JPH0151333B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a laminated sheet material for thermoforming, and in particular, a material in which fiber mat or felt, which has poor structural strength and shape retention, is combined with a thermosetting resin composition or a thin metal plate. This invention relates to a novel laminated sheet material that has structural strength and shape retention, or can be heat-formed into any shape.

Mat and felt (hereinafter simply referred to as mat) made of carbon fiber or glass fiber are widely put into practical use as heat insulating/thermal insulating materials, soundproofing materials, etc. However, these mats have poor structural strength and shape retention (the property of retaining their shape in a deformed state), so when using them, it is necessary to fill or attach them to the back side of the molded product, and then to the back side of the molded product. It was necessary to arrange or wrap the presser material and fix it, which made the work extremely complicated during use.

The present invention solves the above-mentioned drawbacks of mat by using a thermosetting composition containing an uncured thermosetting resin or by combining this with a thin metal plate, thereby achieving appropriate structural strength and shape retention. The present invention aims to provide a novel laminated sheet material that can be obtained and formed into any shape. In other words, the structure of the sheet material of the present invention that achieves the above purpose is that a mat (or felt) made of inorganic and/or organic fibers is coated with a thermosetting resin containing an uncured thermosetting resin on one or both sides of the mat (or felt). The gist is that a curable composition layer is laminated, or a metal thin plate is laminated via the thermosetting composition layer.

The laminated sheet material of the present invention can be used for molding, shape retention,
A thermosetting composition layer containing an uncured thermosetting resin or a thin metal plate is used as a reinforcing material, and pine is used as a material for heat insulation, soundproofing, or shock mitigation. The thermosetting composition layer and the thin metal plate can be formed into any shape by heating and pressure molding, and the thermosetting composition layer can be thermoset to become strong by itself. It forms a strong reinforcing layer or a strong adhesive layer between the metal sheet and the mat. Therefore, the resulting composite molded product exhibits the characteristics of the strong surface layer made of thermosetting resin or metal thin plate and the heat-insulating and sound-insulating pine layer formed on the back side, and is suitable for use in, for example, a heat-retaining tank. It exhibits excellent performance as the body of cars, bathtubs, automobiles, and walls and shutters of prefabricated houses.

The raw materials constituting the laminated sheet material of the present invention will be explained in detail below.

First, as the mat (or felt), any material made of inorganic and/or organic fibers can be used. Glass fiber is the most common type of fiber, but there are also carbon fibers obtained by carbonizing and firing various organic fibers, boron fibers, fused silica fibers, silica fibers, alumina fibers, zirconia fibers, boron nitride fibers, and silicon nitride fibers. Fibers, boron carbide fibers, silicon carbide fibers, asbestos fibers, inorganic fibers such as metal fibers, and natural or synthetic organic fibers such as hemp, vinylon, polyamide, polyester, etc. can be used, and these can be used alone. Alternatively, two or more types may be used in combination.

In addition, the thermosetting resins that are the main constituents of the surface reinforcement layer or the adhesive layer with the thin metal plate include unsaturated polyester resins, epoxy resins, phenol resins, vinyl ester resins, polybutadiene resins, acrylic resins, polyurethane resins, and polyimide resins. , urea melamine resin, polyanhydride-epoxy
All conventionally known thermosetting resins can be used, including styrene resins and their modified resins, as well as thermosetting resins made by adding a curing agent to thermoplastic resins such as vinyl chloride resin. The most suitable resin can be selected depending on the required properties of the final product. For example, unsaturated polyester resin is used when excellent moldability is required, polyurethane resin is used when abrasion resistance is required, epoxy resin is used when corrosion and rust resistance is required, and heat resistance is required when heat resistance is required. Polyimide resin is most suitable, and acrylic resin is most suitable when weather resistance is required. These resins may constitute the thermosetting resin layer alone, but usually an appropriate amount of the various fibers (including monofilament and long-fiber woven fabrics, non-woven fabrics, etc.) exemplified as the above-mentioned mat constituent materials is used as a reinforcing agent. By mixing it, a product with superior strength can be obtained. Further, appropriate amounts of other subcomponents such as curing agents, stabilizers, fillers, colorants, thickeners, flame retardants, etc. can be mixed as necessary. Furthermore, hollow fine particles such as glass balloons, shirasu balloons, phenolic resin balloons, and divinylbenzene-styrene copolymer balloons are effective as subcomponents other than those mentioned above, and these are effective as fillers as well as surface reinforcement layers. It not only improves its thermal insulation and soundproofing properties, but also promotes weight reduction and improves moldability.

The thermosetting resin layer consisting of the above components must be able to retain its latent thermosetting properties and maintain its layered form, and for this purpose, it is necessary to suppress the fluidity characteristic of uncured resin. However, as a means for this purpose, as is well known, a method of semi-curing the resin to form a so-called prepreg, or a method of increasing the viscosity with a thickener may be adopted.

In addition, stainless steel, copper, aluminum, zinc, tin, or various alloys containing these metals, as well as precious metals such as gold and silver, can be used as the metal thin plate, and these can be selected arbitrarily depending on the purpose of the final molded product. do it. The thickness of the metal thin plate can be determined arbitrarily depending on the application and purpose, but the most common thickness is approximately 30μ.
The range is from m to several mm. As for the thin metal sheet, it is possible to use the raw sheet as it is and apply surface anti-corrosion treatment after lamination, but it is better to use one that has been surface-treated in advance.In this case, the surface is printed according to the shape of the final molded product. Alternatively, it is also effective to roughen the contact surface with the thermosetting composition layer to improve interlayer adhesion.

In the case of a laminated sheet material consisting of pine and a thermosetting resin layer, the thermosetting resin layer is exposed on the surface of the final molded product and becomes a surface reinforcement layer, so depending on the application, it may be quite thick. It must have strength, and it is desirable to use a reinforced resin blended with fibers. On the other hand, in a composite sheet material made by laminating thin metal plates on the outer circumferential side of a thermosetting resin layer,
Since the main purpose of the thermosetting resin layer is to bond the mat and the thin metal plate, even a relatively thin resin layer that does not contain fibers etc. satisfactorily fulfills its purpose. However, when a thin metal plate of 500 μm or less is used, the resin layer plays an important role as a back support layer of the metal plate, so it is preferable to have a sufficient thickness depending on the purpose.

Next, there are various methods of laminating matte and thermosetting resin or this and a thin metal plate, but the most common method is to use matte as a support layer and cast uncured thermosetting resin on one or both sides. After that, the resin is semi-cured, and a semi-cured resin layer is formed on the surface of the mat. In this case, if a thin metal plate is pressed against the surface of the cast resin, a thin metal layer can be formed at the same time. A method in which a thermosetting resin is pre-formed into a sheet with a retention structure, and this is laminated on the mat surface using an appropriate adhesive, or a thin metal plate is further laminated on the surface. , If a suitable solvent is sprayed on the joint surface of the thermosetting resin sheet to give the surface tackiness, it can be bonded by itself, so no adhesive is required.
A method in which the mat, thermosetting resin sheet, and metal sheet are cut to a certain size and then laminated in the manner described above, and the mat, thermosetting resin sheet, and metal sheet are shaped into a molded product. Examples include a method in which the materials are cut into appropriate dimensions and laminated using an adhesive (or by imparting tackiness to the surface by spraying a solvent) during or immediately before molding. For example, the first
The figure is a schematic process explanatory diagram showing a series of steps when the above method is employed. That is, in FIG. 1, reference numeral 1 indicates an endless support belt, 2 a belt-shaped mat delivery roller, 3 an adhesive supply section, 4 a thermosetting resin sheet delivery roller, 5 a guide roller, and 6 a pressure roller. First, the belt-shaped mat M is fed onto the upper surface of the endless supporting belt 1 rotating in the direction of the arrow.
A previously formed thermosetting resin sheet S is laminated thereon while adhesive A is applied thereon from the adhesive supply section 3, and both are pressed together by a pressure roller 6. The laminated sheet material obtained in this manner may be sequentially rolled up or cut into appropriate dimensions to form a product. In the above, if the thermosetting resin sheet is also supplied to the lower surface of the mat M, a laminated sheet material having thermosetting resin layers on both sides can be obtained. Further, by supplying a thin metal plate to the upper surface side of the thermosetting resin sheet, a laminated sheet material having a thin metal layer on the outermost periphery can be obtained. In this case, by applying an adhesive or spraying a solvent to the bonding surfaces of the thin metal plate or thermosetting resin sheet, the two can be firmly bonded. In addition, a metal thin plate and a thermosetting resin sheet are laminated in advance, and this is
It can also be laminated on the surface of the pine according to the method shown in the figure. Figure 2 is a schematic process explanatory diagram showing a series of steps when the above method is adopted. In this example, thermosetting resin is formed into a sheet shape using a thin metal plate as a support material and laminated with pine. Shows how. That is, first, the belt-shaped mat M is fed onto the endless support belt 1, which is similar to the example shown in FIG. 7
is located. Then, while feeding out the thin metal plate M' from the feeding roller 7, thermosetting resin R is fed onto the upper surface from the feeding section 8 so as to have a constant thickness, and these are reversed at the guide rollers 5, 5. It is laminated on the upper surface of the mat M. Next, a three-layer laminated sheet material can be obtained by pressing these together using a pressing roller 6 or by heating if necessary to bring the resin R into a semi-cured state. With this method, since the resin R is laminated with the mat M and the thin metal plate M' while being formed into a sheet, high interlayer adhesive strength can be obtained without using an adhesive. In addition, resin R and metal thin plate
If M′ is also sent to the bottom side of mat M,
It is possible to obtain a laminated sheet material having a thin metal plate M' on both sides, and if a supporting film such as polypropylene is used instead of the thin metal plate M', a laminated sheet material having a thermosetting resin layer on one or both sides can be obtained. Obtainable. Furthermore, when forming resin R layers on both sides of the mat M, for example, as shown in Fig. 3 (cutaway diagram of main parts), a large number of through holes H are bored in the mat M, and the pressure contact force during lamination is increased. For example, in the pressure welding process, the resins R constituting the resin layers on both sides are joined together through the through holes H to form a columnar connection part, and the integrity of the laminated sheet material can be further improved.

The present invention is roughly constructed as described above, and its effects can be summarized as follows.

Mat itself has poor moldability, but by laminating and integrating an uncured thermosetting resin layer or this with a thin metal plate, it can be molded into any shape.
In addition, a molded product that is firmly bonded can be obtained by curing the thermosetting resin.

Mat is compressed during the heat and pressure molding process, but after being removed from the mold, it returns to its original state due to its elasticity and becomes a supporting layer with a high porosity, compared to single molded products made of thermosetting resin or thin metal sheets. By doing so, it is possible to obtain a molded article that has high heat insulation and sound insulation effects, is lightweight, has a thick wall feel, and has shock absorbing properties. Moreover, the pine has extremely low penetration resistance against nails, etc., but this difficulty can be sufficiently compensated for by the hardened layer of the molding sheet or the thin metal plate.

Processing is simple, as the thermosetting resin can be molded and bonded to the mat or thin metal plate at the same time in the heating and pressure molding process.

[Brief explanation of drawings]

1 and 2 are schematic process explanatory diagrams illustrating the manufacturing method of the sheet material of the present invention, and FIG. 3 is a cutaway diagram of the main parts illustrating the sheet material of the present invention. DESCRIPTION OF SYMBOLS 1... Endless support belt, 2... Band-shaped mat feeding roller, 3... Adhesive supply section, 4... Thermosetting resin sheet feeding roller, 5... Guide roller, 7... Metal thin plate feeding roller, 8 ...Thermosetting resin supply section.

Claims (1)

[Claims] 1. A thermosetting composition layer containing an uncured thermosetting resin is formed on one or both sides of mat or felt made of inorganic and/or organic fibers. Laminated sheet material for thermoforming. 2. A thin metal plate is laminated on one or both sides of mat or felt made of inorganic and/or organic fibers with a thermosetting composition layer containing an uncured thermosetting resin interposed therebetween. Laminated sheet material for thermoforming.