JPH06320655A - Porous molded product made of fiber reinforced thermoplastic resin and molding method thereof - Google Patents

Abstract

(57) [Summary] [Object] To provide a porous molded article having excellent mechanical properties and having a complicated shape with deep irregularities such as ribs, and a molding method thereof. [Structure] A fiber-reinforced thermoplastic resin layer expanded by a paper-making method, a fiber-reinforced thermoplastic resin layer containing a reinforcing fiber bundle and subjected to a concavo-convex process, and a thermoplastic resin on the surface of these fiber-reinforced thermoplastic resin layers. A porous molded article having a layer. A non-woven material containing reinforcing fiber bundles and a non-woven material in which reinforcing fibers are dispersed in a single state or in a state close to that are overlapped,
Further laminated thermoplastic resin film according to the purpose, when laminating the plate-shaped body to this laminate, on the non-woven material side containing the reinforcing fiber bundle, the plate-shaped body that has been subjected to the uneven processing is overlapped, heating, It is pressurized and decompressed, expanded by spring back of reinforcing fibers, cooled and the plate-like body is removed to form a porous molded product.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber-reinforced thermoplastic resin porous molded article (hereinafter referred to as a porous molded article) and a molding method thereof. INDUSTRIAL APPLICABILITY The porous molded article of the present invention can be widely used for vehicle members, materials for construction / civil engineering, etc. for which wood has been conventionally used.

[0002]

2. Description of the Related Art In recent years, due to global environmental problems, the cutting of South Sea timber has been regarded as a problem. Nanyo wood is processed into plywood and is used in large quantities in vehicle parts, construction and civil engineering materials, etc.
The development of alternative materials is desired.

As a wood substitute, a fiber-reinforced thermoplastic resin molded article composed of a relatively long reinforcing fiber and a thermoplastic resin has the characteristics that it is relatively lightweight and has high strength.
It is attracting attention because it has rigidity. But,
Fiber-reinforced thermoplastic resin molded product has a density of 1 to 1.3 g / cm ³
However, it is not necessarily lighter than 0.5-0.7 g / cm ³ of wood plywood, and in order to develop the same level of strength and rigidity as wood plywood, it leads to an increase in product weight and cost.
Will be tied up.

Papermaking method (Japanese Patent Publication No. 52-12283,
In the porous molded article formed by using the non-woven material according to JP-B-55-9119), mechanical properties are improved due to uniform expansion due to springback of the reinforcing fiber, and a good resin-rich appearance is obtained. , Shows excellent performance as a wood substitute. Although the strength and elastic modulus per area of the porous molded product decrease due to expansion, it is possible to increase the thickness of the molded product with a constant weight, and the flexural strength of the molded product is 2 times the plate thickness of the molded product. In addition, since the bending rigidity is proportional to the cube of the plate thickness of the molded product, the mechanical properties are improved.

However, this method for forming a porous molded product has the following problems in forming a product shape (in the case of performing a complicated uneven processing such as a rib shape) which meets various needs. An example of a conventional method for forming a porous molded article is shown in FIG. The plate-like bodies 10 and 11 are superposed on both sides of the non-woven material 8 produced by the paper-making method of the reinforcing fibers and the thermoplastic resin in which the reinforcing fibers are dispersed in a monofilament (single fiber) or a state close thereto. At least one of the plate-shaped bodies is subjected to uneven processing such as rib shape according to the product shape (11). This laminated body is inserted into the heating press board 12 and heated until the thermoplastic resin is melted. After the thermoplastic resin is heated until it melts, the reinforcing fibers are impregnated with the thermoplastic resin, and therefore, the pressure is applied with a pressure that does not cause fiber breakage (13). Subsequently, the pressure is removed while the thermoplastic resin is still molten, the nonwoven material is expanded by the springback of the reinforcing fibers (14), and the cooling press is performed with the plate-like bodies stacked. It is inserted into the board 15, and the clearance is set to be equal to or less than the expanded thickness of the laminated body and set to a range in which voids included in the fiber-reinforced thermoplastic resin are left, and pressure and cooling are performed under the condition of obtaining a desired expansion ratio. The porous molded product 17 is molded by removing the plate-shaped body.

In the non-woven material used in this molding, since the reinforcing fibers are dispersed in a monofilament or in a state close to the monofilament, the reinforcing fibers are largely expanded by spring back, but the presence of the reinforcing fibers acts as a resistance and the material flows. Sex decreases. Therefore, the thermoplastic resin leached from the non-woven material flows into the rib portion 18 of the plate-like body at the time of heating / pressurizing, but a very large molding pressure is required to completely fill the rib material. 19 is generated. Further, since there is no reinforcing fiber in the rib, there is a problem of insufficient strength.

In the conventional porous molded article, the fiber-reinforced thermoplastic resin expands uniformly, and the intersecting portions of the reinforcing fibers are efficiently adhered by the thermoplastic resin to improve the mechanical properties. Further, in the case where a shallow decorative pattern such as a skin pattern or a wood grain pattern is applied to the porous molded product, it can be easily transferred by molding using a plate-shaped body obtained by processing the pattern.
However, it is difficult to form a porous molded product having a complicated shape with deep irregularities such as ribs.

[0008]

DISCLOSURE OF THE INVENTION The present invention provides a porous molded article having a complicated shape with deep irregularities such as ribs and a method for molding the same, by utilizing the conventional excellent mechanical properties.

[0009]

The gist of the present invention is as follows. (1) Expanded fiber-reinforced thermoplastic resin layer 1 using a non-woven material obtained by a paper-making method of a single fiber or reinforcing fibers dispersed in a state close to the single fiber and a thermoplastic resin, and a plurality of reinforcing fibers A fiber-reinforced thermoplastic resin layer 2 made of a non-woven material obtained by a paper-making method of a reinforcing resin containing a bundle of reinforced fibers and a thermoplastic resin, and a rib shape on the side of the fiber-reinforced thermoplastic resin layer 2 A fiber reinforced thermoplastic resin porous molded product characterized by being subjected to uneven processing such as. (2) Fiber-reinforced thermoplastic resin layer 1 has a reinforcing fiber content of 1
0 to 40% by volume, the apparent density of 0.3 to 1 g / cm ³
The fiber-reinforced thermoplastic resin porous molded article according to (1) above. (3) Fiber-reinforced thermoplastic resin layer 2 has a reinforcing fiber content of 1
Reinforcement fiber bundle is 5 to 80 in 0 to 30% by volume.
The fiber-reinforced thermoplastic resin porous molded article according to the above (1) or (2), which is mixed at a ratio of%. (4) The binder of the reinforcing fiber bundle is a water-insoluble urethane-based or vinyl acetate-based binder (1) to
The fiber-reinforced thermoplastic resin porous molded article according to any one of (3). (5) The fiber-reinforced thermoplastic resin porous molded article according to any one of (1) to (4) above, wherein the reinforcing fiber bundle is a bundle of 10 to 1000 single fibers. (6) The fiber-reinforced thermoplastic resin porous molded article according to any one of (1) to (5) above, wherein the surface has a thermoplastic resin layer or an inorganic filler-containing thermoplastic resin layer.

(7) Reinforcement including a non-woven material produced by a paper-making method of a single fiber or a reinforcing fiber dispersed in a state close thereto and a thermoplastic resin, and a reinforcing fiber bundle in which a plurality of reinforcing fibers are bundled The non-woven material produced by the paper-making method of fibers and thermoplastic resin is overlaid, the plate-like bodies are overlaid on both sides of the non-woven material, and the non-woven material side including the reinforcing fiber bundle is overlaid on the non-woven material side such as a rib shape. Assuming that unevenness has been applied, heat above the melting point or softening point of the thermoplastic resin, pressurize while the thermoplastic resin is molten, and then pressurize while the thermoplastic resin is molten. It is characterized in that it is removed, expanded by springback of the reinforcing fibers, the clearance between the plate-shaped bodies is set to a thickness not greater than the thickness of the expanded fiber-reinforced thermoplastic resin, pressurized and cooled, and then the plate-shaped bodies are removed. Fiber reinforced thermoplastic Molding method of the porous molded article.

(8) Reinforcement including a non-woven material produced by a paper-making method of a single fiber or a reinforcing fiber dispersed in a state close thereto and a thermoplastic resin, and a reinforcing fiber bundle in which a plurality of reinforcing fibers are bundled Nonwoven materials made by papermaking method of fibers and thermoplastic resin are superposed, and further, a thermoplastic resin film is laminated on the surface of the nonwoven material, and plate bodies are superposed on both sides of the laminated body, and a reinforced fiber bundle The plate-like body to be superposed on the non-woven material side including
By heating above the melting point or softening point of the thermoplastic resin, pressurizing while the thermoplastic resin is molten, and then removing the pressure when the thermoplastic resin is molten, by the springback of the reinforcing fiber A fiber-reinforced thermoplastic resin porous molded article characterized in that the plate-shaped body is removed after being expanded and the clearance between the plate-shaped bodies is set to be equal to or less than the thickness of the expanded fiber-reinforced thermoplastic resin, pressurized and cooled. Molding method. (9) The method for forming a fiber-reinforced thermoplastic resin porous molded article according to the above (8), wherein the thermoplastic resin film is a thermoplastic resin film containing 3 to 30% by volume of an inorganic filler.

An example of the porous molded article of the present invention and its molding method is shown in FIGS. Porous molded article 3 of the present invention
Is formed by providing an expanded fiber-reinforced thermoplastic resin layer 1, a fiber-reinforced thermoplastic resin layer 2 including a reinforcing fiber bundle in which a plurality of reinforcing fibers are bundled, and further a thermoplastic resin layer 4 if necessary. ing.

The fiber-reinforced thermoplastic resin layer 1 is uniformly expanded, and since the crossing portions of the reinforcing fibers 5 dispersed in the monofilament or in a state close to the monofilament are efficiently adhered by the thermoplastic resin 6, Excellent mechanical properties are obtained. The reinforcing fiber content of the fiber reinforced thermoplastic resin layer 1 causes stable expansion due to springback.
It is preferably 40% by volume or less, at which the reinforcing fiber and the thermoplastic resin can be bonded to each other and the mechanical properties are sufficiently expressed, when the content is at least 40% by volume.

The expansion ratio of the fiber reinforced thermoplastic resin layer 1 is
Since it occurs due to the springback of the reinforcing fiber, it varies depending on the type (rigidity) of the reinforcing fiber and the content thereof, but is up to about 5 times. Therefore, the apparent density is 0.3-1g /
Determine from the range of cm ³ depending on the application.

The rugged portion such as a rib shape is a fiber-reinforced thermoplastic resin layer in which a reinforcing fiber 5 dispersed in a state of being a monofilament or a filament and a reinforcing fiber bundle 7 in which a plurality of reinforcing fibers are bundled are mixed. It is formed by 2. The reinforcing fiber content of the fiber-reinforced thermoplastic resin layer 2 is 10 to 30% by volume. The fiber-reinforced thermoplastic resin layer 2 needs to control the fluidity of the material in order to flow into the uneven portion. In the fiber-reinforced thermoplastic resin in which the reinforcing fibers are dispersed in a monofilament or in a state close to the monofilament, the presence of the reinforcing fibers causes a great resistance, and the fluidity is remarkably lowered when the content of the fiber is high. In this fiber reinforced thermoplastic resin, the monofilament reinforcing fibers are densely dispersed and strongly bound to each other to form a structure like a fine non-woven fabric, and the fluidity of the material is lowered. In the present invention, this problem has been solved by mixing reinforcing fiber bundles and quantitatively controlling the fluidity. The role of the reinforcing fiber bundle is to control the dispersed state of the reinforcing fibers, which reduces the interaction of the fibers and improves the fluidity. The mixing ratio of the reinforcing fiber bundle varies depending on the total reinforcing fiber content, but it is preferable to mix the reinforcing fiber bundle in the reinforcing fiber at a ratio of 5 to 80%. When the total content of reinforcing fibers is low, good fluidity can be obtained even with a small amount of reinforcing fiber bundles added, and the amount of reinforcing fiber bundles added increases as the total content of reinforcing fibers increases. Need to increase. The reinforcing fiber bundle is made by tightly bundling 10 to 1000 reinforcing fibers with a urethane-based or vinyl acetate-based water-insoluble binder so that the reinforcing fibers do not disperse into monofilaments in the papermaking process for producing a nonwoven material. .

When the reinforcing fiber content of the fiber-reinforced thermoplastic resin layer 2 is 10% by volume or less, good flowability can be obtained only with the monofilament reinforcing fibers, so that it is not always necessary to add a reinforcing fiber bundle. When the thermoplastic resin layer 4 is present on the surface of the porous molded article, the fiber-reinforced thermoplastic resin is covered and a good appearance is obtained.

The method for molding the porous molded article of the present invention will be described below. FIG. 1 is for molding a porous molded product having a rib shape on one side. A non-woven material 8 produced by a paper-making method, in which reinforcing fibers are uniformly dispersed in a monofilament or a thermoplastic resin in a state close to the monofilament, and reinforcing fibers in a state close to the monofilament, a reinforcing fiber bundle, and a thermoplastic resin are made uniform. The dispersed non-woven materials 9 are overlaid. Further, a plate-like body 10 having a smooth surface is placed on the surface of the non-woven material 8, and a plate-like body 11 having a rib-shaped concavo-convex process is superposed on the surface of the non-woven material 9 containing the reinforcing fiber bundles, and heated and pressed. It is inserted into the board 12 and heated until the thermoplastic resin melts. After the thermoplastic resin is heated until it melts, the reinforcing resin is impregnated with the thermoplastic resin, so that the pressure is applied at a pressure that does not cause fiber breakage (1
3). Subsequently, the pressure was removed while the thermoplastic resin was still molten, the nonwoven material was expanded by the springback of the reinforcing fibers (14), and the expanded nonwoven material and the plate-like body were superposed. In this state, it is inserted into the cooling press platen 15 and the clearance is set to be equal to or less than the thickness of these expanded laminated bodies and to the range where the voids included in the fiber reinforced thermoplastic resin are left to obtain a desired expansion ratio. Pressurized under the conditions,
The porous molded article 3 of the present invention is molded by cooling and removing the plate-shaped body.

FIG. 2 shows a porous molded article having ribs on both sides and having a surface covered with a thermoplastic resin layer. On both sides of the non-woven material 8, a non-woven material 9 containing a reinforcing fiber bundle is superposed, and further, a thermoplastic resin film 16 and a plate-shaped body 11 having a rib-shaped concavo-convex process are superposed.
This laminated body is inserted into the heating press board 12 and heated until the thermoplastic resin is melted. After the thermoplastic resin is heated until it is melted, the thermoplastic resin is impregnated between the reinforcing fibers, so that pressure is applied at a pressure that does not cause fiber breakage (13). Subsequently, the pressure was removed while the thermoplastic resin was still molten, the nonwoven material was expanded by the springback of the reinforcing fibers (14), and the expanded nonwoven material and the plate-like body were superposed. In this state, it is inserted into the cooling press platen 15 and the clearance is set to be equal to or less than the thickness of these expanded laminated bodies and to the range where the voids included in the fiber reinforced thermoplastic resin are left to obtain a desired expansion ratio. The porous molded article 3 of the present invention is molded by pressurizing and cooling under the conditions and removing the plate-shaped body.

The heating of the non-woven material and the thermoplastic resin film is carried out by contact heating of a temperature-controlled heating press machine under a very small pressure which does not damage the reinforcing fibers even when the thermoplastic resin is solidified. . The thermoplastic resin of the non-woven material gradually melts from the outside, but the distance between the plate-like bodies (thickness of the non-woven material) decreases accordingly, and uniform heating is performed.

Subsequently, since the thermoplastic resin of the non-woven material is impregnated with the thermoplastic resin in a molten state, the pressure is applied with a pressure that does not cause fiber breakage. At this time, the fiber-reinforced thermoplastic resin layer 2 whose fluidity has been improved by adding the reinforcing fiber bundle flows into the ribs. further,
The pressure is removed while the thermoplastic resin is molten.
The fiber-reinforced thermoplastic resin layer 1 largely expands due to the springback of the reinforcing fibers. Fiber reinforced thermoplastic resin layer 1
Since the reinforcing fibers are dispersed in the monofilament or in a state close to the monofilament, the non-woven material 8 constituting the above has a very bulky property. In this layer, the residual stress of the reinforcing fibers is released, and the springback, which tries to return to the original state, strongly works and greatly expands. Also, since the nonwoven material is heated uniformly, a uniform expansion is obtained. Insert the expanded laminated body and the plate-shaped body in a state of being overlapped with each other in the cooling press board, set the clearance to obtain the desired expansion ratio, pressurize and cool, and expand the expanded state of the fiber reinforced thermoplastic resin. After freezing, the plate-shaped body is removed to form the porous molded article of the present invention.

Since the wet impregnation of the reinforcing fiber and the thermoplastic resin is improved by the pressure impregnation of the non-woven material, the porous molded article has a uniform expansion and the crossing of the reinforcing fibers dispersed in the monofilament or in a state close thereto. The parts are efficiently adhered with a thermoplastic resin and excellent mechanical properties are obtained.

The thermoplastic resin in the non-woven material is impregnated between the reinforcing fibers at the time of pressurization, but at the same time, it is leached at the interface with the plate-like body and a resin-rich layer is formed at the interface. It fuses firmly. When the thermoplastic resin film is laminated, the leached thermoplastic resin and the molten resin of the film are combined to form a more stable resin rich layer. Since the surface of the fiber-reinforced thermoplastic resin expands while being restrained by the surface of the plate-shaped body, a resin-rich appearance in which the surface texture of the plate-shaped body is transferred can be obtained. When the thermoplastic resin film is laminated, the fiber-reinforced thermoplastic resin layer is covered with the stable resin-rich layer, and a better appearance is obtained.

In the molding method shown in FIGS. 1 and 2, the heating and pressurizing step and the pressurizing and cooling step were carried out by separate dedicated press machines.
It is also possible to carry out heating, pressurizing, depressurizing and cooling molding with a single press machine. In addition, preheating the non-woven material for the purpose of shortening the heating time of the non-woven material on the hot press machine is preferable because it shortens the molding cycle.
For the preheating of the non-woven material, there is used a method of passing hot air for heating in a short time by utilizing air permeability of the non-woven material, or heating by an oven. Since the shape of the periphery of the porous molded product molded by this method is unstable, the product is actually trimmed around the periphery of the molded product.

The reinforcing fibers used as the raw material for the non-woven material include
In addition to glass fibers, carbon fibers, and metal fibers, inorganic fibers, organic fibers, and a mixture thereof may be used depending on the application.
The shape of the reinforcing fiber is preferably 3 μm or more from the viewpoint of easy handling and economical, and 30 μm or less in order to express sufficient strength, and the fiber length is 3 mm or more from the viewpoint of strength development, and is uniform. It is desirable to set the thickness to 50 mm or less, which allows various dispersion. The reinforcing fiber is a water-soluble polymer for improving hydrophilicity for the purpose of good dispersion in water, a wetting agent, and a silane coupling agent for improving adhesiveness with the thermoplastic resin for expressing strength. For example, it is desirable to perform surface treatment.

The thermoplastic resin is polyethylene, polypropylene, polystyrene, styrene-butadiene-acrylonitrile copolymer, styrene-acrylonitrile copolymer, polyamide, polycarbonate, polyacetal, polyethylene terephthalate, polybutylene terephthalate, polyphenylene oxide, polysulfone, polyphenylene sulfide. Such as a plasticizer, a heat stabilizer, a light stabilizer, a filler, and the like, which also include a mixture of two or more of these resins.
It is also possible to add dyes and pigments, impact resistance agents, extenders, nucleating agents, processing aids and the like. The shape of the thermoplastic resin is appropriately selected from pellets, powders, flakes, and fibrous shapes.

The thermoplastic resin to be laminated on the non-woven material is preferably used in the form of a film because it is easy to handle and it is necessary to form a porous molded article by fusion bonding with the fiber reinforced thermoplastic resin layer. Use the same non-woven material as. However, when it is necessary to improve heat resistance, surface hardness, wear resistance, etc. in the surface layer, a thermoplastic resin according to the purpose, a mixture of different resins, a laminated film composed of different resin films, a non-woven material It may be used in consideration of the melting point and compatibility of the thermoplastic resin. The thickness of the thermoplastic resin film is appropriately selected within the range of 0.05 to 2 mm depending on the application.

It is also possible to use a thermoplastic resin film further containing an inorganic filler. As the inorganic filler to be added, particulate fillers such as calcium carbonate and talc, flaky fillers such as mica, fibrous fillers such as chopped glass fibers and rock wool fibers are used. The inorganic filler is preferably surface-treated with a silane coupling agent or the like in order to improve the adhesiveness with the thermoplastic resin. The inorganic filler is appropriately selected according to the application. Further, a mixture of two or more kinds of the above inorganic fillers may be added. The amount of the inorganic filler added is 3% by volume or more for the purpose of strengthening the surface layer portion, and 30% by volume or less which enables stable film formation. The inorganic filler-containing thermoplastic resin film is in the range of 0.1 to 2 mm and is appropriately selected depending on the application.

As the plate-like member, one having a smooth surface or one having a complicated uneven processing such as a rib shape is used. The material of the plate-like body may be any material as long as it can withstand the heating temperature of the non-woven material, and examples thereof include those made of metal, inorganic material and resin. These plate-like bodies must have a property that the thermoplastic resin adheres in the molten state but does not adhere in the non-molten state, and is coated with Teflon resin or the like in consideration of the releasability of the porous molded product. Alternatively, a release agent treatment such as silicon may be performed.

The concavo-convex shape of the porous molded product changes depending on the application, but in the prior art, the rib shape is rib height / rib height /
From the rib thickness of 1 or more, the problem of fluidity occurs, and the effect of the present invention is clearly recognized (the rib-shaped plate used in the examples has rib height / rib thickness = 10 mm / 6 mm =
1.7).

[0030]

The present invention will be described in detail with reference to the following examples. Example 1 Glass fiber A having a diameter of 10 μm and a length of 13 mm, which was surface-treated with a water-soluble polymer, a wetting agent, and a silane coupling agent as reinforcing fibers, and a silane coupling agent and a urethane binder, a diameter of 10 μm and a length of 13 mm. 67 fiberglass
A glass fiber bundle B focused on a book was used. As a thermoplastic resin, spherical pellets with a diameter of 3 mm were mechanically pulverized, and the pulverized product was sieved to 70 mesh (opening diameter 0.212).
mm) to 10 mesh (opening diameter 1.7 mm) were used. It is composed of glass fiber A and polypropylene resin powder by a papermaking method, has a composition of glass fiber content of 40% by weight (19% by volume) and polypropylene resin of 60% by weight (81% by volume), and has a basis weight of 120.
0 g / m ² of non-woven material A was produced. In the non-woven material A, the glass fibers A were uniformly dispersed together with the polypropylene resin powder in a state close to a monofilament.

Further, the content of the glass fiber A is 15% by weight (7.1% by volume), the content of the glass fiber bundle B is 25% by weight (11.9% by volume), and the polypropylene resin powder is contained by the papermaking method. The composition is 60% by weight (81% by volume),
A nonwoven material B having a basis weight of 1200 g / m ² was produced. In the non-woven material B, the glass fibers A in a state close to monofilaments, the glass fiber bundles B, and the polypropylene resin powder were uniformly dispersed.

The non-woven materials A and B are cut into 290 × 290 mm and four non-woven materials A and two non-woven materials B are overlapped,
Further, the non-woven material A side has a flat plate made of aluminum (sheet thickness 10 mm) having a smooth surface, and the non-woven material B side is ribbed (rib height / rib thickness = 10 mm / 6 mm =) shown in FIG. 1.
The aluminum plate-shaped bodies subjected to 7) were overlapped, and the porous molded article of the present invention was molded by the molding method shown in FIG. The laminated body was inserted into a heating press machine whose temperature was set to 210 ° C., and preheated under a pressure of 2 kgf / cm ² for about 10 minutes until the temperature of the central part of the nonwoven material increased to 190 ° C. or higher. . At this temperature, the polypropylene resin was sufficiently molten. Then, pressurize with pressure of 20kgf / cm ² for 3 minutes,
Insert the laminate into a cooling press board, set the press board clearance with a spacer, and apply a pressure of 5 kgf / cm ²
After pressing for about 5 minutes and cooling, the plate-shaped body was removed to form a porous molded product having a plate thickness of 10 mm.

After heating and pressurizing, the laminate immediately expanded due to the springback of the reinforcing fibers in a short time when it was moved from the heating plate to the cooling plate. In addition, it was confirmed that the nonwoven material after heating and pressing was in close contact with the end plate very firmly, and that the surface of the non-woven material was expanded while being constrained by the surface of the end plate. The rib shape of the porous molded product was completely molded, the glass fiber was not exposed on the surface of the molded product, and the smooth surface of the plate-like body was transferred to give a good appearance.

By optical microscope and scanning electron microscope observation,
In the fiber-reinforced thermoplastic resin layer composed of the non-woven material A, it was confirmed that the intersecting portions of the glass fibers A were efficiently adhered by the polypropylene resin and uniform expansion was performed. In the fiber-reinforced thermoplastic resin layer on the rib side composed of the non-woven material B, a slight amount of voids was confirmed. Further, the glass fiber A and the glass fiber bundle B are provided in the rib.
However, it was confirmed that they flowed in together with the polypropylene resin.

Example 2 Two non-woven materials B were superposed on each side of the three non-woven materials A of Example 1, and one polypropylene resin film (thickness: 0.3 mm) was laminated on one side, and the other Has a diameter of 2 μm
40% by weight (1
The laminated polypropylene resin film (thickness: 0.3 mm) was laminated. Furthermore, by laminating the aluminum-made plate-like body subjected to the rib processing used in Example 1 on both surfaces of this laminated body, the molding method shown in FIG.
The porous molded article of the present invention was molded under the same molding conditions as in Example 1.

The ribs of the porous molded product were completely molded, and the surface of the molded product was covered with the polypropylene resin layer or the talc-containing polypropylene resin layer and had a good appearance. As in Example 1, in the fiber-reinforced thermoplastic resin layer composed of the non-woven material A, it was observed that the intersecting portions of the glass fibers A were efficiently adhered by the polypropylene resin and uniform expansion was performed. In the fiber-reinforced thermoplastic resin layer made of the non-woven material B, only a few voids were confirmed. It was also confirmed that the glass fibers A and the glass fiber bundles B were flowing into the ribs together with the polypropylene resin.

Comparative Example Six non-woven materials A of Example 1 were laminated, and aluminum plate-like bodies having smooth surfaces used in Example 1 on both sides thereof,
Rib-processed aluminum plate-like bodies were superposed on each other, and a porous molded article was molded by the conventional molding method shown in FIG. 3 under the same molding conditions as in Example 1. The rib shape was missing in the porous molded product. However, the glass fiber was not exposed on the surface of the molded product, and the smooth surface of the plate-like body was transferred to give a good appearance.

By observation with an optical microscope and a scanning electron microscope,
In the fiber-reinforced thermoplastic resin layer, it was confirmed that the intersecting portions of the glass fibers A were efficiently adhered by the polypropylene resin and uniform expansion was performed. However, it was confirmed that only the polypropylene resin had flowed into the ribs that were missing.

[0039]

The porous molded article of the present invention has good mechanical properties due to the uniform expansion of the fiber reinforced thermoplastic resin layer 1 and the formation of irregularities such as ribs due to the fiber reinforced thermoplastic resin layer 2. The appearance of resin-rich molded products makes them excellent substitutes for wood and can be widely applied to industrial materials.

[Brief description of drawings]

FIG. 1 is a schematic view showing an example of a porous molded article of the present invention and a molding method thereof.

FIG. 2 is a schematic view showing another example of the porous molded article of the present invention and the molding method thereof.

FIG. 3 is a schematic view showing an example of a conventional method for molding a porous molded article.

FIG. 4 is a schematic view of a rib-made aluminum plate-like body used in Examples.

[Explanation of Codes] 1 expanded fiber reinforced thermoplastic resin layer 2 fiber reinforced thermoplastic resin layer containing reinforced fiber bundle 3 porous molded article of the present invention 4 thermoplastic resin layer 5 monofilament or dispersed in a state close to it Reinforcing fiber 6 Thermoplastic resin 7 Reinforcing fiber bundle 8 Nonwoven material in which reinforcing fiber is uniformly dispersed with thermoplastic resin in a state of monofilament 9 or near it 9 Reinforcing fiber, reinforcing fiber bundle and thermoplastic resin in a state of monofilament or near it The non-woven material in which are uniformly dispersed. 10 A plate-like body having a smooth surface. 11 A plate-like body having a rib-shaped concavo-convex process. 14 Nonwoven material uniformly expanded by spring back of reinforcing fiber 15 Cooling press platen 16 Thermoplastic resin film 17 Conventional porosity Quality molded product 18 Plate-shaped rib portion 19 Missing rib

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Takao Kimura 1 Toho-cho, Yokkaichi-shi, Mie Mitsubishi Petrochemical Co., Ltd. Yokkaichi Research Institute

Claims (9)

[Claims] 1. An expanded fiber-reinforced thermoplastic resin layer (1) comprising a non-woven material produced by a paper-making method of a thermoplastic resin and reinforcing fibers dispersed in the state of a single fiber or a plurality thereof, and a plurality of layers. A fiber-reinforced thermoplastic resin layer (2) made of a non-woven material produced by a papermaking method of a thermoplastic resin and a reinforcing fiber containing a reinforcing fiber bundle in which the reinforcing fibers of the book are bundled; A fiber-reinforced thermoplastic resin porous molded article characterized in that the side of (2) is subjected to uneven processing such as a rib shape. 2. The fiber-reinforced thermoplastic resin layer (1) has a reinforcing fiber content of 10 to 40% by volume and an apparent density of 0.
The fiber-reinforced thermoplastic resin porous molded article according to claim 1, which has an amount of 3 to 1 g / cm ³ . 3. The fiber-reinforced thermoplastic resin layer (2) has a reinforcing fiber content of 10 to 30% by volume, and the reinforcing fiber bundle is mixed in the reinforcing fiber at a ratio of 5 to 80%. The fiber-reinforced thermoplastic resin porous molded article according to 2. 4. The fiber-reinforced thermoplastic resin porous molded article according to claim 1, wherein the binder of the reinforcing fiber bundle is a water-insoluble urethane-based or vinyl acetate-based binder. 5. The fiber-reinforced thermoplastic resin porous molded article according to claim 1, wherein the reinforcing fiber bundle is a bundle of 10 to 1000 single fibers. 6. The fiber-reinforced thermoplastic resin porous molded article according to claim 1, wherein a thermoplastic resin layer or an inorganic filler-containing thermoplastic resin layer is present on the surface. 7. A non-woven material produced by a paper-making method of a single fiber or a reinforcing fiber dispersed in a state close to the single fiber and a thermoplastic resin, and a reinforcing fiber containing a reinforcing fiber bundle in which a plurality of reinforcing fibers are bundled. And non-woven material by a papermaking method of thermoplastic resin and superimposing a plate-shaped body on both sides of the non-woven material side and superposing it on the non-woven material side containing the reinforcing fiber bundle. Treated, heated above the melting point or softening point of the thermoplastic resin, pressurizing while the thermoplastic resin is molten, and then removing the pressure when the thermoplastic resin is molten Then, the reinforcing fiber is expanded by springback, and the clearance between the plate-shaped bodies is set to be equal to or less than the thickness of the expanded fiber-reinforced thermoplastic resin and pressurized,
A method for molding a fiber-reinforced thermoplastic resin porous molded article, which comprises removing the plate-shaped body after cooling. 8. A non-woven material produced by a paper-making method of a single fiber or a reinforcing fiber dispersed in a state close thereto and a thermoplastic resin, and a reinforcing fiber containing a reinforcing fiber bundle in which a plurality of reinforcing fibers are bundled. And a thermoplastic resin are laminated on each other by a paper-making method, a thermoplastic resin film is further laminated on the surface of the nonwoven material, and a plate-like body is laminated on both sides of the laminate, and a reinforcing fiber bundle is formed. The plate-like body to be laminated on the side of the non-woven material shall be subjected to uneven processing such as rib shape, heated above the melting point or softening point of the thermoplastic resin, and pressed while the thermoplastic resin is molten. Then, the pressure is removed while the thermoplastic resin is in a molten state, the fibers are expanded by the springback of the reinforcing fibers, and the clearance between the plate-shaped bodies is set to a value not greater than the thickness of the expanded fiber-reinforced thermoplastic resin. Plate after pressure and cooling A method for molding a fiber-reinforced thermoplastic resin porous molded article, which comprises removing a cylindrical body. 9. The method for molding a fiber-reinforced thermoplastic resin porous molded article according to claim 8, wherein the thermoplastic resin film is a thermoplastic resin film containing 3 to 30% by volume of an inorganic filler.