Composite molded article, laminate, and method for producing composite molded article

Patent metadata

Field	Value
Publication number	US-2018162093-A1
Application number	US-201515318608-A
Country	US
Kind code	A1
Filing date	Jul 15, 2015
Priority date	Jul 15, 2014
Publication date	Jun 14, 2018
Grant date	—

Abstract

The present invention provides a composite molded article in which aliphatic polyester-based resin expanded beads and a thermosetting resin cured product containing a reinforcing fiber, which is formed between the expanded beads, are integrally fixed, wherein the aliphatic polyester-based resin is a polylactic acid-based resin, and a flexural modulus E (MPa) of the composite molded article and a density ρ (kg/m 3 ) of the composite molded article satisfy Expression (1): E 1/3 /ρ≥0.02 [(MPa) 1/3 (kg/m 3 ) −1 ], and a composite molded article and a laminate having more improved strength.

First claim

1 - 11 . (canceled)

12 . A composite molded article in which aliphatic polyester-based resin expanded beads and a thermosetting resin cured product containing a reinforcing fiber, which is formed between the expanded beads, are integrally fixed,
wherein the aliphatic polyester-based resin is a crystalline polylactic acid-based resin, wherein the thermosetting resin is one or more selected from the group consisting of an unsaturated polyester-based resin and an epoxy-based resin, and a flexural modulus E (MPa) of the composite molded article and a density ρ (kg/m 3 ) of the composite molded article satisfy the following Expression (1):
E 1/3 /ρ≥0.020 [(MPa) 1/3 (kg/m 3 ) −1 ]  (1).

13 . The composite molded article according to claim 12 , wherein a content of the reinforcing fiber in the thermosetting resin cured product is 3% by weight to 50% by weight.

14 . The composite molded article according to claim 12 , wherein the reinforcing fiber is one or more selected from the group consisting of a glass fiber, a carbon fiber, and a vinylon fiber, and a fiber length L of the reinforcing fiber is 0.05 mm to 20 mm, and a value of L/D, which is a ratio of the fiber length L and an average diameter D of a fiber cross-section, is 2 or more.

15 . The composite molded article according to claim 12 , wherein the density of the composite molded article is 120 g/L to 700 g/L.

16 . The composite molded article according to claim 12 , wherein the polylactic acid-based resin is having a melting point of 150° C. or higher.

17 . A laminate in which the composite molded article according to claim 12 and a surface material are laminated.

18 . The laminate according to claim 17 , wherein the surface material is one or more selected from the group consisting of glass, metal, wood, and stone.

19 . The laminate according to claim 17 , wherein a density of the laminate is less than 1 kg/L.

20 . A method for producing a composite molded article comprising:
mixing aliphatic polyester-based resin expanded beads and a thermosetting resin composition containing a reinforcing fiber to obtain a mixture; and heating and curing the mixture to integrally fix expanded beads and a thermosetting resin cured product, wherein the aliphatic polyester-based resin is a crystalline polylactic acid-based resin, wherein the thermosetting resin is one or more selected from the group consisting of an unsaturated polyester-based resin and an epoxy-based resin, and a difference between an endothermic calorific value (Bf:endo) [J/g] of the expanded beads and an exothermic calorific value (Bf:exo) [J/g] of the expanded beads as measured based on Condition 1 described below satisfies the following Expression (2):
( Bf:endo )−( Bf:exo )>20   (2)

Condition 1: the endothermic calorific value (Bf:endo) and the exothermic calorific value (Bf:exo) are values which are determined based on a DSC curve obtained when heating and melting 1 to 4 mg of expanded beads from 23° C. to a temperature that is 30° C. higher than that at the end of a fusion peak, at a heating rate of 10° C./min according to heat flux differential scanning calorimetry as described in JIS K7122 (1987).

21 . The method for producing a composite molded article according to claim 20 , wherein the expanded beads used for obtaining the mixture are expanded beads haying a bulk density of 15 to 250 g/L.

22 . The method for producing the composite molded article according to claim 20 , wherein the mixture is an uncured expanded beads aggregate which is solid or semi-solid at ambient temperature, the uncured expanded beads aggregate is placed and shaped in a mold, and the uncured expanded beads aggregate is heated and cured in the mold.

Assignees

• Jsp Corp

Inventors

• Sasaki Hidehiro

Classifications

• B32B5/18 Primary

  characterised by features of a layer {of} foamed material · CPC title

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title

• C08J9/0061

  characterized by the use of several polymeric components · CPC title

• B32B27/06

  as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)} · CPC title

• C08J9/224

  Surface treatment · CPC title