Laminate and method for producing laminate

Abstract

The invention provides a laminate and a method for manufacturing the laminate, which can utilize waste residues without performing many pre-treatments such as disintegration and classification according to materials and removal of foreign matters. The laminated body is formed by laminating a surface layer material on a core material having a waste residue.

Description

Technical Field

[0001] This invention relates to laminates and methods for manufacturing laminates. Background Technology

[0002] In recent years, efforts to significantly reduce waste generation through the prevention, reduction, recycling, and reuse of waste have become increasingly active. To achieve this, research and development related to recycling has been conducted (e.g., Patent Document 1).

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Publication No. 2022-531085 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] Furthermore, in technologies related to recycling, recovering the desired material from waste into a single material requires numerous pre-processing steps, such as material disassembly and sorting, and removal of foreign matter. Additionally, materials obtained solely from solidified municipal waste have long existed, used in applications such as pallets; however, the surface portion subjected to significant stress in its cross-section exhibits low strength, making it unsuitable for use in structural materials for automobiles, etc.

[0008] To address the aforementioned issues, the purpose of this application is to enable the utilization of waste residues without the need for pretreatment such as dismantling, sorting, or removal of foreign matter. Furthermore, this would significantly contribute to a substantial reduction in waste generation.

[0009] Methods for solving problems

[0010] One aspect of the present invention is a laminate formed by layering a surface material on a core material having waste residue.

[0011] Another aspect of the present invention is a method for manufacturing a laminate, wherein a core material having waste residue and a surface material are placed in a pressing mold, and the pressing mold is used to press the laminate to form the laminate.

[0012] Invention Effects

[0013] According to the present invention, it is possible to easily form a laminate from waste residue without pretreatment such as disassembly and sorting or removal of foreign matter, thereby helping to significantly reduce the generation of waste. Attached Figure Description

[0014] Figure 1 This is a diagram illustrating a structural example of a stacked structure.

[0015] Figure 2 This is a flowchart illustrating the manufacturing process of a laminate.

[0016] Figure 3 This diagram illustrates the simultaneous molding process of the core material and the surface material.

[0017] Figure 4 This diagram illustrates the separate molding process of the core material and the surface material.

[0018] Figure 5 This is a graph representing the flexural modulus of elasticity of the core material.

[0019] Figure 6 This is a diagram showing the bending strength of the core material.

[0020] Figure 7 This is a diagram representing the flexural modulus of elasticity of a laminate.

[0021] Figure 8 This is a diagram representing the bending strength of a laminate.

[0022] Label Explanation

[0023] 1: core material;

[0024] 2, 3: Surface material;

[0025] 10: Layered bodies;

[0026] 20: Pressing mold;

[0027] 21: Fixed mold;

[0028] 22: Movable mold. Detailed Implementation

[0029] [1. First Implementation Method]

[0030] Unless otherwise defined, all technical and / or scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Similar or equivalent methods and materials described herein can be used to implement or test embodiments of the invention. Materials, methods, and examples are merely exemplary and are not intended to be limiting.

[0031] For example, the Automobile Recycling Act mandates the recycling of ASR (Automobile Shredder Residue). ASR is the waste residue remaining after removing components such as airbags, Freon, doors, and engines from end-of-life vehicles (ELVs) and crushing them to recover usable metals. Regarding the composition of ASR, statistics show that, by weight, combustible materials such as thermosetting resins and polyurethanes account for approximately 75%, while non-combustible materials such as metals and glass account for approximately 25%.

[0032] [1. Structure]

[0033] Figure 1 This is a diagram illustrating a structural example of the laminate 10.

[0034] Reference numeral 10 refers to a laminate. In the first embodiment, the laminate 10 includes a core material 1. The core material 1 is an ASR of waste residue with unstable physical properties.

[0035] Surface materials 2 and 3 are stacked on both sides of the core material 1.

[0036] Surface materials 2 and 3 are glass fiber reinforced plastics (GFRP). However, surface materials 2 and 3 are not limited to GFRP. They can be any fiber-reinforced plastics (FRP), such as carbon fiber reinforced plastics (CFRP). Furthermore, FRP can be conceived as FRP containing thermosetting or thermoplastic resins. Surface materials 2 and 3 can also be metals such as iron plates or non-ferrous metals such as aluminum plates. The thickness of surface materials 2 and 3 is not limited to the same thickness. Surface materials 2 and 3 can also have different thicknesses. The thickness of the surface materials can also vary depending on the degree of ASR degradation.

[0037] In addition, surface materials 2 and 3 can be recycled materials obtained by individualizing materials generated through waste sorting, or they can be recycled iron (electromagnetic steel sheet) or recycled aluminum.

[0038] [2. Manufacturing Process]

[0039] Figure 2 This is a flowchart illustrating the manufacturing process of the laminate 10.

[0040] Prepare to use the scrapped car ELV and remove major components such as airbags, Freon, doors, and engine from the ELV (disassembly process S1).

[0041] Next, the ELV is crushed (crushing step S2), and useful metals are recovered from the crushed material (metal recovery step S3).

[0042] Regarding the residual waste residue (ASR) left after the recovery of useful metals, it comprises approximately 75% combustible materials such as thermoplastic resins and polyurethanes by weight, and approximately 25% non-combustible materials such as metals and glass. After the crushing process S2, the particle size of the ASR is smaller than the thickness of the laminate 10. If the ASR becomes a large particle size spanning the surface materials 2 and 3, poor adhesion will occur. Preferably, the particle size of the ASR is smaller than the thickness between the surface materials 2 and 3.

[0043] Next, the core material 1 of the laminate 10 is pre-formed into the desired shape by hot pressing the ASR (core material forming step S4). In this step S4, the thermoplastic resin contained in the ASR melts due to heat, and the shape of the core material 1 is adjusted.

[0044] Next, the process is transferred to the casting process S5.

[0045] Figure 3 This diagram illustrates the molding process in which core material 1 and surface materials 2 and 3 are molded simultaneously.

[0046] In the casting process S5, such as Figure 3 As shown in process A, the core material 1 of the ASR from ELV and the flat surface materials 2 and 3 are prepared to be formed in the core material forming process S4. Then, as... Figure 3 As shown in step B, the core material 1 and the surface materials 2 and 3 are directly placed into the pressing mold 20. The pressing mold 20 includes a fixed mold 21 and a movable mold 22.

[0047] Next, the core material 1 and the surface materials 2 and 3 are hot-pressed between the fixed mold 21 and the movable mold 22 (hot pressing process S6). During hot pressing, the thermoplastic resin contained in the ASR melts due to heat, and the core material 1 and the surface materials 2 and 3 are bonded together by the resin to form a sandwich structure laminate 10.

[0048] This is because the core material 1 of ASR contains approximately 75% by weight of combustible materials such as thermosetting resin and polyurethane, and contains more than 30% by weight of thermosetting resin.

[0049] Then, open the movable module 22, as follows: Figure 3 As shown in step C, the laminate 30 containing the core material 1 and the surface materials 2 and 3 is taken out from the pressing mold 20.

[0050] In the first embodiment, the ASR remaining in the final stage of sorting end-of-life vehicles (ELVs) can be reused as new material, enabling resource recycling.

[0051] Therefore, automobile manufacturing using composite laminates 10 can be achieved without being constrained by materials or classification during disassembly.

[0052] In the first embodiment, in the core material forming process S4, ASR can be used without pretreatment such as disassembly, sorting, and cutting, without the need for mixing.

[0053] In addition, in the hot pressing process S6, the laminate 10 is formed without adhesives or binders, ensuring strength and quality.

[0054] The hot pressing process S6 is not limited to being performed without adhesives or binders. For example, in the core material forming process S4, the ASR may be mixed with polypropylene (PP) resin (adhesive) as a granular thermoplastic resin before hot pressing to form a core material 1, and the hot pressing process S6 (thermoplastic molding) may be performed using this core material 1. The thermoplastic resin mixed with the ASR is not limited to polypropylene resin. Alternatively, in the core material forming process S4, the ASR may be impregnated with epoxy resin (adhesive) as a liquid thermosetting resin before hot pressing to form a core material 1, and the hot pressing process S6 (thermosetting molding) may be performed using this core material 1. The liquid thermosetting resin impregnated in the ASR is not limited to epoxy resin.

[0055] By adding an adhesive to the ASR, poor adhesion between the ASR and surface materials 2 and 3 can be suppressed, and the efficiency of shear load transfer to the surface materials can be reduced.

[0056] Figure 4 This diagram illustrates the separate molding process of core material 1 and surface materials 2 and 3.

[0057] In the split molding process, with Figure 3 The molding process is different. Before the core material 1 and surface materials 2 and 3 are placed into the pressing mold 20, the surface materials 2 and 3 are pre-processed through other processes. Figure 4 As shown in process A, it is shaped into a convex shape with the center protruding downwards. In this state, as... Figure 4 As shown in step B, core material 1 and surface materials 2 and 3 are placed in the pressing mold 20 for hot pressing. Then, the movable mold 22 is opened, as shown... Figure 4 As shown in step C, the laminate 30 containing the core material 1 and the surface materials 2 and 3 is taken out from the pressing mold 20.

[0058] Therefore, even when the surface materials 2 and 3 are as hard as iron plates, they can be molded with high precision, and the laminate 10 can be molded with high precision. In addition, in the split molding process, even if the surface materials 2 and 3 are fiber-reinforced plastics including glass fiber reinforced plastics and carbon fiber reinforced plastics, or non-ferrous metals such as aluminum, they can still be molded with high precision.

[0059] When the surface materials 2 and 3 are metal, the difference in elastic modulus and linear expansion between the surface materials 2 and 3 and the resin-based core material 1 is large. Therefore, the bonding surface of the surface materials 2 and 3 needs to withstand shear forces in the in-plane direction. In this case, surface treatment of the bonding surface (for example, see Japanese Patent No. 6441295) or the use of adhesives are also effective.

[0060] In addition, the core material 1 of the sandwich structure needs to maintain Figure 1 The distance between surface materials 2 and 3 is considered. Therefore, a raw material with high rigidity for compression perpendicular to the surface is desired, and ASR is the preferred raw material. The particle size of the ASR is smaller than the thickness of the laminate 10. In the crushing process S2, even if the ELV is crushed, the ASR is preferably crushed to an appropriate size if the particle size is larger than the thickness of the laminate 10. This is because if the particle size of the ASR is too large and spans the distance between surface materials 2 and 3, poor adhesion due to large particles will occur. Preferably, the particle size of the ASR is smaller than the thickness between surface materials 2 and 3.

[0061] In the first embodiment, the laminate 10 uses low-cost ASR directly as the core material 1 without pretreatment such as disassembly, sorting, or removal of foreign matter, thus obtaining a low-cost composite structure. The laminate 10 can be easily formed simply by laminating surface materials 2 and 3 onto both sides of the core material 1 to form a sandwich structure.

[0062] The physical property deviation of ASR is large, while the physical property deviation of surface materials 2 and 3 is small. In addition, surface materials 2 and 3 are materials with relatively higher elasticity compared to ASR.

[0063] Therefore, the laminate 10, formed by bonding individual valueless waste (ASR) with surface materials 2 and 3, can reduce property deviations as a whole component compared to the case where only ASR is used as the material. This is particularly true when the plate is bent, which reduces the property deviations of the laminate 10. In other words, by combining ASR with surface materials 2 and 3, ASR can be transformed into a material with determinable and valuable properties, thereby contributing to a significant reduction in waste generation.

[0064] In the first embodiment, for resource recycling, there is no need for material identification and classification processes, nor for monomerization and repolymerization, thus saving energy and achieving low-cost resource recycling. It also enables the pulverization and reuse of thermosetting resins and fibers that are difficult to monomerize, achieving sustainable materialization.

[0065] In the first embodiment, a flat surface material 2 and 3 are attached to both sides of the core material 1 of the ASR from ELV. As a result, the surface materials 2 and 3 are subjected to tensile / compressive forces in the in-plane direction, while the core material 1, which has relatively low elasticity, is mainly subjected to compressive forces in the perpendicular direction.

[0066] On the other hand, the tensile strength of pulverized ASR is lower than that of a single material because it becomes an inclusion of different materials, but it has the characteristic that the inclusions have little effect on the strength when compressed.

[0067] Therefore, even if ASR is used in core material 1, it can still function as a material.

[0068] Therefore, ASR can have locally unmelted portions, which can increase the ASR formulation ratio and eliminate the need to remove the magnetic metal contents. Furthermore, the particle size of the ASR only needs to be smaller than the plate thickness. In the prototype, with a particle size of 3.0 mm relative to the thickness of the laminate 10, the laminate 10 can be formed.

[0069] [3. Experimental Results]

[0070] Figure 5 This is a graph where the horizontal axis represents the original rate of change in the amount of adhesive added, and the vertical axis represents the flexural modulus (MPa). Additionally, Figure 6 It is a graph where the horizontal axis represents the original rate and the vertical axis represents the bending strength (MPa).

[0071] The laminate 10 in Example 1 is in Figure 2 In the hot pressing process S6, epoxy resin is used as the adhesive, and the laminate is formed by thermosetting molding. The laminate 10 of Example 2 is... Figure 2 In the hot pressing process S6, polypropylene resin is used as the adhesive, and the laminate is formed by thermoplastic molding. The flexural modulus and flexural strength of the laminate 10 are determined by the method described in Japanese Industrial Standard JIS K7171.

[0072] It can be seen that if the original ratio increases, the flexural modulus and flexural strength of the laminate 10 in Example 1 and the laminate 10 in Example 2 both increase.

[0073] If the original ratio is 1, then the flexural modulus and flexural strength will both reach their maximum values.

[0074] The results of this experiment show that even with a raw yield of 0, that is, even when ASR is used directly to form laminate 10 without adding adhesive, the flexural modulus is about 500 MPa and the flexural strength is about 10 MPa. The flexural modulus and flexural strength of laminate 10 are sufficient for use.

[0075] In addition, it is desirable to change the amount of adhesive added to the ASR according to the required application and performance of the laminate 10.

[0076] Figure 7 This indicates the flexural modulus of elasticity in Examples 3 and 4. Figure 8 The values ​​represent the bending strength of Examples 3 and 4.

[0077] In the figures, the laminate 10 of Example 3 is... Figure 2 The laminate in Example 4 is formed by thermoplastic molding in the hot pressing process S6, while the laminate 10 in Example 4 is formed by thermosetting molding. The flexural modulus and flexural strength of the laminate 10 were measured by the method described in Japanese Industrial Standard JIS K7171.

[0078] Regarding the laminate 10 of Examples 3 and 4, refer to... Figure 7 The flexural modulus of elasticity is above 12000MPa, referring to... Figure 8 All of them have a flexural strength of over 110 MPa, which can be fully used as the flexural modulus and flexural strength of the laminate 10.

[0079] [4. Other Implementation Methods]

[0080] The above-described embodiments are merely one aspect of the present invention, and can be arbitrarily modified and applied within the scope of the present invention.

[0081] The above-described embodiments illustrate the use of ASR (Automatic Residue Storage) from scrapped automobiles, but are not limited thereto. For example, the waste residue can also be used from scrapped household appliances, slag from steel production, aircraft prepreg scrap, and mixtures thereof.

[0082] When slag is used in the core material 1, the slag particles are typically large, which can become the starting point for damage. Therefore, when used in the core material 1, it is preferable to control the particle size to be less than the thickness of the molded plate of the laminate 10 and to perform additional crushing.

[0083] In addition, when the content of thermoplastic resins such as polypropylene resin is insufficient in waste residues from discarded household appliances, slag from steel production, and prepreg scraps from aircraft, it is preferable to add an appropriate amount of adhesive as needed.

[0084] The above-described embodiments utilize waste as the core material 1 of the composite material, without envisioning the waste itself as a product.

[0085] Therefore, the core material 1 can be made of a coarser material as a whole, so that it can be a laminate 10 with high physical properties and low deviation as a whole composite material.

[0086] Aircraft prepreg scraps, comprising resin and fibers, exhibit anisotropic rigidity and strength, making them prone to significant deviations in physical properties. Therefore, when using aircraft prepreg scraps in the core material 1, it is preferable to crush and mix these scraps to reduce anisotropy. This results in a core material 1 with isotropic material uniformity and minimal deviations.

[0087] In addition, the cut edges of the FRP prepreg from aircraft can be used as core material 1.

[0088] If the FRP prepreg of the aircraft is a thermosetting resin CFRP, it can be directly used for the core material 1, just like in the above embodiments.

[0089] Generally speaking, ASRs are composed of approximately 70% polymeric materials formed from plastics such as polypropylene (PP), polyethylene (PE), and polyvinyl chloride (PVC), as well as elastomers such as fibers, rubber, and polyurethane, and approximately 30% metals, wood, dust, etc. That is, if the polymeric materials contained in the ASR used as core material 1 are sufficient, the ASR can be directly used as core material 1.

[0090] When ASR is used in core material 1, particle size control is crucial. In the crushing step S2 of the ELV, if it is not possible to reduce the particle size of the ASR, a crushing step for crushing the ASR can be included before the ASR is formed. By making the ASR that becomes the raw material for core material 1 finer, the number of ASR particles with a cross-sectional size between the surface materials is reduced, and poor adhesion caused by the cross-sectional particle size of the ASR can be suppressed.

[0091] [5. Structure supported by the above embodiments]

[0092] The above implementation supports the following structures.

[0093] (Structure 1) A laminate formed by laminating a surface material on a core material containing waste residue.

[0094] Therefore, waste residues treated through incineration or landfill can be used as new materials, thus enabling resource recycling. Furthermore, by forming laminates from waste residues without pretreatment such as dismantling, sorting, or removal of foreign matter, it is possible to significantly reduce waste generation.

[0095] (Structure 2) In the laminate of Structure 1, the particle size of the waste residue is smaller than the thickness of the laminate.

[0096] Therefore, it is possible to form a laminate while suppressing poor adhesion caused by the particle size of waste residue crossing the surface material and reducing the efficiency of shear load transfer to the surface material, thus helping to significantly reduce waste generation.

[0097] (Structure 3) In the laminate of structure 1 or 2, the surface material is any one of fiber-reinforced plastics including glass fiber reinforced plastics, carbon fiber reinforced plastics, metals, and non-ferrous metals.

[0098] Therefore, by combining the surface material with the core material, it is possible to form a laminate with improved bending properties, which can help to significantly reduce waste generation.

[0099] (Structure 4) In any of the stacks of structures 1 to 3, the waste residue is the waste residue from a scrapped automobile.

[0100] Therefore, waste residues treated through incineration or landfill can be used as new materials, thus enabling resource recycling. In other words, it can help to significantly reduce waste generation.

[0101] (Structure 5) In any of the stacks of structures 1 to 4, the waste residue is the waste residue from discarded household appliances.

[0102] Therefore, waste residues treated through incineration or landfill can be used as new materials, thus enabling resource recycling. In other words, it can help to significantly reduce waste generation.

[0103] (Structure 6) In any of the stacks of structures 1 to 5, the waste residue is slag produced during steel production.

[0104] Therefore, waste residues treated through incineration or landfill can be used as new materials, thus enabling resource recycling. In other words, it can help to significantly reduce waste generation.

[0105] (Structure 7) In any of the stacks of structures 1 to 6, the waste residue is aircraft prepreg edge material.

[0106] Therefore, waste residues treated through incineration or landfill can be used as new materials, thus enabling resource recycling. In other words, it can help to significantly reduce waste generation.

[0107] (Structure 8) A method for manufacturing a laminate, wherein a core material and a surface material having waste residue are placed in a pressing mold and pressed using the pressing mold to form the laminate.

[0108] Therefore, waste residues treated through incineration or landfill can be used as new materials, thus enabling resource recycling. Furthermore, the waste residues can be laminated without pretreatment such as dismantling, sorting, or cutting, which can significantly reduce waste generation.

[0109] (Structure 9) In the manufacturing method of the laminate of Structure 8, the waste residue contains thermoplastic resin, the core material and the surface material are heated, and the core material and the surface material are pressed using the pressing mold to form the laminate.

[0110] Therefore, it is possible to use the thermoplastic resin contained in the waste residue to bond the surface material to form a laminate, which can help to significantly reduce the generation of waste.

[0111] (Structure 10) In the manufacturing method of the laminate of structure 8 or 9, the surface material is any one of fiber-reinforced plastics including glass fiber reinforced plastics, carbon fiber reinforced plastics, metals, non-ferrous metals, etc.

[0112] Therefore, by combining the surface material with the core material, it is possible to form a laminate with improved bending properties, which can help to significantly reduce waste generation.

[0113] (Structure 11) In the method of manufacturing the laminate of any one of Structures 8 to 10, the waste residue is the waste residue of a scrapped automobile.

[0114] Therefore, waste residues treated through incineration or landfill can be used as new materials, thus enabling resource recycling. In other words, it can help to significantly reduce waste generation.

Claims

1. A laminate formed by laminating a surface material on a core material having waste residue.

2. The laminated body according to claim 1, wherein, The particle size of the waste residue is smaller than the thickness of the laminate.

3. The laminated body according to claim 1, wherein, The surface material is any one of fiber-reinforced plastics, including glass fiber reinforced plastics and carbon fiber reinforced plastics, as well as metals.

4. The laminated body according to claim 1, wherein, The waste residue refers to the waste residue from scrapped automobiles.

5. The laminated body according to claim 1, wherein, The waste residue refers to the waste residue from discarded household appliances.

6. The laminate according to claim 1, wherein, The waste residue is slag produced during steel production.

7. The laminated body according to claim 1, wherein, The waste residue is edge material from aircraft prepreg.

8. A method for manufacturing a laminated body, wherein, The core material and surface material containing waste residue are placed into a pressing mold and pressed using the pressing mold to form the product.

9. The method for manufacturing a laminate according to claim 8, wherein, The waste residue contains thermoplastic resin. The core material and the surface material are heated and then pressed using the pressing mold to form the product.

10. The method for manufacturing a laminate according to claim 8, wherein, The surface material is any one of fiber-reinforced plastics, including glass fiber reinforced plastics and carbon fiber reinforced plastics, as well as metals.

11. The method for manufacturing a laminate according to claim 8, wherein, The waste residue refers to the waste residue from scrapped automobiles.

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