JP7175496B2 - plastic laminate - Google Patents

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plastic laminate in which a plate material is joined to a corrugated core.

A plastic laminate has been developed in which plates are joined to both sides of a corrugated core. (See Patent Documents 1 to 3)

Japanese Unexamined Patent Application Publication No. 2003-1735 JP-A-06-170993 JP-A-07-148867 JP 2006-328913 A

The plastic laminate, in which the plate material is heat-welded to the surface of the corrugated core, has a structure in which the plate material is heat-welded to the corrugated core. There is a feature that can strengthen Furthermore, the plastic laminate with the above structure uses fiber-reinforced plastic in which reinforcing fibers such as carbon fiber and glass fiber are embedded in the core and plate material, thereby improving strength and bending resistance to various applications. Rigidity can be achieved.

Since plastic laminates are used after being surface-treated in most applications, techniques for applying paint to the surface have been developed. (See Patent Document 4)
Surface-treated plastic laminates can achieve various properties, such as decorating the surface with a coating film or improving thermal insulation properties. However, it is difficult to adhere a coating film firmly to the surface of a plastic plate without delamination, and it is even more difficult to adhere the coating to the surface without delamination, especially over a long period of time.

The present invention was developed with the aim of overcoming this drawback, and an important object of the present invention is to provide a plastic laminate to which a surface treatment layer such as a coating film can be strongly adhered without being peeled off. It is in.

The plastic laminate of the present invention comprises a plate material 2 made of a plate-shaped fiber-reinforced plastic in which reinforcing fibers are embedded in a thermoplastic resin, and a reinforcing fiber thermally welded to the plate material 2 and embedded in the thermoplastic resin. It consists of a core 3 made of corrugated fiber reinforced plastic, and a smooth surface 2a and an uneven surface 2b having larger unevenness than the smooth surface 2a are provided on a part or the entire surface of the plate material, and the smooth surface 2a and the uneven surface 2b. The uneven surfaces 2b are alternately arranged in stripes.

Although the present invention does not limit the plastic laminate to the following, it can be configured as follows.
A plastic laminate according to an aspect of the present invention can form a fine uneven surface 2b by forming the uneven surface 2b of the plate material 2 with reinforcing fibers embedded in a thermoplastic resin. Further, in this plastic laminate, by melting the thermoplastic resin of the fiber-reinforced plastic and moving the thermoplastic resin in the gaps between the fibers, the fine uneven surface 2b can be formed with the reinforcing fibers. This plastic laminate can form a fine uneven surface with reinforcing fibers, and can effectively adhere a surface treatment layer such as a coating film by an anchor effect.

In addition, the plastic laminate according to an aspect of the present invention can form the uneven surface 2b with a structure in which the reinforcing fibers embedded in the thermoplastic resin are exposed on the surface of the plate material 2, and this structure increases the anchor effect. can. In this plastic laminate, the reinforcing fibers are exposed on the surface to form an uneven surface, so the thermoplastic resin in which the reinforcing fibers are embedded can be melted and flowed to provide fine unevenness. The uneven surface formed by exposing the fibers on the surface has the advantage of being able to more firmly bond a surface treatment layer such as a coating film with an excellent anchoring effect. This is because the reinforcing fibers exposed on the surface provide undercut-like fine irregularities, and the paint penetrates into these irregularities to achieve a high anchoring effect.

Furthermore, the plastic laminate according to an aspect of the present invention preferably has parallel grooves 3E provided alternately on both sides at a predetermined pitch, with slope portions 3B and joint portions 3A arranged alternately. The plate material 2 has a smooth surface 2a on the surface of the joint region 2x to which the joint 3A of the core 3 is thermally welded to the back surface, and an uneven surface on the surface of the non-bonded region 2y of the core 3 that is not thermally welded. 2b.

In this plastic laminate, fine unevenness can be provided in stripes while the core and the plate material are firmly welded by heat. This plastic laminate has slopes and joints alternately arranged, and the joints of the corrugated core formed by alternately providing parallel grooves on both sides at a predetermined pitch are thermally welded to the plate material. This is because the bonding area where the core is heat-welded is a smooth surface, and the non-bonding area where the core is not heat-welded is an uneven surface. As shown in FIGS. 3 and 4, the plastic laminate having this structure can be manufactured by locally pressurizing the joining portion of the core and the plate material from both sides and heat-sealing them. At the locally pressurized joining portion, the heat-melted thermoplastic resin is firmly heat-sealed to the plate material. Also, in this plastic laminate, the core and the plate material are firmly heat-welded by making the surface of the plate material to which the core is to be heat-welded to the back surface a bonding region, and making the surface a beautiful smooth surface. Furthermore, the surface of the plate material to which the core is not thermally welded to the back surface can be used as a non-joining region, and the surface can be made uneven. In the bonded area, the bonded portion of the core and the plate material are pressed from both sides to form a smooth surface. This is because the reinforcing fibers form unevenness. In the bonded area, the plate material and the core are laminated and pressure is applied from both sides, so the surface becomes smooth. The heat-melted thermoplastic resin moves from between the reinforcing fibers to form an uneven surface due to the reinforcing fibers. Therefore, in the step of heat-welding the core to the plate material, this plastic laminate can be provided with a striped smooth surface and an uneven surface on the surface of the plate material. No process required. In addition, since the joining portion of the core and the plate material are pressurized and heat-sealed, a strong joining feature can also be realized. In other words, this plastic laminate has a feature that the plate material and the core can be strongly heat-welded by providing a striped smooth surface and an uneven surface on the surface of the plate material in the manufacturing process of heat-welding the core to the plate material. .

In the plastic laminate of the present invention, a surface treatment layer is attached to the surface of the plate material. This plastic laminate has the advantage that it is possible to select the most suitable surface treatment layer for various uses to obtain a plastic laminate having the optimum surface state for each use.

Further, in the plastic laminate of the present invention, the surface treatment layer is a coating film. Furthermore, the surface treatment layer can be a coating film having a laminate structure in which a finishing coating is laminated on a base coating.

Further, in the plastic laminate according to one aspect of the present invention, plate materials can be thermally welded to one side or both sides of the core, and carbon fibers are embedded in the plate material and the core as reinforcing fibers. A very high strength is realized as a plastic laminate, and the thermoplastic resin of the plate material and the core can be any one of nylon resin, polycarbonate, acrylic resin, PET, PP, PPS , and phenoxy resin.

The plastic laminate described above is characterized in that the surface treatment layer can be firmly adhered in a non-peeling state while the surface is treated by adhering the surface treatment layer suitable for the application to the surface. This is because the above plastic laminate has smooth surfaces and uneven surfaces alternately arranged in stripes on the surface, and the anchor effect of the uneven surfaces arranged in stripes firmly bonds the surface treatment layer. is. In the plastic laminate described above, the smooth surface and the uneven surface are arranged in stripes without making the entire surface uneven. It has the characteristic that the surface treatment layer can be strongly adhered to the surface by the anchor effect of the uneven surface provided in stripes. In particular, in the plastic laminate of the present invention, since the smooth surface and the uneven surface are alternately arranged in stripes, the smooth surface finishes the surface to a beautiful smooth surface, and the anchors of the uneven surface provided on both sides of the smooth surface can be used. As a result, the surface treatment layer as a whole can be strongly adhered without being peeled off.

1 is a partially enlarged cross-sectional view of a plastic laminate according to one embodiment of the present invention; FIG. FIG. 4 is a partially enlarged cross-sectional view of a plastic laminate according to another embodiment of the present invention; FIG. 4 is a partially enlarged cross-sectional view showing an example of heat-sealing a core to a plate material; FIG. 10 is a front view showing another example of heat-sealing the core to the plate material. 5 is an enlarged view showing a joining state between the plate material and the core shown in FIG. 4. FIG. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view of a plastic laminate according to an embodiment of the present invention and a graph showing an uneven state of a surface of a plate; 1 is a plan view of a plastic laminate according to an embodiment of the present invention, and a graph showing the results of measurement of unevenness on the plate material surface of the plastic laminate. FIG.

The present invention will now be described in detail with reference to the drawings. In the following description, terms indicating specific directions and positions (e.g., "upper", "lower", and other terms including those terms) are used as necessary, but the use of these terms is These terms are used to facilitate understanding of the invention with reference to the drawings, and the technical scope of the invention is not limited by the meaning of these terms. Also, parts with the same reference numerals appearing in a plurality of drawings indicate the same or equivalent parts or members.
Further, the embodiments shown below are specific examples of the technical idea of the present invention, and the present invention is not limited to the following. In addition, unless there is a specific description, the dimensions, materials, shapes, relative arrangements, etc. of the components described below are not intended to limit the scope of the present invention, but are intended to be examples. It is intended. In addition, the contents described in one embodiment and example can also be applied to other embodiments and examples. Also, the sizes and positional relationships of members shown in the drawings may be exaggerated for clarity of explanation.

The plastic laminate of the present invention comprises a plate material and a core, and the plate material and the core are plate-shaped fiber-reinforced plastics in which reinforcing fibers are embedded in a thermoplastic resin. The core has a trapezoidal corrugated shape and plate materials are heat-sealed on one or both sides. Further, in the plastic laminate, a smooth surface and an uneven surface having greater unevenness than the smooth surface are provided on the surface of the plate material, and the smooth surface and the uneven surface are alternately arranged in stripes. The surface of the plate material is neither entirely smooth nor entirely uneven. The plate material has a striped uneven surface on its surface. The striped uneven surface adheres the coating applied to the surface by an anchor effect so that it does not peel off.

The preferred plastic laminate of the present invention will be described in detail below with reference to the drawings.
A plastic laminate 1 shown in FIG. 1 comprises a planar plate 2 and a trapezoidal corrugated core 3 joined to the plate 2 by thermal welding. The plate material 2 and core 3 are made of fiber-reinforced plastic in which reinforcing fibers are embedded in thermoplastic resin. As shown in FIG. 1, the plastic laminate 1 can be easily bent by heat-sealing the plate material 2 to one side of the core 3, so this structure is most suitable for use in a bent state. However, as shown in FIG. 2, the plastic laminated body can also be improved in flexural rigidity by heat-sealing plate members 2 on both sides of the core 3 .

The plastic laminate 1 is suitable for applications requiring light weight and high flexural rigidity. More preferably, it should be 2 mm or more. Although the plastic laminate 1 can be made thick and strong, it is bulky and heavy. Below.

Considering the strength, the thickness (d; t) of the plate 2 and the core 3 is, for example, 0.15 mm or more, preferably 0.2 mm or more. Since the thickness of the plate 2 and the core 3 increases, the weight of the plate 2 and the core 3 is reduced. The plate 2 and core 3 have the same thickness in consideration of strength and overall thickness (D), or the plate is thicker than the core to improve surface strength, or the core is thicker than the plate. thicker to increase bending strength.

The plastic laminate of the present invention is preferably used for body steel plates of vehicles, cases of electronic devices such as mobile phones and tablets, etc., instead of metal plates such as aluminum and magnesium. For example, the plastic laminate can be thinned to achieve weight reduction and bending strength. , 7 times the flexural rigidity of 0.65 mm thick high-strength steel used for vehicle body steel, and 1/9 the weight. In a variety of other applications, including vehicle body steel, weight reduction and bending stiffness are extremely important properties. This is because properties that are thin, light, and resistant to bending are required for all uses.

In the plastic laminate 1, a trapezoidal corrugated core 3 is heat-sealed to the back surface of a plate material 2. As shown in FIG. The central core 3 has a trapezoidal wave shape in which slope portions 3B and joint portions 3A are alternately arranged and parallel grooves 3E are provided alternately on both surfaces at a predetermined pitch, and the crest portion of the trapezoidal wave is used as the joint portion 3A. The joining portion 3A is thermally welded to the back surface of the plate material 2. As shown in FIG. The central core 3 in the figure has a flat slanted surface 3D formed on the slanted surface 3B of the slanted surface 3B of the central core 3, and both surfaces of the slanted surface 3D are exposed to achieve excellent bending strength.

The plate material 2 and the core 3 are made of fiber-reinforced plastic, and reinforcing fibers are embedded in the plastic. The plate material 2 and the core 3 are made of fiber-reinforced plastic, which is a thermoplastic resin, at least in the state of being thermally welded to each other. The thermoplastic resin of the fiber-reinforced plastic is, for example, a thermoplastic resin such as nylon or polycarbonate, or an amphoteric plastic that exhibits thermosetting physical properties in an uncured state and thermoplastic physical properties in a heated and cured state, such as phenoxy Reinforcing fibers are embedded in resin. An amphoteric plastic that exhibits thermosetting physical properties in an uncured state is a plastic that is liquid or pasty in an uncured state and exhibits thermoplastic physical properties when cured. However, in the present invention, the thermoplastic resin of the fiber-reinforced plastic is not limited to amphoteric plastics such as nylon, polycarbonate, or phenoxy resin. of thermoplastic resins can also be used.

The reinforcing fibers are preferably carbon fibers. Since fiber-reinforced plastics using carbon fibers as reinforcing fibers have high strength, they are suitable for plastic laminates that require particularly high strength. However, instead of carbon fiber, fiber reinforced plastic is reinforced by embedding it in thermoplastic resin such as glass fiber, aromatic polyamide resin, PBO fiber, ultra-high strength polyethylene fiber, and high strength polyarylate fiber. Any available fiber can also be used.

Fiber-reinforced plastics are made by braiding reinforcing fibers into a mesh, or by arranging them in parallel and laminating them in multiple layers, or by assembling them three-dimensionally without directionality to form a fiber sheet, and then embedding this fiber sheet in a thermoplastic resin. Manufactured by A fiber sheet formed by gathering reinforcing fibers in a three-dimensional manner without directionality is produced by a wet papermaking method, or is produced in a sheet form as a non-woven fabric by gathering the fibers to a predetermined thickness by a dry process. Sheet-like or plate-like fiber-reinforced plastic is used for the plate material 2 and the core 3, or a prepreg in which a fiber sheet is impregnated with plastic is used. The thermoplastic resin prepreg is formed into the plastic laminate 1 by hardening the plastic in the process of heat-sealing the core 3 to the plate material 2 .

In the wet papermaking method, reinforcing fibers are suspended in water to form a papermaking slurry, and the papermaking slurry is wet-made into a sheet. In this method, a plurality of types of reinforcing fibers and additives such as inorganic powder can be suspended to produce a fiber sheet as a slurry for papermaking. A hardened amphoteric plastic is suspended in water to prepare a slurry for papermaking, which is made into a fiber sheet containing plastic, dried and pressed in a heated state to produce a fiber-reinforced plastic. This production method can uniformly disperse the fiber sheet and produce a fiber-reinforced plastic having excellent bending rigidity. Furthermore, it has the characteristic that various additives can be added and uniformly dispersed to mass-produce fiber-reinforced plastics. Furthermore, since fiber-reinforced plastics can be manufactured by uniformly dispersing various reinforcing fibers of different materials, lengths, thicknesses, etc., fiber-reinforced plastics with excellent physical properties can be produced by using inexpensive recycled raw materials for reinforcing fibers. It has the advantage of mass production. However, the present invention does not specify the manufacturing method of the fiber-reinforced plastic.

In the plastic laminate 1 of FIG. 1, as shown in the partial enlarged cross-sectional view of the drawing, a joining portion 3A provided at the top of a core 3 having a trapezoidal wave shape is heat-sealed to the back surface of a plate material 2. As shown in FIG. The trapezoidal wave-shaped core 3 has a trapezoidal wave shape by alternately arranging sloped portions 3B and joint portions 3A, and the sloped portions 3B are flat sloped surfaces 3D.

In the plastic laminate 1 shown in the figure, the inclination angle (α) of the inclined surface 3B with respect to the plate 2 is about 70 degrees, and the width (W) of the joint 3A is about 50% of the thickness (D) of the entire plastic laminate. However, the slope portion 3B of the core 3 can have an inclination angle (α) of 30 degrees or more and less than 90 degrees, preferably 45 degrees or more and 80 degrees or less. The width (W) is 20% or more and 100% or less, preferably 30% or more and 70% or less, more preferably 35% or more of the thickness (D) of the entire plastic laminate 1. It can be 60% or less.

In the plastic laminate 1, the surface of the plate material 2 is provided with a smooth surface 2a and an uneven surface 2b. The uneven surface 2b is a surface with greater unevenness than the smooth surface 2a, and the smooth surface 2a and the uneven surface 2b are alternately arranged in stripes. The uneven surface 2 b firmly adheres the surface treatment layer 30 such as the coating film 31 adhered to the surface of the plate material 2 . Preferably, the plastic laminate 1 is provided with a striped smooth surface 2a and an uneven surface 2b over the entire surface, and the entire surface treatment layer is adhered without being peeled off. However, the uneven surface 2b does not necessarily have to be arranged in stripes over the entire surface of the plastic laminate 1, and the smooth surface 2a and the uneven surface 2b may be locally arranged in stripes in areas where peeling is likely to occur.

The plastic laminate 1 preferably forms the uneven surface 2b with reinforcing fibers embedded in the thermoplastic resin of the fiber-reinforced plastic forming the plate member 2 . This plastic laminate 1 forms an uneven surface 2b by protruding a part of reinforcing fibers embedded in the thermoplastic resin of the plate material 2 to the surface of the plate material. In this plastic laminate 1, the plate material 2 is heated to melt the thermoplastic resin of the fiber-reinforced plastic of the plate material 2, thereby exposing the embedded reinforcing fibers to the surface. The hot melted thermoplastic resin migrates from the surface of the reinforcing fibers to expose the reinforcing fibers. The uneven surface 2b formed of the reinforcing fibers forms fine unevenness with the fine reinforcing fibers, and furthermore, the reinforcing fibers provide the undercut-like uneven surface 2b, and the surface treatment layer 30 is more strongly bonded by the anchor effect. do.

The fiber-reinforced plastic plate material 2 in which the reinforcing fibers are embedded three-dimensionally without any direction is reinforced by heat-melting the thermoplastic resin and exposing the reinforcing fibers to the surface, so that the reinforcement is three-dimensionally gathered without any direction. The fibers can be exposed to the surface to form irregular irregularities. In particular, in this fiber-reinforced plastic, since the reinforcing fibers are gathered in a three-dimensional manner without directivity, the intersection points of the fibers protrude high, and the uneven surface 2b having a high anchoring effect can be formed. The plate material 2 made of fiber-reinforced plastic, on which reinforcing fibers are arranged in a parallel posture on the surface, heat-melts the thermoplastic resin, moves the thermoplastic resin between the reinforcing fibers to the back side, and fills the gaps between the reinforcing fibers. is provided to form the uneven surface 2b.

The plastic laminate 1 is produced by heating the plate material 2 and the core 3 to melt the thermoplastic resin, and pressurizing the joint 3A between the mutually laminated plate material 2 and the core 3 to form the core 3 and the plate material. 2 can be heat-sealed. In this plastic laminate 1, the plate material surface of the joint region 2x to which the joint portion 3A of the core 3 is thermally welded can be made into a smooth surface 2a, and the plate material surface of the non-bonded region 2y to which the joint portion 3A of the core 3 is not thermally welded. can be used as the uneven surface 2b. This is because the bonded region 2x is pressurized from both sides in the process of heat-welding the core 3 and the plate 2, and the core 3 is not pressed against the plate 2 in the non-bonded region 2y. In the bonded region 2x, since the plate material 2 and the core 3 are laminated and pressed from both sides, the surface of the plate material becomes a smooth surface 2a due to the pressure surface. The molten thermoplastic resin moves from between the reinforcing fibers to form the uneven surface 2b due to the reinforcing fibers. In particular, the uneven surface 2b can be finely uneven with reinforcing fibers. In addition, in this plastic laminate 1, the welded portion 3A of the trapezoidal corrugated core 3 is thermally welded to the plate member 2, thereby forming a smooth surface 2a in the joint region 2x of the plate member 2 and unevenness in the non-bonded region 2y. Since the surfaces 2b are formed, striped smooth surfaces 2a and uneven surfaces 2b are alternately formed on the surface of the plate material.

The plastic laminate 1 is produced by heating the plate material 2 and the core 3 to a temperature at which the thermoplastic resin is thermally melted, laminating the plate material 2 and the core 3 with the thermoplastic resin thermally melted, and The core 3 and the plate material 2 can be heat-sealed by locally pressurizing the laminated portion of the core 3 and the joint portion 3A. This method is a step of heat-welding the plate material 2 and the core 3. After laminating the plate material 2 and the core 3 in which the thermoplastic resin is heated to a heat-melting state, the joining portion 3A of the core 3 is attached to the plate material 2. The central core 3 and the plate material 2 are heat-sealed by locally pressurizing to .

The fiber reinforced plastic of the core 3 is molded into a trapezoidal wave shape by a molding device 10 shown in FIG. A molding apparatus 10 shown in this figure includes a pair of molding dies 11 and an actuator cylinder 12 for reciprocating one of the molding dies 11 . The pair of molding dies 11 has opposing molding surfaces 11X formed in mutually meshing trapezoidal wavy shapes so that the fiber reinforced plastic 9 is sandwiched between them and molded in a trapezoidal wavy shape. A pair of molding dies 11 sandwich and pressurize the fiber-reinforced plastic 9, and heat it in this state to mold it into a trapezoidal wave shape. The fiber-reinforced plastic 9 of thermoplastic resin is pressurized in a heated state and shaped into a trapezoidal wave shape, and then cooled to harden the thermoplastic resin and removed from the molding die 11 . Amphoteric plastic is made by heating thermosetting resin to make thermoplastic resin. Therefore, fiber reinforced plastic of amphoteric plastic is pressurized in a heated state and molded into a trapezoidal wave shape to harden the thermosetting resin. Amphoteric plastics can be ejected from the mold without necessarily having to be cooled, as heating cures the thermosetting resin.

The opposing molding surfaces 11X of the molding die 11 are formed into a trapezoidal wave shape that fits together with the fiber reinforced plastic 9 therebetween, and the fiber reinforced plastic 9 of the core 3 is sandwiched in a heated state and formed into a trapezoidal wave shape. As shown in FIG. 4, the molding die 11 has an elongated trapezoidal wave shape in which parallel ridges 13 are provided on a molding surface 11X at a constant pitch, and grooves 14 are provided between adjacent ridges 13. As shown in FIG. The pair of molding dies 11 are configured such that the ridges 13 provided on one molding surface 11X face the grooves 14 provided on the other molding surface 11X and engage with each other. The fiber reinforced plastic 9 is sandwiched from both sides, and the opposing ridges 13 and grooves 14 are fitted to form a trapezoidal wave shape. The molding die 11 shown in the figures has chamfered portions 13B on both side edges of the tip surface 13A of the ridge 13 and curved corner portions 14B on both side edges of the bottom surface 14A of the groove 14 . The chamfered portion 13B and the curved corner portion 14B are curved surfaces, and by sandwiching the fiber reinforced plastic 9 from both sides in a heated state, the curved portion 3C is formed at the boundary between the slope portion 3B of the core 3 and the joint portion 3A. .

The pair of molding dies 11 heats and pressurizes the fiber-reinforced plastic 9 and further cools them, so that circulation paths (not shown) for heating and cooling are provided inside. The heating circulation path circulates a fluid such as heating oil to heat the molding surface 11X, and the cooling circulation path circulates a fluid such as cooling water to cool the molding surface 11X. The heating circuit is connected to a heating system that circulates a liquid such as hot water or heating oil, or a gas such as water vapor. A cooling system is connected to circulate the fluid. The heating system heats and circulates the fluid through the mold 11 circuit. A cooling system cools and circulates the fluid through the mold 11 circuit.

The molding apparatus 10 described above molds the fiber-reinforced plastic 9 into a trapezoidal wave in the following steps.
1. The molding surface 11X is placed in a horizontal posture, and the upper molding die 11B is lifted by the cylinder 12 to open the pair of molding dies 11. As shown in FIG. In this state, the sheet-like fiber reinforced plastic 9 is set on the molding surface 11X, which is the upper surface of the lower molding die 11A.
2. A heating fluid such as heating oil or heated steam is circulated in the circulation paths of both molding dies 11 to heat the molding surfaces 11X of the molding dies 11 .
3. The upper molding die 11B is lowered by the cylinder 12, and the fiber reinforced plastic 9 is heated and pressurized by the molding surfaces 11X of the pair of molding dies 11 to be molded into a trapezoidal wave shape.
4. The circulation of the heating fluid that has been circulating in the circulation paths of both molds 11 is stopped, and the cooling liquid is circulated in the circulation paths to cool the molding surface 11X.
5. After cooling the fiber reinforced plastic 9 molded into the trapezoidal wave shape, the upper molding die 11B is lifted by the cylinder 12, and the core 3 molded into the trapezoidal wave shape of the fiber reinforced plastic 9 is demolded.
The fiber-reinforced plastic core 3 of the thermoplastic resin is cooled to a temperature at which the thermoplastic resin hardens and is demolded from the mold 11, and the amphoteric plastic core is made thermoplastic as the thermoplastic resin descends. It can be demolded in a resin state.

The plastic laminate 1 is obtained by laminating the joint portion 3A of the plate material 2 and the core 3, and by sandwiching the laminated portion from both sides and applying heat and pressure, the thermoplastic resin of the joint portion 3A of the plate material 2 and the core 3 is formed. are thermally melted, and the joining portion 3A of the plate material 2 and the core 3 is locally pressurized to heat-weld the core 3 and the plate material 2 together. In this method, a core 3 formed into a trapezoidal wave shape and a plate material 2 are laminated, and the laminated body of the core 3 and the plate material 2 is sandwiched between a pair of heated hot plates to heat and press the plate material 2. and the core 3 are heat-sealed.

In the plastic laminate 1 shown in FIG. 1, the plate material 2 and core 3 are heat-sealed by a joining device 25 shown in FIGS. The bonding device 25 includes a pair of hot plates 26 and an actuator cylinder 27 for reciprocating one of the hot plates 26 . The joining device 25 shown in the figure laminates the core 3 on the plate 2, and presses the welded portion 3A of the core 3 to the plate 2 in a heated state with the lower hot plate 26A and the upper hot plate 26B to thermally weld them. The lower hot plate 26A has a flat surface, and the upper hot plate 26B is provided with press projections 28 for locally heating and pressurizing the welded portion 3A of the core 3 at a trapezoidal wave pitch of the core 3. In this hot plate 26, the plate material 2 is placed on the upper surface of the lower hot plate 26A, the plate material 2 is heated by the lower hot plate 26A, the core 3 is laminated on the plate material 2, and the upper hot plate 26B is pressed. The welded portion 3A of the core 3 is heated and pressurized by the protrusion 28, and the plate material 2 and the core 3 are thermally welded. The surface of the plate material 2 heated and thermally melted by the lower hot plate 26A is the bonding area 2x where the press protrusions 28 of the upper hot plate 26B heat and pressurize the welding portion 3A of the core 3 to thermally weld the surface. A smooth surface 2a is formed by being pressed by the flat lower hot plate 26A, and in the non-bonding region 2y where the core 3 is not thermally welded, unevenness is formed by reinforcing fibers without being pressed by the lower hot plate 26A. A face 2b is formed. The method of joining the core 3 to the plate material 2 with the hot plate 26 can join the plate material 2 and the core 3 by making the surface of the plate material smoother. Furthermore, the plastic laminate 1 can also be formed by heating and pressing the surface of the plate material with a hot plate having an uneven surface to form the uneven surface 2b.

The lower hot plate 26A and the upper hot plate 26B heat and pressurize the plate material 2 and the core 3 to bond them together, cool the plate material 2 and the core 3, release the pressurized state, and form the plastic laminate 1. to carry out. The upper and lower hot plates 26 are heated by circulating a heating coolant such as heating oil therein, and then cooled by circulating a cooling liquid. The pair of hot plates 26 pressurize the plate material 2 and the core 3 in a heated state to heat-weld them, and then cool them. (not shown) are provided. The heating circulation path circulates a fluid such as heating oil to heat the surface of the lower hot plate 26A and the press projections 28 of the upper hot plate 26B, and the cooling circulation path circulates a fluid such as cooling water. The surface of the lower hot plate 26A and the press projections 28 of the upper hot plate 26B are cooled. The heating circuit is connected to a heating system that circulates a liquid such as hot water or heating oil, or a gas such as pressurized steam. A cooling system that circulates a fluid such as The heating system heats the fluid and circulates it through the hot plate 26 circuit. A cooling system cools and circulates the fluid in the hot plate 26 circuit.

The joining device 25 described above joins the plate material 2 and the core 3 in the following steps.
1. The upper and lower hot plates 26 are placed horizontally, and the upper hot plate 26B is lifted by the cylinder 22 to open the pair of hot plates 26.例文帳に追加In this state, the plate material 2 is set on the lower hot plate 26A, and the core 3 is laminated on the plate material 2. As shown in FIG. The core 3 is set at a position where the pressing protrusions 28 of the upper hot plate 26B are guided by the parallel grooves 3E.
2. A heating fluid such as heating oil or heated steam is circulated in the circulation path of both hot plates 26 to heat the surface of the lower hot plate 26A and the press projections 28 of the upper hot plate 26B.
3. The upper hot plate 26B is lowered by the cylinder 27, the central core 3 and the plate material 2 are pressed to a heated state by the upper and lower hot plates 26, and the joining portion A of the central core 3 is thermally welded to the plate material 2 to form a plastic laminate. 1.
4. The circulation of the heating fluid circulating in the circulation paths of both hot plates 26 is stopped, and the cooling liquid is circulated in the circulation paths to cool the surface of the lower hot plate 26A and the press projections 28 of the upper hot plate 26B.
5. After cooling the heating portion of the plastic laminate 1 where the core 3 and the plate material 2 are thermally welded, the upper hot plate 26B is lifted by the cylinder 27 to remove the plastic laminate 1 from the hot plate 26. FIG.
The plastic laminate 1 is removed from the hot plate 26 by cooling until the thermoplastic resin of the fiber-reinforced plastic becomes hard. Fiber reinforced plastic of amphoteric plastic, or plastic laminate 1 in which core 3 and plate material 2 are heat-sealed with amphoteric plastic, is in a state in which thermoplastic resin of amphoteric plastic hardens and becomes thermoplastic resin. Cool and demold.

The fiber-reinforced plastic of thermoplastic resin is heat-sealed by applying pressure from both sides to the plate material 2 and core 3 in a state where the thermoplastic resin is melted by heating. Therefore, the fiber-reinforced plastic plate 2 and core 3 can be heat-sealed without using an adhesive. However, the plastic laminate 1 can also be heat-sealed via an adhesive. The plate material 2 and the core 3 can be heat-sealed via, for example, an adhesive that melts when heated.

The plastic laminate 1, in which the plate material 2 and the core 3 are thermally welded via an adhesive, can use a thermoplastic resin such as hot-melt that is melted by heating as the adhesive. As such a hot melt adhesive, for example, a sheet-like adhesive is prepared in a non-melted state, and this sheet-like adhesive can be laminated on the back side of the plate material 2 for use. The sheet-like adhesive melts the thermoplastic resin by heating the plate 2 and presses the plate 2 and the core 3 from both sides to weld them together. At this time, the thermoplastic resin of the plate member 2 that is heated together with the hot melt is also melted. For this reason, a smooth surface 2a is formed in the bonding region 2x where the melted thermoplastic resin is pressed from both sides and thermally welded, and an uneven surface 2b is formed in the non-bonded region 2y, which is not thermally welded without being pressurized. be.

Amphoteric plastic prepregs can also be used for fiber-reinforced plastics. Amphoteric plastic prepreg is a fiber sheet impregnated with uncured amphoteric plastic. Amphoteric plastics are plastics that exhibit the physical properties of both thermosetting resins and thermoplastic resins. Thermoplastic epoxy resins that exhibit thermoplastic properties in the uncured state in a liquid or paste state, and exhibit thermoplastic properties when cured. is a phenoxy resin. "NS-TEPreg (registered trademark)" manufactured by Nippon Steel & Sumikin Materials Co., Ltd. can be used as the amphoteric plastic prepreg.

The amphoteric plastic prepreg is used for the plate 2 and the core 3, and the plate 2 and the core 3 are joined by curing the amphoteric plastic. The amphoteric plastic prepreg is heated while being laminated as the plate material 2 and the core 3 to thermally cure the amphoteric plastic. The hardened amphoteric plastic becomes a thermoplastic resin, and presses the welded portion 3A of the plate 2 and the core 3 from both sides to thermally weld the plate 2 and the core 3 together. Amphoteric plastic prepregs are used for either the board 2 or the core 3 or both the board 2 and the core 3 . The plastic laminate 1 manufactured by using the amphoteric plastic prepreg for the plate material 2 is hardened by heating and pressurizing the amphoteric plastic of the prepreg and thermally welded, so that the surface of the plate material in the joint region 2x is made a smoother smooth surface. In the non-bonding region 2y where pressure is not applied, the surface of the plate material is formed with an uneven surface 2b. The prepreg used for the core 3 is formed into a trapezoidal wave shape, laminated on the plate material 2, and heat-sealed. The plastic laminate 1 using prepreg for both the plate material 2 and the core 3 can increase the bonding strength between the plate material 2 and the core 3 .

The above prepreg can control the shape retention in the uncured state of the amphoteric plastic. The prepreg for the core is molded into a trapezoidal wave shape in a sheet-like state that can be deformed by controlling the uncured state, and then laminated on the plate material 2 and heat-sealed. The prepreg is sandwiched between a pair of heat forming rollers and formed into a trapezoidal wave shape. The thermoforming roller for forming the prepreg into a trapezoidal wave shape heats and presses the amphoteric plastic to completely harden it, or does not completely harden the amphoteric plastic. Harden to a firm state.

The plastic laminate 1 is molded into a three-dimensional shape for many uses. The fiber reinforced plastics of the plate material 2 and the core 3 are made of a thermoplastic resin for the plastic in which the reinforcing fibers are embedded, and the plastic laminate 1 in which the plate material 2 and the core 3 are bonded with the thermoplastic resin is formed into a plate shape. After mass production, it is heated and pressurized to form a three-dimensional shape suitable for the application. The plate material 2 and the core 3 are thermally welded via a thermoplastic resin so that the plate-like plastic laminate 1 can be formed into a three-dimensional shape.

In the process of pressurizing the welding portion 3A of the core 3 and thermally welding it to the plate 2 shown in FIG. As shown in , it is pressed by the joining portion 3A and the plate member 2, and is extruded between the curved portion 3C and the plate member 2 to become the gap-filling adhesive 4A. The plastic laminate 1 shown in the figures has a curved portion 3C at the corner portion between the slope portion 3B and the joint portion 3A, and the space between the curved portion 3C and the plate material 2 is filled with a gap-filling adhesive 4A. The extruded gap-filling adhesive 4A is heated and cured to heat-weld the plate member 2 and the core 3 together. The gap-filling adhesive 4A extruded between the curved portion 3C and the plate material 2 is adjusted by adjusting the pressing force between the joint portion 3A of the core 3 and the plate material 2, and the amount extruded from the joint portion 3A to the curved portion 3C is adjusted. Adjustable.

Furthermore, the plastic laminate 1 shown in FIG. 1 has a surface treatment layer 30 attached to the surface of the plate material 2 . The plastic laminate 1 can be provided on the plate material surface by selecting the optimum surface treatment layer 30 according to various uses. As such a surface treatment layer 30, a coating film 31 can be adhered to the plate material surface. However, the surface treatment layer 30 is not limited to a coating film, and any other treatment layer that can adhere to the surface of the plate to cover or decorate the surface of the plate can also be employed. For example, the surface treatment layer 30 can be formed by adhering a sheet material or a metal foil to be an exterior sheet or an exterior film via an adhesive or an adhesive layer. Even in this case, the uneven surface 2b provided on the surface of the plate allows the adhesive or the adhesive layer to be firmly adhered by an anchoring effect so that the surface treatment layer is not peeled off.

The above-described plastic laminate 1 can be coated with a coating film 31 as the surface treatment layer 30 on the surface of the plate material by the following steps.
A base paint 32 is applied to the plate material surface of the plastic laminate 1 in a base coating step. The base paint 32 strongly adheres a coating material to the surface of the plate material, smoothes the surface of the plate material 2, and further colors the surface of the plate material 2 with a base color. The undercoating process includes a first undercoating process of applying a sealer 32A to the surface of the plate material 2 and adhering the sealer 32A to the uneven surface 2b of the plate material 2 by an anchor effect, and applying a base color paint 32B to the surface of the sealer 32A. An undercoating film 32 is formed in the second undercoating step of coloring the plate material 2 with a base color.

In the first undercoating step, the undercoating 32 is adhered to the plate material 2 without being peeled off. The sealer 32A used in this step penetrates into the uneven surface 2b of the surface of the plate material and adheres the base paint 32 to the plate material 2 firmly. The sealer 32A is a low-viscosity polyester-based or urethane-based liquid paint that penetrates into the minute gaps of the uneven surface 2b of the plate 2 and firmly adheres to the plate 2 by an anchor effect.

The base color paint 32B in the second undercoating process colors the surface of the plate material 2 in a color close to white. The base color paint 32B almost completely hides the color unevenness of the base and colors the entire surface of the plate material 2 in a uniform and uniform color.

Furthermore, in the undercoating process, an ultraviolet curing paint is applied to the surface of the sealer 32A as a process after the first undercoating process, or an ultraviolet curing paint is applied to the surface of the base color paint 32B as a process after the second undercoating process. can also These UV curable paints are rapidly cured by irradiation with UV rays. The UV curable paint is cured with UV rays, and then the entire surface is uniformly ground with a brush sander or the like to make a smooth surface. By applying the ultraviolet curable coating in this manner, the base coating 32 can be made into a tough coating film.

In the top coating process, a transparent or translucent finishing coating 33 is applied to the surface of the base color coating 32B. In the top coating process, for example, the finish paint 33 is applied using a roll coater. Furthermore, as a post-process of the top coating process, an ultraviolet curable coating can be applied to the surface of the applied finish coating 33 . By applying the ultraviolet curable paint in this way, the surface of the finish paint 33 can be hardened and made tough.

In the plastic laminate 1 described above, the plate material 2 is joined to one side of the core 3, but the plate material 2 can be joined to both sides of the core 3. In the plastic laminate 1 having the plate members 2 joined on both sides, the plate member 2 first joined to one surface of the core 3 is thermally welded to the plate member 2 by locally pressing the joining portion 3A of the core 3. , The plate material 2 to be joined to the other surface is joined by applying an adhesive between the plate material 2 and the joint portion 3A of the core 3, or by bonding the opposing surfaces of the plate material 2 and the core 3 It can be joined by pressing while being heated by the heater 10 and thermally melted.

[Example 1]
The plastic laminate 1 shown in FIG. 1 can be manufactured by the following steps.
In the plastic laminate 1 shown in this figure, a plate material 2 is adhered to one side of a core 3 .
The plate member 2 and core 3 are made of carbon fiber reinforced plastic in which carbon fibers are embedded in nylon 6 .
This carbon fiber reinforced plastic has a total specific gravity of 1.32, where the mixing ratio of nylon 6 and carbon fiber is the volume ratio.
In carbon fiber reinforced plastic, carbon fibers are three-dimensionally aggregated without directivity and embedded in nylon 6.
The thickness (d, t) of the plate material 2 and core 3 is 0.15 mm.
The center core 3 has a trapezoidal wave shape that alternately connects the joint portion 3A and the inclined surface portion 3B of the inclined surface 3D. ) is 70 degrees, and the plastic laminate 1 is shaped into trapezoidal waves with a wave height of 3 mm in overall thickness (D).

As shown in FIGS. 5 and 6, the plate material 2 and the core 3 are joined by heat welding using a pair of hot plates 26 . The pair of hot plates 26 are provided with press projections 23 for locally pressing the joining portion 3A of the core 3 against the plate material 2, as shown in FIG. The hot plate 26 presses the joining portion 3A and the plate member 2 with the press projections 28 to thermally weld the plate member 2 and the core 3, and then cools and joins them.

In the plate material 2, bonded regions 2x where the bonded portion 3A of the core 3 is thermally welded and non-bonded regions 2y where the core 3 is not thermally welded are alternately arranged in stripes. The bonding region 2x of the plate material 2 is cooled while the core 3 is thermally welded to the back surface of the smooth roll 15, so that the surface becomes a smooth surface 2a. Since the non-bonding region 2y of the plate material 2 is cooled without the smooth roll 15 being in close contact with the surface, the heat-melted thermoplastic resin moves and the surface becomes the uneven surface 2b.

As shown in the plan view of FIG. 7, the plastic laminate 1 manufactured by the above steps has smooth surfaces 2a and uneven surfaces 2b alternately formed in stripes on the surface of the plate material. In addition, in FIG. 7, the uneven surface 2b is indicated by cross hatching in order to make it easy to distinguish between the smooth surface 2a and the uneven surface 2b. Furthermore, FIG. 7 shows the results of measuring the surface conditions of the smooth surface 2a and the uneven surface 2b formed on the surface of the plate material using a non-contact three-dimensional measuring device (NH-3N, manufactured by Mitaka Kohki Co., Ltd.). it's shown. The specifications and measurement method of this non-contact three-dimensional measuring device were as follows.

A non-contact laser probe was used to measure the unevenness of the surface of the object to be measured. A spot of laser light was irradiated on the surface of the object to be measured, and the surface was probed using this as a probe to measure the width and height of the surface of the object to be measured.
Measurement range: XY: 150 mm, Z: 100 mm
Measurement accuracy: XY: (1+5L/150) μm, Z: (1+5L/100) μm
Resolution……XY: 0.1 μm, Z: 0.01 μm

As shown in this figure, an uneven surface 2b having greater unevenness than the smooth surface 2a is formed in stripes on the surface of the plate material. In this plastic laminate 1, when the surface treatment layer 30 is provided on the surface of the plate material, the surface treatment layer 30 can be strongly adhered by the anchor effect of the uneven surface 2b.

A coating film 31 is formed on the surface of the plastic laminate 1 manufactured by the above steps in the following undercoating step and topcoating step.
(1) Undercoating Step The sanding sealer 32A is applied in the first undercoating step. After that, after curing the sanding sealer 32A, as a post-process of the first undercoating process, an ultraviolet curable paint (not shown) that is cured by irradiating ultraviolet rays is applied. After irradiating ultraviolet rays to cure the ultraviolet curable paint, the surface is polished to a smooth surface. A brush sander is used for sanding. Next, as a second undercoating step, a base color paint 32B is applied thickly using a flow rotor machine to almost completely hide the base color and color the surface of the plate material 2 white. After curing the base color coating 32B, as a step after the second undercoating step, an ultraviolet curable coating is further applied to the surface and cured. After curing the ultraviolet curable paint with ultraviolet rays, the surface is polished to a smooth surface.

(2) Top Coating Process For the plastic laminate 1 whose surface has been colored in the under coating process, a transparent finish coating 33 is applied to the surface of the plate material 2 . In the top coating process, a transparent finish coating 33 is applied with a roll coater. In the top coating process, a urethane-based, polyester-based, or acrylic-based paint is applied. After this paint is cured, a transparent UV curable paint (not shown) is applied to the surface of the finish paint 33 as a step after the overcoating process. For example, a urethane-based UV curable coating is used as the UV curable coating.

The plastic laminate 1 manufactured by the above steps can achieve light weight and high bending strength, and can strongly adhere the coating film 31 adhered to the surface of the plate material by the anchor effect of the uneven surface 2b of the surface of the plate material. The above-described plastic laminate 1 has a clean smooth surface, and is repeatedly bent 90 degrees with a radius of curvature of 1 cm and flattened 1000 times to achieve bonding strength that does not peel off. Compared to high-strength steel with a thickness of 0.65 mm, which is used for vehicle body steel plates, it is 1/9 lighter, and its flexural rigidity is 7 times that of high-strength steel.

By arranging a smooth surface and an uneven surface on the surface, the plastic laminate of the present invention can be used as a plastic laminate that can adhere a surface treatment layer firmly to the surface without peeling, such as a steel plate for the body of a vehicle or a mobile phone. It is effectively used in place of metal plates for cases such as

REFERENCE SIGNS LIST 1 Plastic laminate 2 Plate material 2a Smooth surface 2b Uneven surface 2x Bonded area 2y Non-bonded area 3 Center core 3A Bonded portion 3B Inclined portion 3C Curved portion 3D Inclined surface 3E Parallel groove 4A Gap filling adhesive 9 Fiber reinforced plastic 10 Molding device 11 Mold 11A Lower mold 11B Upper mold 11X Molding surface 12 Cylinder 13 Projection 13A Tip surface 13B Chamfer Part 14 Groove 14A Bottom surface 14B Curved corner part 25 Joining device 26 Hot plate 26A Lower hot plate 26B Upper hot plate 27 Cylinder 28 Press projection 30 Surface treatment layer 31 Coating film 32 Base paint 32A... Sealer 32B... Base color paint 33... Finish paint

Claims (9)

A plate material made of a plate-shaped fiber-reinforced plastic in which reinforcing fibers are embedded in a thermoplastic resin;
A plastic laminate comprising a core made of fiber-reinforced plastic having a trapezoidal wave shape, in which reinforcing fibers thermally welded to the plate material are embedded in a thermoplastic resin,
A smooth surface and an uneven surface having greater unevenness than the smooth surface are provided on a part or the entire surface of the plate material, and the smooth surface and the uneven surface are alternately arranged in stripes. become,
Furthermore, a plastic laminate comprising a surface treatment layer of a coating film attached to the surface of the plate material, wherein the surface treatment layer is a coating film . 2. The plastic laminate according to claim 1, wherein said plate material has said uneven surface formed by said reinforcing fibers embedded in a thermoplastic resin. 3. The plastic laminate according to claim 1, wherein the reinforcing fibers embedded in a thermoplastic resin protrude from the surface of the plate material to form the uneven surface. The core has a trapezoidal wave shape in which slope portions and joint portions are alternately arranged and parallel grooves are alternately provided on both surfaces at a predetermined pitch,
The surface of the plate material is characterized in that the bonded area formed by heat-welding the core core to the back surface is the smooth surface, and the non-bonded area where the core is not heat-welded is the uneven surface. Item 4. A plastic laminate according to any one of items 1 to 3. 5. The plastic laminate according to any one of claims 1 to 4, wherein the surface treatment layer is a coating film having a laminated structure in which a finish coating is laminated on a base coating. 6. The plastic laminate according to any one of claims 1 to 5 , wherein the plate material is thermally welded to one side of the core. 6. The plastic laminate according to any one of claims 1 to 5 , wherein the plate members are thermally welded to both surfaces of the core. 8. The plastic laminate according to any one of claims 1 to 7 , wherein the plate material and the fiber-reinforced plastic of the core are formed by embedding carbon fibers as reinforcing fibers. 9. The plastic laminate according to any one of claims 1 to 8 , wherein the thermoplastic resin of said fiber-reinforced plastic is any one of nylon resin, polycarbonate, acrylic resin, PET, PP, PPS , and phenoxy resin. body.

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