Laminate and method for manufacturing laminate

Abstract

To provide a laminate that can utilize waste residue without requiring numerous pre-treatments such as dismantling and sorting by material and removing foreign matter, and a method for manufacturing the same.SOLUTION: A laminate is formed by laminating a surface layer material onto a core material containing waste residue.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a laminate and a method for manufacturing the laminate. [Background technology]

[0002] In recent years, efforts to significantly reduce waste generation have been intensified through the prevention, reduction, recycling, and reuse of waste. To achieve this, research and development into recycling is being conducted (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Special Publication No. 2022-531085 Summary of the Invention [Problem to be solved by the invention]

[0004] In recycling technology, when returning desired materials from waste to single materials, a large amount of pre-processing is required, such as dismantling and sorting each material, removing foreign matter, etc. Furthermore, there have been materials made by simply solidifying municipal waste, and while this material has been used for pallets and the like, it has not been possible to use it as a structural material for automobiles and the like because the strength of the surface area, which is subjected to relatively large stresses in the cross section, is low. In order to solve the above problems, the present invention aims to achieve the utilization of waste residues without pre-processing such as dismantling, sorting, removal of foreign matter, etc., thereby contributing to a significant reduction in waste generation. [Means for solving the problem]

[0005] One aspect of the present invention is a laminate formed by laminating a surface layer material onto a core material having waste residue. Another aspect of the present invention is a method for producing a laminate, which comprises setting a core material having waste residue and a surface layer material in a press mold and pressing and molding the core material and surface layer material into the press mold. [Effects of the Invention]

[0006] According to the present invention, a laminate can be easily formed using waste residue without pre-processing such as dismantling and sorting or removal of foreign matter, which can ultimately contribute to a significant reduction in waste generation. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 10 is a diagram showing an example of the structure of a stacked body. [Figure 2] 1 is a flowchart showing a manufacturing process of a laminate. [Figure 3] FIG. 1 is a diagram showing the simultaneous molding process of the core material and the surface layer material. [Figure 4] 10A and 10B are diagrams showing a process of separately molding a core material and a surface layer material. [Figure 5] FIG. 10 is a diagram showing the bending modulus of elasticity of a core material. [Figure 6] FIG. 10 is a diagram showing the bending strength of the core material. [Figure 7] FIG. 2 is a diagram showing the flexural modulus of a laminate. [Figure 8] FIG. DETAILED DESCRIPTION OF THE INVENTION

[0008] [1. First embodiment] Unless otherwise defined, all technical and / or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention. The materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.

[0009] For example, the Automobile Recycling Act requires the recycling of Automobile Shredder Residue (ASR). ASR is the waste residue that remains after parts such as airbags, fluorocarbons, doors, and engines are removed from end-of-life vehicles (ELVs) and crushed to recover useful metals. Statistics show that ASR is composed of approximately 75% combustible materials such as thermosetting resins and urethane, and approximately 25% non-combustible materials such as metals and glass, by weight.

[0010] [1. Configuration] FIG. 1 is a diagram showing an example of the configuration of a laminate 10. As shown in FIG. Reference numeral 10 denotes a laminate. In the first embodiment, the laminate 10 includes a core material 1. The core material 1 is ASR, which is a waste residue with unstable physical properties.

[0011] Surface layer materials 2 and 3 are laminated on both sides of the core material 1. The surface layer materials 2 and 3 are glass fiber reinforced plastics (GFRP). However, the surface layer materials 2 and 3 are not limited to GFRP. Any fiber reinforced plastics (FRP) such as carbon fiber reinforced plastics (CFRP) may be used. Note that FRP may be an FRP containing a thermosetting resin or a thermoplastic resin. The surface layer materials 2 and 3 may be metals such as iron plates or non-ferrous metals such as aluminum plates. The thickness of the surface layer materials 2 and 3 is not limited to the same thickness. The surface layer materials 2 and 3 may have different thicknesses. The thickness of the surface layer materials may be changed depending on the degree of ASR deterioration.

[0012] The surface layer materials 2 and 3 may be recycled materials obtained by monomerizing materials generated by separating waste materials, or may be recycled iron (electromagnetic steel sheet) or recycled aluminum.

[0013] [2. Manufacturing process] FIG. 2 is a flowchart showing the manufacturing process of the laminate 10. An end-of-life vehicle (ELV) is prepared, and major parts such as airbags, fluorocarbons, doors, and engines are removed from the ELV (disassembly process S1).

[0014] Next, the ELVs are crushed (crushing step S2), and useful metals are recovered from the crushed material (metal recovery step S3). After the useful metals are recovered, the remaining waste residue (ASR) is, for example, approximately 75% combustible materials such as thermoplastic resins and urethanes, and approximately 25% non-combustible materials such as metals and glass, by weight. After the crushing step S2, the particle size of the ASR is smaller than the thickness of the laminate 10. If the ASR has a large particle size that straddles the surface layer materials 2 and 3, poor adhesion will occur. Desirably, the particle size of the ASR is smaller than the thickness between the surface layer materials 2 and 3.

[0015] Next, the core material 1 of the laminate 10 is preformed into a desired shape by hot press molding the ASR (core material molding step S4). In this step S4, the thermoplastic resin contained in the ASR is melted by heat, and the shape of the core material 1 is adjusted.

[0016] Next, the process moves to the casting step S5. FIG. 3 is a diagram showing a molding process in which the core material 1 and the surface layer materials 2 and 3 are molded simultaneously. In the casting process S5, as shown in process A of Fig. 3, a core material 1 made of ASR derived from ELV molded in the core material molding process S4 and flat surface layer materials 2 and 3 are prepared. Then, as shown in process B of Fig. 3, the core material 1 and the surface layer materials 2 and 3 are set as they are in a press mold 20. The press mold 20 includes a fixed mold 21 and a movable mold 22.

[0017] Next, the core material 1 and the surface layer materials 2 and 3 are hot-press molded between the fixed mold 21 and the movable mold 22 (hot-press step S6). During the hot-press molding, the thermoplastic resin contained in the ASR melts with heat, and the core material 1 and the surface layer materials 2 and 3 are bonded together by the resin, forming the sandwich-structured laminate 10. This is because the core material 1 of the ASR contains approximately 75% by weight of combustible materials such as thermosetting resin and urethane, and contains approximately 30% or more of thermosetting resin. Then, the movable mold 22 is opened, and the laminate 30 including the core material 1 and the surface layer materials 2 and 3 is removed from the press mold 20 as shown in step C of FIG.

[0018] 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. This makes it possible to manufacture automobiles using the composite laminate 10 without being subject to restrictions on materials or on separation during dismantling.

[0019] In the first embodiment, in the core material forming step S4, ASR can be used without blending, without performing pre-processing such as dismantling, sorting, or cutting. Furthermore, in the heat pressing step S6, the laminate 10 is formed without a binder or adhesive, so that strength and quality are maintained.

[0020] The heat-pressing step S6 is not limited to being performed without a binder or adhesive. For example, in the core material molding step S4, ASR may be mixed in advance with polypropylene (PP) resin (binder), which is a pellet-shaped thermoplastic resin, and the mixture may be heat-press molded to form the core material 1, and the heat-pressing step S6 may be performed using this core material 1 (thermoplastic molding). The thermoplastic resin mixed with ASR is not limited to polypropylene resin. Also, in the core material molding step S4, ASR may be impregnated in advance with epoxy resin (binder), which is a liquid thermosetting resin, and the mixture may be heat-press molded to form the core material 1, and the heat-pressing step S6 may be performed using this core material 1 (thermosetting molding). The liquid thermosetting resin impregnated into the ASR is not limited to epoxy resin.

[0021] Adding a binder to ASR can prevent poor adhesion between ASR and surface materials 2 and 3 and a decrease in the efficiency of shear load transmission to the surface materials.

[0022] FIG. 4 shows a process for separately molding the core material 1 and the surface layer materials 2 and 3. As shown in FIG. In the separate molding process, unlike the simultaneous molding process of Fig. 3, before the core material 1 and surface layer materials 2, 3 are set in the press mold 20, the surface layer materials 2, 3 are previously formed in a separate process into a convex shape at the bottom center, as shown in process A of Fig. 4. In this state, the core material 1 and surface layer materials 2, 3 are set in the press mold 20, and hot press molding is performed, as shown in process B of Fig. 4. Then, the movable mold 22 is opened, and the laminate 30 including the core material 1 and surface layer materials 2, 3 is removed from the press mold 20, as shown in process C of Fig. 4.

[0023] According to this, even if the surface layer materials 2, 3 are as hard as iron plates, for example, the surface layer materials 2, 3 can be molded with high precision, and the laminate 10 can be molded with high precision. It goes without saying that in the separate molding process, the surface layer materials 2, 3 can be molded with high precision even if they are fiber-reinforced plastics, including glass fiber-reinforced plastics and carbon fiber-reinforced plastics, or non-ferrous metals, such as aluminum.

[0024] When the surface layer materials 2 and 3 are metal, there is a large difference in the modulus of elasticity and linear expansion between the surface layer materials 2 and 3 and the resin-based core material 1, so the bonding surfaces of the surface layer materials 2 and 3 require bonding strength that can withstand shear forces, especially in the in-plane direction. In this case, surface treatment of the bonding surfaces (see, for example, Japanese Patent No. 6441295) or the use of adhesives or the like is effective.

[0025] Furthermore, since the core material 1 of the sandwich structure must maintain a distance between the surface layer materials 2 and 3 in Figure 1, a material with high rigidity in compression perpendicular to the surface is desirable, and ASR is a suitable material for this purpose. The particle size of the ASR is smaller than the thickness of the laminate 10. If the particle size of the ASR is larger than the thickness of the laminate 10 even after the ELV is crushed in the crushing step S2, it is desirable to crush the ASR to an appropriate size. This is because if the particle size of the ASR becomes large and straddles the surface layer materials 2 and 3, poor adhesion will occur due to the large particles. Desirably, the particle size of the ASR is smaller than the thickness between the surface layer materials 2 and 3.

[0026] In the first embodiment, ASR, which has low economic value, is used as the core material 1 without pre-processing such as dismantling and sorting or removal of foreign matter, resulting in an inexpensive composite structure for the laminate 10. The laminate 10 can be easily formed by simply composite surface layer materials 2 and 3 on both sides of the core material 1 to form a sandwich structure. ASR has a large variation in physical properties, while surface layer materials 2 and 3 have a small variation in physical properties. Furthermore, surface layer materials 2 and 3 are relatively highly elastic materials compared to ASR. As a result, laminate 10, which is a composite made by bonding scrap material (ASR), which has no value on its own, with surface layer materials 2 and 3, can reduce the variation in physical properties of the entire component compared to when ASR alone is used as the material. In particular, it is possible to reduce the variation in physical properties of laminate 10 when bending the plate. In other words, by combining ASR with surface layer materials 2 and 3, it is possible to transform ASR into a valuable material with identifiable physical properties, which can ultimately contribute to a significant reduction in waste generation.

[0027] In the first embodiment, the identification and separation of material types is no longer necessary for resource recycling, and monomerization and repolymerization are no longer necessary, which saves energy and enables lower resource recycling costs. Thermosetting resins and fibers that are difficult to monomerize can be crushed and reused, leading to sustainable materialization.

[0028] In the first embodiment, flat surface layers 2 and 3 are attached to both sides of a core material 1 made of ASR derived from ELV. In this way, the surface layers 2 and 3 bear tensile and compressive forces in the in-plane direction, respectively, while the core material 1, which has a relatively low elasticity, bears mainly compressive forces in the direction perpendicular to the plane. On the other hand, crushed ASR has a lower tensile strength than a single material due to inclusions that are different materials, but the inclusions have the property of not affecting the strength when compressed. This allows ASR to function as a material even when used as the core material 1. Therefore, some ASR may not melt, allowing for a higher ASR blend ratio and eliminating the need to remove magnetic metal content. Furthermore, the particle size of the ASR should be less than the plate thickness. In prototype testing, a particle size of 3.0 mm was sufficient for molding the laminate 10, which was 3.0 mm thick.

[0029] [3. Test Results] Fig. 5 is a graph showing the virgin ratio on the horizontal axis and the flexural modulus (MPa) on the vertical axis when the amount of binder added is changed, and Fig. 6 is a graph showing the virgin ratio on the horizontal axis and the flexural strength (MPa) on the vertical axis. The laminate 10 of Example 1 is a laminate molded by thermosetting molding using an epoxy resin as a binder in the heat press step S6 of Fig. 2. The laminate 10 of Example 2 is a laminate molded by thermoplastic molding using a polypropylene resin as a binder in the heat press step S6 of Fig. 2. The flexural modulus and flexural strength of the laminate 10 were measured by the methods specified in JIS K7171.

[0030] It can be seen that as the virgin ratio increases, the flexural modulus and flexural strength of both the laminate 10 of Example 1 and the laminate 10 of Example 2 increase. When the virgin ratio is 1, both the flexural modulus and flexural strength show their maximum values. The test results showed that even when the virgin ratio was 0, i.e., when the laminate 10 was formed using ASR as is without adding a binder, the flexural modulus was about 500 MPa and the flexural strength was about 10 MPa, and the flexural modulus and flexural strength of the laminate 10 were sufficiently usable. It is desirable to change the amount of binder added to the ASR depending on the application and performance required of the laminate 10.

[0031] FIG. 7 shows the flexural modulus of elasticity of Examples 3 and 4, and FIG. 8 shows the flexural strength of Examples 3 and 4. In each figure, the laminate 10 of Example 3 is a laminate molded by thermoplastic molding in the hot press step S6 of Fig. 2, and the laminate 10 of Example 4 is a laminate molded by thermosetting molding. The flexural modulus and flexural strength of the laminate 10 were measured by the method described in JIS K7171.

[0032] The laminates 10 of Examples 3 and 4 both have a flexural modulus of 12,000 MPa or more (see FIG. 7) and a flexural strength of 110 MPa or more (see FIG. 8), which are sufficient for use as laminates 10 in terms of flexural modulus and flexural strength.

[0033] 4. Other Embodiments The above-described embodiment merely shows one aspect of the present invention, and any modifications and applications are possible within the scope of the present invention. The above-described embodiment describes the use of ASR from waste residue from used automobiles, but the present invention is not limited to this. The waste residue can also be, for example, waste residue from used home appliances, slag from steel production, aircraft prepreg scraps, or mixtures of these.

[0034] When slag is used for the core material 1, the slag generally has a large particle size and thus becomes the starting point for fracture. Therefore, when using slag for the core material 1, it is desirable to control the particle size so that it is equal to or smaller than the formed plate thickness of the laminate 10, and then perform additional crushing. Furthermore, when the content of thermoplastic resin such as polypropylene resin is insufficient in waste residue from used home appliances, slag from steel production, aircraft prepreg offcuts, etc., it is desirable to add an appropriate amount of binder as needed.

[0035] The above-described embodiment utilizes waste as the core material 1 of the composite material, and does not assume that the waste itself will be made into a product. Therefore, the core material 1 itself may have rougher properties, and the composite material as a whole will have higher physical properties and a laminate 10 with less variation.

[0036] Aircraft prepreg scraps contain resin and fiber, and are anisotropic in stiffness and strength, leading to large variations in physical properties. Therefore, when using aircraft prepreg scraps for the core material 1, it is desirable to crush and knead the scraps to reduce the anisotropy. This allows for the provision of an isotropic, homogeneous core material 1 with minimal variation. In addition, scraps of aircraft FRP prepreg can be used as the core material 1. If the FRP prepreg of the aircraft is CFRP, a thermosetting resin, it can be used as it is for the core material 1, as in the above embodiment.

[0037] Generally, ASR is composed of approximately 70% polymeric materials such as plastics such as polypropylene (PP), polyethylene (PE), and polyvinyl chloride (PVC), as well as fibers, rubber, and elastomers such as urethane, with approximately 30% being metals, wood, dust, etc. In other words, if the polymeric materials contained in the ASR to be used as the core material 1 are sufficient, the ASR can be used as the core material 1 as is.

[0038] When using ASR for the core material 1, controlling the particle size is important. If the particle size of the ASR cannot be reduced in the ELV crushing step S2, for example, a crushing step of crushing the ASR before molding the ASR may be included. By reducing the size of the ASR used as the raw material for the core material 1, the amount of ASR with a particle size that crosses over between surface layer materials is reduced, and poor adhesion caused by the ASR particle size crossing over between surface layer materials can be suppressed.

[0039] 5. Configurations supported by the above embodiments The above embodiment supports the following configurations.

[0040] (Configuration 1) A laminate formed by laminating a surface material onto a core material having waste residue. This allows waste residues that would otherwise be disposed of by incineration or landfill to be used as new materials, circulating resources. Furthermore, the waste residues can be used to form laminates without pre-processing such as dismantling and sorting or removing foreign matter, which ultimately contributes to a significant reduction in waste generation.

[0041] (Configuration 2) The laminate according to Configuration 1, wherein the particle size of the waste residue is smaller than the thickness of the laminate. This allows the formation of a laminate that can suppress poor adhesion and reduced efficiency of shear load transmission to the surface material caused by the particle size of the waste residue crossing over the surface material, thereby contributing to a significant reduction in waste generation.

[0042] (Configuration 3) The laminate according to configuration 1 or 2, wherein the surface layer material is any one of fiber reinforced plastics including glass fiber reinforced plastics and carbon fiber reinforced plastics, metals, non-ferrous metals, and the like. This allows for the formation of a laminate with improved bending properties by combining a surface layer material with a core material, which can contribute to a significant reduction in waste generation.

[0043] (Configuration 4) The laminate according to any one of Configurations 1 to 3, wherein the waste residue is waste residue from used automobiles. This allows waste residues that would otherwise be disposed of by incineration or landfill to be used as new materials, enabling resources to be recycled and used, which in turn contributes to a significant reduction in waste generation.

[0044] (Configuration 5) The laminate according to any one of Configurations 1 to 4, wherein the waste residue is waste residue from used home appliances. This allows waste residues that would otherwise be disposed of by incineration or landfill to be used as new materials, enabling resources to be recycled and used, which in turn contributes to a significant reduction in waste generation.

[0045] (Configuration 6) The laminate according to any one of Configurations 1 to 5, wherein the waste residue is slag from steel production. This allows waste residues that would otherwise be disposed of by incineration or landfill to be used as new materials, enabling resources to be recycled and used, which in turn contributes to a significant reduction in waste generation.

[0046] (Configuration 7) The laminate according to any one of Configurations 1 to 6, wherein the waste residue is aircraft prepreg offcuts. This allows waste residues that would otherwise be disposed of by incineration or landfill to be used as new materials, enabling resources to be recycled and used, which in turn contributes to a significant reduction in waste generation.

[0047] (Configuration 8) A method for producing a laminate, comprising setting a core material having waste residue and a surface layer material in a press mold and pressing and molding the core material and surface layer material in the press mold. This allows waste residues that would otherwise be disposed of by incineration or landfill to be used as new materials, circulating resources. Furthermore, the waste residues can be used to form laminates without pre-processing such as dismantling, sorting, or cutting, which ultimately contributes to a significant reduction in waste generation.

[0048] (Configuration 9) The method for producing a laminate according to Configuration 8, wherein the waste residue contains a thermoplastic resin, and the core material and the surface layer material are heated and pressed and molded using the press mold. This allows the surface materials to be bonded together using the thermoplastic resin contained in the waste residue to form a laminate, which in turn contributes to a significant reduction in the amount of waste generated.

[0049] (Configuration 10) The method for producing a laminate according to Configuration 8 or 9, wherein the surface layer material is any one of fiber reinforced plastics including glass fiber reinforced plastics and carbon fiber reinforced plastics, metals, non-ferrous metals, and the like. This allows for the formation of a laminate with improved bending properties by combining a surface layer material with a core material, which can contribute to a significant reduction in waste generation.

[0050] (Configuration 11) The method for producing a laminate according to any one of Configurations 8 to 10, wherein the waste residue is waste residue from used automobiles. This allows waste residues that would otherwise be disposed of by incineration or landfill to be used as new materials, enabling resources to be recycled and used, which in turn contributes to a significant reduction in waste generation. [Explanation of symbols]

[0051] 1 Core material 2, 3 Surface material 10 Laminate 20 Press mold 21 Fixed type 22 Movable type

Claims

1. It is formed by laminating a surface layer material onto a core material having waste residues. Laminate.

2. The particle size of the waste residue is smaller than the thickness of the laminate; The laminate according to claim 1 .

3. The surface layer material is any one of fiber reinforced plastics including glass fiber reinforced plastics and carbon fiber reinforced plastics, metals, non-ferrous metals, etc. The laminate according to claim 1 .

4. The waste residue is waste residue from used automobiles. The laminate according to claim 1 .

5. The waste residue is waste residue from used home appliances. The laminate according to claim 1 .

6. The waste residue is slag from steel production. The laminate according to claim 1 .

7. The waste residue is aircraft prepreg scraps. The laminate according to claim 1 .

8. The core material having the waste residue and the surface layer material are set in a press mold, and pressed and molded using the press mold. A method for manufacturing a laminate.

9. The waste residue contains a thermoplastic resin, The core material and the surface layer material are heated and pressed into a mold using the press die. A method for producing the laminate according to claim 8.

10. The surface layer material is any one of fiber reinforced plastics including glass fiber reinforced plastics and carbon fiber reinforced plastics, metals, non-ferrous metals, etc. A method for producing the laminate according to claim 8.

11. The waste residue is waste residue from used automobiles. A method for producing the laminate according to claim 8.

Images