JPH07256801A - Phenol resin laminate and production of phenol resin molding using the same - Google Patents
Phenol resin laminate and production of phenol resin molding using the sameInfo
- Publication number
- JPH07256801A JPH07256801A JP6055739A JP5573994A JPH07256801A JP H07256801 A JPH07256801 A JP H07256801A JP 6055739 A JP6055739 A JP 6055739A JP 5573994 A JP5573994 A JP 5573994A JP H07256801 A JPH07256801 A JP H07256801A
- Authority
- JP
- Japan
- Prior art keywords
- phenol resin
- honeycomb
- sheet body
- paper
- resin laminate
- 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.)
- Granted
Links
Landscapes
- Molding Of Porous Articles (AREA)
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は自動車の内装部品等の成
形品に用いられるフェノール樹脂積層体、及びこのフェ
ノール樹脂積層体を用いたフェノール樹脂成形品の製造
方法に関するものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a phenol resin laminate used for molded articles such as automobile interior parts, and a method for producing a phenol resin molded article using the phenol resin laminate.
【０００２】[0002]
【従来の技術】フェノール樹脂とガラス繊維からなるＳ
ＭＣ（シートモールディングコンパウンド）を加熱加圧
した成形品を、自動車の天井材等の内装部品に用いるこ
とが知られている。しかし、近年、自動車の内装部品は
高い剛性と共により軽量化が求められているため、従来
のＳＭＣでは軽量になると剛性が低下する問題があっ
た。この解決策として、紙製の芯材の両側に、フェノー
ル樹脂が浸透したガラス繊維マットを積層したフェノー
ル樹脂積層体を加熱加圧した成形品が提案されている。
しかし、自動車の内装部品は、自動車のボディの内面に
沿う曲面形状に成形する必要があり、上記成形品では要
求される曲面成形ができないという問題がある。2. Description of the Related Art S consisting of phenolic resin and glass fiber
It is known to use a molded product obtained by heating and pressurizing MC (sheet molding compound) for an interior part such as a ceiling material of an automobile. However, in recent years, automobile interior parts have been required to have higher rigidity and lighter weight, so that there has been a problem that the conventional SMC has reduced rigidity when the weight is reduced. As a solution to this problem, there has been proposed a molded product obtained by heating and pressing a phenol resin laminate in which glass fiber mats impregnated with a phenol resin are laminated on both sides of a paper core material.
However, the interior parts of the automobile must be molded into a curved shape along the inner surface of the body of the automobile, and there is a problem that the above-mentioned molded product cannot be formed into the curved surface required.
【０００３】[0003]
【発明が解決しようとする課題】本発明は上述の事実に
鑑みてなされたもので、その目的とするところは、剛性
が高く、曲面成形ができると共に、軽量化に優れる成形
品が得られるフェノール樹脂積層体、及びこの積層体を
用いたフェノール樹脂成形品の製造方法を提供すること
にある。SUMMARY OF THE INVENTION The present invention has been made in view of the above facts, and an object of the present invention is to obtain a molded product which has high rigidity and can be molded into a curved surface and which is excellent in weight reduction. It is intended to provide a resin laminate and a method for producing a phenol resin molded product using the laminate.
【０００４】[0004]
【課題を解決するための手段】本発明の請求項１に係る
フェノール樹脂積層体は、表層に、２５℃で液状のレゾ
ール型フェノール樹脂と発泡剤を成分とする樹脂組成物
（６）に繊維長１０〜５０ｍｍのガラス繊維（７）を配
合した、５０〜１０００ｇ／ｍ2 のＳＭＣ（２）、及
び、芯層に、セル（１２）の対向する辺間の距離が２〜
１０ｍｍの紙製のハニカム状シート体（１）からなるこ
とを特徴とする。A phenol resin laminate according to claim 1 of the present invention comprises a resin composition (6) containing a resol type phenol resin liquid at 25 ° C. and a foaming agent as a surface layer, and a fiber. The SMC (2) having a length of 10 to 50 mm and a glass fiber (7) of 50 to 1000 g / m 2 and the core layer have a distance between opposing sides of the cell (12) of 2 to 2.
It is characterized by comprising a honeycomb-shaped sheet body (1) made of 10 mm paper.
【０００５】本発明の請求項２に係るフェノール樹脂積
層体は、請求項１記載のフェノール樹脂積層体におい
て、上記紙製のハニカム状シート体（１）が、波板紙
（１６）と平板紙（１７）を有するダンボール紙（１
４）を複数枚平積みしたダンボール紙集合体（１３）
で、且つ、上下に開口したセル（１２）を有することを
特徴とする。A phenol resin laminate according to a second aspect of the present invention is the phenol resin laminate according to the first aspect, wherein the honeycomb sheet body (1) made of paper is corrugated paperboard (16) and flat paper ( 17) Cardboard paper (1)
Cardboard paper assembly (13) in which a plurality of 4) are stacked flat
And has a cell (12) opened vertically.
【０００６】本発明の請求項３に係るフェノール樹脂積
層体は、請求項１記載のフェノール樹脂積層体におい
て、上記紙製のハニカム状シート体（１）が、ダンボー
ル紙（１４）の平板紙（１７）の上下に波板紙（１６）
を有し、この上下の波板紙（１６）の波形方向がクロス
することを特徴とする。A phenol resin laminate according to a third aspect of the present invention is the phenol resin laminate according to the first aspect, wherein the paper honeycomb sheet body (1) is a corrugated cardboard (14) flat paper ( 17) Corrugated paperboard above and below (16)
And the corrugated directions of the upper and lower corrugated paperboards (16) cross each other.
【０００７】本発明の請求項４に係るフェノール樹脂積
層体は、請求項１乃至請求項３いずれか記載のフェノー
ル樹脂積層体において、上記ＳＭＣ（２）のハニカム状
シート体（１）面側に、ポリエチレンフィルム（４）が
付着していることを特徴とする。A phenol resin laminate according to claim 4 of the present invention is the phenol resin laminate according to any one of claims 1 to 3, wherein the honeycomb sheet body (1) surface side of the SMC (2) is provided. The polyethylene film (4) is attached.
【０００８】本発明の請求項５に係るフェノール樹脂成
形品の製造方法は、請求項１乃至請求項４いずれか記載
のフェノール樹脂積層体を加熱加圧することにより、上
記フェノール樹脂を硬化することを特徴とする。A method for producing a phenol resin molded article according to a fifth aspect of the present invention is to cure the phenol resin by heating and pressing the phenol resin laminate according to any one of the first to fourth aspects. Characterize.
【０００９】以下、本発明を詳細に説明する。図１
（ａ）は本発明の一実施例に係るフェノール樹脂積層体
を層毎に示した斜視図であり、（ｂ）は本発明の一実施
例に係るフェノール樹脂積層体を用いたフェノール樹脂
成形品の斜視図であり、図２（ａ）は本発明の一実施例
に用いられるハニカム状シート体の層構成を示す斜視図
であり、（ｂ）は本発明の一実施例に用いられるハニカ
ム状シート体の斜視図であり、図３（ａ）は本発明の他
の実施例に用いられるハニカム状シート体の斜視図であ
り、（ｂ）は本発明の他の実施例に係るフェノール樹脂
積層体を層毎に示した斜視図であり、図４は本発明に用
いられるＳＭＣの製造装置の側面図であり、図５は図４
で作製されたシートの断面図であり、図６（ａ）は本発
明の一実施例に係るフェノール樹脂積層体の層毎に示し
た断面図であり、（ｂ）は本発明の他の実施例を示した
断面図である。The present invention will be described in detail below. Figure 1
(A) is a perspective view showing each layer of a phenol resin laminate according to one embodiment of the present invention, and (b) is a phenol resin molded product using the phenol resin laminate according to one embodiment of the present invention. 2A is a perspective view showing a layer structure of a honeycomb sheet body used in one embodiment of the present invention, and FIG. 2B is a honeycomb shape used in one embodiment of the present invention. FIG. 3A is a perspective view of a sheet body, FIG. 3A is a perspective view of a honeycomb sheet body used in another embodiment of the present invention, and FIG. 3B is a phenol resin laminate according to another embodiment of the present invention. FIG. 5 is a perspective view showing a body layer by layer, FIG. 4 is a side view of an SMC manufacturing apparatus used in the present invention, and FIG.
FIG. 6A is a cross-sectional view of the sheet prepared in FIG. 6, FIG. 6A is a cross-sectional view showing each layer of the phenolic resin laminate according to an embodiment of the present invention, and FIG. 6B is another embodiment of the present invention. It is sectional drawing which showed the example.
【００１０】図１（ａ）に示す如く、本発明のフェノー
ル樹脂積層体は、表層に２５℃で液状のレゾール型フェ
ノール樹脂を成分とするＳＭＣ（２）（シートモールデ
ィングコンパウンド）、芯層に紙製のハニカム状シート
体（１）からなる積層体（９）である。上記フェノール
樹脂積層体は、ＳＭＣ（２）とハニカム状シート体
（１）が分離した状態の積層体（９）でも、ＳＭＣ
（２）とハニカム状シート体（１）が接着した状態の積
層体（９）でも、限定しない。As shown in FIG. 1 (a), the phenol resin laminate of the present invention comprises an SMC (2) (sheet molding compound) containing a resol type phenol resin liquid at 25 ° C. on the surface layer and a paper on the core layer. It is a laminated body (9) made of a honeycomb sheet body (1) made of. The above-mentioned phenol resin laminated body has the same structure as the laminated body (9) in which the SMC (2) and the honeycomb-shaped sheet body (1) are separated.
The laminated body (9) in a state where the (2) and the honeycomb-shaped sheet body (1) are adhered is not limited.
【００１１】上記紙製のハニカム状シート体（１）はセ
ル（１２）の対向する辺間の距離が２〜１０ｍｍの範囲
である。上記範囲であると、フェノール樹脂積層体を曲
面成形した際に、得られたフェノール樹脂成形品の外観
が良好となる。上記セル（１２）の対向する辺間の距離
が１０ｍｍを越えると、曲面成形の際に、フェノール樹
脂成形品にヒビ等が生じ易い。より好ましくは、上記セ
ル（１２）の対向する辺間の距離は２〜５ｍｍである。
このセル（１２）が平板と波板の２辺で形成されている
場合、セル（１２）の対向する辺間の距離とは、平板と
波板の頂点の距離である。In the above honeycomb-shaped sheet body (1) made of paper, the distance between the opposing sides of the cell (12) is in the range of 2 to 10 mm. Within the above range, the appearance of the obtained phenol resin molded article becomes good when the phenol resin laminate is curved. When the distance between the opposite sides of the cell (12) exceeds 10 mm, cracks or the like are likely to occur in the phenol resin molded product during curved surface molding. More preferably, the distance between the opposing sides of the cell (12) is 2-5 mm.
When the cell (12) is formed by two sides of a flat plate and a corrugated plate, the distance between the opposite sides of the cell (12) is the distance between the apex of the flat plate and the corrugated plate.
【００１２】上記紙製のハニカム状シート体（１）とし
ては、ダンボール紙製のハニカム状シート体が挙げられ
る。次にこのダンボール紙製のハニカム状シート体の作
製方法について説明する。図２（ａ）に示す如く、複数
のセル（１２）の対向する辺間の距離が２〜１０ｍｍの
波形を形成した波板紙（１６）と平板紙（１７）を有す
るダンボール紙（１４）を、複数枚平積みし、ダンボー
ル紙集合体（１３）を得る。このダンボール紙集合体
（１３）を、上記平板紙（１７）とクロス方向に切断す
ると、図２（ｂ）に示す如く、上下に開口したセル（１
２）を有するダンボール紙製のハニカム状シート体が得
られる。他のダンボール紙製のハニカム状シート体の作
製方法を図３（ａ）に示す。セル（１２）の対向する辺
間の距離が２〜１０ｍｍの波形を形成した波板紙（１
６）の片側に平板紙（１７）を有するダンボール紙（１
４）を２枚用い、この平板紙（１７）どおしを、波板紙
（１６）の波形がクロスする方向で重ね合わせる。この
ダンボール紙製のハニカム状シート体を図３（ｂ）に示
す如く、ハニカム状シート体（１）として用いる。Examples of the paper-made honeycomb sheet body (1) include cardboard paper honeycomb sheet bodies. Next, a method for manufacturing this honeycomb-shaped sheet body made of cardboard paper will be described. As shown in FIG. 2 (a), a corrugated paperboard (14) having corrugated paperboard (16) and a flat paperboard (17) in which the distance between opposing sides of a plurality of cells (12) is 2 to 10 mm is formed. Then, a plurality of cardboard paper aggregates (13) are obtained by stacking a plurality of them flatly. When this cardboard paper aggregate (13) is cut in the cross direction with the flat paper (17), as shown in FIG.
A honeycomb-shaped sheet body made of cardboard paper having 2) is obtained. Another method for manufacturing a honeycomb-shaped sheet body made of cardboard paper is shown in FIG. The corrugated paperboard (1 having a corrugated shape in which the distance between the opposite sides of the cell (12) is 2 to 10 mm
6) Cardboard paper (1) having a flat paper (17) on one side
4) are used, and the flat papers (17) are superposed in the direction in which the corrugations of the corrugated paperboard (16) cross. This honeycomb sheet body made of cardboard paper is used as a honeycomb sheet body (1) as shown in FIG. 3 (b).
【００１３】次に、図４〜図５に基づいて上記ＳＭＣ
（２）について説明する。上記ＳＭＣ（２）は液状レゾ
ール型フェノール樹脂と発泡剤を成分とする樹脂組成物
（６）に、繊維長１０〜５０ｍｍのガラス繊維（７）を
配合し、上記フェノール樹脂をＢステージ化した樹脂シ
ートである。Next, the SMC will be described with reference to FIGS.
(2) will be described. The SMC (2) is a resin obtained by blending a resin composition (6) containing a liquid resol-type phenol resin and a foaming agent with a glass fiber (7) having a fiber length of 10 to 50 mm and converting the phenol resin into a B-stage. It is a sheet.
【００１４】上記樹脂組成物（６）が２５℃で液状のレ
ゾール型フェノール樹脂を主成分とするので、ガラス繊
維（７）への樹脂の含浸が良好である。この液状のレゾ
ール型フェノール樹脂は２５℃で粘度が１０００〜８０
００ｃｐｓの樹脂が適当である。上記発泡剤は加熱によ
り気泡ができるので成形品の軽量化に寄与し、発泡剤と
しては、例えば、ジニトロソペンタメチレンテトラミン
等のニトロソテトラミン類が挙げられる。さらに、上記
樹脂組成物（６）は必要により、固形ノボラック型フェ
ノール樹脂、ヘキサメチレンテトラミン等の硬化剤、シ
リコーン類等の界面活性剤、ステアリン酸亜鉛等の離型
剤が添加される。配合比率の一例を示すと、液状レゾー
ル型フェノール樹脂１００重量部（以下部と記す）に対
して、発泡剤は０．５〜１０部、固形ノボラック型フェ
ノール樹脂は０〜３０部、硬化剤は０〜５部、界面活性
剤は０．１〜５部、離型剤は０．１〜８部が好ましい。Since the resin composition (6) contains a resol type phenolic resin which is liquid at 25 ° C. as a main component, the glass fiber (7) can be well impregnated with the resin. This liquid resol type phenol resin has a viscosity of 1000 to 80 at 25 ° C.
A resin of 00 cps is suitable. The foaming agent contributes to the weight reduction of the molded product because bubbles are formed by heating, and examples of the foaming agent include nitrosotetramines such as dinitrosopentamethylenetetramine. Furthermore, if necessary, a solid novolac type phenol resin, a curing agent such as hexamethylenetetramine, a surfactant such as silicones, and a release agent such as zinc stearate are added to the above resin composition (6). As an example of the mixing ratio, 0.5 to 10 parts of the foaming agent, 0 to 30 parts of the solid novolac phenol resin, and the curing agent of 100 parts by weight of the liquid resol-type phenol resin (hereinafter referred to as "part") are used. 0-5 parts, 0.1-5 parts of the surfactant and 0.1-8 parts of the release agent are preferable.
【００１５】上記ガラス繊維（７）は繊維長１０〜５０
ｍｍである。繊維長が１０ｍｍ未満であると、剛性が低
下し、繊維長が５０ｍｍを越えると、上記樹脂組成物
（６）とガラス繊維（７）が分離し易くなり、フェノー
ル樹脂積層体の曲面成形が困難になる。上記樹脂組成物
（６）とガラス繊維（７）の配合比率は、樹脂組成物
（６）が２０〜９０重量％、ガラス繊維（７）が１０〜
８０重量％の範囲に設定することが好ましい。The glass fiber (7) has a fiber length of 10 to 50.
mm. When the fiber length is less than 10 mm, the rigidity is lowered, and when the fiber length is more than 50 mm, the resin composition (6) and the glass fiber (7) are easily separated from each other, which makes it difficult to form the curved surface of the phenol resin laminate. become. The resin composition (6) and the glass fiber (7) are compounded in a proportion of 20 to 90% by weight of the resin composition (6) and 10 to 10 of the glass fiber (7).
It is preferably set in the range of 80% by weight.
【００１６】上記ＳＭＣ（２）の目付け量は、５０〜１
０００ｇ／ｍ2 の範囲である。上記目付け量が１０００
ｇ／ｍ2 を越えると得られるフェノール樹脂成形品の軽
量化の効果が低下し、上記目付け量が５０ｇ／ｍ2 未満
であると、ハニカム状シート体（１）への樹脂の浸透が
不足となる。The weight of the SMC (2) is 50 to 1
It is in the range of 000 g / m 2 . The above basis weight is 1000
If it exceeds g / m 2 , the effect of reducing the weight of the obtained phenol resin molded article decreases, and if the above basis weight is less than 50 g / m 2 , the penetration of the resin into the honeycomb-shaped sheet body (1) is insufficient. Become.
【００１７】図４に示す如く、樹脂組成物（６）の溜ま
ったディップ槽（２４）とベルト（２６）の出口（２
５）から所望量の樹脂組成物（６）を、離型フェイルム
（３）上に塗布する。その上からチョッパー（２２）で
切断したガラス繊維（７）を散布し、さらにその上に離
型フェイルム（３）を重ね、プレスロール（２１）で圧
着する。離型フェイルム（３）に挟んだ状態でこの複合
体（５）を巻き取り、熟成すると、フェノール樹脂がＢ
ステージ状態になる。これを所望のサイズに切断する
と、図５に示す離型フェイルム（３）に挟まれたＳＭＣ
（２）が得られる。上記熟成の温度、及び時間は材料の
配合比、目付け量により適宜決定される。上記離型フェ
イルム（３）は、例えば、ポリプロピレン、ポリエチレ
ンのフィルムが挙げられる。As shown in FIG. 4, the dip tank (24) containing the resin composition (6) and the outlet (2) of the belt (26).
A desired amount of the resin composition (6) from 5) is applied on the release film (3). The glass fibers (7) cut by the chopper (22) are sprinkled thereon, and the release film (3) is further laid on the glass fiber (7), which is then pressure-bonded by a press roll (21). When the composite (5) is wound up and aged while being sandwiched between the release films (3), the phenol resin becomes B.
Enter the stage. When this is cut into a desired size, the SMC sandwiched between the release films (3) shown in FIG.
(2) is obtained. The aging temperature and time are appropriately determined depending on the compounding ratio of the materials and the basis weight. Examples of the release film (3) include polypropylene and polyethylene films.
【００１８】上記離型フェイルム（３）は、図６（ａ）
に示す如く、ハニカム状シート体（１）に配設する際は
除去されるが、図６（ｂ）に示す如く、離型フェイルム
（３）にポリエチレンフィルム（４）を用いる場合は、
ポリエチレンフィルム（４）の融点が加熱温度より低い
ので、加熱加圧の際にポリエチレンフィルム（４）がフ
ェノール樹脂と共に溶融するため、上記ＳＭＣ（２）の
ハニカム状シート体（１）面側にこのポリエチレンフィ
ルム（４）を付着させたままで積層できる。従って、離
型フェイルム（３）にポリエチレンフィルム（４）を用
いると、離型フィルム（３）の除去作業が略せるので、
作業効率が良くなる。The release film (3) is shown in FIG. 6 (a).
As shown in FIG. 6, it is removed when it is placed on the honeycomb-shaped sheet body (1). However, as shown in FIG. 6B, when the polyethylene film (4) is used for the release film (3),
Since the melting point of the polyethylene film (4) is lower than the heating temperature, the polyethylene film (4) is melted together with the phenol resin during heating and pressurization. It can be laminated with the polyethylene film (4) attached. Therefore, if the polyethylene film (4) is used for the release film (3), the removal work of the release film (3) can be omitted.
Work efficiency improves.
【００１９】本発明のフェノール樹脂成形品の製造方法
は、上記ハニカム状シート体（１）の上下に上記ＳＭＣ
（２）を積層した積層体（９）を、所望の形状の金型に
挟み加熱加圧する。この加熱加圧により、ハニカム状シ
ート体（１）内部にフェノール樹脂が浸入し、フェノー
ル樹脂が溶融し、硬化する。上記フェノール樹脂の硬化
により、図１（ｂ）に示す、一体化したフェノール樹脂
成形品が得られる。この製造方法は、上記フェノール樹
脂積層体を用いているので、曲面成形されると共に、軽
量化に優れたフェノール樹脂成形品を得ることができ
る。The method for producing a phenol resin molded article according to the present invention comprises the SMC above and below the honeycomb sheet (1).
The laminated body (9) in which (2) is laminated is sandwiched in a mold having a desired shape and heated and pressed. By this heating and pressurization, the phenol resin penetrates into the honeycomb sheet body (1), and the phenol resin is melted and cured. By curing the above-mentioned phenol resin, an integrated phenol resin molded article shown in FIG. 1 (b) is obtained. Since this manufacturing method uses the above-mentioned phenol resin laminate, it is possible to obtain a phenol resin molded product which is curved and is excellent in weight saving.
【００２０】なお、本発明で得られるフェノール樹脂成
形品は、自動車の内装材の他に、建材等にも使用するこ
とができるものである。The phenol resin molded product obtained by the present invention can be used not only as interior materials for automobiles but also as building materials and the like.
【００２１】[0021]
【作用】本発明の請求項１乃至請求項４いずれか記載の
フェノール樹脂積層体は、紙製のハニカム状シート体
（１）のセル（１２）の対向する辺間の距離が２〜１０
ｍｍの範囲であるので、曲面成形が容易にでき、得られ
るフェノール樹脂成形品が軽量である。樹脂組成物
（６）の液状レゾール型フェノール樹脂はガラス繊維
（７）となじみが良く、樹脂組成物（６）の発泡剤は加
熱により気泡ができるのでフェノール樹脂成形品が軽量
となる。ガラス繊維（７）の繊維長が１０〜５０ｍｍで
あるので、樹脂組成物（６）とガラス繊維（７）が分離
することがない。In the phenol resin laminate according to any one of claims 1 to 4 of the present invention, the distance between the opposing sides of the cell (12) of the paper-like honeycomb sheet body (1) is 2 to 10.
Since it is in the range of mm, curved surface molding can be easily performed, and the obtained phenol resin molded product is lightweight. The liquid resol-type phenol resin of the resin composition (6) is well compatible with the glass fiber (7), and the foaming agent of the resin composition (6) forms bubbles due to heating, so that the phenol resin molded product becomes lightweight. Since the fiber length of the glass fiber (7) is 10 to 50 mm, the resin composition (6) and the glass fiber (7) are not separated.
【００２２】[0022]
実施例１ 液状のレゾール型フェノール樹脂１００部、固形ノボラ
ックフェノール樹脂２０部、発泡剤としてジニトロソペ
ンタメチレンテトラミン（永和化成工業株式会社製、セ
ルラーＤ）を５部、硬化剤としてヘキサメチレンテトラ
ミンを３部、界面活性剤としてポリエーテル変性シリコ
ーン（東芝シリコーン株式会社製、ＴＦＡ４２０５）を
３部、離型剤としてステアリン酸亜鉛を２部配合し、樹
脂組成物（６）を調製した。Example 1 100 parts of liquid resol type phenol resin, 20 parts of solid novolac phenol resin, 5 parts of dinitrosopentamethylenetetramine (Cellular D manufactured by Eiwa Chemical Industry Co., Ltd.) as a foaming agent, and 3 parts of hexamethylenetetramine as a curing agent. Parts, 3 parts of polyether-modified silicone (TFA4205 manufactured by Toshiba Silicone Co., Ltd.) as a surfactant, and 2 parts of zinc stearate as a release agent were mixed to prepare a resin composition (6).
【００２３】上記樹脂組成物（６）をポリプロピレンフ
ィルム製の離型フィルム（３）上に塗布し、上面から繊
維長が２５ｍｍに切断したガラス繊維（７）を散布し、
さらにその上にポリプロピレンフィルム製の離型フィル
ム（３）を載せた。樹脂組成物（６）の塗布量は４５ｇ
／ｍ2 、ガラス繊維（７）の散布量は５ｇ／ｍ2 であっ
た。その後、プレスロール（２１）で圧着した後に、４
０℃で２日間熟成し、フェノール樹脂がＢステージ状態
となった離型フィルム（３）付きのＳＭＣ（２）を得
た。ＳＭＣ（２）の目付け量は５０ｇ／ｍ2 であった。The above resin composition (6) is applied on a release film (3) made of polypropylene film, and glass fibers (7) cut into a fiber length of 25 mm are sprinkled from the upper surface,
Further, a release film (3) made of polypropylene film was placed on it. The coating amount of the resin composition (6) is 45 g
/ M 2 , and the amount of the glass fiber (7) sprayed was 5 g / m 2 . Then, after pressing with a press roll (21), 4
Aging was carried out at 0 ° C. for 2 days to obtain SMC (2) with a release film (3) in which the phenol resin was in the B stage state. The basis weight of SMC (2) was 50 g / m 2 .
【００２４】紙製のハニカム状シート体（１）として、
セル（１２）の対向する辺間の距離が５ｍｍの波形を形
成し、上下に開口したセル（１２）を有するダンボール
紙製のハニカム状シート体を用いた。このダンボール紙
製のハニカム状シート体は３００ｇ／ｍ2 の重さであっ
た。As a paper-made honeycomb sheet body (1),
A corrugated cardboard-made honeycomb sheet body having cells (12) formed in a corrugation with a distance between opposing sides of the cells (12) of 5 mm was formed. The honeycomb-shaped sheet body made of cardboard paper had a weight of 300 g / m 2 .
【００２５】上記ダンボール紙製のハニカム状シート体
の上下に、離型フィルム（３）を剥がしたＳＭＣ（２）
を積層し、フェノール樹脂積層体を得た。このフェノー
ル樹脂積層体を、１７０℃、１０ｋｇ／ｃｍ2 、１２０
秒加熱加圧することにより、厚さが約５ｍｍのフェノー
ル樹脂成形品を作製した。SMC (2) in which a release film (3) is peeled off above and below the honeycomb-shaped sheet body made of cardboard paper.
Were laminated to obtain a phenol resin laminate. This phenolic resin laminate was treated at 170 ° C., 10 kg / cm 2 , 120
By heating and pressurizing for 2 seconds, a phenol resin molded product having a thickness of about 5 mm was produced.
【００２６】実施例２ 実施例１の樹脂組成物（６）の塗布量が２５０ｇ／
ｍ2 、ガラス繊維（７）の散布量が２５０ｇ／ｍ2 、Ｓ
ＭＣ（２）の目付け量が５００ｇ／ｍ2 であった以外は
実施例１と同様にして、フェノール樹脂積層体を得た。
このフェノール樹脂積層体を用いて実施例１と同様にし
てフェノール樹脂成形品を作製した。Example 2 The coating amount of the resin composition (6) of Example 1 was 250 g /
m 2 , the amount of glass fiber (7) sprayed is 250 g / m 2 , S
A phenol resin laminate was obtained in the same manner as in Example 1 except that the basis weight of MC (2) was 500 g / m 2 .
Using this phenol resin laminate, a phenol resin molded article was produced in the same manner as in Example 1.
【００２７】実施例３ 実施例１の樹脂組成物（６）の塗布量が２００ｇ／
ｍ2 、ガラス繊維（７）の散布量が８００ｇ／ｍ2 、Ｓ
ＭＣ（２）の目付け量が１０００ｇ／ｍ2 であった以外
は実施例１と同様にして、フェノール樹脂積層体を得
た。このフェノール樹脂積層体を用いて実施例１と同様
にしてフェノール樹脂成形品を作製した。Example 3 The coating amount of the resin composition (6) of Example 1 was 200 g /
m 2 , the amount of glass fiber (7) sprayed is 800 g / m 2 , S
A phenol resin laminate was obtained in the same manner as in Example 1 except that the basis weight of MC (2) was 1000 g / m 2 . Using this phenol resin laminate, a phenol resin molded article was produced in the same manner as in Example 1.
【００２８】実施例４ 実施例１と同様の樹脂組成物（６）をポリプロピレンフ
ィルム製の離型フィルム（３）上に塗布し、上面から繊
維長が５０ｍｍに切断したガラス繊維（７）を散布し、
さらにその上にポリプロピレンフィルム製の離型フィル
ム（３）を載せた。樹脂組成物（６）の塗布量は２５０
ｇ／ｍ2 、ガラス繊維（７）の散布量は２５０ｇ／ｍ2
であった。その後、プレスロール（２１）で圧着した後
に、４０℃で２日間熟成し、フェノール樹脂がＢステー
ジ状態となった離型フィルム（３）付きＳＭＣ（２）を
得た。ＳＭＣ（２）の目付け量は５００ｇ／ｍ2 であっ
た。Example 4 The same resin composition (6) as in Example 1 was applied on a release film (3) made of polypropylene film, and glass fibers (7) cut from the upper surface to a fiber length of 50 mm were sprinkled. Then
Further, a release film (3) made of polypropylene film was placed on it. The coating amount of the resin composition (6) is 250
g / m 2 , the amount of glass fiber (7) sprayed is 250 g / m 2
Met. Then, it was pressure-bonded with a press roll (21) and then aged at 40 ° C. for 2 days to obtain an SMC (2) with a release film (3) in which the phenol resin was in a B stage state. The basis weight of SMC (2) was 500 g / m 2 .
【００２９】紙製のハニカム状シート体（１）として、
平板紙（１７）の上下に波板紙（１６）を有し、この波
形方向がクロスし、平板紙（１７）と波板紙（１６）の
波形の頂点までの距離が３ｍｍのダンボール紙製のハニ
カム状シート体を用いた。As the honeycomb-shaped sheet body (1) made of paper,
A corrugated cardboard honeycomb having corrugated paperboards (16) above and below the flat paperboard (17), whose corrugation directions cross each other, and the distance between the corrugated paperboard (17) and the apex of the corrugated paperboard (16) is 3 mm. The sheet-like body was used.
【００３０】上記ダンボール紙製のハニカム状シート体
の上下に、離型フィルム（３）を剥がしたＳＭＣ（２）
を積層し、フェノール樹脂積層体を得た。このフェノー
ル樹脂積層体を、１７０℃、１０ｋｇ／ｃｍ2 、１２０
秒加熱加圧することにより、厚さが約５ｍｍのフェノー
ル樹脂成形品を作製した。SMC (2) in which a release film (3) is peeled off above and below the honeycomb-shaped sheet body made of cardboard paper.
Were laminated to obtain a phenol resin laminate. This phenolic resin laminate was treated at 170 ° C., 10 kg / cm 2 , 120
By heating and pressurizing for 2 seconds, a phenol resin molded product having a thickness of about 5 mm was produced.
【００３１】比較例１ 実施例１の樹脂組成物の塗布量が１４２５ｇ／ｍ2 、ガ
ラス繊維の散布量が７５ｇ／ｍ2 、ＳＭＣの目付け量が
１５００ｇ／ｍ2 であった以外は実施例１と同様にし
て、フェノール樹脂積層体を得た。このフェノール樹脂
積層体を用いて実施例１と同様にしてフェノール樹脂成
形品を作製した。The non-coating amount of the resin composition of Comparative Example 1 Example 1 1425 g / m 2, the basis weight of the scattering amount of the glass fibers is 75g / m 2, SMC was 1500 g / m 2 Example 1 A phenol resin laminate was obtained in the same manner as in. Using this phenol resin laminate, a phenol resin molded article was produced in the same manner as in Example 1.
【００３２】比較例２ 実施例１と同様の樹脂組成物をポリプロピレンフィルム
製の離型フィルム上に塗布し、上面から繊維長が１００
ｍｍに切断したガラス繊維を散布し、さらにその上にポ
リプロピレンフィルム製の離型フィルムを載せた。樹脂
組成物の塗布量は１４２５ｇ／ｍ2 、ガラス繊維の散布
量は７５ｇ／ｍ2 であった。その後、プレスロールで圧
着した後に、４０℃で２日間熟成し、離型フィルム付き
ＳＭＣを得た。ＳＭＣの目付け量は１５００ｇ／ｍ2 で
あった。Comparative Example 2 The same resin composition as in Example 1 was applied onto a release film made of polypropylene film, and the fiber length from the top surface was 100.
The glass fiber cut into mm was scattered, and a release film made of polypropylene film was placed thereon. The coating amount of the resin composition 1425 g / m 2, spraying of the glass fibers was 75 g / m 2. Then, it was pressure-bonded with a press roll and then aged at 40 ° C. for 2 days to obtain an SMC with a release film. The basis weight of SMC was 1500 g / m 2 .
【００３３】セルのサイズが１３ｍｍ、厚さ５ｍｍの紙
製のハニカム状シート体の上下に、離型フィルムを剥が
したＳＭＣを積層して、実施例１と同様の条件で加熱し
てフェノール樹脂成形品を得た。SMC from which the release film was peeled off was laminated on the upper and lower sides of a paper honeycomb sheet body having a cell size of 13 mm and a thickness of 5 mm, and heated under the same conditions as in Example 1 to form a phenol resin. I got the goods.
【００３４】比較例３ 実施例１と同様の樹脂組成物をポリプロピレンフィルム
製の離型フィルム上に塗布し、上面から繊維長が２５ｍ
ｍに切断したガラス繊維を散布し、さらにその上にポリ
プロピレンフィルム製の離型フィルムを載せた。樹脂組
成物の塗布量は７５０ｇ／ｍ2 、ガラス繊維の散布量は
７５０ｇ／ｍ2 であった。その後、プレスロールで圧着
した後に、４０℃で２日間熟成し、離型フィルム付きＳ
ＭＣを得た。ＳＭＣの目付け量は１５００ｇ／ｍ2 であ
った。その後、ＳＭＣを実施例１と同様の条件で加熱
し、成形品を作製した。Comparative Example 3 The same resin composition as in Example 1 was applied onto a release film made of polypropylene film, and the fiber length from the upper surface was 25 m.
The glass fiber cut into m was sprinkled, and a release film made of polypropylene film was placed thereon. The amount of resin composition applied was 750 g / m 2 , and the amount of glass fiber sprayed was 750 g / m 2 . Then, after pressure bonding with a press roll, aging for 2 days at 40 ° C, S with release film
I got MC. The basis weight of SMC was 1500 g / m 2 . Then, the SMC was heated under the same conditions as in Example 1 to produce a molded product.
【００３５】[0035]
【表１】 [Table 1]
【００３６】実施例１〜４、及び比較例１〜３のフェノ
ール樹脂成形品の比重、比強度、比剛性、及びフェノー
ル樹脂積層体の曲面成形性を評価した。The specific gravity, specific strength and specific rigidity of the phenol resin molded articles of Examples 1 to 4 and Comparative Examples 1 to 3 and the curved formability of the phenol resin laminate were evaluated.
【００３７】上記比強度は、比重に対する曲げ強度の比
率（曲げ強度／比重）で求め、上記比剛性は、比重に対
する弾性率の比率（弾性率／比重）で求めた。この曲げ
強度、及び弾性率はＡＳＴＭの曲げ試験に基づき、長さ
１５０ｍｍ、幅５０ｍｍのフェノール樹脂成形材料をス
パン距離１００ｍｍ、荷重速度５０ｍｍの条件で押圧し
て測定した。曲面成形性は、フェノール樹脂積層体を加
熱加圧する際に、図７に示すＲ＝５ｍｍの曲率半径で成
形した。このフェノール樹脂成形品のＲ部を目視で観察
し、ひび等の有無を調査した。ひび等が無いものは○、
ひび等が有るものは×で表示した。The specific strength was determined by the ratio of bending strength to specific gravity (bending strength / specific gravity), and the specific rigidity was determined by the ratio of elastic modulus to specific gravity (elastic modulus / specific gravity). The bending strength and elastic modulus were measured based on an ASTM bending test by pressing a phenol resin molding material having a length of 150 mm and a width of 50 mm under conditions of a span distance of 100 mm and a load speed of 50 mm. As for the curved surface formability, when the phenol resin laminate was heated and pressed, it was formed with a radius of curvature of R = 5 mm shown in FIG. 7. The R part of this phenol resin molded product was visually observed to check for cracks. Those without cracks are ○,
Those with cracks etc. are indicated by x.
【００３８】結果は表２に示す如く、実施例１〜４はい
ずれも比較例に比べ、比重は低く、比強度、比剛性とも
高い値であった。また、外観は良好であった。As shown in Table 2, in each of Examples 1 to 4, the specific gravity was lower and the specific strength and the specific rigidity were higher than those of the comparative examples. The appearance was good.
【００３９】[0039]
【表２】 [Table 2]
【００４０】[0040]
【発明の効果】本発明の請求項１乃至請求項４記載のフ
ェノール樹脂積層体は、重量が５０〜１０００ｇ／ｍ2
で、液状のレゾール型フェノール樹脂、発泡剤、及び繊
維長１０〜５０ｍｍのガラス繊維からなるＳＭＣと、セ
ルの対向する辺間の距離が２〜１０ｍｍの紙製のハニカ
ム状シート体からなるので、このフェノール樹脂積層体
を用いると、重量当たりの剛性が高く、曲面成形が容易
であると共に、軽量化に優れるフェノール樹脂成形品を
得ることができる。The phenol resin laminate according to any one of claims 1 to 4 of the present invention has a weight of 50 to 1000 g / m 2.
Since the liquid resol phenolic resin, the foaming agent, and the SMC made of glass fiber having a fiber length of 10 to 50 mm and the honeycomb-shaped sheet body made of paper with the distance between the opposing sides of the cell being 2 to 10 mm, When this phenol resin laminate is used, it is possible to obtain a phenol resin molded product having high rigidity per weight, easy curved surface molding and excellent weight saving.
【００４１】本発明のフェノール樹脂積層体は、特に、
自動車の内装部品等に用いられるフェノール樹脂成形品
に有用である。The phenolic resin laminate of the present invention is, in particular,
It is useful for phenol resin moldings used for automobile interior parts.
【００４２】本発明のフェノール樹脂成形品の製造方法
は請求項１乃至請求項４いずれか記載のフェノール樹脂
積層体を用いているので、曲面成形されると共に、軽量
化に優れたフェノール樹脂成形品を得ることができる。Since the method for producing a phenol resin molded product of the present invention uses the phenol resin laminate according to any one of claims 1 to 4, the phenol resin molded product is curved and is excellent in weight saving. Can be obtained.
【図１】（ａ）は本発明の一実施例に係るフェノール樹
脂積層体を層毎に示した斜視図であり、（ｂ）は本発明
の一実施例に係るフェノール樹脂積層体を用いたフェノ
ール樹脂成形品の斜視図である。FIG. 1A is a perspective view showing a phenol resin laminate according to an embodiment of the present invention layer by layer, and FIG. 1B is a phenol resin laminate according to an embodiment of the present invention. It is a perspective view of a phenol resin molding.
【図２】（ａ）は本発明の一実施例に用いられるハニカ
ム状シート体の層構成を示す斜視図であり、（ｂ）は本
発明の一実施例に用いられるハニカム状シート体の斜視
図である。FIG. 2 (a) is a perspective view showing a layer structure of a honeycomb sheet body used in one embodiment of the present invention, and (b) is a perspective view of the honeycomb sheet body used in one embodiment of the present invention. It is a figure.
【図３】（ａ）は本発明の他の実施例に用いられるハニ
カム状シート体の斜視図であり、（ｂ）は本発明の他の
実施例に係るフェノール樹脂積層体を層毎に示した斜視
図である。FIG. 3 (a) is a perspective view of a honeycomb sheet body used in another embodiment of the present invention, and FIG. 3 (b) shows a phenol resin laminate according to another embodiment of the present invention layer by layer. FIG.
【図４】本発明に用いられるＳＭＣの製造装置の側面図
である。FIG. 4 is a side view of an SMC manufacturing apparatus used in the present invention.
【図５】図４で作製されたシートの断面図である。FIG. 5 is a cross-sectional view of the sheet manufactured in FIG.
【図６】（ａ）は本発明の一実施例に係るフェノール樹
脂積層体の層毎に示した断面図であり、（ｂ）は本発明
の他の実施例を示した断面図である。FIG. 6A is a sectional view showing each layer of a phenol resin laminate according to an embodiment of the present invention, and FIG. 6B is a sectional view showing another embodiment of the present invention.
【図７】実施例及び比較例で成形した曲面成形した成形
品の破断斜視図である。FIG. 7 is a cutaway perspective view of a curved surface molded product molded in Examples and Comparative Examples.
１ ハニカム状シート体 ２ ＳＭＣ ６ 樹脂組成物 ７ ガラス繊維 ９ 積層体 １２ セル 1 Honeycomb Sheet 2 SMC 6 Resin Composition 7 Glass Fiber 9 Laminate 12 Cell
フロントページの続き (51)Int.Cl.6 識別記号 庁内整理番号 ＦＩ 技術表示箇所 Ｂ３２Ｂ 27/18 Ｚ 8413−4Ｆ 27/42 １０１ 7421−4Ｆ // Ｂ２９Ｋ 61:04 Ｂ２９Ｌ 31:58 Continuation of the front page (51) Int.Cl. 6 Identification number Office reference number FI technical display location B32B 27/18 Z 8413-4F 27/42 101 7421-4F // B29K 61:04 B29L 31:58
Claims (5)
ノール樹脂と発泡剤を成分とする樹脂組成物（６）に繊
維長１０〜５０ｍｍのガラス繊維（７）を配合した、５
０〜１０００ｇ／ｍ2 のＳＭＣ（２）、及び、芯層に、
セル（１２）の対向する辺間の距離が２〜１０ｍｍの紙
製のハニカム状シート体（１）からなることを特徴とす
るフェノール樹脂積層体。1. A resin composition (6) comprising a resol type phenolic resin which is liquid at 25 ° C. and a foaming agent, and glass fibers (7) having a fiber length of 10 to 50 mm are mixed in the surface layer.
For the SMC (2) of 0 to 1000 g / m 2 and the core layer,
A phenol resin laminate, comprising a paper honeycomb sheet body (1) having a distance between opposing sides of cells (12) of 2 to 10 mm.
が、波板紙（１６）と平板紙（１７）を有するダンボー
ル紙（１４）を複数枚平積みしたダンボール紙集合体
（１３）で、且つ、上下に開口したセル（１２）を有す
ることを特徴とする請求項１記載のフェノール樹脂積層
体。2. A honeycomb-shaped sheet body (1) made of the paper.
Is a cardboard paper assembly (13) in which a plurality of cardboard papers (14) having corrugated paperboards (16) and flat papers (17) are flatly stacked, and has cells (12) opened vertically. The phenol resin laminate according to claim 1.
が、ダンボール紙（１４）の平板紙（１７）の上下に波
板紙（１６）を有し、この上下の波板紙（１６）の波形
方向がクロスすることを特徴とする請求項１記載のフェ
ノール樹脂積層体。3. A honeycomb-shaped sheet body (1) made of the paper.
The corrugated paperboard (16) above and below the flat paperboard (17) of the cardboard paper (14), and the corrugated directions of the upper and lower corrugated paperboards (16) cross each other. Resin laminate.
（１）面側に、ポリエチレンフィルム（４）が付着して
いることを特徴とする請求項１乃至請求項３いずれか記
載のフェノール樹脂積層体。4. The phenolic resin according to any one of claims 1 to 3, wherein a polyethylene film (4) is attached to the honeycomb-shaped sheet body (1) surface side of the SMC (2). Laminate.
ェノール樹脂積層体を加熱加圧することにより、上記フ
ェノール樹脂を硬化することを特徴とするフェノール樹
脂成形品の製造方法。5. A method for producing a phenol resin molded article, which comprises curing the phenol resin by heating and pressing the phenol resin laminate according to any one of claims 1 to 4.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP6055739A JP3067513B2 (en) | 1994-03-25 | 1994-03-25 | Phenolic resin laminate and method for producing phenolic resin molded product using this laminate |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP6055739A JP3067513B2 (en) | 1994-03-25 | 1994-03-25 | Phenolic resin laminate and method for producing phenolic resin molded product using this laminate |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH07256801A true JPH07256801A (en) | 1995-10-09 |
| JP3067513B2 JP3067513B2 (en) | 2000-07-17 |
Family
ID=13007232
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP6055739A Expired - Fee Related JP3067513B2 (en) | 1994-03-25 | 1994-03-25 | Phenolic resin laminate and method for producing phenolic resin molded product using this laminate |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3067513B2 (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR100427555B1 (en) * | 2001-02-21 | 2004-04-27 | 주식회사 엘지화학 | Sheet Molding Compound Water-Proof Flooring Having Core Layer and the Method of Manufacturing thereof |
| JP2014509271A (en) * | 2011-02-04 | 2014-04-17 | フォルシア オートモーティブ インダストリー | Automotive structural components and related manufacturing methods |
| JP2015139633A (en) * | 2014-01-30 | 2015-08-03 | 株式会社イトーキ | Laminated light-weight top board for furniture |
| CN106275379A (en) * | 2015-06-05 | 2017-01-04 | 哈尔滨飞机工业集团有限责任公司 | A kind of composite big thickness deep camber honeycomb parts forming method |
| CN114274567A (en) * | 2021-12-31 | 2022-04-05 | 北京奥星雅博科技发展有限责任公司 | Phenolic filling aramid fiber honeycomb structure and preparation method and application thereof |
-
1994
- 1994-03-25 JP JP6055739A patent/JP3067513B2/en not_active Expired - Fee Related
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR100427555B1 (en) * | 2001-02-21 | 2004-04-27 | 주식회사 엘지화학 | Sheet Molding Compound Water-Proof Flooring Having Core Layer and the Method of Manufacturing thereof |
| JP2014509271A (en) * | 2011-02-04 | 2014-04-17 | フォルシア オートモーティブ インダストリー | Automotive structural components and related manufacturing methods |
| JP2015139633A (en) * | 2014-01-30 | 2015-08-03 | 株式会社イトーキ | Laminated light-weight top board for furniture |
| CN106275379A (en) * | 2015-06-05 | 2017-01-04 | 哈尔滨飞机工业集团有限责任公司 | A kind of composite big thickness deep camber honeycomb parts forming method |
| CN114274567A (en) * | 2021-12-31 | 2022-04-05 | 北京奥星雅博科技发展有限责任公司 | Phenolic filling aramid fiber honeycomb structure and preparation method and application thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| JP3067513B2 (en) | 2000-07-17 |
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