Molded body

Abstract

The present application may provide a plate-shaped body, a manufacturing method thereof, and a use of the plate-shaped body. The present application may provide a plate-shaped body having an uneven shape with recessed and embossed parts and having pores formed therein, a manufacturing method thereof, and a use of the plate-shaped body. The present application may provide such a plate-shaped body having uniform mechanical properties.

Description

[Technical field]

[0001] The present application relates to a molded body, a method for producing the same, and uses of the molded body. [Background technology]

[0002] Materials containing pores can be used in a variety of applications.

[0003] For example, the material as described above may be used as a material for treating heat generated from a product. As described above, the importance of technology for treating heat generated from a product is increasing.

[0004] It is necessary to process heat in products that are composed of a group of heat-generating elements (heat-generating elements). For example, a battery module or a battery pack includes a number of battery cells or a number of battery modules that are relatively adjacent to each other. Therefore, heat generated from any battery cell or battery module may affect other adjacent elements, and in some cases, cause problems such as chain fires or chain explosions.

[0005] Therefore, in such products, it is necessary to prevent heat, explosion, fire, or the like generated by any one of the elements from affecting other adjacent elements. Summary of the Invention [Problem to be solved by the invention]

[0006] The present application aims to provide a plate-shaped body, a manufacturing method thereof, and uses of the plate-shaped body. The main object of the present application is to provide a plate-shaped body having an uneven shape with recessed and embossed parts and having pores formed therein, a manufacturing method thereof, and uses of the plate-shaped body. Another object of the present application is to provide such a plate-shaped body in a state in which it has uniform mechanical properties. [Means for solving the problem]

[0007] The present application relates to a molded body. The molded body may be manufactured to have a desired shape using a plastic such as a thermoplastic resin as a raw material. In one example, the molded body may be a plate-shaped molded body.

[0008] The molded body may contain at least a resin component and a filler component.

[0009] The molded body includes pores formed therein. The pores may be formed at least at the interface between the resin component and the filler component in the molded body. The molded body of the present application is manufactured through a molding step in which pressure is applied to a raw roll containing a resin component and a filler component to form an uneven shape, as described below. At this time, pores can be formed in the molded body by adjusting the type of filler component contained in the raw roll and / or the conditions of the molding step, and the pores can be formed in the interface between the resin component and the filler component in particular. This method is different from the conventional method of forming pores through a foaming process or the like.

[0010] The porosity of the molded body may be adjusted to a suitable range depending on the purpose. For example, the lower limit of the porosity of the molded body may be about 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45% or 50%, and the upper limit may be about 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20% or 15%. The porosity may be equal to or greater than any of the lower limits, or less than or equal to any of the upper limits, or may be equal to or greater than any of the lower limits but less than or equal to any of the upper limits. The porosity may be determined by the method of the Examples section described below.

[0011] There is no particular limit to the type of resin component contained in the molded body, and for example, a necessary type may be appropriately selected from resin components known to be moldable and used. For example, the resin component may include a thermoplastic polymer. Types of thermoplastic polymers applicable in this process include various crystalline or non-crystalline polymers, examples of which include polyolefin-based polymers such as PP (polypropylene) and PE (polyethylene), polyalkylene oxide-based polymers such as mPPO (modified PPO (polyethylene oxide)), polyamide-based polymers such as PA (polyamide), acetal-based polymers such as POM (polyoxymethylene), polyester-based polymers such as PC (polycarbonate), PBT (polybutylene terephthalate) or PET (polyethylene terephthalate), acrylic polymers such as PMMA (poly(methylmethacrylate)), and polystyrene-based polymers such as PS (polystyrene) and ABS (Acrylonitrile butadiene styrene), but are not limited thereto.

[0012] The resin component may have a specific glass transition temperature (Tg) depending on the type. Although not particularly limited, the lower limit of the glass transition temperature of the resin component applied in the present application may be about 50°C, 55°C, 60°C, 65°C, 70°C, 75°C, 80°C, 85°C, 90°C, 95°C, 100°C, 105°C, 110°C, 115°C, 120°C, 125°C, 130°C, 135°C, 140°C, or 145°C, and the upper limit may be about 500°C, 450°C, 400°C, 4,350°C, 300°C, 250°C, 200°C, or 150°C. The glass transition temperature of the resin component may be equal to or greater than any of the lower limits mentioned above, or may be less than or equal to any of the upper limits mentioned above, or may be equal to or greater than any of the lower limits but less than or equal to any of the upper limits mentioned above.

[0013] The ratio of the resin component in the molded body is not particularly limited, and may be adjusted to an appropriate ratio depending on the purpose. For example, the lower limit of the ratio of the resin component in the molded body may be about 50% by weight, 55% by weight, 60% by weight, 65% by weight, 70% by weight, 75% by weight, 80% by weight, 85% by weight, 90% by weight, or 95% by weight, and the upper limit may be about 100% by weight, 95% by weight, 90% by weight, 85% by weight, 80% by weight, 75% by weight, 70% by weight, 65% by weight, 60% by weight, or 55% by weight. The ratio of the resin component may be equal to or greater than any of the lower limits described above, or may be less than or equal to any of the upper limits described above, or may be equal to or greater than any of the lower limits described above but less than or equal to any of the upper limits described above.

[0014] The molded article may contain a filler component as an additional component. Such a filler component may be contained, for example, as a reinforcing material.

[0015] Examples of applicable filler components are not particularly limited, and for example, organic fillers, inorganic fillers, or organic / inorganic fillers such as glass filler, carbon filler, and / or silica filler may be applied.

[0016] The shape of the filler is not particularly limited, and the filler may be, for example, a particulate filler (a particulate filler having a spherical, angular, irregular or other shape), a plate-like filler, or a fibrous filler.

[0017] The lower limit of the size of the filler may be, for example, about 1 μm, 5 μm, or 10 μm, and the upper limit may be about 100 μm, 95 μm, 90 μm, 85 μm, 80 μm, 75 μm, 70 μm, 65 μm, 60 μm, 55 μm, 50 μm, 45 μm, 40 μm, 35 μm, 30 μm, 25 μm, 20 μm, or 15 μm. The size of the filler may be equal to or greater than any of the lower limits mentioned above, or less than or equal to any of the upper limits mentioned above, or may be equal to or greater than any of the lower limits mentioned above but less than or equal to any of the upper limits mentioned above.

[0018] The size of the filler may be the average diameter (D50 particle size or median diameter) of the filler if the filler is particulate, may be the thickness of the filler or the long or short side in a direction perpendicular to the thickness direction of the filler if the filler is plate-shaped, or may be the diameter of the cross section of the filler if the filler is fibrous.

[0019] In one example, the filler may be a fibrous filler. When a fibrous filler is used, pores can be formed more efficiently in a molding step described below depending on the aspect ratio of the filler. In addition, the fibrous filler exhibits orientation during the manufacturing process of a molded body through the aspect ratio, and thus can effectively form pores of an appropriate shape according to the applied pressure.

[0020] In the case of a fibrous filler, the aspect ratio of the filler may have a lower limit of about 3, 5, 7, 9, 10, 12, 14, 16, 18, 20, 22, or 24, and an upper limit of about 60, 55, 50, 45, 40, 35, 30, or 25. The aspect ratio may be equal to or greater than any of the lower limits mentioned above, or less than or equal to any of the upper limits mentioned above, or may be equal to or greater than any of the lower limits but less than or equal to any of the upper limits mentioned above. The aspect ratio of a fibrous filler is the length of the filler divided by the diameter of the cross section of the filler.

[0021] In the case of a fibrous filler, the lower limit of the cross-sectional diameter of the filler may be, for example, about 1 μm, 5 μm or 10 μm, and the upper limit may be about 100 μm, 95 μm, 90 μm, 85 μm, 80 μm, 75 μm, 70 μm, 65 μm, 60 μm, 55 μm, 50 μm, 45 μm, 40 μm, 35 μm, 30 μm, 25 μm, 20 μm or 15 μm. The cross-sectional diameter of the fibrous filler may be equal to or greater than any of the lower limits mentioned above, or may be less than or equal to any of the upper limits mentioned above, or may be equal to or greater than any of the lower limits mentioned above but less than or equal to any of the upper limits mentioned above.

[0022] The lower limit of the weight ratio of the filler component to 100 parts by weight of the resin component in the molded body may be about 1 part by weight, 5 parts by weight, 10 parts by weight, 15 parts by weight, 20 parts by weight, or 25 parts by weight, and the upper limit may be about 100 parts by weight, 95 parts by weight, 90 parts by weight, 85 parts by weight, 80 parts by weight, 75 parts by weight, 70 parts by weight, 65 parts by weight, 60 parts by weight, 55 parts by weight, 50 parts by weight, 45 parts by weight, 40 parts by weight, 35 parts by weight, 30 parts by weight, or 25 parts by weight. The weight ratio of the filler component may be equal to or greater than any of the lower limits described above, or less than or equal to any of the upper limits described above, or may be equal to or greater than any of the lower limits described above but less than or equal to any of the upper limits described above. In addition, the weight ratio of the filler component may be changed within or outside the above range in consideration of the desired physical properties.

[0023] The molded article of the present application containing the above-mentioned components may be a plate-like molded article, or may be a molded article having an uneven shape formed by including a relief portion and an intaglio portion.

[0024] The specific form of the uneven shape, for example, the depth or height, area, shape and / or number of the recessed or embossed shape, is not particularly limited, and an appropriate uneven shape may be applied in consideration of the application of the molded body.

[0025] A typical example of a conventional molding method for manufacturing a molded body having an uneven shape and containing a filler component is injection molding. In such a conventional method, the manufacturing conditions of the molded body are controlled so that pores are not generated inside the molded body as much as possible during the molding process. This is because if pores are generated inside the molded body during the molding process, the mechanical properties of the molded body are reduced, and if the pores are formed unevenly, the mechanical properties of the molded body are also uneven from part to part.

[0026] However, in the present application, conditions are adjusted to actively form pores in the molding step described below. Also, by adjusting the molding conditions during this process, the molded product can exhibit uniform and stable mechanical properties overall.

[0027] For example, when the plate-like molded body of the present application has an edge formed in a first direction, the standard deviation of the tensile breaking strength of each of the upper, middle and lower sections obtained by dividing the molded body into three equal parts in a direction perpendicular to the edge in the first direction may be controlled to a certain level or less.

[0028] The first direction is a direction parallel to any side of the plate-like molded body observed when the molded body is observed along the thickness direction of the molded body. For example, referring to FIG. 1, when the molded body is rectangular as shown in FIG. 1, the direction of the horizontal side 100 or the vertical side 200 of the rectangle may be the first direction. In FIG. 1, the vertical side 200 is set as the first direction, and the molded body is divided into three equal parts in a direction perpendicular to the side in the first direction to define an upper part U, a middle part M, and a lower part L, which are shown by dotted lines. In some cases, when the side of the molded body is not straight, the direction of a virtual straight line connecting both ends of the side (2001, 2002 in the case of FIG. 1) can be the first direction.

[0029] In the above, dividing the molded body into three equal parts along the first direction means dividing the molded body such that the upper portion U, the middle portion M and the lower portion L have equal areas.

[0030] On the other hand, the standard deviation is S U、 S M、 S L Let A be the arithmetic mean of these two, then {[(S U -A) 2 +(S M -A) 2 +(S L -A) 2 ] / 3} 0.5 This is the value calculated as follows:

[0031] In suitable examples, the upper limit of the standard deviation of the tensile break strength of each of the upper, middle and lower sections may be on the order of 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15 or 10, and the lower limit may be on the order of 0, 2, 4, 6, 8, 10, 12 or 14. The standard deviation may be less than or equal to any of the upper limits mentioned above, or may be greater than or equal to or greater than any of the lower limits mentioned above, but less than or equal to any of the upper limits mentioned above.

[0032] The method for measuring the tensile breaking strength is summarized in the Examples section of this specification. The tensile breaking strength may be measured at room temperature (about 25° C.) using a Universal Testing Machine (UTM) for a test piece cut to have a horizontal length of about 45 mm and a vertical length of about 12.5 mm.

[0033] The width of the specimen may be parallel to the machine direction (MD) or transverse direction (TD) of the raw material. In the above, MD and TD refer to the MD and TD directions of the raw material, which are described below, and refer to the MD and TD directions in the extrusion process for manufacturing the raw material.

[0034] Both lateral ends of the specimen were fixed to the equipment at about 8 mm each, and the specimen was pulled in the lateral direction at a speed of about 50 mm / sec, and the strength at which the specimen broke was measured, and this strength was taken as the tensile breaking strength.

[0035] The molded body of the present application may be manufactured to have physical properties at a certain ratio or more with respect to the physical properties of the original roll. In the above, the original roll means a film or sheet-like material applied to manufacture the molded body having the uneven shape. That is, the process of manufacturing the molded body of the present application may include a molding step in which a material containing the resin component and the filler component is applied to an extrusion process to manufacture a plate material (sheet or film) and an uneven portion is formed on the plate material. If pores are generated at the interface between the resin component and the filler component inside the plate material due to the pressure applied in the molding process, the physical properties of the final molded body may differ from those of conventional plate materials, and in this case, it is better to keep the variation in the physical properties of the original roll and the molded body as small as possible. When the method of the present application is applied, the change in the physical properties of the original roll can be controlled to an appropriate level.

[0036] For example, the molded product may have a rate of change in tensile breaking strength relative to the original fabric that is equal to or greater than a predetermined range. In the above, the rate of change in tensile breaking strength relative to the original fabric may be determined by dividing the tensile breaking strength of the original fabric by S R The tensile breaking strength of the molded body is S S When this is set, it becomes 100×S S / S R The unit of the value is %. In addition, the tensile breaking strength S of the molded body is S may be the tensile breaking strength of the engraved portion or the relief portion of the molded body, or may be the arithmetic average of the tensile breaking strengths of the engraved portion and the relief portion.

[0037] In the molded article, the lower limit of the rate of change in tensile break strength is 20%, 22%, 24%, 26%, 28%, 30%, 32%, 34%, 36%, 38%, 40%, 42%, 44%, 46%, 48%, 50%, 52%, 54%, 56%, 58%, 60%, 62%, 64%, 66%, 68%, 70%, 72%, 74%, 76%, 78%, 80%, 82%, 84%, 86%, 88%, 90%, 92%, 94%, 96% or 98%. The upper limit may be about 100%, 98%, 96%, 94%, 92%, 90%, 88%, 86%, 84%, 82%, 80%, 78%, 76%, 74%, 72%, 70%, 98%, 66%, 64%, 62%, 60%, 58%, 56%, 54%, 52%, 50%, 48%, 46%, 44%, 42%, 40%, 38%, 36%, 34%, 32%, 30%, 28%, 26%, 24%, or 22%. The rate of change in tensile breaking strength may be greater than or equal to any of the lower limits described above, or greater than or equal to any of the lower limits described above but less than or equal to any of the upper limits described above.

[0038] The thickness of the molded body may be adjusted to an appropriate level depending on the purpose, and is not limited to a large extent. For example, the lower limit of the thickness of the molded body may be about 100 μm, 500 μm, 1,000 μm, 1,500 μm, or 2,000 μm, and the upper limit may be about 100 mm, 95 mm, 90 mm, 85 mm, 80 mm, 75 mm, 70 mm, 65 mm, 60 mm, 55 mm, 50 mm, 45 mm, 40 mm, 35 mm, 30 mm, 25 mm, 20 mm, 15 mm, 10 mm, 8 mm, 6 mm, 4 mm, or 2 mm. The thickness may be greater than or equal to any of the lower limits described above, or less than or equal to any of the upper limits described above, or greater than or equal to any of the lower limits described above but less than or equal to any of the upper limits described above.

[0039] The engraved or relief portion of the molded body may have a certain level of tensile breaking strength.

[0040] For example, the lower limit of the tensile breaking strength of the engraved or embossed portion of the molded body may be about 50 MPa, 52 MPa, 54 MPa, 56 MPa, 58 MPa, 60 MPa, 62 MPa, 64 MPa, 66 MPa, 68 MPa, 70 MPa, 72 MPa, 74 MPa, 76 MPa, 78 MPa, 80 MPa, 82 MPa or 84 MPa, and the upper limit thereof may be about 1000 MPa, 950 MPa, 900 MPa, 850 MPa, 800 MPa, 750 MPa, 700 MPa, 650 MPa, 600 MPa, 550 MPa, 500 MPa, 450 MPa, 400 MPa, 350 MPa, 300 MPa, 250 MPa, 200 MPa, 150 MPa, 100 MPa or 90 MPa. The tensile break strength may be greater than or equal to any one of the lower limits mentioned above, or greater than or equal to any one of the lower limits mentioned above but less than or equal to any one of the upper limits mentioned above.

[0041] The molded article may be used for various purposes, an example of which is an insulator. An insulator is a material that can block the transmission of heat or flame generated from a point or part to another point or part. The molded article includes pores formed therein and has stable and uniform mechanical properties, so that it may be stably used as an insulator.

[0042] The heat insulating material may include at least the plate-shaped molded body described above. The heat insulating material may be composed of only the plate-shaped molded body, or may include the plate-shaped molded body and other necessary materials at the same time.

[0043] The contents of the plate-shaped molding contained in the insulation material, for example, the contents of the resin component and the filler component, the absolute value of the difference in tensile breaking strength between the engraved portion and the relief portion, the rate of change in specific tensile breaking strength with respect to the original roll, the standard deviation of the tensile breaking strength of each of the upper, middle and lower portions obtained by dividing the roll into three equal parts, and the thickness of the plate-shaped molding may be similarly applied to the contents described above.

[0044] The present application further relates to a method for producing said shaped bodies.

[0045] The manufacturing method of the present application may include a step of manufacturing a molded product having a concave-convex shape including the engraved portion and the relief portion by molding a sheet or film including the resin component and the filler component.

[0046] The pressure applied to form the uneven shape may generate pores inside the molded body (particularly at the interface between the resin component and the filler component).

[0047] The sheet or film containing the resin component and the filler component may be the raw material described above. Such raw material may be manufactured by subjecting the material containing the resin component and the filler component to a known molding process, such as an extrusion process. The specific types and blending ratios of the resin component and the filler component used in manufacturing the raw material are the same as those described for the molded product.

[0048] Such a raw material may be in the form of a sheet or film as described above.

[0049] In this case, the thickness of the raw film may be adjusted to an appropriate level depending on the purpose, and is not limited to a large extent. For example, the lower limit of the thickness of the raw film may be about 100 μm, 500 μm, 1,000 μm, 1,500 μm, or 2,000 μm, and the upper limit may be about 100 mm, 95 mm, 90 mm, 85 mm, 80 mm, 75 mm, 70 mm, 65 mm, 60 mm, 55 mm, 50 mm, 45 mm, 40 mm, 35 mm, 30 mm, 25 mm, 20 mm, 15 mm, 10 mm, 8 mm, 6 mm, 4 mm, or 2 mm. The thickness may be greater than or equal to any of the lower limits described above, or less than or equal to any of the upper limits described above, or greater than or equal to any of the lower limits described above but less than or equal to any of the upper limits described above.

[0050] In the present application, a molding step is carried out using the raw material to form the concave and convex shapes.

[0051] In the molding step, a mold 3000 having a recess corresponding to a desired concave-convex shape is used as shown in Fig. 2. The recess shape of the mold can be determined according to the concave-convex shape.

[0052] In the molding step, the raw web 1000 may be placed on the mold 3000, and a suction force (applying a suction force in the L direction in FIG. 2) may be applied to the raw web from below the mold 3000.

[0053] In the forming step, in addition to applying the suction force as described above, pressure can be applied from above the raw roll (U direction in FIG. 2). The pressure from above may or may not be applied to the raw roll in the forming step, but it is appropriate to apply it from the viewpoint of maintaining uniform physical properties of the formed body.

[0054] When a force is applied, the method of applying the force from above the raw web 1000 is not particularly limited.

[0055] For example, as shown in Figures 3 and 4, the pressure from above may be applied using an additional mold 4000 (hereinafter, also referred to as a second mold). That is, a second mold 4000 having a relief shape corresponding to the intaglio of a mold having an intaglio corresponding to the above-mentioned concave-convex shape is prepared, and the second mold 4000 is moved toward the raw web 1000 to apply the pressure by pressing the raw web 1000, as shown in Figures 3 and 4.

[0056] In another example, the pressure may be applied from above by injecting gas from above the raw web.

[0057] Such an example is shown in Fig. 5. As shown in Fig. 5, after forming a sealed space by covering with a lid 5000 or the like, the pressure can be applied from above through a gas U such as air.

[0058] In the forming step, the temperature of the raw web, for example, the surface temperature of the raw web, may be adjusted. Specifically, the temperature of the raw web may be adjusted so that the absolute value of ΔT according to the following formula 1 is within a predetermined range.

[0059] [Formula 1] △T=100×(Ts-Tg) / Tg

[0060] In formula 1, Ts is the surface temperature of the raw material during the molding step, and Tg is the glass transition temperature of the resin component.

[0061] For example, the upper limit of the absolute value of ΔT may be about 50%, 48%, 46%, 44%, 42%, 40%, 38%, 36%, 34%, 32%, 30%, 28%, 26%, 24%, or 22%, and the lower limit may be about 0%, 5%, 10%, 15%, 20%, 25%, or 30%. In the above formula 1, ΔT may be equal to or greater than any of the lower limits described above, or may be less than or equal to any of the upper limits described above, or may be equal to or greater than any of the lower limits described above but less than or equal to any of the upper limits described above.

[0062] The surface temperature Ts of the raw sheet may be higher or lower than the glass transition temperature of the resin component, so long as the absolute value of ΔT in the formula 1 is within the range.

[0063] There is no particular limitation on the method for adjusting the surface temperature of the raw sheet, and for example, the surface temperature may be adjusted by using a known heater such as a ceramic heater or a coil heater.

[0064] In addition, when a force is applied from the upper side, the relationship between the suction force applied from the lower side of the web and the pressure applied from the upper side of the web during this process may also be adjusted.

[0065] For example, the suction from the lower portion and the application of pressure from the upper portion may be controlled so that the absolute value of ΔP according to the following formula 2 falls within a predetermined range.

[0066] [Formula 2] △P = 100 × (P U- P L ) / P L

[0067] In Equation 2, P U is the pressure applied to the raw roll by the pressure applied from above the raw roll in the forming stage, and P L is the pressure applied to the web by suction from underneath the web.

[0068] For example, the upper limit of the absolute value of ΔP in the formula 2 may be about 100%, 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15% or 5%, and the lower limit may be about 0%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55% or 60%. ΔP in the formula 2 may be equal to or greater than any of the lower limits described above, or may be less than or equal to any of the upper limits described above, or may be equal to or greater than any of the lower limits described above but less than or equal to any of the upper limits described above.

[0069] In Equation 2, the force P U means the instantaneous load applied to the web when only the suction force is applied, and P L means the instantaneous load applied to the blank when only the pressure is applied.

[0070] In the above formula 2, ΔP may be a positive number or a negative number, so long as its absolute value satisfies the above range.

[0071] In the above, the pressure applied to the raw web by suction from the bottom of the raw web (P in Equation 2) L ) The lower limit is 100gf / cm 2 , 150gf / cm 2 , 200gf / cm 2 , 250gf / cm 2 , 300gf / cm 2 , 350gf / cm 2 , 400gf / cm 2 , 450gf / cm 2 , 500gf / cm 2 , 550gf / cm 2 , 600gf / cm 2 or 650 gf / cm 2 The upper limit is about 2000 gf / cm 2 , 1900gf / cm 2 , 1800gf / cm2 , 1700gf / cm 2 , 1600gf / cm 2 , 1500gf / cm 2 , 1400gf / cm 2 , 1300gf / cm 2 , 1200gf / cm 2 , 1100gf / cm 2 , 1000gf / cm 2 , 950gf / cm 2 , 900gf / cm 2 , 850gf / cm 2 , 800gf / cm 2 , 750gf / cm 2 or 700 gf / cm 2 The force may be greater than or equal to any of the lower limits mentioned above, or less than or equal to any of the upper limits mentioned above, or greater than or equal to or greater than any of the lower limits but less than or equal to any of the upper limits mentioned above.

[0072] The molded article of the present application may be produced through the above steps.

[0073] That is, a molded body having the above-mentioned pores formed therein may be manufactured through the above-mentioned process, and when the above-mentioned fibrous filler is applied in this process, a molded body having the desired pores formed therein can be manufactured more appropriately.

[0074] The method of the present application may further include any necessary steps in the above steps. For example, the method may further include a step of fixing the formed shape through a cooling step or the like after the molding step. Effect of the Invention

[0075] The present application may provide a plate-shaped body, a manufacturing method thereof, and a use of the plate-shaped body. The present application may provide a plate-shaped body having an uneven shape with recessed and embossed parts and having pores formed therein, a manufacturing method thereof, and a use of the plate-shaped body. The present application may provide such a plate-shaped body having uniform mechanical properties. [Brief description of the drawings]

[0076] [Figure 1] FIG. 1 is a diagram for explaining a method for dividing a molded body into three equal parts. [Diagram 2] FIG. 2 is a diagram for explaining the method for producing the molded article of the present application. [Diagram 3] FIG. 3 is a diagram for explaining the method for producing the molded article of the present application. [Figure 4] FIG. 4 is a diagram for explaining the method for producing the molded article of the present application. [Diagram 5] FIG. 5 is a diagram for explaining the method for producing the molded article of the present application. [Figure 6] FIG. 6 is a photograph of the molded article produced in the example. [Figure 7] FIG. 7 is a SEM image of the molded body produced in the example. [Figure 8] FIG. 8 is a SEM image of the molded body produced in the example. [Figure 9] FIG. 9 is an SEM image of the molded body produced in the example. [Figure 10] FIG. 10 is an SEM image of the molded body produced in the example. [Figure 11] FIG. 11 is an SEM image of the molded body produced in the example. [Figure 12] FIG. 12 is an SEM image of the molded body produced in the example. [Figure 13] FIG. 13 is a photograph for explaining the locations where test pieces were taken for measuring the tensile breaking strength. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0077] The present application will be described in detail with reference to the following examples, but the scope of the present application is not limited to the following examples. EXAMPLES

[0078] Example 1. As shown in Fig. 6, a molded body was produced in which a concave-convex shape having a recessed shape 100 and a embossed shape 200 was formed. The molded body in Fig. 6 is a rectangular plate with a horizontal length of about 608 mm, a vertical length of about 308 mm, and a thickness of about 2 mm.

[0079] First, a raw roll was manufactured. The raw roll was manufactured to a thickness of about 2 mm by applying an extrusion process to a material in which mPPO (Modified PPO (Polyethylene oxide)) as a resin component and glass fiber as a filler component were blended in a weight ratio of 8:2 (mPPO:filler component). The mPPO as the resin component had a glass transition temperature of about 145°C, and the glass fiber had a cross-sectional diameter of about 12.5 μm and an aspect ratio of about 24.

[0080] The green body shown in Fig. 6 was manufactured using the green body in the following manner. As shown in Fig. 3, the green body 1000 was placed on a first mold 3000 on which recesses corresponding to the recesses and protrusions of the green body were formed. In addition, a second mold 4000 on which relief shapes corresponding to the recesses and protrusions were formed was placed on the green body 1000.

[0081] Next, a ceramic heater was used to maintain the surface temperature of the raw web at a level of about 195° C. The ceramic heater was placed inside a heating device, and the raw web was heated to a desired temperature through temperature control of a programmable logic controller (PLC) system while the ceramic heater was placed above the raw web. Whether the surface temperature of the raw web was controlled to a desired temperature was confirmed using a non-contact infrared thermometer.

[0082] Next, while maintaining the temperature, suction (L) was performed at the bottom of the first mold 3000 as shown in FIG. 3, and at the same time, the second mold 4000 was moved downward to apply pressure to the raw sheet in the form shown in FIG. 4.

[0083] In the above process, suction (L) was performed with the gauge of the equipment fully open. In this case, the vacuum flow rate was about 1 atm, and the instantaneous load applied to the raw material in this case was about 690.2gf / cm 2 The pressure applied by the second mold 4000 to the raw material is about 274.4 gf / cm 2 It is designed so that a level (applied load of approximately 500 kg) can be applied.

[0084] The state of the first mold 3000 and the second mold 4000 as shown in FIG. 4 was maintained for about 10 seconds, and the temperature of the molded body (raw fabric) 1000 was then reduced to about 40° C. to carry out a cooling process.

[0085] After the cooling step, the first and second molds 3000, 4000 were separated and the molded body was collected.

[0086] Example 2. Using the same raw material as in Example 1, a molded article having the same shape as in Example 1 was produced in the following manner.

[0087] As shown in FIG. 5, the raw web 1000 was placed on a first mold 3000 on which engravings corresponding to the engraving shapes of a desired molded product were formed, and covered with a lid 5000 to form a sealed space.

[0088] Next, a coil heater was used to maintain the surface temperature of the raw web at a level of about 175° C. The heater was placed inside a heating device, and the temperature was raised to a desired temperature through temperature control of a PLC (Programmable Logic Controller) system while the heater was placed above the raw web. Whether the surface temperature of the raw web was controlled to a desired temperature was confirmed using a non-contact infrared thermometer.

[0089] Next, suction was performed under the first mold 3000, while air pressure was applied to the upper part of the raw web 1000. The suction was performed in the same manner as in Example 1, and the air pressure was set so that the load applied to the raw web was about 548.7 gf / cm. 2 The applied load was set to about 1000 kg.

[0090] The step of applying the suction force and air pressure was maintained for about 10 seconds, and then the temperature was reduced to less than about 40° C. to perform a cooling process, thereby producing a compact.

[0091] Example 3. A molded product was produced in the same manner as in Example 2, but the surface temperature of the raw sheet was maintained at about 195° C. using a coil heater as in Example 2. Apart from the above, a molded product was produced in the same manner as in Example 2.

[0092] Example 4. A molded article was produced in the same manner as in Example 2, but the process was carried out while maintaining the surface temperature of the raw sheet at about 195° C. Other than the above, a molded article was produced in the same manner as in Example 2.

[0093] Example 5. A molded product was produced in the same manner as in Example 1, but the process was carried out while maintaining the surface temperature of the raw sheet at about 175° C. using a coil heater. Apart from the above, a molded product was produced in the same manner as in Example 1.

[0094] Example 6. A molded body was produced in the same manner as in Example 1, but the process was carried out without applying pressure using the second mold.

[0095] Test example 1. Check for pore formation The cross section of the molded body was photographed with a scanning electron microscope (SEM) (JEOL, JSM-7800F model) to evaluate moldability. The molded body was cross-sectionally treated with a TXP pretreatment device and then photographed with the SEM device. The BED-C observation mode was applied during the photographing, and the magnification, working distance, and acceleration voltage were 100 times, 15 mm (working distance), and 15.0 kV, respectively. Figures 7 to 12 show the results of Examples 1 to 6, respectively. It can be seen from the figures that pores were formed inside the molded body by the process of the examples. Such pores are mainly formed at the interface between the resin component and the filler component, and it can be seen that the density of the pores changes depending on the molding conditions.

[0096] Test Example 2. Evaluation of porosity and thermal conductivity The porosity of the molded body was confirmed by analyzing the SEM image obtained in Test Example 1 with an analysis tool (Geodict software, Trinity Engineering). The analysis tool (Geodict software) is software that can grasp the characteristics of materials through multi-scale 2D and 3D image processing, material modeling, visualization, and characteristic analysis. The SEM image obtained in Test Example 1 was input into the analysis tool, and a correction filter (Non-local Means Filter) was applied first, and then the pores, resin components, and filler components were distinguished through gray value difference secondarily to confirm the porosity.

[0097] The image filters of Geodict analysis tools include Non-Local Means Filter, Median Filter, Mean Filter, Gauss Filter, Sharpen Filter, Morphological Filter, H-Minima Transform Filter, Compute Gradient Filter, Watershed Filter and User Defined Filter, among which the Non-Local Means Filter was applied.

[0098] Such an image filter helps to clearly analyze the SEM image. The applied Non-Local Means Filter is a filter that can remove noise from the SEM image and blur the coarsely expressed surface, making it easier to distinguish components on the image.

[0099] After applying the filter, the boundaries of the gray value were set to distinguish between the resin component, the pores, and the filler component. When the SEM image is adjusted with the gray value applicable in the Geodict analysis tool, the gray value range of the material components in the SEM image is divided within the gray value range of 0 to 255. The components can be distinguished by the gray value depending on the resolution of the SEM image and the type of material in the SEM image. In this embodiment, the gray value range of 0 to 31 may be distinguished as the pores, the gray value range of 32 to 95 as the resin component, and the gray value range of 96 to 255 as the filler component.

[0100] After processing the images, the porosity of the compacts under different conditions was compared based on the images.

[0101] In addition, the thermal conductivity was evaluated using the analysis tool (Geodict Software, Trinity Engineering) based on the types and ratios of the applied resin and filler components and the analyzed porosity.

[0102] The evaluation results are summarized in Table 1 below.

[0103] [Table 1]

[0104] Test Example 3. Evaluation of tensile breaking strength The plate-shaped molded bodies manufactured in the Examples and Comparative Examples were cut into three equal parts of equal length in the vertical direction (arrow direction in FIG. 10) to manufacture upper, middle and lower test pieces, and the tensile breaking strength of each part was evaluated. At this time, the test pieces were cut using a water jet process to prevent cracks at the edges.

[0105] As shown in FIG. 13, specimens were obtained from the engraved portion (rectangle filled with dots in FIG. 13) and the embossed portion (rectangle filled with diagonal lines in FIG. 13) of the molded body, and specimens were obtained from the upper, middle, and lower portions in the same manner as described above. In this case, the specimens were cut to have a horizontal length of about 45 mm and a vertical length of about 12.5 mm. When cutting the specimens, the specimens were cut so that the TD (transverse direction) of the molded body was the horizontal direction. The TD direction is the direction based on the extrusion process for manufacturing the original cloth. Using the above method, four specimens each from the engraved portion and the embossed portion of the upper portion (total of eight specimens) were obtained, and specimens were similarly obtained from the middle and lower portions.

[0106] The test pieces were evaluated for tensile strength at break.

[0107] The tensile breaking strength was measured at room temperature (about 25°C) using a Universal Testing Machine (UTM). The specimen was fixed to the equipment at both ends in the horizontal direction by about 8 mm each, and the strength at the point when the specimen broke while being pulled in the horizontal direction was measured and recorded as the tensile breaking strength. The pulling was performed at a constant pulling speed of about 50 mm / sec.

[0108] The measurement results are summarized in Table 2 below. In Table 2, strength MPa is the tensile breaking strength, which is the average value of the tensile breaking strengths measured for the test pieces taken from the upper, middle and lower parts. In Table 2, deviation is the ratio of the average value to the tensile breaking strength of the original fabric, and the tensile breaking strength of the original fabric is S. R The average value is S S Then, 100×S S / S R This is the value calculated as follows:

[0109] [Table 2]

Claims

1. Contains a resin component and a filler component, The edge is formed along a first direction, The uneven shape includes both raised and recessed parts. A plate-like molded product having a porosity of 10% or more.

2. The plate-like molded article according to claim 1 , comprising pores formed at the interface between the resin component and the filler component.

3. 2. The plate-like molded product according to claim 1, wherein the standard deviation of the tensile breaking strength of each of an upper portion, a middle portion and a lower portion obtained by dividing the plate-like molded product into three equal parts in a direction perpendicular to the side in the first direction is 100 or less.

4. 2. The plate-like molded article according to claim 1, wherein the resin component is a thermoplastic polymer.

5. The plate-like molded product according to claim 1 , wherein the filler component comprises a fibrous filler.

6. The plate-like molded product according to claim 5, wherein the fibrous filler has an aspect ratio in the range of 3 to 60.

7. The plate-like molded product according to claim 6, wherein the fibrous filler has a cross-sectional diameter in the range of 1 μm to 100 μm.

8. The plate-like molded article according to claim 1, comprising 1 to 100 parts by weight of a filler component per 100 parts by weight of the resin component.

9. The plate-like molded product according to claim 1, having a thickness in the range of 100 μm to 100 mm.

10. A method for producing a plate-shaped molded product having an uneven shape including an intaglio portion and a relief portion and a porosity of 10% or more by molding a raw material containing a resin component and a filler component, comprising: A method for manufacturing a plate-shaped molded product, comprising a molding step of placing the original sheet on a corresponding intaglio of a mold having intaglios corresponding to the concave-convex shape, and sucking the original sheet from a lower portion of the mold.

11. The method for producing a plate-like molded product according to claim 10, wherein pressure is applied from above the original roll while suction is applied to the original roll from below the mold.

12. The method for producing a plate-like molded product according to claim 11, wherein the pressure is applied by injecting gas from above the raw sheet.

13. The method for producing a plate-like molded product according to claim 11, wherein the pressure is applied by pressing the raw material against a relief shape of a second mold having a relief shape corresponding to the intaglio shape of the mold.

14. The method for producing a plate-shaped molded product according to claim 10, wherein in the molding step, the temperature of the raw sheet is maintained so that the absolute value of ΔT according to the following formula 1 is 5% or more. [Formula 1] △T=100×(Ts-Tg) / Tg In formula 1, Ts is the surface temperature of the raw material during the molding step, and Tg is the glass transition temperature of the resin component.

15. The method for producing a plate-like molded product according to claim 11, wherein the suction from the lower part and the application of pressure from the upper part are performed so that the absolute value of ΔP according to the following formula 2 is 5%. [Formula 2] △P=100×(P Ｕ－ P Ｌ ) / P Ｌ In formula 2, P Ｕ is the pressure applied to the raw material by the pressure applied from above the raw material during the forming process, and P Ｌ is the pressure applied to the web by suction from underneath the web.

16. The pressure applied to the roll by suction at the bottom of the roll is 100 gf / cm ２ ~2,000gf / cm ２ The method for producing a plate-like molded product according to claim 15, wherein the range is

17. The method for producing a plate-like molded product according to claim 10 , wherein the filler component includes a fibrous filler.

18. The method for producing a plate-like molded product according to claim 17, wherein the fibrous filler has an aspect ratio in the range of 3 to 60.

19. The method for producing a plate-shaped molded product according to claim 18, wherein the fibrous filler has a cross-sectional diameter in the range of 1 μm to 100 μm.

20. A heat insulating material comprising the plate-like molded product according to any one of claims 1 to 9.

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