about 800 g / m ² was obtained in the same manner as in the example.

When the surface of the obtained thermoformable core material was observed in the same manner as in the examples, a large number of pores having a diameter of about 0.3 mm were recognized on both surfaces of the core material. Further, as a result of measuring the air permeability and the mechanical strength (flexural modulus) of the thermoformable core material piece, the air permeability was confirmed as shown in Table 1.

Then, a concave shaped body was obtained in the same manner as in the example. The obtained shaped body had almost the same shape as the shape of the mold, and when the surface of this shaped body was observed in detail, innumerable pores with a diameter of about 0.5 mm were recognized on both surfaces of the shaped body. .. In addition, as a result of measuring the physical property values of the shaped sample pieces, Table 1
As shown in FIG. 5, breathability was recognized, and mechanical strength and rigidity were inferior to those of the examples.

[0057]

[Table 1]

[0058]

EFFECTS OF THE INVENTION According to the present invention, a tough heat-resistant and rigid resin layer is laminated on at least one surface of a mat-like material having inorganic fibers and thermoplastic resin fibers as main materials and inorganic fibers bound by a thermoplastic resin. Since they are arranged, as described above, the thermoformable core material which is excellent in ventilation blocking property and mechanical strength is obtained. Further, according to the present invention, since the heat-resistant and rigid resin having a large thermoforming reduction ratio and the adhesive resin layer having a large adhesive strength are arranged, a thermoformable core material having a performance suitable for heat shaping can be obtained. Further, according to the manufacturing method of the present invention, the thermoformable core material having the above-described effects can be manufactured with good workability.

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Claims (11)

[Claims] 1. A sheet-shaped material made of a heat-resistant and rigid resin (d) having a melting temperature higher than that of the thermoplastic resin is laminated on at least one surface of a mat-shaped material in which inorganic fibers are bound by a thermoplastic resin. A thermoformable core material in which fibers are expanded in the thickness direction. 2. The thermoformable core material according to claim 1, wherein the mat-like material is obtained by melt-impregnating a thermoplastic resin fiber and / or a thermoplastic resin sheet-like material. 3. A sheet-like material comprising a heat-resistant and rigid resin layer (d) and a thermoplastic resin layer (c), which are laminated so that the thermoplastic resin layer (c) is on the outside. Claim 1
Alternatively, the thermoformable core material described in 2. 4. The heat-resisting and rigid resin (d) has a heat-drawing ratio (H / D; H = height, D = diameter) of the heat-resisting and rigid resin of 0.5 or more, and a bending elastic modulus of 15000 kg / cm ^2. The thermoformable core material according to any one of claims 1 to 3, which is as described above. 5. The thermoformable core according to claim 1, wherein the peel strength between the mat-like material and the sheet-like material is 100 g / 15 mm width or more. Material. 6. A thermoplastic resin sheet material (a) (b) is laminated on both sides of a mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers, and at least a sandwich laminate obtained is obtained. A laminated sheet, on one side of which the thermoplastic resin fibers and a sheet-like material having a higher melting temperature than the thermoplastic resin and made of the heat-resistant and rigid resin (d) are laminated, is heated at a temperature not higher than the melting temperature of the heat-resistant and rigid resin. Then, the thermoplastic resin fiber and the thermoplastic resin are melted and compressed, respectively, and the thermoplastic resin (a) and (b) are impregnated in the mat-like material to bind the inorganic fibers to each other. Let me meanwhile,
The method for producing a thermoformable core material, wherein the heat-resistant and rigid resin (d) is not impregnated in the mat-like material. 7. A thermoplastic resin sheet material (a) (b) is laminated on both surfaces of a mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers, and at least a sandwich laminate obtained is obtained. On one side, the thermoplastic resin fiber and the melting temperature higher than the thermoplastic resin, heat-resistant rigid resin layer (d)
And a thermoplastic resin layer (c)
The laminated sheet laminated so that is on the outside is heated at a temperature equal to or lower than the melting temperature of the heat-resistant and rigid resin to melt and compress the thermoplastic resin fiber and the thermoplastic resin, respectively. A thermoplastic resin (a) (b) is impregnated into the mat-like material to bind the inorganic fibers and the inorganic fibers together, while the heat-resistant and rigid resin (d) is not in contact with the mat-like material. (c) is a method for producing a thermoformable core material, wherein the mat-like material is not impregnated. 8. A laminated sheet, wherein a thermoplastic resin sheet material (a) is laminated on one surface of a mat-like material, and the thermoplastic resin fiber and the thermoplastic resin are laminated on the other surface of the mat-like material. It should be a laminate of multi-layered sheets consisting of a heat-resistant and rigid resin layer (d) with a high melting temperature and a thermoplastic resin layer (b) (c) sandwiching it, with the layer (c) facing outward. The method for producing a thermoformable core material according to claim 7, wherein 9. A laminated sheet, wherein a layer (c) is provided on both sides of a mat-like material with a multilayer sheet-like material comprising a heat-resistant and rigid resin layer (d) and a thermoplastic resin layer (b) (c) sandwiching it. The thermoformable core material according to claim 7, wherein the heat-resistant rigid resin has a melting temperature higher than that of the thermoplastic resin fiber and the thermoplastic resin. Production method. 10. The thermoformable core material according to any one of claims 6 to 9, wherein an adhesive resin layer is provided on at least one surface of the heat-resistant and rigid resin layer (d). Production method. 11. The heat-resisting and rigidifying resin (d) has a heat-drawing ratio (H / D; H = height, D = diameter) of the heat-resisting and rigidifying resin of 0.5 or more, and a bending elastic modulus of 15000 kg / cm ² or more. The method for producing a thermoformable core material according to any one of claims 6 to 10, wherein