JP2001129909A - Base material for hybrid composite material and hybrid composite material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a hybrid composite material which shows a presentable appearance such as surface smoothness and outstanding mechanical properties, thermal properties and chemical resistance. SOLUTION: The base material is composed of a plain woven cloth consisting of an inorganic fiber such as glass fiber or an organic fiber such as aramid fiber and an adhesive layer of a polyolefin adhesive, preferably an ionomer-based adhesive formed on the plain woven cloth. This base material, a plastic such as an olefin resin or a metal such as aluminum and an appropriate designed film and a protecting film are laminated in a sandwich fashion. Thus a variety of the hybrid composite materials suitable especially for use as a building material are obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to a base material suitable for forming various hybrid composite materials, particularly, a hybrid composite material molded article having excellent physical properties, chemical resistance and dimensional stability.

[0002]

2. Description of the Related Art Since plastic materials have excellent physical properties and moldability, almost all industrial fields such as automobiles and other transportation equipment, machine parts, building materials, electric and electronic products, toys and leisure products, and wrapping materials are used. It is widely used in the sundries field, and its production in Japan has been steadily increasing since 1990, exceeding 15 million tons per year in 1997. Plastics are roughly classified into thermosetting resins and thermoplastic resins, and their consumption is about 1: 5. The production volume by resin is polyethylene, polypropylene, vinyl chloride and polystyrene in the order. It accounts for more than 70% of the total production. This indicates that thermoplastic resins, particularly the above four types of resins, are excellent in physicochemical properties and relatively inexpensive, and are used as general-purpose industrial materials.

[0003] Among them, vinyl chloride resin is excellent in mechanical properties, chemical resistance and flame retardancy, and has a wide latitude in filling and processing, so that it is processed into various products from hard products to soft products. In fact, it is used in almost every field, from daily necessities such as toys, footwear and packaging containers, to industrial products such as pipes, joints and electric wire coverings, and the production volume will exceed 2.5 million tons in 1997. Has reached. In particular, it is an inexpensive, self-extinguishing, water-resistant, oil-resistant, chemical-resistant, and moldable material. Coated laminated products are used in the fields of footwear, furniture and automotive interior materials as leather products such as so-called lasers, sponge lasers, sintered lasers, and flooring materials, wallpaper, and nickel chloride steel sheets. It is also used as a building material in houses, offices, factories, etc., and is closely related to everyday life.

[0004] In recent years, as environmental problems have become more serious, it has been found that vinyl chloride resin products can be a source of highly toxic chlorine gas and dioxin depending on combustion conditions during incineration. Has been viewed as a problem, and with the progress of LCA analysis research and global interest in environmental conservation, the need for urgent measures to avoid the processing and use of vinyl chloride resin has been urgent. ing. Accordingly, there is a strong need to develop new materials that reduce or replace the use of vinyl chloride resins.

[0005]

SUMMARY OF THE INVENTION In view of the above circumstances, the inventors of the present invention have developed, in particular, the chemical properties of vinyl chloride such as processability, mechanical properties, thermal properties, physical properties, flame retardancy and chemical resistance. In consideration of the characteristics that all the properties are well-balanced and excellent, the price is also low, and instead of using it as a single material, instead of using it as a hybrid composite material, we have been developing alternative materials for vinyl chloride resin, and have been conducting intensive studies . As a result, when developing a hybrid composite material using reinforced fiber products and inexpensive polyolefins with excellent physical properties, the optimal combination of the reinforced fiber material and resin and the lamination structure are required to achieve the desired engineering characteristics. Obviously, the choice must be made, but the thermal dimensional stability, especially in the laminating process, and the embossing of the reinforcing fibrous material on the surface of the molded product are common technical challenges in the construction of such composites. They have found that solving such a technical problem facilitates the development of a hybrid composite material having various properties.

[0006]

As a result of further studies, the present inventors have surprisingly solved such technical problems when plain woven fabric (preferably plain woven fabric) is used as a reinforcing fiber material. It was found that a hybrid composite material excellent in engineering properties such as moldability, mechanical properties, etc. was obtained, and that in the construction of the hybrid composite material, the allowable selection range in the combination of materials and the lamination structure was widened. The present invention has been completed.

That is, the present invention provides (1) a base material for forming a hybrid composite material having excellent mechanical stability, which is obtained by adhering a polyolefin adhesive to a plain woven fabric, an orthogonally laminated net or a knitted fabric; (2) The plain woven fabric, the orthogonal laminated net or the knitted fabric is made of glass fiber,
(1) The base material for forming the hybrid composite material described in (1), (3) the plain woven fabric, the cross-laminated net or the knitted fabric is made of synthetic fibers.
(4) The base material for forming the hybrid composite material described in (1), (4) the plain woven fabric, the cross-laminated net or the knitted fabric, wherein the aperture ratio is about 10% to 99.9%. (5) The polyolefin adhesive is an ionomer.
A substrate for forming the hybrid composite material according to any one of (1) to (3),
(6) a composite material obtained by laminating a plastic material or a metal material on a substrate for forming the hybrid composite material described in the above (1) to (5); (7) the plastic material is foamed or unfoamed The composite material according to (6), which is a polyolefin-based material of
(8) The composite material described in the above (6) to (7), wherein the metal material is an aluminum material, and (9) a design film and a protective film are further laminated and provided on the base material, The present invention relates to the composite material described in the above (6) to (8), which is suitable for use as a member.

According to the present invention, a plain woven fabric made of glass fiber or high-performance synthetic fiber is coated on both sides with an ionomer, an ethylene-acrylic acid copolymer, an ethylene-methacrylic acid copolymer or the like. Since the base material is formed by providing an adhesive layer with a heat-sensitive adhesive such as a water-based adhesive or a hot-melt adhesive, a simple bonding method such as thermocompression bonding of various plastic materials and metal materials can be used. When sandwich lamination is performed by using this, a hybrid composite material having good mechanical properties, excellent surface appearance, and particularly excellent shape retention can be obtained. For example,
Using the base material of the present invention, a foamed olefin resin is laminated on the upper surface by thermocompression bonding with a picture printing design film provided with a transparent surface protective plastic layer on the lower surface and a protective film layer is further provided on the surface. By embossing, it is possible to obtain a flooring material with good walking feeling, excellent heat insulation and sound insulation effects, and therefore excellent livability, as well as aluminum plate, steel plate, etc. and olefin resin and suitable decorative surface. By sandwiching and laminating a plastic layer, an interior / exterior siding material is obtained. In addition, by adjusting the weaving density, unit weight, thickness and opening ratio of the plain woven fabric used at this time and mixing a flame retardant into the adhesive layer, it is possible to support an appropriate flame retardancy, and thus Building materials based on vinyl chloride resin which has been conventionally used for steel sheets, such as vinyl tiles, vinyl laminated tiles, and vinyl chloride steel sheets can be effectively substituted.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The substrate for forming the hybrid composite according to the present invention comprises a plain woven fabric and preferably an ionomer adhesive. In order to construct a plain woven fabric, inorganic fibers such as glass fiber and carbon fiber and organic fibers such as polyester fiber, nylon fiber, polyolefin fiber and aramid fiber can be used alone or in combination with each other. To elaborate,
As the glass fiber, a fiber made of E glass or C glass having particularly excellent corrosion resistance is suitable, and the carbon fiber is preferably a carbon fiber for high strength or high elastic modulus. Of the organic fibers, fibers such as polyester and nylon which are conventionally used can be used as they are, but as the aramid fiber, Kevlar-49 is particularly preferable. The type of fiber is appropriately selected in consideration of desired mechanical, thermal, physical properties, and cost.

[0010] By forming these fibers singly or in combination into a woven structure in which the fibers are interlaced one by one as a warp and a weft, the opening ratio is about 10% to 99.9% and the thickness is about 0.1%. A plain woven fabric having a size of about 02 mm to 0.5 mm is used. However, the aperture ratio is woven cloth 25m
m-square, that is, the percentage ratio of the opening portion in the area of 625 mm ² . Plain woven fabric is structurally tightly interwoven with fibers, and therefore has a strong formation. In the case of a composite material, the stress burden is uniform and large, and in addition to the design film that is overlaid on the upper surface, protection. It has a great feature that the eyes of a plain woven fabric do not appear on the surface plastic layer such as a film, and is distinguished from other woven fabrics such as twill weave and satin weave.

In the present invention, an orthogonally laminated net or a knitted fabric may be used instead of a plain woven fabric. The opening ratio and the thickness of the cross laminated net or the knitted fabric may be the same as those of the plain woven fabric. Such an orthogonal laminated net or knit can be easily manufactured by a known method or a method analogous thereto. Therefore, in the following description of the present application, all parts described as plain woven fabric may be read as plain woven fabric, orthogonally laminated net or knitted fabric.

Various adhesives can be used to provide an adhesive layer on both sides of the plain woven fabric. However, all of the plain woven fabric and the plastic or metal material which is the adherend to be sandwich-laminated are used. A dispersion-type or hot-melt-type adhesive exhibiting appropriate adhesiveness is used, but the dispersion-type adhesive is particularly preferable. The dispersion type adhesive may be used by drying and drying at a high temperature after dipping the woven fabric to be bonded.
After being softened or melted by heating, the woven fabric to be bonded may be subjected to a dipping treatment or a coating application treatment, and then fixed by cooling. In any of the adhesives, as the base polymer, an ethylene ionomer or a modified polyolefin such as EAA or EMAA is used. An ionomer having a bond is preferred. Such a base polymer is used after appropriately compounding a tackifier, a wax, an antioxidant, a flame retardant, a filler, a plasticizer, and the like, if necessary. Prior to the application of the adhesive, an appropriate primer may be applied to the surface of the plain woven fabric to secure stronger adhesion. Recently developed ionomer base
The aqueous dispersion type adhesive is particularly excellent in adhesiveness and workability, and after the immersion treatment, 150 to 160
It is possible to conveniently provide an adhesive layer by heating and drying at a temperature of ° C. Examples of such an aqueous adhesive include Chemipearl (manufactured by Mitsui Chemicals, Inc.) and Aquatex (manufactured by Chuo Rika Co., Ltd.). Is mentioned. The application ratio of the adhesive to the plain woven fabric depends on the type of the base resin of the adhesive, but is 5 to 20% by weight, preferably 5 to 15% by weight.

To apply such an adhesive to a plain woven fabric,
A desired amount of the adhesive is applied to both sides of the plain woven fabric using an appropriate means such as an applicator, or immersed in a spear containing a molten adhesive and pulled up to squeeze out the excess amount. I just need. Thus, it can be used as a substrate for forming the hybrid composite material of the present invention.

The base material for forming the hybrid composite material thus produced may be supplied and sold as an intermediate material for producing various hybrid composite materials by appropriately wrapping with a film as it is. Sandwich lamination of elastic, hard or flexible plastic or metal materials to the desired hybrid composite materials, such as elastic floor finishes, siding materials, interior wallpaper, and mechanical properties such as waterproof roofing materials; It can be processed into industrial materials with excellent dimensional stability in addition to chemical resistance and thermal properties.

The base material for molding the hybrid composite material of the present invention thus manufactured is preferably provided on both sides when it is supplied and sold as an intermediate material, preferably having a chemical resistance and a gas permeation resistance. Removably covered and packaged with a single-layer film or a multi-layer laminate film with a strength of
What is necessary is to prevent contamination of the base material and leakage and dissipation of the compound components to maintain the quality, secure shape retention and prevention of mutual adhesion, and facilitate handling and storage.

The base material for forming the hybrid composite material of the present invention thus produced is a foamed or non-foamed plastic material, preferably a board-shaped or flexible sheet-shaped olefin resin board. Endless elastic flooring, interior wallpaper, waterproofing by sandwiching and laminating a metal film such as aluminum plate, stainless steel plate, galvanized plate and other suitable materials and patterns and design films including patterns and surface protection films It can also be a final product of a hybrid composite material such as a roofing material or a siding board material.

The olefin resin used for the substrate and the sandwich lamination according to the present invention includes low-density, medium-density and high-density polyethylene, ultra-high-molecular-weight polyethylene,
Cross-linked polyethylene, ethylene-vinyl acetate copolymer,
Various thermoplastic olefins comprising ethylene-propylene copolymer, ethylene-propylene-dienter polymer, propylene homopolymer and copolymer, butadiene, various thermoplastic elastomers based on isoprene and styrene, and the like. . These olefin resins are foamed plastics by a known method using a low-foaming molding method or a high-foaming molding method using a volatile foaming agent such as a decomposable foaming agent or a petroleum-based solvent depending on the resin used, if necessary. A heat insulation function, a shock absorption function, a lightweight function, a sound insulation / sound absorption function, an elastic function, a decoration function, and the like may be provided.

The protective film on the surface has mechanical properties,
A film excellent in transparency in addition to thermal properties is particularly preferable, and examples thereof include a single plastic film such as polyester and aramid, and a plastic laminate film such as polyester, nylon, polyethylene, and saponified EVA.

Thus, the general-purpose plastic-based hybrid composite material obtained by using the substrate for forming the hybrid composite material according to the present invention can be used in combination with different types of base materials and high-performance materials, and Various properties such as mechanical strength, thermal properties, chemical resistance, appearance, etc. are remarkably improved due to the use of plain woven fabric as a base material. Has a wide range of uses as a functional material.

[0020]

The present invention will be described in detail with reference to the following examples. As a base material for producing the hybrid composite material, an opening plain woven glass fiber cloth (manufactured by Unitika Glass Fiber Co., Ltd., product number M85F104) is ionomer-aqueous adhesive dispersion liquid (manufactured by Mitsui Chemicals, Inc., trade name, Chemipearl S-300), squeezing out excess adhesion dispersion with a mangle so that the adhesive adhesion rate becomes 15%, and then drying and drying at 150 ° C. to obtain a hybrid composite according to the present invention. A substrate for a material was manufactured.

Continued on the front page F-term (reference) 2E110 AB05 AB22 AB23 GA33Z GA42Z GB43Z 4F100 AB01B AB10B AG00A AK01A AK01B AK01C AK01D AK03A AK03B AK42 AK48 AK70A BA02 BA03 BA04 BA06 BA07 BA10B BA10 DBA13 CB01 J13 DJB12A YY00A

Claims (9)

[Claims] 1. A substrate for forming a hybrid composite material having excellent mechanical stability, comprising a plain woven fabric, an orthogonally laminated net or a knitted fabric and a polyolefin-based adhesive adhered thereto. 2. The substrate for forming a hybrid composite material according to claim 1, wherein the plain woven fabric, the cross-laminated net or the knitted fabric is made of glass fiber. 3. The substrate for forming a hybrid composite material according to claim 1, wherein the plain woven fabric, the orthogonally laminated net or the knitted fabric is made of synthetic fibers. 4. The flat woven fabric, cross-laminated net or knitted fabric having an opening ratio of about 10% to 99.9%.
A substrate for forming the hybrid composite material described in 1. 5. The method according to claim 1, wherein the polyolefin adhesive is ionomer.
A substrate for forming the hybrid composite material according to any one of claims 1 to 3, characterized in that: 6. A composite material obtained by laminating a plastic material or a metal material on a substrate for forming the hybrid composite material according to claim 1. 7. The composite material according to claim 6, wherein the plastic material is a foamed or unfoamed polyolefin-based material. 8. The composite material according to claim 6, wherein the metal material is an aluminum material. 9. The composite material according to claim 6, wherein a design film and a protective film are further laminated on the base material and provided, and the composite material is suitable for use as a building member.