JPH0588185B2 - - Google Patents
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- Publication number
- JPH0588185B2 JPH0588185B2 JP19716485A JP19716485A JPH0588185B2 JP H0588185 B2 JPH0588185 B2 JP H0588185B2 JP 19716485 A JP19716485 A JP 19716485A JP 19716485 A JP19716485 A JP 19716485A JP H0588185 B2 JPH0588185 B2 JP H0588185B2
- Authority
- JP
- Japan
- Prior art keywords
- resin
- steel plate
- lightweight
- sandwiched
- lightweight steel
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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- Laminated Bodies (AREA)
Description
〈産業上の利用分野〉
本発明は、複合積層鋼板に係り、特に軽量化を
目的とした多層構造の軽量鋼板およびその製造方
法に関する。
〈先行技術とその問題点〉
鋼板と鋼板の間に熱可塑性樹脂を挾装した積層
鋼板の１つに、表層部に極薄の鋼板を使用して強
度を確保し、中間層は厚くて軽量な樹脂である、
軽量鋼板と呼ばれる軽量材料がある。
この軽量鋼板は、その軽量化という利点を生か
して、自動車用材料や、建築用材料などに大いに
使用されることが期待されている。
例えば自動車ボデイーに軽量鋼板を使用する場
合には、鋼板端部にヘミング加工と呼ばれる折り
返し曲げを施す必要があるため、軽量鋼板は曲げ
加工性に優れていなければならない。そのため鋼
板間に挾装する単層の樹脂は比較的硬度の低いも
のを使用することが良いとされる。
しかし、硬度の低い軟い樹脂は、その融点が低
く、自動車ボデイーに高温で焼付塗装（180〜200
℃、30分程度）を行つた際、樹脂が溶けて流れ出
し、軽量鋼板が変形するという欠点がある。
逆に、上記樹脂の流れ出しをおそれて融点の高
い樹脂を用いれば、常温下で樹脂は硬くなり、そ
のためヘミング加工をした際樹脂が割れを生じや
すくなるので適当ではない。
そこで上記耐熱性と曲げ加工性を両立すること
ができる軽量鋼板およびその製造方法の開発が望
まれていた。
〈発明の目的〉
本発明の目的は、上記従来技術の欠点を解消
し、耐熱性および曲げ加工性共に優れた軽量鋼板
を提供し、またそのような軽量鋼板を容易に製造
することができる軽量鋼板の製造方法を提供する
ことにある。
〈発明の構成〉
本願発明者は、上記耐熱性と曲げ加工性を両立
する方法として、融点が比較的高い単層の発泡樹
脂を鋼板間に挾装し、曲げ加工時に樹脂に体積変
化（弾力性）を持たせることを想起した。しかる
に上記方法では発泡樹脂と鋼板との界面に気泡が
存在するため、鋼板と樹脂との接着力が弱くなり
軽量鋼板の諸品質の低下をもたらすこととなる。
そこで本願発明者は鋭意研究の結果、鋼板との
強固な接着力を担う非発泡樹脂により曲げ加工時
に体積減少をする発泡樹脂を挾み、この積層樹脂
を鋼板間に挾装することにより所期の目的を達す
ることができることを知見し、本発明の軽量鋼板
に至つた。
即ち、本発明は、鋼板間に熱可塑性樹脂を挾装
した積層型軽量鋼板において、前記熱可塑性樹脂
は、樹脂層間に発泡樹脂層を挾装した少なくとも
３層で構成されることを特徴とする軽量鋼板を提
供するものである。
また、本発明は鋼板間に熱可塑性樹脂を挾装し
た積層型軽量鋼板を製造するに際し、発泡樹脂を
樹脂間に挾んだ、少なくとも３層で構成される樹
脂材を形成し、次いで前記樹脂材を鋼板で挾持
し、前記鋼板を短時間で加熱した後、圧着ロール
にて加圧接着することを特徴とする軽量鋼板の製
造方法を提供するものである。
以下、本発明の軽量鋼板およびその製造方法を
添付図面に示す好適実施例について詳細に説明す
る。
第１図は、本発明の軽量鋼板の部分断面図であ
る。
第１図に示すように、本発明の軽量鋼板１は、
最外層が鋼板２，２、次いで気泡の混在していな
い熱可塑性樹脂による樹脂層３，３、そしてその
内側に熱可塑性の発泡樹脂層４の合計５層で構成
されている。
鋼板１，１には冷延鋼板、各種めつき鋼板、化
成処理鋼板等いかなる鋼板を用いることも可能で
ある。
樹脂層３，３および発泡樹脂層４を構成する熱
可塑性樹脂としては、成形性、耐熱性の点から、
ポリプロピレンなどのポリオレフイン類、ナイロ
ンなどのポリアミド類を挙げることができ、また
これらの共重合体、変性体や、その他の添加物を
含む組成物であつてもよい。しかし、特に耐熱性
に優れるナイロンなどのポリアミド類の樹脂を用
いるのが好ましい。また、樹脂層３，３と発泡樹
脂層４を構成する樹脂は、同一でも異つてもよい
が、樹脂層３，３と発泡樹脂層４との密着力を強
固にするために、同質の樹脂を用いるのが好まし
い。樹脂層３，３は気泡をほとんど含まず従つて
鋼板２，２との接着力が強固なものとなる。
また、発泡樹脂層４は、曲げ変形した際、気泡
５が収縮して体積減少を生じるので、軽量鋼板１
に曲げ加工を施しても、割れたり折れたりするこ
とがない。この発泡樹脂層４は、独立気泡型発砲
樹脂で構成することが好ましい。即ち独立気泡型
発砲樹脂とは、気泡５が樹脂層４中を移動したり
気泡５どうしが結合したりすることがない発泡樹
脂をいう。このような独立気泡型発泡樹脂を用い
ることにより、樹脂層３，３との界面を越えて樹
脂層３，３中へ気泡５が移動して混入することが
ないので、鋼板２，２と樹脂層３，３との接着力
が低下することがない。
このような軽量鋼板１の板厚T0には特に制限
はないが、十分な強度を有しかつ軽量化が十分に
なされるように、樹脂層３，３および発泡樹脂層
４の厚さを合計した樹脂厚T1が、T1／T0＝0.3〜
0.8となるようにするのがよい。
また発泡樹脂層４の厚さT2は、T2／T1≧1/5
とするのがよい。T2／T1が1/5未満であると曲げ
加工時の体積減少が小さすぎるからである。
なお、以上説明した例では、軽量鋼板１の樹脂
層は合計３層で構成されたものであるが、本発明
の軽量鋼板はこれに限らず、樹脂層が４層以上で
構成されたものであつてもよい。
以下、本発明の軽量鋼板１の製造方法について
説明する。
本発明の軽量鋼板の製造方法の工程を第２ａ図
〜第２ｃ図に示す。
第２ａ図に示すようにシート状の独立気泡型の
発泡樹脂４と樹脂３を形成し、樹脂３，３間に発
泡樹脂４を挾んで第２ｂ図に示すような樹脂積層
体６を形成する。この樹脂積層体６の形成は、ド
ライラミネーターまたは３層押出しによつて行う
のが好ましい。
次に、上記樹脂積層体６をアンコイラーから巻
き出される２枚の鋼板２，２で挾持し、第２ｃ図
に示すようにピンチローラー７，７で押圧し、加
熱炉８で鋼板２，２を短時間で加熱する。この鋼
板２，２の加熱は、高周波誘導加熱により行うの
が好ましい。その理由は、軽量鋼板１全体を加熱
した場合、最内部の発泡樹脂シート４が溶融する
と気泡５が樹脂層３，３内に拡散して、鋼板２，
２と樹脂層３，３との接着力を低下させるが、短
時間の高周波誘導加熱によれば、鋼板２，２のみ
が加熱されるため、せいぜい樹脂層３，３の鋼板
２，２の界面付近が溶融されるにとどまり、発泡
樹脂層４が溶融されることなく接着することがで
きるからである。
上記短時間での加熱を行つた後は、適当な圧下
力を与える圧着ロール９，９にて軽量鋼板１を加
圧接着する。
その後は、軽量鋼板１の冷却およびレベラーに
よる形状の矯正を行いコイラーで巻き取つて製品
となる。
〈実施例〉
（本発明例 １）
ナイロン６（0.15mm厚）／発泡ナイロン（0.3mm
厚）／ナイロン６（0.15mm厚）の３層構造の樹脂
を0.2mm厚の超深しぼり用鋼板KTUX（川崎製鉄
［株］製）の間に挾んだ軽量鋼板（全板厚１mm）
を作成した。
（比較例 １）
KTUX間にナイロン６（0.6mm厚）の単層から
成る樹脂を挾んだ以外は本発明例１と同様とし
た。
（比較例 ２）
KTUX間に発泡ナイロン（0.6mm厚）の単層か
ら成る樹脂を挾んだ以外は本発明例１と同様とし
た。
上記本発明例１、比較例１および比較例２の軽
量鋼板について、密着曲げ試験、およびＴ−Peel
強度の測定を行つた。その結果を表１に示す。
<Industrial Application Field> The present invention relates to a composite laminated steel plate, and particularly to a lightweight steel plate with a multilayer structure aimed at reducing weight, and a method for manufacturing the same. <Prior art and its problems> One of the laminated steel plates with thermoplastic resin sandwiched between the steel plates, an ultra-thin steel plate is used for the surface layer to ensure strength, and the middle layer is thick and lightweight. It is a resin that
There is a lightweight material called lightweight steel plate. This lightweight steel sheet is expected to be widely used in automobile materials, construction materials, etc. by taking advantage of its light weight. For example, when lightweight steel plates are used in automobile bodies, it is necessary to bend the ends of the steel plates by hemming, so the lightweight steel plates must have excellent bending properties. Therefore, it is recommended that the single layer of resin sandwiched between the steel plates be of relatively low hardness. However, soft resins with low hardness have a low melting point and are baked on car bodies at high temperatures (180 to 200
℃ for about 30 minutes), the resin melts and flows out, causing deformation of the lightweight steel plate. On the other hand, if a resin with a high melting point is used for fear of the resin flowing out, the resin will become hard at room temperature and will therefore be prone to cracking during hemming, which is not appropriate. Therefore, it has been desired to develop a lightweight steel plate that can achieve both the above-mentioned heat resistance and bending workability, and a method for manufacturing the same. <Object of the Invention> The object of the present invention is to eliminate the drawbacks of the above-mentioned prior art, provide a lightweight steel plate with excellent heat resistance and bending workability, and provide a lightweight steel plate that can be easily produced. The object of the present invention is to provide a method for manufacturing steel plates. <Structure of the Invention> As a method for achieving both the above-mentioned heat resistance and bending workability, the inventors of the present application sandwiched a single layer of foamed resin with a relatively high melting point between steel plates, and created a volumetric change (elasticity) in the resin during bending. I was reminded of the idea of giving it a certain gender. However, in the above method, since air bubbles are present at the interface between the foamed resin and the steel plate, the adhesive force between the steel plate and the resin becomes weaker, resulting in deterioration of various qualities of the lightweight steel plate. Therefore, as a result of intensive research, the inventors of this application sandwiched the foamed resin, which decreases in volume during bending, with a non-foamed resin that has a strong adhesive force with the steel plate, and by sandwiching this laminated resin between the steel plates, the desired result was achieved. The inventors have discovered that the above objectives can be achieved, and have arrived at the lightweight steel sheet of the present invention. That is, the present invention provides a laminated lightweight steel plate in which a thermoplastic resin is sandwiched between steel plates, wherein the thermoplastic resin is composed of at least three layers in which a foamed resin layer is sandwiched between the resin layers. It provides lightweight steel plates. Furthermore, when manufacturing a laminated lightweight steel plate in which a thermoplastic resin is sandwiched between steel plates, the present invention forms a resin material composed of at least three layers in which a foamed resin is sandwiched between the resins, and then the resin The present invention provides a method for manufacturing a lightweight steel plate, which comprises sandwiching a material between steel plates, heating the steel plates for a short time, and then bonding them under pressure using a pressure roll. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of the lightweight steel plate and method for manufacturing the same according to the present invention will be described in detail with reference to the accompanying drawings. FIG. 1 is a partial sectional view of a lightweight steel plate of the present invention. As shown in FIG. 1, the lightweight steel plate 1 of the present invention is
The outermost layer is composed of steel plates 2, 2, resin layers 3, 3 made of thermoplastic resin without air bubbles, and a thermoplastic foam resin layer 4 inside thereof, making up a total of five layers. For the steel plates 1, 1, any steel plates such as cold-rolled steel plates, various plated steel plates, and chemically treated steel plates can be used. As the thermoplastic resin constituting the resin layers 3, 3 and the foamed resin layer 4, from the viewpoint of moldability and heat resistance,
Examples include polyolefins such as polypropylene and polyamides such as nylon, and compositions containing copolymers and modified products of these and other additives may also be used. However, it is particularly preferable to use polyamide resins such as nylon, which have excellent heat resistance. Further, the resins constituting the resin layers 3, 3 and the foamed resin layer 4 may be the same or different, but in order to strengthen the adhesion between the resin layers 3, 3 and the foamed resin layer 4, it is preferable to use the same resin. It is preferable to use The resin layers 3, 3 contain almost no air bubbles and therefore have strong adhesive strength with the steel plates 2, 2. In addition, when the foamed resin layer 4 is bent and deformed, the air bubbles 5 contract and the volume decreases, so the lightweight steel plate 1
Even if it is bent, it will not crack or break. This foamed resin layer 4 is preferably composed of closed cell foamed resin. That is, the closed-cell foamed resin refers to a foamed resin in which the air bubbles 5 do not move within the resin layer 4 and the air bubbles 5 do not combine with each other. By using such a closed-cell foamed resin, the air bubbles 5 do not move beyond the interface with the resin layers 3, 3 and become mixed into the resin layers 3, 3, so that the steel plates 2, 2 and the resin The adhesive strength between layers 3 and 3 does not decrease. Although there is no particular limit to the thickness T 0 of such a lightweight steel plate 1, the thickness of the resin layers 3 and 3 and the foamed resin layer 4 should be adjusted so that it has sufficient strength and is sufficiently lightweight. The total resin thickness T 1 is T 1 /T 0 = 0.3 ~
It is best to set it to 0.8. Further, the thickness T 2 of the foamed resin layer 4 is T 2 /T 1 ≧1/5
It is better to This is because if T 2 /T 1 is less than 1/5, the volume reduction during bending will be too small. In addition, in the example explained above, the resin layer of the lightweight steel plate 1 is composed of three layers in total, but the lightweight steel plate of the present invention is not limited to this, and the resin layer is composed of four or more layers. It may be hot. Hereinafter, a method for manufacturing the lightweight steel sheet 1 of the present invention will be explained. The steps of the method for manufacturing a lightweight steel plate of the present invention are shown in FIGS. 2a to 2c. As shown in FIG. 2a, a sheet-like closed cell foamed resin 4 and resin 3 are formed, and the foamed resin 4 is sandwiched between the resins 3 and 3 to form a resin laminate 6 as shown in FIG. 2b. . The resin laminate 6 is preferably formed using a dry laminator or three-layer extrusion. Next, the resin laminate 6 is sandwiched between the two steel plates 2, 2 uncoiled from the uncoiler, pressed by pinch rollers 7, 7 as shown in FIG. Heats up in a short time. The heating of the steel plates 2, 2 is preferably performed by high frequency induction heating. The reason is that when the entire lightweight steel plate 1 is heated, when the innermost foamed resin sheet 4 melts, the air bubbles 5 diffuse into the resin layers 3, 3, and the steel plate 2,
2 and the resin layers 3, 3, but with short-term high-frequency induction heating, only the steel plates 2, 2 are heated, so at most the interface between the steel plates 2, 2 of the resin layers 3, 3 This is because only the vicinity is melted, and the foamed resin layer 4 can be bonded without being melted. After heating for a short period of time, the lightweight steel plate 1 is bonded under pressure using pressure rolls 9, 9 that apply an appropriate rolling force. Thereafter, the lightweight steel plate 1 is cooled, its shape is corrected using a leveler, and the product is wound up using a coiler. <Example> (Example 1 of the present invention) Nylon 6 (0.15 mm thick)/foamed nylon (0.3 mm
Thickness) / Light steel plate (total plate thickness 1mm) with a three-layer resin structure of nylon 6 (0.15mm thick) sandwiched between 0.2mm thick ultra-deep drawing steel plates KTUX (manufactured by Kawasaki Steel Corporation)
It was created. (Comparative Example 1) The same procedure as Inventive Example 1 was carried out except that a resin consisting of a single layer of nylon 6 (0.6 mm thick) was sandwiched between KTUX. (Comparative Example 2) The same procedure as Inventive Example 1 was carried out except that a resin consisting of a single layer of foamed nylon (0.6 mm thick) was sandwiched between KTUX. The lightweight steel plates of Invention Example 1, Comparative Example 1, and Comparative Example 2 were subjected to a contact bending test and a T-Peel test.
The strength was measured. The results are shown in Table 1.
【表】
上記結果から明らかなように本発明の軽量鋼板
は、曲げ加工性に優れ、しかも鋼板と樹脂との接
着力が強固（Ｔ−Peel強度が高い）であることが
わかる。
〈発明の効果〉
本発明の軽量鋼板によれば、鋼板間に挾装され
る熱可塑性樹脂が、樹脂層間に発泡樹脂を挾装し
た少なくとも３層で構成されるものであることに
より、耐熱性および曲げ加工性に優れ、しかも鋼
板と樹脂との接着力が強固な軽量鋼板となる。即
ち、本発明の軽量鋼板を例えば自動車ボデイーに
使用した場合、焼付け塗装の熱により樹脂の流れ
出しを生じることがなく、また軽量鋼板の端部を
ヘミング加工する際、樹脂の割れや折れを生じる
ことがなく、さらに鋼板と樹脂との界面破壊が生
じにくいため軽量鋼板の製品品質が向上する。
また本発明の軽量鋼板の製造方法によれば、上
記構成の軽量鋼板を容易に製造することができ
る。特に高周波誘導加熱により短時間で鋼板を加
熱した場合には、発泡樹脂層を溶融することなく
樹脂層の鋼板との界面付近のみを溶融し、強固に
接着を行うことができる。[Table] As is clear from the above results, the lightweight steel plate of the present invention has excellent bending workability, and the adhesive strength between the steel plate and the resin is strong (high T-Peel strength). <Effects of the Invention> According to the lightweight steel plate of the present invention, the thermoplastic resin sandwiched between the steel plates is composed of at least three layers in which foamed resin is sandwiched between the resin layers, so that heat resistance is improved. This results in a lightweight steel plate with excellent bending workability and strong adhesive strength between the steel plate and the resin. That is, when the lightweight steel sheet of the present invention is used, for example, in an automobile body, the resin will not flow out due to the heat of baking paint, and the resin will not crack or break when hemming the edges of the lightweight steel sheet. Furthermore, the product quality of the lightweight steel sheet is improved because it is less likely to cause interfacial failure between the steel sheet and the resin. Moreover, according to the method for manufacturing a lightweight steel plate of the present invention, a lightweight steel plate having the above structure can be easily manufactured. In particular, when the steel plate is heated in a short time by high-frequency induction heating, only the vicinity of the interface between the resin layer and the steel plate is melted without melting the foamed resin layer, and strong adhesion can be achieved.
第１図は、本発明の軽量鋼板の部分断面図であ
る。第２ａ図〜第２ｃ図は本発明の軽量鋼板の製
造工程を示す側面図である。
符号の説明、１……軽量鋼板、２……鋼板、３
……樹脂（層）、４……発泡樹脂（層）、５……気
泡、６……樹脂積層体、７……ピンチロール、８
……加熱炉、９……圧着ロール。
FIG. 1 is a partial sectional view of a lightweight steel plate of the present invention. Figures 2a to 2c are side views showing the manufacturing process of the lightweight steel plate of the present invention. Explanation of symbols, 1... Light steel plate, 2... Steel plate, 3
... Resin (layer), 4 ... Foamed resin (layer), 5 ... Bubbles, 6 ... Resin laminate, 7 ... Pinch roll, 8
...Heating furnace, 9...Crimping roll.
Claims (1)
鋼板において、 前記熱可塑性樹脂は、樹脂層間に発泡樹脂層を挾
装した少なくとも３層で構成されることを特徴と
する軽量鋼板。 ２ 鋼板間に熱可塑性樹脂を挾装した積層型軽量
鋼板を構造するに際し、発泡樹脂を樹脂間に挾ん
だ、少なくとも３層で構成される樹脂財を形成
し、 次いで前記樹脂材を鋼板で挾持し、前記鋼板を
短時間で加熱した後、圧着ロールにて加圧接着す
ることを特徴とする軽量鋼板の製造方法。[Claims] 1. A laminated lightweight steel plate in which a thermoplastic resin is sandwiched between steel plates, characterized in that the thermoplastic resin is composed of at least three layers in which a foamed resin layer is sandwiched between the resin layers. lightweight steel plate. 2. When constructing a laminated lightweight steel plate in which a thermoplastic resin is sandwiched between steel plates, a resin product consisting of at least three layers is formed by sandwiching a foamed resin between the resins, and then the resin material is sandwiched between the steel plates. A method for producing a lightweight steel plate, which comprises clamping the steel plate, heating the steel plate for a short time, and then bonding the steel plate under pressure using a pressure roll.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP19716485A JPS6256129A (en) | 1985-09-06 | 1985-09-06 | Light-weight steel plate and manufacture thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP19716485A JPS6256129A (en) | 1985-09-06 | 1985-09-06 | Light-weight steel plate and manufacture thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS6256129A JPS6256129A (en) | 1987-03-11 |
| JPH0588185B2 true JPH0588185B2 (en) | 1993-12-21 |
Family
ID=16369842
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP19716485A Granted JPS6256129A (en) | 1985-09-06 | 1985-09-06 | Light-weight steel plate and manufacture thereof |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS6256129A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2019181731A (en) * | 2018-04-04 | 2019-10-24 | 日本製鉄株式会社 | Composite laminate |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP7529970B2 (en) * | 2020-03-26 | 2024-08-07 | 日本製鉄株式会社 | Sandwich type resin composite steel plate |
-
1985
- 1985-09-06 JP JP19716485A patent/JPS6256129A/en active Granted
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2019181731A (en) * | 2018-04-04 | 2019-10-24 | 日本製鉄株式会社 | Composite laminate |
Also Published As
| Publication number | Publication date |
|---|---|
| JPS6256129A (en) | 1987-03-11 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| LAPS | Cancellation because of no payment of annual fees |