JPH11105048A - Decorative fiber reinforced thermoplastic resin sheet for decoration and method for producing fiber reinforced thermoplastic resin foam using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative fiber-reinforced thermoplastic resin sheet for efficiently decorating with high quality fiber-reinforced thermoplastic resin foam, and a method for decoratively molding by using the sheet. SOLUTION: The thermoplastic resin foam has a decorative surface of high quality without wrinkle, flute, flow of design or the like by the steps of laminating a thermoplastic resin layer having a thickness of 10 to 500 μm and colored or given by a design on one surface of a fiber-reinforced thermoplastic resin sheet having at least one layer containing continuous fiber made of a plurality of filaments drawn and aligned in one direction, supplying foamable thermoplastic resin composition H thereinto while foaming the composition H while shaping a sheet F covered with a non-melt or high-temperature melt synthetic resin film having glossiness of 5 to 90% to a hollow material T and shaping the material T along a regulating member 26 to a desired sectional shape by its foaming pressure.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber-reinforced thermoplastic resin sheet for decoration and a method for decorative molding of a fiber-reinforced thermoplastic resin foam using the same. The present invention relates to a sheet and a molding method suitable for use in producing a reinforced thermoplastic resin foam or the like.

[0002]

2. Description of the Related Art Conventionally, as a method for producing a fiber-reinforced resin molded article having a surface decorated with a color, a pattern, or the like, conventionally, a pulverization using a thermosetting resin has been performed by releasing a mold formed by forming a coating film. A method in which a functional film is drawn into a drawing die together with a fiber base material impregnated with a resin, and simultaneously with molding of a fiber reinforced resin, a coating film is transferred to the surface thereof (Japanese Patent Laid-Open No. Hei 3-184832).
Also, a method in which a surface decorative material such as a film or a sheet is pressed via an adhesive and continuously laminated on the surface of a molded body in a high-temperature state pulled out from a mold after pultrusion molding (JP-A-4-323924). No.) are known.

However, in order to obtain a molded article having a complicated cross-sectional shape, if the former method is used among the above-mentioned conventional methods, the release film is formed along the complicated cross-sectional shape. Not only is it difficult to insert into a mold without wrinkles, but also it is difficult to correctly position the film in a portion requiring painting. Further, even when the latter method is used, it is extremely difficult to laminate a film or sheet-like surface decorative material along the surface of a molded article having a complicated cross-sectional shape without wrinkling.

[0004] In view of this, the present inventor has worked with others to continuously form a fiber-reinforced thermoplastic resin sheet whose surface has been decorated in advance into a hollow body, and to form a foamable thermoplastic resin composition inside the hollow body. A method has been proposed in which a foam is supplied while being foamed, or foamed after being supplied, and the cross-sectional shape is shaped into a desired shape by causing the hollow body to follow the regulating member by the foaming pressure (JP-A-8-300373). issue).

According to this method, since the surface of the fiber-reinforced thermoplastic resin layer forming the skin layer of the molded article has been already decorated, even if the molded article has a complicated cross-sectional shape, it is added simultaneously with the molding. Can be decorated. In this proposal, by laminating a protective film on the decorative surface of the fiber-reinforced thermoplastic resin sheet, damage due to the decorative surface coming into contact with the shaping regulating member can be prevented. It also suggests.

[0006]

By the way, when the method proposed in Japanese Patent Application Laid-Open No. Hei 8-300373 is used, the decorated fiber-reinforced thermoplastic resin sheet is distorted in the longitudinal direction at the time of shaping depending on conditions. In some cases, as a result, there is a problem that the form of decoration changes. In addition, in some cases, problems such as damage to the protective film due to heat or shearing force during molding and loss of decoration may occur.

An object of the present invention is to provide a fiber-reinforced thermoplastic resin sheet for decoration which can be more reliably and accurately decorated by developing and improving the above proposal, and a fiber-reinforced thermoplastic resin using the same. An object of the present invention is to provide a decorative molding method for a foam.

[0008]

In order to achieve the above-mentioned object, a fiber-reinforced thermoplastic resin sheet of the present invention has a structure in which continuous fibers composed of a plurality of filaments are aligned in one direction, and On one surface of a fiber reinforced thermoplastic resin sheet having at least one integrated composite layer, a thermoplastic resin layer having a thickness of 10 to 500 μm, which is colored or has a pattern on the surface, is laminated. The thermoplastic resin layer is not thermally fused to the surface of the thermoplastic resin layer, and has a higher or lower melting temperature than any of the above-mentioned thermoplastic resins. It is characterized by the fact that a synthetic resin film adjusted to 90% is laminated so that its adjustment surface is in close contact with the surface of the thermoplastic resin layer.

Further, in the decorative molding method for a fiber-reinforced thermoplastic resin foam according to the present invention, the decorative fiber-reinforced thermoplastic resin sheet described above may be formed such that the surface on which the synthetic resin film is laminated is the outer surface. While continuously shaping the hollow body, the foamed thermoplastic resin composition is supplied into the hollow body while being foamed, and the foaming pressure causes the outer surface of the hollow body to conform to the regulating member, thereby forming a cross-sectional shape. Is shaped into a desired shape.

[0010] The present invention relates to the above-mentioned JP-A-8-30037.
The present inventors have made intensive studies based on the method proposed in No. 3 and have succeeded in solving some problems arising in the method.

That is, as the decorative fiber reinforced thermoplastic resin sheet used in the method of the present invention, a sheet having at least one composite layer in which a reinforcing fiber in which continuous fibers are arranged in a longitudinal direction and a thermoplastic resin are used is used. By doing so, it is possible to prevent the sheet from being distorted in the longitudinal direction of the continuous fiber (axial direction of the hollow body) due to heat or tensile stress at the time of molding, and to prevent decoration distortion.

Further, the decorative fiber-reinforced thermoplastic resin sheet is not heat-fused with the resin layer on the surface of the colored or patterned fiber-reinforced thermoplastic resin layer which is the decorative surface. Moreover, since the melting temperature is higher than the thermoplastic resin used for the thermoplastic resin layer and the fiber-reinforced thermoplastic resin sheet body or the synthetic resin film that does not melt is laminated, the decorative surface of the sheet is reduced. Effective protection from heat and various forces during molding. By adjusting the glossiness of the synthetic resin film in the range of 5 to 90%, that is, by appropriately roughening the film surface, the synthetic resin film can be heated or foamed by molding or by a shearing force. It is possible to prevent the occurrence of a displacement between the film and the thermoplastic resin layer thereunder, and to prevent a problem such as a flow of a picture. In addition, the glossiness of the synthetic resin film is transferred to the thermoplastic resin layer thereunder, and contributes to the adjustment of the surface glossiness of the molded product.

In the decorative molding method for a fiber-reinforced thermoplastic resin foam of the present invention, the fiber-reinforced thermoplastic resin sheet of the present invention as described above is formed into a hollow body while continuously forming it into a hollow body. By supplying the thermoplastic resin composition while foaming it, and by applying the foaming pressure to the outer surface of the hollow body along the regulating member, it is shaped from a simple cross-sectional shape to a complicated desired cross-sectional shape. In combination with the function of the fiber-reinforced thermoplastic resin sheet for decoration of the present invention described above, it is possible to perform high-quality decoration without wrinkles on the surface of the molded product.

In the present invention, the thermoplastic resin used for the sheet body of the decorative fiber reinforced thermoplastic resin sheet includes polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyamide, polyethylene terephthalate, polybutylene terephthalate, polycarbonate, and the like. Examples include polyvinylidene fluoride, polyphenylene sulfide, polyphenylene oxide, polyether sulfone, polyether ether ketone, and polymethyl methacrylate. Further, a copolymer or graft resin containing such a thermoplastic resin as a main component, or a blend resin, such as chlorinated polyvinyl chloride, ethylene-vinyl chloride copolymer, vinyl acetate-ethylene copolymer, vinyl acetate- Vinyl chloride copolymer, urethane-vinyl chloride copolymer, acrylonitrile-butadiene-styrene copolymer, acrylonitrile-styrene copolymer, silane-modified polyethylene, acrylic acid-modified polypropylene, maleic acid-modified polyethylene, and the like can also be used. In addition, a thermoplastic elastomer or a crosslinked thermoplastic resin can also be used. Of these, considering the molding temperature,
Polyethylene, polypropylene, polyvinyl chloride, polystyrene, chlorinated polyvinyl chloride, ethylene-vinyl chloride copolymer, vinyl acetate-ethylene copolymer, vinyl acetate-vinyl chloride that can be molded at a relatively low temperature of 120 to 250 ° C It is preferable to use a copolymer, a urethane-vinyl chloride copolymer, an acrylonitrile-butadiene-styrene copolymer, and an acrylonitrile-styrene copolymer.

The thermoplastic resin used for the fiber-reinforced thermoplastic resin sheet body in the present invention may be used alone or in combination. The dibutyltin maleate polymer and the dibutyltin bis ( Organic tin malates, such as monoalkyl malates, dibutyl tin laurates, and organic tin laurates, such as monobutyl tin fatty acid salts;
Dioctyltin sulfide, dibutyltin 3 mercaptopropionate and other organic tin mercapto, tribasic lead sulfate, lead group such as basic lead sulfite, calcium stearate, heat stabilizer such as metal soap such as lead stearate,
Lubricants such as fatty acid ester wax, low molecular weight polyethylene wax, metal soap, polyhydric alcohol, fatty acid alcohol and fatty acid amide; processing aids such as acrylic resin and olefin resin; plasticizers such as dibutyl phthalate and dioctyl phthalate; Agent, UV absorber,
Additives such as modifiers and colorants, and fillers such as talc, mica, calcium carbonate, wood flour, and fiber-reinforced thermosetting resin pulverizers may be blended.

Further, the fiber-reinforced thermoplastic resin sheet used in the present invention has at least one composite layer in which continuous fibers composed of a plurality of filaments are aligned in one direction and integrated with the thermoplastic resin. Although it has layers, any layers other than such a composite layer can be laminated. The total fiber content in the sheet is 5 to 5.
It is preferably in the range of 80% by weight, especially in the range of 10 to 50% by weight. When the content of the fiber is less than 5% by weight, the reinforcing effect is small, and when the content is more than 80% by weight, the resin binding between the fibers is reduced, so that it is weakened.

As the material of the fiber used for the fiber-reinforced thermoplastic resin sheet, those which do not melt-soften and carbonize by the heat applied in the method of the present invention can be used. Specifically, glass fiber, carbon fiber, silicon -Titanium-carbon fiber, boron fiber, fine metal fiber, or organic fiber such as aramid fiber, polyester fiber, polyamide fiber, natural fiber such as silk, cotton, hemp, etc. , Glass fiber,
Carbon fibers are preferred. Filament diameter is 1-50
μm, particularly preferably 3 to 30 μm. When the diameter of the filament is smaller than 1 μm, the reinforcing effect by the fiber is reduced. When the diameter is larger than 50 μm, the contact area between the thermoplastic resin and the fiber is smaller than that of the same type and the same amount of fiber. The reinforcing effect of the fibers is undesirably small.

The thickness of the decorative fiber reinforced thermoplastic resin sheet used in the present invention is preferably from 0.1 to 10 mm, more preferably from 0.3 to 2 mm. When the thickness is less than 0.1 mm, the strength is insufficient, and when the thickness is more than 10 mm, it is difficult to form a hollow body.

One example of a method for producing a fiber-reinforced thermoplastic resin sheet having a composite layer in which continuous fibers are aligned in the longitudinal direction and integrated with a thermoplastic resin is as follows. , After aligning in one direction,
A method in which a film made of a thermoplastic resin is stacked and passed between heating pinch rollers, and the molten thermoplastic resin is caused to enter between filaments to form a sheet.

As another example of the method for producing the sheet, a continuous reinforcing fiber bundle aligned in one direction is drawn into a tank in which a powdery thermoplastic resin is flowing, and the reinforcing fiber bundle is filamentized. After adhering the powdered thermoplastic resin while unwoven, the resin is passed through a heating pinch roller to melt the thermoplastic resin and penetrate between the filaments to form a sheet.

The resin material used for the colored or patterned thermoplastic resin layer laminated on one surface of the decorative fiber reinforced thermoplastic resin sheet of the present invention may be a fiber reinforced thermoplastic resin sheet body. There is no particular limitation as long as it is heat-fusible with the thermoplastic resin used for the part. If the thickness of the thermoplastic resin layer is less than 10 μm, sufficient concealing properties cannot be imparted, so that the color and pattern are not uniform, and if it exceeds 500 μm, heat, foaming pressure, or shearing force during molding. As a result, the thermoplastic resin layer flows, causing a shift in the pattern on the decorative surface.

The form of decoration for the thermoplastic resin layer is a decoration by printing, transfer, plating, or the like, and a three-dimensional pattern for providing fine irregularities such as embossing and fine irregularities such as wood-like fine grooves. Decoration. In addition, decoration may be performed by laminating a printed thermoplastic resin sheet or film, and further, only coloring may be performed.

As a method of decorating by printing, gravure printing, pad printing, screen printing and the like can be mentioned. As a paint used for printing, a solution obtained by dissolving or decomposing an organic pigment or an inorganic pigment in an organic solvent can be used, and a paint having excellent adhesion to a thermoplastic resin must be used.

The decorating method by transfer is a method of transferring an ink layer printed on a film, paper, or the like to a body to be decorated.
At the time of transfer, a method called hot stamping involving heating and pressurizing can be adopted, and this method is a method of laminating a paint foil, a metal foil, or the like on the object to be decorated by thermocompression bonding.

The method of decorating by plating is to impart conductivity to the decorated object whose surface has been roughened by a solvent or machining,
A chemical electroplating method of forming a metal film in a plating solution, a vacuum plating method of depositing a metal constituting the metal film in a vacuum, and attaching the metal to the surface of the object to be decorated, and the like can be employed. .

In order to decorate the surface of a sheet-like resin to be a thermoplastic resin layer, such as printing, transferring, and plating, a sheet manufactured in advance is processed by a commonly used device such as a printing machine or a transferring device. I just need. Further, at the time of manufacturing the sheet, a thermoplastic resin sheet or film decorated in advance by printing or the like may be laminated while the resin constituting the sheet is in a molten state.

Next, as the synthetic resin film used for the decorative fiber reinforced thermoplastic resin sheet of the present invention, the thermoplastic resin layer used for the fiber reinforced thermoplastic resin sheet body and the colored / patterned thermoplastic resin layer is used. It is required that the melting temperature is higher than that of the resin or the resin is not melted. For example, the resin used for the fiber-reinforced thermoplastic resin sheet or the thermoplastic resin layer is polyvinyl chloride, polypropylene, or polyethylene that melts at 200 ° C. In case 2
Polyethylene terephthalate, polyphenylene sulfide, polycarbonate,
When a film made of polyamide or the like, or a resin that is melted at a high temperature by a sheet or a resin layer is used, a film that does not melt by crosslinking or vulcanization may be used.

This synthetic resin film has a thickness of 10 to 15
When the thickness is less than 10 μm, problems such as breakage due to heat, foaming pressure, and shearing force during molding, and difficulty in peeling after molding occur, and a thickness of 150 μm.
Exceeding the limit, the corners of the molded product are not sharp.

The synthetic resin film has a gloss of 5
Fine irregularities having a surface roughness of about Rz (ten-point average roughness) = 0.6 to 7 μm are formed so that the surface roughness is in the range of about 90%. As a method of providing such unevenness, a method of sandblasting the film surface by spraying silica sand or the like, a mechanical method such as polishing, or a method of etching with a chemical, or a method of directly applying an inorganic filler or the like to the film itself is used. By kneading and forming a film, a method of forming fine irregularities on the surface can be adopted, and the method is not particularly limited.

If the glossiness of the synthetic resin film is less than 5%, the unevenness becomes large, making it difficult to use the laminated synthetic resin film. On the other hand, when the glossiness exceeds 90%, the laminating of the synthetic resin film will spontaneously peel off after lamination, or the interface between the synthetic resin film and the thermoplastic resin layer will shift and the picture will flow, and the effect will be exhibited. Can not.

The thermoplastic resin of the expandable thermoplastic resin composition used in the decorative molding method of the fiber-reinforced thermoplastic resin foam of the present invention is selected from thermoplastic resins used for the resin used in the fiber-reinforced thermoplastic resin sheet. The same resin as the resin can be used, but it is preferable to use a resin that can be thermally fused to the fiber-reinforced thermoplastic resin sheet. Specifically, it is preferable to use the same type of thermoplastic resin (a thermoplastic resin polymerized from the same monomer). As a combination when using different kinds of thermoplastic resins, for example, polyethylene and polypropylene, polyethylene and vinyl acetate-ethylene copolymer,
Polyethylene and chlorinated polyethylene, polystyrene and acrylonitrile-butadiene-styrene copolymer, polystyrene and acrylonitrile-styrene copolymer, polyvinyl chloride and chlorinated polyvinyl chloride, polyvinyl chloride and ethylene-vinyl chloride copolymer, polychlorinated Vinyl and vinyl acetate-vinyl chloride copolymer, polyvinyl chloride and urethane-vinyl chloride copolymer, polyvinyl chloride and polymethyl methacrylate, polyvinyl chloride and acrylonitrile
Butadiene-styrene copolymer, polybutylene terephthalate and polyethylene terephthalate, acrylonitrile-butadiene-styrene copolymer and acrylonitrile-styrene copolymer, and the like. Further, a combination of a thermoplastic resin and the same type of modified thermoplastic resin can also be used. Examples thereof include polyethylene and silane-modified polyethylene, polystyrene and acrylic acid-modified polystyrene, and polyethylene and maleic acid-modified polyethylene.

As a foaming agent used in the foamable thermoplastic resin composition, a decomposition-type foaming agent that chemically decomposes by heat to generate a gas and a volatile-type foaming agent that utilizes gasification of a volatile liquid are used. be able to. Alternatively, a gas such as carbon dioxide or nitrogen may be injected under pressure while kneading the thermoplastic resin at a melting temperature or higher, dispersed in the thermoplastic resin, and foamed by releasing the pressure.

Examples of the decomposable blowing agent include azodicarbonamide, azobisisobutyronitrile, N, N'-dinitropentamethylenetetramine, p, p'-oxybisbenzenesulfonyl human azide, barium azodicarboxylate, and trihydra. Dinotriazine, p-toluenesulfonyl hydrazide, sodium bicarbonate, ammonium carbonate and the like.

Examples of the volatile foaming agent include aliphatic hydrocarbons such as propane, butane, pentane, hexane and heptane; carbonized aliphatic hydrocarbons such as methyl chloride and methylene dichloride; and 1,1-dichloro-1-trichloromethane. Fluoroethane,
2,2-dichloro-1,1,1-trifluoroethane,
Freon gas such as 1,1,1,2-tetrafluoroethane and the like can be mentioned.

The amount of the foaming agent to be mixed must be appropriately adjusted since the amount of gas generated varies depending on the type of the foaming agent.
It is preferable to mix in the range of parts by weight. If the blending amount of the foaming agent is too small, a foamed molded article cannot be obtained, and if the blending amount of the foaming agent is too large, cells are broken and a dense cell cannot be obtained. For example, when producing a thermoplastic resin foam having an expansion ratio of 10 using azodicarbonamide, it is appropriate to mix 5-7.5 parts by weight with respect to 100 parts by weight of the resin.

The expansion ratio of the inner foam layer (core layer) of the molded product obtained by foaming the foamable thermoplastic resin composition includes the strength and specific gravity required for the manufactured product, the type of the thermoplastic resin used, and the like. Is appropriately selected according to
A range of 0 times is preferred. When the expansion ratio is less than 1.2, the effect of reducing the weight by foaming is small, and when the expansion ratio exceeds 20 times, the strength becomes very weak.

The hollow body referred to in the present invention is not only a hollow body in which the side edges of the sheet are abutted with each other or are superimposed to form a void inside, but also a side edge of the sheet. It also includes those in which some gaps are formed in the parts.

The method of shaping the decorative fiber-reinforced thermoplastic resin sheet into a hollow body as described above includes the following.
A method in which a sheet is gradually bent with a synthetic resin shoe or roll, and a mold provided with a sheet passage such that the sheet is gradually bent and shaped into a hollow body, and the mold is used. For example, a method of passing a sheet through a mold can be adopted. When shaping into a hollow body, it is desirable to shape the thermoplastic resin in a softened state in order to prevent the sheet from cracking or tearing.

Here, the softened state is defined as JIS-K-72.
Refers to a state in which the thermoplastic resin is heated to a temperature equal to or higher than the Vicat softening temperature, which is measured in accordance with J.06. Generally, it refers to a state in which the thermoplastic resin starts to deform and is heated to a temperature at which the mechanical properties decrease.

A sheet used for shaping into a hollow body is formed by abutting two side edges of one sheet, or by overlapping, or abutting through a slight gap, and using a plurality of sheets. In a state where these are made parallel to each other, these side edges may be abutted or overlapped with each other, or may be abutted through a slight gap to form a single hollow body as a whole.

As a method of supplying the foamable thermoplastic resin composition into the hollow body while foaming the foamed resin composition, the nozzle of the extruder is made to face the inside from the opening portion of the hollow body during shaping, and the nozzle is exposed from the nozzle. A method in which the foamable thermoplastic resin composition is extruded while being foamed can be employed. In this case, in an extruder, a foamable thermoplastic resin composition containing a decomposable foaming agent or a volatile foaming agent is kneaded at a gas generation temperature or higher, and the generated gas is dispersed in the thermoplastic resin to form a foamable thermoplastic resin. It is extruded into a hollow body through a nozzle whose temperature has been adjusted to the melting temperature of the thermoplastic resin composition or higher. Alternatively, while kneading the thermoplastic resin at a melting temperature or higher, a gas such as carbon dioxide or nitrogen is press-fitted to disperse the thermoplastic resin into the hollow resin through a nozzle whose temperature has been adjusted to a temperature higher than the melting temperature of the thermoplastic resin. put out.

As a method for shaping the hollow body by the foaming pressure of the foamable thermoplastic resin composition, the outer surface of the hollow body is inserted into a mold, and the hollow body is formed by the foaming pressure of the foamable thermoplastic resin composition. A method in which the outer surface of the body is pressed against the inner surface of the mold to shape the resin, or a method in which the outer surface of the hollow body is regulated by a roll or shoe while heating from the surroundings to expand the foamable thermoplastic resin composition. Can be mentioned. When shaping in a mold, shaping may be assisted by evacuation or compressed air.

Here, when the hollow body is shaped into a desired cross-sectional shape along the regulating member by the foaming pressure of the foamable thermoplastic resin composition inside, it is generated by the foaming operation of the foamable thermoplastic resin composition. If the foaming pressure alone does not provide enough pressure to press the hollow body against the regulating member, additional pressure may be additionally applied to the inside of the hollow body, and the method of the present invention provides such an auxiliary method. The case where pressure is applied is also included.
When an auxiliary pressure is used, it is preferable to have a structure having a pipe through which gas can be supplied into the hollow body.

When the hollow body is shaped into a desired cross-sectional shape by the internal foaming pressure, the hollow body can be shaped while being spread. That is, it is also possible to shape the outer peripheral length of the molded article to be larger than the outer peripheral length of the hollow body. In this case, in consideration of the spreading of the hollow body, the intended decoration is performed after the spreading. Decoration must be applied to obtain a surface.

[0045]

EXAMPLES Examples of the present invention will be described below together with comparative examples.

Example 1 Production of Decorative Fiber-Reinforced Thermoplastic Resin Sheet The compounding of the resin used in the fiber-reinforced thermoplastic resin sheet is shown in Table 1. This blend was mixed at 100 ° C. with a mixer.

[0047]

[Table 1]

The fibers used in the fiber-reinforced thermoplastic resin sheet were glass fibers (manufactured by Nitto Boseki Co., Ltd., fiber diameter 23 μm, 4400 TEX).

On the other hand, the resin used for the colored or patterned thermoplastic resin layer laminated on one surface of the fiber reinforced thermoplastic resin sheet is an acrylic resin (manufactured by Mitsubishi Rayon Co., Ltd., black, 65 μm thick) And

The synthetic resin film for protecting the decorative surface is made of polyethylene terephthalate (manufactured by Teijin Limited, 2
Axial stretching, thickness 38 μm, single-side sandblasting, glossiness = 12%).

A decorative fiber-reinforced thermoplastic resin sheet was manufactured using the above-mentioned materials and using a manufacturing apparatus as shown in FIG.

That is, the polyvinyl chloride powder A having the composition shown in Table 1 was accommodated in the fluidized tank 1 and flowed by blowing air from the bottom of the fluidized tank 1 through the porous plate 1a. . Sixteen glass fiber bundles B were drawn into the flowing polyvinyl chloride powder A, and a vinyl chloride resin was adhered to each filament in the glass fibers.
The glass fiber bundle B to which the resin powder A has adhered is aligned in the longitudinal direction, guided to the heating roll 2, and pinched at a linear pressure of 12 kg / cm while heating to 210 ° C., whereby the glass fiber and the vinyl chloride resin are integrated. Fiber reinforced thermoplastic resin sheet C was obtained. Further, the fiber-reinforced thermoplastic resin sheet C obtained in this manner is successively placed on another heating roll 3.
Acrylic film D and polyethylene terephthalate film E heated to 150 ° C. were subjected to a linear pressure of 2 kg /
cm, cooled by a cooling roll 4 and taken up by a take-off roll 5 to form an acrylic resin film d having a thickness of 65 μm on one surface of a fiber-reinforced thermoplastic resin sheet C having a thickness of 0.5 mm, and a thickness of 38 μm. Of polyethylene terephthalate film E was sequentially laminated to obtain a decorative fiber-reinforced thermoplastic resin sheet F, which was wound around a winder 6. Here, the polyethylene terephthalate film E was laminated such that the surface having a surface roughness of 12% by sandblasting was in contact with the surface of the acrylic resin film D.

This decorative fiber reinforced thermoplastic resin sheet F
The width of the main body of the fiber-reinforced thermoplastic resin sheet C is 170 mm, and the acrylic resin film D and the polyethylene terephthalate film E are each 160 mm.
As shown in a schematic cross-sectional view in FIG. 2, each of the sheets was laminated on the center portion in the width direction of the fiber-reinforced thermoplastic resin sheet C.

Production of Fiber Reinforced Thermoplastic Resin Foam The decorative fiber reinforced thermoplastic resin sheet F obtained as described above and, apart from this, an acrylic resin film D and a polyethylene terephthalate film E are not laminated. A fiber-reinforced thermoplastic resin sheet G having a width of 100 mm, which is composed only of the fiber-reinforced thermoplastic resin layer of the sheet F, is used as a skin layer, and a foamable thermoplastic resin having a composition shown in the following [Table 2] as a core material layer Using the composition H, a fiber-reinforced thermoplastic resin foam was decoratively molded by an apparatus as shown in FIG.

[0055]

[Table 2]

The apparatus comprises two sheet feeding machines 21 and 21
2, an extruder 23, an extruding die 24 mounted on the extruder 23, an outer die 25 arranged around the outer periphery of the extruding die 24, a shaping die 26, a cooling die 28, And the product take-up machine 29 as a main component.

The above-mentioned decorative fiber-reinforced thermoplastic resin sheet F was wound around one sheet feeding machine 21, and the fiber-reinforced thermoplastic resin sheet G was wound around the other sheet feeding machine 22.

The decorative fiber reinforced thermoplastic resin sheet F wound around the sheet feeder 21 is inserted between an extrusion die 24 mounted on an extruder 23 and an outer die 25. Between the extrusion die 24 and the outer die 25, FIG.
A gap is formed in the shape shown in the cross-sectional view of the decorative fiber reinforced thermoplastic resin sheet F at a location indicated by X '. Although not shown, on the upstream side (right side in the figure) of the extrusion die 24, the decorative fiber reinforced thermoplastic resin sheet F is gradually formed from a flat plate into a cross-sectional shape shown in FIG. A shaping jig capable of performing the shaping and a hot air heating device for heating and softening the sheet F are provided.

The outer mold 25 has an introduction hole 2 for introducing the fiber reinforced thermoplastic resin sheet G into a lower portion thereof.
51 are formed, and the fiber-reinforced thermoplastic resin sheet G introduced from the introduction hole 251 is so formed as to cover the opening of the decorative fiber-reinforced thermoplastic resin sheet F shaped in the shape of FIG. The decorative fiber reinforced thermoplastic resin sheet F
5, a hollow body T is formed by two sheets F and G as a whole, as shown in a cross-sectional view taken along a line YY 'in FIG. The decorative fiber-reinforced thermoplastic resin sheet F and the fiber-reinforced thermoplastic resin sheet G are each 5 m apart from the folded portions formed on both sides of the opening of the sheet F.
The width of m overlaps. The fiber reinforced thermoplastic resin sheet G is also heated and softened by a hot air heating device (not shown) before the introduction into the introduction hole 251.

The extrusion die 24 includes a core die 241 for shaping the sheet F into a shape as shown in FIG. 4 in cooperation with the outer die 25, and a downward right angle from the core die 241. And has a vertical portion 242 connected to the extruder 23 through an opening portion of the sheet F being formed, and the resin flow opening toward the inside of the hollow body T through the entirety thereof. A plurality of paths 243 are formed in parallel. Then, the expandable thermoplastic resin composition H supplied from the extruder 23 through the resin flow path 243 can be extruded into the hollow body T.

A shaping die 26 is provided downstream of the extrusion die 24 and the outer die 25. This shaping mold 26
The cross-sectional shape of the outer mold (the extrusion mold 24, the outer mold 25)
6 is the same as the cross-sectional shape of the hollow body T shown in FIG. 5, but at the downstream end, FIG.
The cross-sectional shape of the product at the location indicated by ZZ 'in FIG. 7, that is, the same shape as the final cross-sectional shape of the product, during which the cross-sectional shape gradually changes.

The shaping mold 26 and the above-described outer mold 2
5 is a heater 26 provided on each outer peripheral surface.
a, 25a allows heating to a desired temperature.

A cooling mold 28 is connected to the downstream side of the shaping mold 26 via a heat insulating material 27. This heat insulating material 27
The cross-sectional shape of the cooling mold 28 is the same as the cross-sectional shape at the downstream end of the shaping mold 26. Then, the cooling mold 28
A take-up machine 29 for taking out a molded product is provided downstream of the machine.

In the manufacturing apparatus and the mold described above, the fiber-reinforced thermoplastic resin sheet F for decoration was heated to 100 ° C. by a hot-air heater while the temperature of the extrusion mold 24 was adjusted to 170 ° C.
While being softened by heating, the material is shaped into the shape shown in FIG. 4 by a shaping jig and inserted into a gap formed between the extrusion mold 24 and the outer mold 25 and passed therethrough. Inlet hole 25
To 1, a fiber-reinforced thermoplastic resin sheet G heated and softened to 100 ° C. by a hot-air heating device was inserted, and the hollow body T shown in FIG. at the same time,
205 ° C. inside the extruder 23 inside the hollow body T.
The foamable thermoplastic resin composition H, which had been heated and kneaded, was extruded while foaming through a resin channel 243. Thereafter, the entirety of the hollow body T and the resin composition H inside thereof is
Introduced into the shaping mold 26 heated to 0 ° C., the outer peripheral surface of the hollow body T is pressed against the inner circumferential surface of the shaping mold 26 by the foaming pressure of the expandable thermoplastic resin composition H, and the take-off machine 29 is pressed. The shape of the acrylic resin film D was gently changed by taking it over, the shape was changed to the shape shown in FIG. 6, and then cooled by the cooling mold 28, so that the acrylic resin film D was arranged in the region indicated by the dashed line in FIG. A fiber-reinforced thermoplastic resin foam having an irregular cross-sectional shape was obtained, which was provided with a skin layer composed of a decoration fiber-reinforced thermoplastic resin layer and a core material layer composed of a thermoplastic resin foam.

The obtained fiber-reinforced thermoplastic resin foam is
A colored acrylic resin film D was fused and integrated on one surface thereof, and a polyethylene terephthalate film E was laminated on the acrylic resin surface. The polyethylene terephthalate film E could be easily peeled off. The surface of the molded product after peeling the film had a gloss of 8%, and had a uniform surface without fine vertical streaks or the like during cooling sizing.

<Example 2> Instead of the acrylic resin film used in Example 1, a 150 μm thick semi-rigid vinyl chloride resin sheet having a wood grain gravure printed on the surface was used. A fiber-reinforced thermoplastic resin sheet for decoration was manufactured in the same manner as in Example 1 and a fiber-reinforced thermoplastic resin foam was manufactured using the sheet in the same manner as in Example 1.

The foamed thermoplastic resin thus obtained had the same surface as in Example 1, and could be molded in a state in which the printed pattern of the grain appeared almost as it was at the time of printing.

Comparative Example 1 A decorative fiber-reinforced thermoplastic resin sheet was manufactured based on the same materials and processes as in Example 1 except that the polyethylene terephthalate film was not laminated, and the sheet was used for other purposes. Manufactured a fiber-reinforced thermoplastic resin foam using the same materials and steps as in Example 1.

The obtained fiber-reinforced thermoplastic resin foam is
There were portions where the acrylic resin was peeled off, and fine vertical stripes were formed on the surface of the molded product.

Comparative Example 2 A decorative fiber-reinforced thermoplastic resin sheet was manufactured based on the same materials and steps as in Example 2 except that the polyethylene terephthalate film was not laminated, and the sheet was used for Manufactured a fiber-reinforced thermoplastic resin foam under the same materials and steps as in Example 2.

The obtained fiber-reinforced thermoplastic resin foam is
The printed pattern flowed entirely, and the semi-rigid vinyl chloride resin was partially peeled off.

[0072]

As described above, according to the fiber-reinforced thermoplastic resin sheet for decoration of the present invention, a non-melting or high-temperature melting synthetic resin film is laminated on the decorative surface. When molding fiber-reinforced thermoplastic resin foam, the decorative surface can be protected from heating, foaming pressure, or shearing force during molding, and at the same time, generation of fine vertical streaks during sizing should be eliminated. Can be.

Further, since the above-mentioned synthetic resin film is previously provided with fine irregularities in a range where the glossiness is 5 to 90%, the interface between the synthetic resin film and the thermoplastic resin layer thereunder is provided. Can be prevented, the picture pattern can be protected reliably, the glossiness of the synthetic resin film can be transferred to the surface of the molded product, and the glossiness of the surface of the molded product is arbitrary. be able to. Furthermore, this synthetic resin film can also be used as a protective film for molded articles.

According to the method for producing a fiber-reinforced thermoplastic resin foam of the present invention, the decorative fiber-reinforced thermoplastic resin sheet which has been decorated in advance as described above is shaped into a hollow body. Since the hollow body is shaped into a desired cross-sectional shape along the regulating member by the foaming pressure of the foamable thermoplastic resin composition therein, a conventional decorating method of decorating the product surface after molding is performed. In addition to greatly simplifying the decorating process, even products with complex cross-sectional shapes can be easily decorated with high precision without wrinkles on the surface. Can be.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of an apparatus for producing a decorative fiber reinforced thermoplastic resin sheet used in Example 1 of the present invention.

FIG. 2 is a schematic cross-sectional view of a decorative fiber-reinforced thermoplastic resin sheet manufactured in Example 1 of the present invention.

FIG. 3 is an explanatory diagram of an apparatus for producing a fiber-reinforced thermoplastic resin foam used in Example 1 of the present invention.

4 is a cross-sectional view of the decorative fiber-reinforced thermoplastic resin sheet F at a location indicated by XX 'in FIG.

FIG. 5 shows a hollow body T at a position indicated by YY ′ in FIG.
Cross section of

FIG. 6 is a sectional view of a molded product at a location indicated by ZZ ′ in FIG. 3;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Fluid tank 2,3 Heating roll 4 Cooling roll 21,22 Sheet feeding machine 23 Extruder 24 Extrusion mold 25 Outer mold 26 Shaping mold 28 Cooling mold 29 Take-off machine C Fiber-reinforced thermoplastic resin sheet D Colored acrylic Resin film E Polyethylene terephthalate film F Decorative fiber reinforced thermoplastic resin sheet G Fiber reinforced thermoplastic resin sheet H Foamable thermoplastic resin composition T Hollow body

Claims (2)

[Claims] 1. A fiber-reinforced thermoplastic resin sheet having at least one composite layer formed by integrating continuous fibers composed of a plurality of filaments in one direction and being integrated with a thermoplastic resin, While being colored, or a thermoplastic resin layer having a thickness of 10 to 500 μm with a pattern provided on the surface is laminated, the thermoplastic resin layer is not thermally fused to the surface of the thermoplastic resin layer, and A synthetic resin film whose melting temperature is higher than or not melted than any of the above thermoplastic resins, and whose one surface is adjusted to have a glossiness of 5 to 90%, has its adjusted surface on the surface of the thermoplastic resin layer. A decorative fiber reinforced thermoplastic resin sheet which is laminated so as to be in close contact with each other. 2. The decorative fiber-reinforced thermoplastic resin sheet according to claim 1, which is continuously formed into a hollow body such that the surface on which the synthetic resin film is laminated is an outer surface, A fiber characterized in that the foamed thermoplastic resin composition is supplied into the hollow body while being foamed, and the cross-sectional shape is shaped into a desired shape by causing the outer surface of the hollow body to follow the regulating member by the foaming pressure. A decorative molding method for a reinforced thermoplastic resin foam.