JP7601780B2 - Molded body and method for manufacturing the same - Google Patents

Description

The present invention relates to a molded body and a method for manufacturing a molded body.

In the fields of automobiles and motorcycles, the shift from metal to resin as a component material is being considered in order to reduce weight. Fiber-reinforced resins containing glass or carbon fiber are sometimes used as resin materials to obtain the same strength, rigidity, and low linear expansion coefficient as metal parts. However, fiber-reinforced resins have the problem that unevenness caused by the fibers appears on the surface of the molded product, which is known as fiber lifting, which mars the appearance.

As a method for improving the appearance of fiber-reinforced resin, a method of covering the surface of a part made of fiber-reinforced resin with a sheet has been investigated (for example, Patent Documents 1 and 2).

JP 2000-158481 A JP 2010-260251 A

However, using such sheets makes it difficult to improve the appearance, and in some cases may even worsen the appearance, so there is an even greater demand for technology to improve the appearance of fiber-reinforced resins. Furthermore, the technology in Patent Document 1 aims to improve the appearance by sandwich molding a decorative sheet, a fiber-free resin, and a fiber-containing resin, but this has problems such as increasing the thickness of the molded body, compromising the weight reduction effect, and imposing restrictions on the shape of the molded body. With the technology in Patent Document 2, particularly when the molded body is formed by injection molding, it is not possible to expect an improvement in appearance.

The object of the present invention is to provide a fiber-reinforced resin molding having an excellent appearance.

The present inventors have considered the reason why the appearance cannot be improved even if the above-mentioned covering sheet (surface sheet) is used as follows. That is, since the fibers are randomly present in the fiber-reinforced resin, the distance between the surface sheet and the fibers varies depending on the location. This difference in distance causes unevenness in the amount of shrinkage of the matrix resin made of fiber-reinforced resin, which causes unevenness on the sheet surface and impairs the surface smoothness, i.e., the appearance. Here, when the fiber-reinforced resin is injection molded toward a mold, the side in contact with the mold is cooled and a so-called "skin layer" with a low crystallinity is formed. In the skin layer, the fibers are oriented in the flow direction, so the distance between the sheet surface and the fibers is easily made uniform. However, when the surface sheet is used, the skin layer is not sufficiently formed in the fiber-reinforced resin due to the insulating effect of the surface sheet, and the proportion of the so-called "core layer" with random fiber orientation increases, which promotes differences in the distance from the fibers and increases the formation of unevenness on the sheet surface, resulting in a loss of appearance.
The inventors discovered that by using a polypropylene having a specific crystallization rate as the polypropylene contained in the fiber-reinforced resin, the formation of a skin layer in the fiber-reinforced resin is promoted, resulting in a molded body having high surface smoothness and an excellent appearance, and thus completed the present invention.

According to the present invention, the following molded body and the like are provided.
1. A molded body including polypropylene and a fibrous reinforcing material;
A resin sheet including at least a resin layer and covering at least a part of a surface of the molded body;
Including,
The crystallization rate of the polypropylene at 135°C is 0.6 min ^-1 or more.
2. The molded article according to 1, wherein the polypropylene has a crystallization rate of 1.0 min ⁻¹ or more at 135° C.
3. The molded product according to 1 or 2, wherein the resin layer in the resin sheet contains polypropylene.
4. The molded article according to 3, wherein the polypropylene contained in the resin layer has a crystallization rate at 130° C. of 2.5 min ⁻¹ or less.
5. The molded article according to 3 or 4, wherein the polypropylene contained in the resin layer has an isotactic pentad fraction of 80 mol % or more and 99 mol % or less.
6. The molded article according to any one of 3 to 5, wherein the content of the nucleating agent for the polypropylene contained in the resin layer is 1.0% by mass or less of the resin layer.
7. The molded product according to any one of 3 to 6, wherein the polypropylene contained in the resin layer does not contain a nucleating agent.
8. The molded body according to any one of 1 to 7, wherein the resin sheet includes a print layer on the molded body side as viewed from the resin layer.
9. The resin sheet includes an easy-adhesion layer on the molded body side as viewed from the resin layer,
The molded body according to any one of 1 to 8, wherein the easy-adhesion layer comprises one or more selected from the group consisting of urethane resins, acrylic resins, polyolefins, and polyesters.
10. The resin sheet includes an undercoat layer located on the molded body side as viewed from the resin layer, and a metal layer laminated on the molded body side as viewed from the undercoat layer,
the undercoat layer comprises one or more resins selected from the group consisting of urethane resins, acrylic resins, polyolefins, and polyesters;
10. The molded body according to any one of 1 to 9, wherein the metal layer contains one or more metal elements selected from the group consisting of tin, indium, chromium, aluminum, nickel, copper, silver, gold, platinum, and zinc.
11. A method for producing a molded product according to any one of 1 to 10, comprising: placing a resin sheet on a mold; and supplying a molding resin composition containing polypropylene having a crystallization rate of 0.6 min ^-1 or more at 135°C and a fibrous reinforcing material onto the resin sheet, thereby integrating the molding resin composition and the resin sheet while shaping the resin sheet to match the mold.
12. A method for producing a molded product according to any one of 1 to 10, comprising: shaping a resin sheet to fit a mold; and supplying a molding resin composition containing polypropylene having a crystallization rate of 0.6 min ^- 1 or more at 135°C and a fibrous reinforcing material onto the shaped resin sheet, thereby integrating the molding resin composition with the resin sheet.
13. Heating a molding resin composition containing polypropylene and a fibrous reinforcing material so that the polypropylene melts;
Supplying the heated molding resin composition onto a resin sheet placed in a mold; and
and cooling and solidifying the molding resin composition on the resin sheet to obtain a molded body including a molded body main body made of the solidified molding resin composition and the resin sheet covering at least a part of a surface of the molded body,
The polypropylene contained in the molding resin composition subjected to melting has a crystallization rate at 135°C of 0.6 min ^-1 or more.
A method for producing a molded body.

The present invention provides a fiber-reinforced resin molding having excellent appearance.

FIG. 1 is a schematic cross-sectional view showing a molded body according to one embodiment of the present invention. FIG. 4 is a schematic cross-sectional view showing a molded body according to another embodiment of the present invention. FIG. 2 is a schematic diagram of an apparatus used for producing a resin sheet in the examples.

(Molded body)
A molded body according to one aspect of the present invention includes a molded body main body and a resin sheet. The molded body main body includes polypropylene and a fibrous reinforcing material. The resin sheet includes at least a resin layer and covers at least a part of the surface of the molded body main body. The crystallization rate of the polypropylene included in the molded body main body at 135°C is 0.6 min ^-1 or more. Due to the above-mentioned configuration, the molded body according to one aspect of the present invention has a high smoothness of the surface of the molded body, i.e., the resin sheet surface, and has an excellent appearance.

In the molded body according to one aspect of the present invention, the crystallization rate of polypropylene at 135 ° C. is 0.6 min ⁻¹ or more, so that the solidification temperature of the molding resin composition (fiber reinforced resin) supplied to form the molded body during injection molding is increased, and solidification is accelerated. When such a fiber reinforced resin is supplied onto a resin sheet, the formation of a skin layer on the resin sheet side of the fiber reinforced resin is promoted. In such a skin layer, the fibrous reinforcing material is oriented in the flow direction (parallel to the resin sheet). Therefore, by forming a thicker skin layer, the distance between the surface of the resin sheet and the fibrous reinforcing material in the fiber reinforced resin is made more uniform, surface unevenness due to the shrinkage difference of the resin is mitigated, and a molded body (fiber reinforced resin molded body) with excellent surface smoothness is obtained.
The terms "skin layer" and "core layer" are names for the respective parts of a single resin layer of the same composition, distinguished by the degree of crystallinity in the thickness direction, and usually no clear boundary is observed between the two.

(Molded body morphology)
A schematic cross-sectional view of a molded article according to one embodiment of the present invention is shown in Fig. 1. Note that Fig. 1 is merely for explaining the layer structure of the molded article according to one embodiment, and the aspect ratio and film thickness ratio are not necessarily accurate.
As shown in FIG. 1, the molded body 1 includes a molded body main body 2 and a resin sheet 3 (resin layer 31 ) that covers the molded body main body 2 .

The molded article may be any article that includes a molded body and a resin sheet. The shape of the molded article is not particularly limited, and may be, for example, a layered shape or a specific three-dimensional shape.
In one embodiment, when the molded body is layered, the molded body may be a laminate including a layered molded body and a resin sheet. The layer structure of such a laminate is not particularly limited, and may be, for example, a two-layer structure of molded body/resin sheet, or a three-layer structure of resin sheet/molded body/resin sheet.
The resin sheet may cover a part of the surface of the molded body, or may cover the entire surface (entire surface) of the molded body.

The fact that the molded body includes a resin sheet and a molded body can be confirmed, for example, by the fact that the constituent materials or material compositions of the resin sheet and the molded body are different, or by the existence of an interface between the resin sheet and the molded body. The existence of the interface can be confirmed, for example, by cross-sectional observation using a phase contrast microscope or a polarizing microscope. For example, even if the constituent materials or material compositions of the resin sheet and the molded body are the same, the resin sheet and the molded body undergo different molding processes, resulting in different crystalline states, and an interface is formed between the resin sheet and the molded body.
Generally, the resin sheet does not contain a fibrous reinforcing material.

(Main body: polypropylene)
The crystallization rate of the polypropylene used for the molded body at 135°C is 0.6 min ^-1 or more, and may be 0.65 min ^- 1 or more, 0.7 min ^-1 or more, 0.75 min ^- 1 or more, 0.8 min ^- 1 or more, 0.9 min ^-1 or more, 1.0 min ^-1 or more, 1.1 min ^-1 or more, or 1.2 min ^-1 or more. The upper limit is not particularly limited, and may be, for example, 20 min ^-1 or less, 15 min ^-1 or less, 10 min ^-1 or less, 8 min-1 or less, 6 min ^-1 or less, 5 min ^{-1 or} less, 4 min ^-1 or less, or 3 min ^-1 or less.
The crystallization rate is measured by the method described in the Examples.

(Molded body: fibrous reinforcing material)
Examples of fibrous reinforcing materials include inorganic fibers and organic fibers such as glass fibers, carbon fibers, aramid fibers, alumina fibers, boron fibers, and cellulose fibers. These materials may be used alone or in combination of two or more. From the viewpoint of improving the strength of the molded body, glass fibers and carbon fibers are preferred.

The average fiber length of the fibrous reinforcing material is not particularly limited and may be, for example, 0.1 mm or more, 0.2 mm or more, 0.5 mm or more, or 1 mm or more. The upper limit is not particularly limited and is, for example, 10 mm or less.
The fiber length is the length in the longitudinal direction of the fibrous reinforcing material, and the average fiber length is the arithmetic mean value of the fiber lengths measured for 20 reinforcing materials randomly selected from the fibrous reinforcing materials observed in the field of view under a stereomicroscope after burning the resin component of a molded body containing the fibrous reinforcing material in an electric furnace and spreading the remaining fibrous reinforcing material on a preparation or the like.

The average fiber diameter of the fibrous reinforcing material is not particularly limited and may be, for example, 2 μm or more, 6 μm or more, or 10 μm or more. The upper limit is not particularly limited and is, for example, 100 μm or less.
The fiber diameter (diameter) is the diameter of a reinforcing material with a circular cross section, and is the diameter of a perfect circle of the same area when the cross section is converted into a perfect circle of the same area for reinforcing materials with other cross sections. The average fiber diameter is the arithmetic mean value of fiber diameters (diameters) measured for 20 reinforcing materials randomly selected from the fibrous reinforcing materials observed in the field of view under a stereomicroscope after burning the resin component of a molded product containing the fibrous reinforcing material in an electric furnace and spreading the remaining fibrous reinforcing material on a preparation or the like.

The content of the reinforcing fibers in the molded body is not particularly limited, and from the viewpoint of imparting sufficient strength to the molded body, it may be, for example, 7% by mass or more, 10% by mass or more, 12% by mass or more, or 15% by mass or more. The upper limit is not particularly limited, and is, for example, 75% by mass or less, 70% by mass or less, 60% by mass or less, 50% by mass or less, 38% by mass or less, or 28% by mass or less.
The content of the reinforcing fibers relative to the polypropylene used in the molded body is not particularly limited, and may be, for example, 7% by mass or more, 10% by mass or more, 12% by mass or more, or 15% by mass or more. The upper limit is not particularly limited, and may be, for example, 75% by mass or less, 70% by mass or less, 60% by mass or less, 50% by mass or less, 38% by mass or less, or 28% by mass or less.

(Molded body: nucleating agent)
A nucleating agent may be added to the polypropylene used for the molded body. The crystallization rate of the polypropylene can be adjusted by the type and amount of the nucleating agent, and the crystallization rate at 135° C. can be made 0.6 min ⁻¹ or more.

Specific examples of nucleating agents include organic carboxylic acids or their metal salts, aromatic sulfonates or their metal salts, organic phosphate compounds or their metal salts, dibenzylidene sorbitol or its derivatives, partial metal salts of rosin acid, inorganic fine particles, imides, amides, quinacridones, quinones, or mixtures thereof.

Examples of metal salts of organic carboxylic acids include aluminum benzoate, aluminum p-t-butylbenzoate, sodium adipate, sodium thiophenecarboxylate, sodium pyrrolecarboxylate, etc.

Examples of dibenzylidene sorbitol or derivatives thereof include dibenzylidene sorbitol, 1,3:2,4-bis(o-3,4-dimethylbenzylidene)sorbitol, 1,3:2,4-bis(o-2,4-dimethylbenzylidene)sorbitol, 1,3:2,4-bis(o-4-ethylbenzylidene)sorbitol, 1,3:2,4-bis(o-4-chlorobenzylidene)sorbitol, 1,3:2,4-dibenzylidene sorbitol, etc. Specific examples include "Gelall MD" and "Gelall MD-R" (trade names) manufactured by New Japan Chemical Co., Ltd.

Examples of partial metal salts of rosin acid include "Pine Crystal KM1600", "Pine Crystal KM1500", and "Pine Crystal KM1300" (product names) manufactured by Arakawa Chemical Industries, Ltd.

Examples of inorganic microparticles include talc, clay, mica, asbestos, glass fiber, glass flakes, glass beads, calcium silicate, montmorillonite, bentonite, graphite, aluminum powder, alumina, silica, diatomaceous earth, titanium oxide, magnesium oxide, pumice powder, pumice balloons, aluminum hydroxide, magnesium hydroxide, basic magnesium carbonate, dolomite, calcium sulfate, potassium titanate, barium sulfate, calcium sulfite, molybdenum sulfide, etc.

Examples of amide compounds include adipic acid dianilide, suberic acid dianilide, etc.

Among the above nucleating agents, it is preferable to use an organic metal phosphate (metal phosphate ester salt) represented by the following general formula, as it is highly effective in increasing the crystallization rate.

（式中、Ｒ^１８は水素原子又は炭素数１～４のアルキル基を示し、Ｒ^１９及びＲ^２０はそれぞれ水素原子、炭素数１～１２のアルキル基、シクロアルキル基、アリール基又はアラルキル基を示す。Ｍはアルカリ金属、アルカリ土類金属、アルミニウム及び亜鉛のうちのいずれかを示し、Ｍがアルカリ金属のときｍは０を、ｎは１を示し、Ｍがアルカリ土類金属又は亜鉛のときｎは１又は２を示し、ｎが１のときｍは１を、ｎが２のときｍは０を示し、Ｍがアルミニウムのときｍは１を、ｎは２を示す。）

(In the formula, R ¹⁸ represents a hydrogen atom or an alkyl group having 1 to 4 carbon atoms, R ¹⁹ and R ²⁰ each represent a hydrogen atom, an alkyl group having 1 to 12 carbon atoms, a cycloalkyl group, an aryl group, or an aralkyl group. M represents any one of an alkali metal, an alkaline earth metal, aluminum, and zinc, and when M is an alkali metal, m represents 0 and n represents 1, when M is an alkaline earth metal or zinc, n represents 1 or 2, when n is 1, m represents 1, when n is 2, m represents 0, and when M is aluminum, m represents 1 and n represents 2.)

Specific examples of organic phosphate metal salts include "ADK STAB NA-11," "ADK STAB NA-21," and "ADK STAB NA-71" (all manufactured by Asahi Denka Co., Ltd.).

The amount of nucleating agent in the molded body may be, for example, 0.005% by mass or more, 0.01% by mass or more, 0.05% by mass or more, or 0.1% by mass or more, and may be 4% by mass or less, 3% by mass or less, 2% by mass or less, 1% by mass or less, or 0.5% by mass or less.

(Main body: other components)
The molded body may contain components other than those described above. Examples of the other components include additives such as weather resistance agents and antioxidants, and coloring materials (colorants) such as pigments and dyes.

(Molded body: composition)
50% by mass or more, 60% by mass or more, 70% by mass or more, 80% by mass or more, 90% by mass or more, 95% by mass or more, 98% by mass or more, 99% by mass or more, 99.5% by mass or more, 99.8% by mass or more, 99.9% by mass or more, or 100% by mass of the molded body is
It may be polypropylene and a fibrous reinforcing material, or polypropylene, a fibrous reinforcing material, and a nucleating agent.

(Resin sheet: resin of resin layer)
The resin used in the resin layer is not particularly limited, and examples thereof include polyolefins such as polyethylene (PE), polypropylene (PP), and cyclic polyolefins, polyesters such as polyethylene terephthalate (PET), polypropylene terephthalate (PPT), polybutylene terephthalate (PBT), and polyethylene naphthalate (PEN), polyamides such as nylon 6 (PA6) and nylon 66 (PA66), polyamideimide (PAI), polymethyl methacrylate (PMMA), polycarbonate (PC), polysulfone (PSF), polyacetal (POM), polyphenylene ether (PPE), polyphenylene sulfide (PPS), polyarylate (PAR), polyetherimide (PEI), polyethersulfone (PES), and polyetherketone (PEK), and may be blended resins or alloy resins using two or more of these. Copolymer resins such as AS resin, ABS resin, AES resin, AAS resin, and ACS resin may also be used.

The resin type used in the resin layer may be the same as or different from that of the molded body. In one embodiment, the resin type used in the resin layer includes polypropylene.
Polypropylene is a polymer containing at least propylene. Specific examples include homopolypropylene, copolymers of propylene and olefin, etc. In particular, homopolypropylene is preferred for reasons of heat resistance and hardness.
The copolymer may be a block copolymer, a random copolymer, or a mixture thereof. The olefin may be ethylene, butylene, cycloolefin, or the like.

The polypropylene contained in the resin layer preferably has an isotactic pentad fraction of 80 mol% or more and 99 mol% or less. Such an isotactic pentad fraction may be 80 mol% or more and 98 mol% or less, 86 mol% or more and 98 mol% or less, or 91 mol% or more and 98 mol% or less.
When the isotactic pentad fraction is 80 mol % or more, the rigidity of the resin sheet is improved, whereas when the isotactic pentad fraction is 99 mol % or less, the transparency of the resin sheet is improved.
The isotactic pentad fraction is the isotactic fraction of a pentad unit (five consecutive propylene monomers isotactically bonded) in the molecular chain of a resin composition.
The isotactic pentad fraction is measured by the method described in the Examples.

From the viewpoint of moldability, it is preferable that the polypropylene contained in the resin layer has a crystallization rate at 130° C. of 2.5 min ⁻¹ or less.
The crystallization rate of the polypropylene contained in the resin layer is preferably 2.5 min ^-1 or less, more preferably 2.0 min ^-1 or less. When the crystallization rate is 2.5 min ^-1 or less, rapid hardening of the part in contact with the mold can be suppressed, and deterioration of the design can be prevented. The lower limit is not particularly limited, but is usually 0.1 min ^-1 or more.
The crystallization rate is measured by the method described in the Examples.

The crystalline structure of polypropylene preferably contains Smectic crystals. Smectic crystals are a metastable intermediate phase, and each domain size is small, so they are preferred because they have excellent transparency. In addition, since they are metastable, they are preferred because they have excellent moldability, as compared with α crystals, because they soften the sheet with a low amount of heat.
The crystalline structure of polypropylene may also include other crystalline forms such as β crystals, γ crystals, and amorphous portions.
The polypropylene in the resin sheet may be 30% by mass or more, 50% by mass or more, 70% by mass or more, 85% by mass or more, or 90% by mass or more of smectic crystals.

The presence or absence of smectic crystals in a resin sheet can be confirmed by the following method.
The crystal structure of the polypropylene in the resin sheet is identified by measuring the wide-angle X-ray scattering pattern under the following measurement conditions using an X-ray generator ("Model Ultra X 18HB" manufactured by Rigaku Corporation). If a Smectite crystal type peak is observed even after peak separation, it can be confirmed that Smectite crystals are present in the obtained resin sheet.
(Measurement conditions)
Light source wavelength: 300 mA CuKα ray (wavelength = 1.54 Å) monochromatic light Source output voltage/current: 50 kV/250 mA
Irradiation time: 60 minutes Camera length: 1.085m
-Sample thickness: The sheets are stacked so that the thickness is 1.5 to 2.0 mm. The sheets are stacked so that the film-forming (MD) direction is aligned.
In order to shorten the measurement time, the sheets are overlapped to a distance of 1.5 to 2.0 mm, but if the measurement time is extended, measurement is possible with a single sheet without overlapping.

When the resin layer contains a polyolefin such as polypropylene, it is preferable that the polyolefin does not contain a nucleating agent. In addition, when the polyolefin does not contain a nucleating agent, it can be said that the resin layer does not contain a nucleating agent. When the nucleating agent is contained, it is preferable that the content is small, for example, 1.0 mass% or less of the resin sheet, preferably 0.5 mass% or less.
Examples of the nucleating agent include those described above for the molded body.

The method for forming the resin layer is not particularly limited, and examples thereof include an extrusion method.
The extrusion method includes cooling the molten resin, and the cooling is preferably performed at 80°C/sec or more until the internal temperature of the resin layer becomes equal to or lower than the crystallization temperature. This allows the crystal structure of the polypropylene contained in the resin layer to be a smectic crystal, and also allows the crystallization rate of the polypropylene to be 2.5 min ^-1 or less without adding a nucleating agent to the polypropylene. The cooling is more preferably performed at 90°C/sec or more, and even more preferably at 150°C/sec or more.

In one embodiment, a molded article with excellent design can be obtained by setting the crystallization rate of polypropylene to 2.5 min ^-1 or less without adding a nucleating agent and by incorporating the above-mentioned Smectic crystals. In addition, by heating and shaping the resin sheet as described later regarding molding, the resin sheet transitions to α crystals while maintaining the microstructure derived from the Smectic crystals. This transition can further improve the surface hardness and transparency of the molded article surface.

(Resin sheet: composition of resin layer)
In one embodiment, 50% by weight or more, 60% by weight or more, 70% by weight or more, 80% by weight or more, 90% by weight or more, 95% by weight or more, 98% by weight or more, 99% by weight or more, 99.5% by weight or more, 99.8% by weight or more, 99.9% by weight or more, or 100% by weight of the resin layer is resin (polypropylene).

The thickness of the resin sheet is not particularly limited, but may be, for example, 10 μm or more, 50 μm or more, or 150 μm or more, and may be, for example, 1200 μm or less, 700 μm or less, 500 μm or less, or 350 μm or less.

(Resin sheet: layer structure)
As described above, the resin sheet may form a molded body by covering the molded body with the resin layer alone, or may form a molded body by covering the molded body with the resin layer and one or more other layers in addition to the resin layer.
When the resin sheet includes a layer other than the resin layer, the layer other than the resin layer may be disposed on the molded body side as viewed from the resin layer, may be disposed on the opposite side to the molded body, or may be disposed on both sides. In addition, the layer other than the resin layer may be laminated on the entire surface of the resin layer, or may be laminated partially on the resin layer. The same applies when there are multiple layers other than the resin layer, and one layer may be laminated on the entire surface of the other layer, or may be laminated partially.

Examples of layers other than the resin layer in the resin sheet include an easy-adhesion layer, an undercoat layer, a metal layer, a printed layer, etc.

In one embodiment, the resin sheet includes a printed layer on the molded body side as viewed from the resin layer.
In one embodiment, the resin sheet includes an easy-adhesion layer on the molded body side as viewed from the resin layer.
In one embodiment, the resin sheet includes an undercoat layer on the molded body side as viewed from the resin layer, and includes a metal layer on the molded body side as viewed from the undercoat layer.

A schematic cross-sectional view of a molded product according to an embodiment in which the resin sheet includes a layer other than the resin layer is shown in Fig. 2. Note that the aspect ratio and film thickness ratio in Fig. 2 are not necessarily accurate.
In the molded body 1, the resin sheet 3 is a laminate including a resin layer 31 and four other layers, and covers the molded body 2. The resin sheet 3 is a laminate including, from the molded body 2 side, a printed layer 35, a metal layer 34, an undercoat layer 33, an easy-adhesion layer 32, and a resin layer 31 in this order.
Each of the other layers is described in more detail below.

(Easy-adhesion layer)
The easy-adhesion layer preferably contains one or more resins selected from the group consisting of urethane-based resins, acrylic-based resins, polyolefin-based resins, and polyester-based resins.
By providing such an easy-adhesion layer, even if the molded body is molded into a complex non-planar shape, the easy-adhesion layer can conform to the resin sheet to form a good layer structure, thereby preventing cracks and peeling.

The urethane resin is preferably a urethane resin obtained by reacting a diisocyanate, a high molecular weight polyol, and a chain extender. The high molecular weight polyol may be a polyether polyol or a polycarbonate polyol. Examples of commercially available urethane resins include Hydran WLS-202 (manufactured by DIC Corporation).
Examples of the acrylic resin include Acrylit 8UA-366 (manufactured by Taisei Fine Chemical Co., Ltd.).
An example of the polyolefin resin is Arrowbase DA-1010 (manufactured by Unitika Ltd.).
Examples of polyester resins include polyethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalate.

The adhesive layer may be made of one or more of the above-mentioned materials.

Of the urethane-based resins, acrylic-based resins, polyolefin-based resins and polyester-based resins contained in the easy-adhesion layer, urethane-based resins are preferred in consideration of adhesion to the metal layer and printed layer and formability described below.

In addition, when the easy-adhesion layer contains a polypropylene-based resin, the polypropylene-based resin contained in the easy-adhesion layer is usually different from the polypropylene that may be contained in the resin sheet or the molded body.

The easy-adhesion layer may be made of one or more resins selected from the group consisting of urethane-based resins, acrylic-based resins, polyolefin-based resins, and polyester-based resins, at 80% by mass or more, 90% by mass or more, 95% by mass or more, 98% by mass or more, 99% by mass or more, 99.5% by mass or more, 99.9% by mass or more, or 100% by mass. For example, the easy-adhesion layer may be a layer made of only urethane resin.

The glass transition temperature of the easy-adhesion layer is preferably -100°C or higher and 100°C or lower. If the glass transition temperature is -100°C or higher, the distortion of the easy-adhesion layer does not exceed the conformability of the metal layer and printed layer described below, so defects due to cracking do not occur even with long-term use. If the glass transition temperature is 100°C or lower, the softening temperature is appropriate, so elongation during pre-shaping is good, and uneven elongation of the stretched part and cracking of the metal layer and printed layer can be suppressed.

The glass transition temperature of the easy-adhesion layer can be determined, for example, by measuring a differential scanning calorimeter ("DSC-7" manufactured by PerkinElmer Japan Co., Ltd.) under the following conditions.
Measurement start temperature: -90℃
Measurement end temperature: 220°C
Temperature rise: 10° C./min

The tensile elongation at break of the easy-adhesion layer is, for example, 150% or more and 900% or less, preferably 200% or more and 850% or less, and more preferably 300% or more and 750% or less.
The tensile elongation at break of the easy-adhesion layer may be 150% or more, 200% or more, or 300% or more, and may be 900% or less, 850% or less, or 750% or less.
When the tensile elongation at break of the easy-adhesion layer is 150% or more, the easy-adhesion layer can follow the elongation of the resin sheet during thermoforming without any problems, so that cracks in the easy-adhesion layer and cracks and peeling of the metal layer and the printing layer can be suppressed. When the tensile elongation at break is 900% or less, the water resistance is good.

The tensile elongation at break of the easy-adhesion layer can be evaluated, for example, by applying a resin (composition) of the same composition as that used to form the easy-adhesion layer onto a glass substrate using a bar coater, drying at 80°C for 1 minute, and then separating it to create a sample with a thickness of 150 μm, and measuring it using a method in accordance with JIS K7311:1995.

The softening temperature of the easy-adhesion layer is, for example, 50° C. or more and 180° C. or less, preferably 90° C. or more and 170° C. or less, and more preferably 100° C. or more and 165° C. or less.
The softening temperature of the easy-adhesion layer may be 50° C. or more, 90° C. or more, or 100° C. or more, and may be 180° C. or less, 170° C. or less, or 165° C. or less.
When the softening temperature is 50° C. or higher, the adhesive layer has excellent strength at room temperature and can suppress cracking and peeling of the metal layer and the printed layer. When the softening temperature is 180° C. or lower, the adhesive layer is sufficiently softened during thermoforming, so that cracking of the adhesive layer and cracking and peeling of the metal layer and the printed layer can be suppressed.

The softening temperature of the easy-adhesion layer can be evaluated, for example, by applying a resin (e.g., urethane resin) that will become the easy-adhesion layer onto a glass substrate using a bar coater, drying it at 80°C for 1 minute, and then separating it to create a sample with a thickness of 150 μm, and measuring the flow start temperature using a high-speed flow tester (Shimadzu Corporation's ``Constant Test Force Extrusion Type Capillary Rheometer Flow Tester CFT-500EX'').

The easy-adhesion layer may consist of a single layer or may be a laminated structure of two or more layers.

The thickness of the easy-adhesion layer may be 35 nm or more and 3000 nm or less, 50 nm or more and 2000 nm or less, or 50 nm or more and 1000 nm or less.
The thickness of the easy-adhesion layer may be 35 nm or more, or 50 nm or more, and may be 3000 nm or less, 2000 nm or less, or 1000 nm or less.

The easy-adhesion layer can be formed, for example, by applying the above-mentioned resin with a gravure coater, kiss coater, bar coater, etc., and drying it at 40 to 100°C for 10 seconds to 10 minutes.

On the adhesive layer, various coatings such as ink, hard coat, anti-reflection coat, and heat-shielding coat can be laminated.
In addition, in the resin sheet, another easy-adhesion layer (second easy-adhesion layer) may be provided on the surface opposite to the easy-adhesion layer (first easy-adhesion layer). In this way, functionality such as surface treatment and hard coating can be imparted to the polyolefin resin layer that becomes the surface of the molded product.

(Undercoat Layer)
The undercoat layer is a layer that can bond the easy-adhesion layer and the metal layer to each other. By providing the undercoat layer, even if stress is applied during thermoforming, countless extremely fine cracks can be generated in the metal layer, and the occurrence of the rainbow phenomenon can be eliminated or reduced.
Examples of materials for forming the undercoat layer include urethane resins, acrylic resins, polyolefins, and polyesters.

From the standpoint of whitening resistance during molding (how unlikely the whitening phenomenon is to occur) and adhesion to the metal layer, acrylic resin is preferred as the material for forming the undercoat layer, and for example, "DA-105" manufactured by Arakawa Chemical Industries Co., Ltd. can be used.

The above materials may be used alone or in combination of two or more.

In the undercoat layer, the above-mentioned resin component (main agent) may be used in combination with a curing agent. Examples of the curing agent include aziridine compounds, blocked isocyanate compounds, epoxy compounds, oxazoline compounds, carbodiimide compounds, etc., and for example, "CL102H" manufactured by Arakawa Chemical Industries, Ltd. can be used.

When a curing agent is used, the content ratio of the base agent to the curing agent in the undercoat layer is, for example, 35:4 to 35:40, preferably 35:4 to 35:32, and more preferably 35:12 to 35:32, in terms of the mass ratio of solids. It may also be 35:12 to 35:20.
When the blending ratio of the hardener is 4 or more to the base resin 35, the hardening reaction proceeds smoothly and the whitening resistance can be maintained. When the blending ratio is 40 or less, the extensibility of the undercoat layer is good and cracks during molding can be suppressed.

The undercoat layer can be formed, for example, by applying the above-mentioned material with a gravure coater, kiss coater or bar coater, drying at 50 to 100°C for 10 seconds to 10 minutes, and aging at 40 to 100°C for 10 to 200 hours.

The thickness of the undercoat layer may be 0.05 μm to 50 μm, 0.1 μm to 10 μm, or 0.5 μm to 5 μm.
The thickness of the undercoat layer may be 0.05 μm or more, 0.1 μm or more, or 0.5 μm or more, and may be 50 μm or less, 10 μm or less, or 5 μm or less.

(Metal Layer)
The metal layer is a layer containing a metal or a metal oxide.
The metal that forms the metal layer is not particularly limited as long as it is a metal that can impart a metallic design to the laminate, and examples thereof include tin, indium, chromium, aluminum, nickel, copper, silver, gold, platinum, and zinc. An alloy containing at least one of these metals may also be used.
Among the above, indium and aluminum are preferable because they are particularly excellent in terms of ductility and color tone. When the metal layer has excellent ductility, cracks are less likely to occur when the laminate is three-dimensionally molded.

There are no particular limitations on the method for forming the metal layer, but from the viewpoint of imparting a high-quality, luxurious metallic design to the laminate, for example, deposition methods using the above-mentioned metals, such as vacuum deposition, sputtering, and ion plating, can be used. In particular, vacuum deposition is low cost and can reduce damage to the substrate. The conditions for the vacuum deposition can be set appropriately according to the melting temperature or evaporation temperature of the metal used.

In addition to the above methods, methods such as applying a paste containing the above metals or metal oxides, and plating methods using the above metals can also be used.

The thickness of the metal layer may be 5 nm or more and 80 nm or less. If it is 5 nm or more, the desired metallic luster can be obtained without problems, and if it is 80 nm or less, cracks are less likely to occur.

(Printing layer)
The shape of the printed layer is not particularly limited, but may be, for example, a solid shape, a carbon pattern, a wood grain pattern, or the like.
As the printing method, general printing methods such as screen printing, offset printing, gravure printing, roll coating, spray coating, etc. In particular, screen printing can make the ink film thick, so ink cracks are less likely to occur when the product is molded into a complex shape.
For example, in the case of screen printing, an ink that has excellent elongation during molding is preferred, and examples thereof include "FM3107 High Density White" and "SIM3207 High Density White" manufactured by Jujo Chemical Co., Ltd., but are not limited to these.

(Method for producing molded body)
The method for producing the above-described molded article is not particularly limited.
In one embodiment, a molded body can be produced by injection molding a composition for forming a molded body body (a molding resin composition) on a resin sheet. Specific examples of the molding method include in-mold molding and insert molding.

(In-mold molding)
In one embodiment, the method for producing a molded body is a method for producing a molded body according to one aspect of the present invention described above, and includes placing a resin sheet on a mold, and supplying a molding resin composition containing polypropylene having a crystallization rate of 0.6 min ⁻¹ or more at 135° C. and a fibrous reinforcing material onto the resin sheet, thereby shaping the resin sheet to match the mold and integrating the molding resin composition with the resin sheet. Here, the molding resin composition is cooled and solidified on the resin sheet to form a molded body.
In such a method for producing a molded article (in-mold molding method), a resin sheet is placed in a mold and molded into a desired shape by the pressure of a molding resin composition supplied into the mold, thereby obtaining a molded article.

(insert molding)
In another embodiment, the method for producing a molded body is a method for producing a molded body according to one aspect of the present invention described above, and includes shaping a resin sheet to fit a mold, and supplying a molding resin composition containing polypropylene having a crystallization rate of 0.6 min ⁻¹ or more at 135° C. and a fibrous reinforcing material onto the shaped resin sheet, thereby integrating the molding resin composition with the resin sheet. Here, the molding resin composition is cooled and solidified on the resin sheet to form a molded body.
In such a manufacturing method for a molded body (insert molding method), a molded body can be obtained by preforming a shaped body (resin sheet) to be placed in a mold and filling the molding resin composition according to the shape of the preform. In insert molding, a molded body having a more complicated shape can be formed compared to the above-mentioned in-mold molding.
Shaping (pre-shaping) to fit a mold can be performed by vacuum forming, pressure forming, vacuum pressure forming, press forming, plug assist forming, etc. When shaping, the resin sheet can be heated in advance.

In addition, a method for producing a molded body in one aspect of the present invention includes heating a molding resin composition containing polypropylene and a fibrous reinforcing material so that the polypropylene melts, supplying the heated molding resin composition onto a resin sheet arranged in a mold, and cooling and solidifying the molding resin composition on the resin sheet to obtain a molded body including a molded body main body made of the solidified molding resin composition and the resin sheet covering at least a part of the surface of the molded body. The crystallization rate at 135°C of the polypropylene contained in the molding resin composition subjected to melting is 0.6 min ^-1 or more.

(Use of Molded Article)
The applications of the molded article described above are not particularly limited, and the molded article can be used for various applications. In one embodiment, the molded article can be used as an exterior part of a saddle-type vehicle or an exterior part of a four-wheeled vehicle. The molded article can also be used as an interior material, an exterior material, a housing for home appliances, a decorative steel plate, a decorative plate, a housing for housing equipment, a housing for information and communication devices, and the like.

Examples of the present invention are described below, but the present invention is not limited to these examples.

Example 1
(1) Production of Resin Sheet A resin sheet was produced using the apparatus shown in Fig. 3. As a raw material for the resin sheet, polypropylene (Prime Polypro F133A manufactured by Prime Polymer Co., Ltd., hereinafter sometimes referred to as "PP-1") was used.
The operation of this device will be described. Molten polypropylene resin extruded from a T-die 52 of an extruder is sandwiched between a metallic endless belt 57 and a fourth cooling roll 56 on a first cooling roll 53. In this state, the molten resin is pressed against the first and fourth cooling rolls 53 and 56 and rapidly cooled to form a resin sheet.
The resin sheet is then sandwiched between the metallic endless belt 57 and the fourth cooling roll 56 at a circular arc portion corresponding to the approximately lower half of the fourth cooling roll 56 and pressed against each other in a plane. After being pressed against each other in a plane and cooled by the fourth cooling roll 56, the resin sheet in close contact with the metallic endless belt 57 is moved onto the second cooling roll 54 with the rotation of the metallic endless belt 57. As described above, the resin sheet is pressed against each other in a plane by the metallic endless belt 57 at a circular arc portion corresponding to the approximately upper half of the second cooling roll 54 and is cooled again. The resin sheet 51 cooled on the second cooling roll 54 is then peeled off from the metallic endless belt 57. The surfaces of the first and second cooling rolls 53 and 54 are covered with an elastic material 62 made of nitrile-butadiene rubber (NBR). The third cooling roll 55 also serves the function of supporting and rotating the metallic endless belt 57 from below.
The manufacturing conditions for the resin sheet are as follows.
Extruder diameter: 75 mm
Width of T die 52: 900 mm
Thickness: 200μm
Take-up speed of the resin sheet 51: 4.5 m/min. Surface temperature of the fourth cooling roll 56 and the metallic endless belt 57: 20° C.
・Cooling rate: 8,100℃/min

(2) Crystallization rate of polypropylene in resin sheet (crystallization rate at 130°C)
The crystallization rate of the polypropylene used in the resin sheet was measured using a differential scanning calorimeter (DSC) (PerkinElmer's "Diamond DSC"). Specifically, a piece taken from the resin sheet was heated from 50 ° C. to 230 ° C. at 80 ° C./min, held at 230 ° C. for 5 minutes, cooled from 230 ° C. to 130 ° C. at 80 ° C./min, and then held at 130 ° C. to crystallize the polypropylene. Measurement of the change in heat quantity was started when the temperature reached 130 ° C., and a DSC curve was obtained. The crystallization rate was determined from the obtained DSC curve by the following steps (i) to (iv).
(i) The baseline was determined by approximating the change in heat quantity from a point 10 times the time from the start of measurement to the peak top to a point 20 times the time by a straight line.
(ii) The intersection points between the tangent line having a slope at the inflection point of the peak and the baseline were determined to determine the start and end times of crystallization.
(iii) The time from the obtained crystallization start time to the peak top was measured as the crystallization time.
(iv) The crystallization rate was calculated from the reciprocal of the obtained crystallization time.

(3) Isotactic pentad fraction of polypropylene in resin sheet
The isotactic pendant fraction of the polypropylene of the resin sheet was measured by evaluating the ¹³ C-NMR spectrum. Specifically, the measurement was performed using the following apparatus, conditions, and calculation formula according to the peak assignments proposed by A. Zambelli et al. in "Macromolecules, 8, 687 (1975)". As a result, the isotactic pendant fraction of the resin sheet was 98 mol%.
(Apparatus and conditions)
Apparatus: ¹³ C-NMR apparatus ("JNM-EX400" manufactured by JEOL Ltd.)
Method: Proton complete decoupling method (concentration: 220 mg/ml)
Solvent: 90:10 (volume ratio) mixture of 1,2,4-trichlorobenzene and heavy benzene Temperature: 130°C
Pulse width: 45°
Pulse repetition time: 4 seconds Accumulation: 10,000 times (calculation formula)
Isotactic pendant fraction [mmmm] = m / S × 100
(In the formula, S represents the signal intensity of the side chain methyl carbon atom of all propylene units, and m represents a meso pentad chain (21.7 to 22.5 ppm).)

(4) Preparation of molding resin composition A molding resin composition was prepared by adding a master batch containing a phosphate metal salt as a nucleating agent ("ADEKA STAB NA-11" manufactured by ADEKA CORPORATION, hereinafter referred to as "phosphate metal salt-1") to short glass fiber reinforced polypropylene ("Prime Polypro V7100" manufactured by Prime Polymer Co., Ltd., glass fiber content 20 mass% (average fiber length: 0.3 mm, average fiber diameter (diameter): 0.013 mm), hereinafter referred to as "fiber reinforced PP-1") so that the concentration of the phosphate metal salt relative to the total amount of the composition was 1500 ppm. During the above addition, mixing by dry blending was performed.

(5) Production of molded body The resin sheet obtained in (1) was cut to 100 mm x 100 mm and attached to the fixed cavity surface of a flat plate-shaped mold (125 mm x 125 mm, thickness 2 mm), and the molding resin composition obtained in (4) was fed into the mold using a hydraulic injection molding machine ("IS-80EPN" manufactured by Toshiba Machine Co., Ltd.) and integrated to obtain a molded body. At this time, the temperature of the molding resin composition fed to the mold was 230°C, and the mold temperature was 50°C.

(6) Measurement of crystallization rate of polypropylene in molding resin composition (crystallization rate at 135°C)
Using a differential scanning calorimeter (DSC) (PerkinElmer's "Diamond DSC"), the crystallization rate of polypropylene of the molding resin composition (containing short glass fiber reinforced polypropylene and a nucleating agent) sampled from the molded body in the molded body was measured. Specifically, the molding resin composition was heated from 50°C to 230°C at 80°C/min, held at 230°C for 5 minutes, cooled from 230°C to 135°C at 80°C/min, and then held at 135°C to crystallize the polypropylene. Measurement of the change in heat quantity was started when the temperature reached 135°C, and a DSC curve was obtained. From the obtained DSC curve, the crystallization rate was obtained by the following steps (i) to (iv).
(i) The baseline was determined by approximating the change in heat quantity from a point 10 times the time from the start of measurement to the peak top to a point 20 times the time by a straight line.
(ii) The intersection points between the tangent line having a slope at the inflection point of the peak and the baseline were determined to determine the start and end times of crystallization.
(iii) The time from the obtained crystallization start time to the peak top was measured as the crystallization time.
(iv) The crystallization rate was calculated from the reciprocal of the obtained crystallization time.

(7) Maximum height Rz of the molded body surface
For the molded article obtained in (5), a "Handysurf E-35B" manufactured by Tokyo Seimitsu Co., Ltd. was used to measure the surface shape in the direction perpendicular to the flow direction on the molded article surface (resin sheet surface) in accordance with JIS B 0601:2001 under the following measurement conditions. The distance between the crest line and the valley line in the cross-sectional curve thus obtained was taken as the maximum height Rz. The results are shown in Table 1.
<Measurement conditions>
Measurement distance: 10 mm
Cutoff: None Stylus: Tip diameter 5 μm, tip accuracy 90° cone, material diamond Measuring force: 4 mN or less

(8) Glossiness For the molded article obtained in (5), a glossmeter (VG7000 manufactured by Nippon Denshoku Industries Co., Ltd.) was used to irradiate light from the resin sheet surface of the molded article at an incident angle of 60 degrees in accordance with the 60-degree specular gloss measurement method of JIS Z 8741:1997, and the reflected light flux ψs was measured when the reflected light was received at the same 60 degrees. The glossiness was calculated from the ratio of the reflected light flux ψ0s from a glass surface with a refractive index of 1.567 according to the following formula (1). The results are shown in Table 1.
Glossiness (Gs) = (ψs / ψ0s) * 100 ... (1)

Example 2
A molded article was produced and evaluated in the same manner as in Example 1, except that a phosphate metal salt ("ADEKA STAB NA-21" manufactured by ADEKA CORPORATION, hereinafter sometimes referred to as "phosphate metal salt-2") was used as the nucleating agent for the molding resin composition instead of the phosphate metal salt-1. The results are shown in Table 1.

Example 3
A molded article was produced and evaluated in the same manner as in Example 1, except that a phosphate metal salt ("ADEKA STAB NA-71" manufactured by ADEKA CORPORATION, hereinafter sometimes referred to as "phosphate metal salt-3") was used as the nucleating agent for the molding resin composition instead of the phosphate metal salt-1. The results are shown in Table 1.

Example 4
A molded article was produced and evaluated in the same manner as in Example 3, except that the nucleating agent, phosphate metal salt 3, was added in an amount of 3000 ppm based on the total amount of the molding resin composition. The results are shown in Table 1.

Example 5
In Example 4, a molded body was produced and evaluated in the same manner as in Example 4, except that a glass short fiber reinforced polypropylene ("Mostron L-4040P" manufactured by Prime Polymer Co., Ltd., glass fiber content 40 mass% (average fiber length: 1.0 mm, average fiber diameter (diameter): 0.015 mm), hereinafter referred to as "fiber reinforced PP-2") was used instead of the fiber reinforced PP-1. The results are shown in Table 1.

Comparative Example 1
Except for not adding a nucleating agent to the molding resin composition, a molded article was produced and evaluated in the same manner as in Example 1. The results are shown in Table 1.

Comparative Example 2
A molded article was produced and evaluated in the same manner as in Example 5, except that no nucleating agent was added to the molding resin composition. The results are shown in Table 1.

From Table 1, it can be seen that the molded body of the present invention has high surface smoothness and excellent appearance. The maximum height Rz of Example 5 is larger than that of Comparative Example 1, but this is because the maximum height Rz is highly dependent on the physical properties (particularly fiber length) and content of the fibrous reinforcing material contained in the molded body. Since Example 5 contains a large amount of fibrous reinforcing material with long fiber length, the Rz value is high, but compared to Comparative Example 2 (where the conditions other than the nucleating agent are the same), Rz is significantly lower, which shows the effect of improving the surface smoothness of the molded body by specifying the crystallization rate of the polypropylene that constitutes the molded body.

Although some embodiments and/or examples of the present invention have been described in detail above, those skilled in the art can easily make many modifications to these exemplary embodiments and/or examples without substantially departing from the novel teachings and advantages of the present invention, and therefore many such modifications are within the scope of the present invention.
The contents of all documents cited in this specification and of the application from which this application claims priority under the Paris Convention are incorporated by reference in their entirety.

Claims (12)

A molded body including polypropylene and a fibrous reinforcing material;
A resin sheet including at least a resin layer and covering at least a part of a surface of the molded body;
Including,
The molded article, wherein the crystallization rate of the polypropylene at 135°C is 1.25 min ^-1 or more. The molded article according to claim 1 , wherein the resin layer in the resin sheet contains polypropylene. The molded article according to claim 2 , wherein the polypropylene contained in the resin layer has a crystallization rate at 130° C. of 2.5 min ⁻¹ or less. The molded article according to claim 2 or 3 , wherein the polypropylene contained in the resin layer has an isotactic pentad fraction of 80 mol % or more and 99 mol % or less. The molded body according to any one of claims 2 to 4 , wherein the content of the nucleating agent for the polypropylene contained in the resin layer is 1.0 mass% or less of the resin layer. The molded article according to any one of claims 2 to 5 , wherein the polypropylene contained in the resin layer does not contain a nucleating agent. The molded body according to claim 1 , wherein the resin sheet includes a printed layer on the molded body side as viewed from the resin layer. The resin sheet includes an easy-adhesion layer on the molded body side as viewed from the resin layer,
The molded article according to any one of claims 1 to 7 , wherein the easy-adhesion layer comprises at least one selected from the group consisting of urethane resins, acrylic resins, polyolefins, and polyesters. The resin sheet includes an undercoat layer located on the molded body side as viewed from the resin layer, and a metal layer laminated on the molded body side as viewed from the undercoat layer,
the undercoat layer comprises one or more resins selected from the group consisting of urethane resins, acrylic resins, polyolefins, and polyesters;
The molded article according to any one of claims 1 to 8 , wherein the metal layer contains one or more metal elements selected from the group consisting of tin, indium, chromium, aluminum, nickel, copper, silver, gold, platinum, and zinc. 10. The method for producing a molded article according to claim 1, comprising: placing a resin sheet on a mold; and supplying a molding resin composition containing polypropylene having a crystallization rate of 1.25 min ^- 1 or more at 135°C and a fibrous reinforcing material onto the resin sheet, thereby integrating the molding resin composition and the resin sheet while shaping the resin sheet to match the mold. 10. The method for producing a molded article according to claim 1, comprising: shaping a resin sheet to fit a mold; and supplying a molding resin composition containing a polypropylene having a crystallization rate of 1.25 min ^- 1 or more at 135°C and a fibrous reinforcing material onto the shaped resin sheet, thereby integrating the molding resin composition with the resin sheet. Heating a molding resin composition containing polypropylene and a fibrous reinforcing material so that the polypropylene melts;
Supplying the heated molding resin composition onto a resin sheet placed in a mold; and
and cooling and solidifying the molding resin composition on the resin sheet to obtain a molded body including a molded body main body made of the solidified molding resin composition and the resin sheet covering at least a part of a surface of the molded body,
The polypropylene contained in the molding resin composition subjected to melting has a crystallization rate at 135°C of 1.25 min ^-1 or more;
A method for producing a molded body.

Images