Molded body

Abstract

The present application may provide a molded body, a manufacturing method thereof, and uses of the molded body. The present application may provide a molded body including an uneven shape having an intaglio portion and a relief portion, in which the physical properties of the intaglio portion and the relief portion are uniform, a manufacturing method thereof, and uses of the molded body. The present application may provide a molded body including an uneven shape having an intaglio portion and a relief portion, in which the physical properties of the original roll used for manufacturing the molded body are stably maintained, a manufacturing method thereof, and uses of the molded body.

Description

Technical Field

[0001] This application relates to a molded body, a method for manufacturing the same, and uses of the molded body.

Background Art

[0002] Various methods for molding plastics such as thermoplastic resin components are known, and examples thereof include extrusion molding, injection molding, or blow molding.

[0003] Among the above molding methods, the methods most commonly applied to manufacture a molded body having unevenness are injection molding and blow molding.

[0004] Injection molding is a method in which molten raw material is injected into a mold, and after cooling, the mold is opened and discharged to complete the shape. Since it is possible to mold a complex shape, it is often used.

[0005] Blow molding is mainly often used to manufacture bottle-shaped molded bodies. A preform is placed in a mold, and a strong wind is instantaneously injected to complete the molded body.

[0006] However, the above molding methods have the following disadvantages.

[0007] [[ID=三十二]]

[0008] Even when using any of the injection molding method, the blow molding method, or other molding methods, in the process of manufacturing a molded body having an uneven shape, different pressures are applied to the concave portion and the convex portion of the uneven shape. Therefore, in the manufactured molded body, there is a high possibility that variations in physical properties will occur between the concave portion and the convex portion.

[0009] ​When a resin component and a reinforcing material are mixed, pressure applied during the molding process may cause pores to form at the interface between the resin component and the reinforcing material. In the process of manufacturing a molded body with an uneven shape having engraved and raised areas, differences in pore size and density, as described above, occur more significantly in the engraved and raised areas, and therefore, the differences in physical properties between the engraved and raised areas may become even greater. [Overview of the Initiative] [Problems that the invention aims to solve]

[0010] This application aims to provide a molded article, a method for manufacturing the same, and applications for the molded article. This application primarily aims to provide a molded article having an indented portion and an embossed portion, wherein the physical properties of the indented portion and the embossed portion are uniform, a method for manufacturing the molded article, and applications for the molded article. This application primarily aims to provide a molded article having an indented portion and an embossed portion, wherein the physical properties of the raw material for manufacturing the molded article are stably maintained, a method for manufacturing the molded article, and applications for the molded article. [Means for solving the problem]

[0011] This application relates to a molded article. The molded article may be manufactured using a plastic such as a thermoplastic resin as a raw material to have a desired predetermined shape.

[0012] The molded article may contain at least a resin component and a filler component.

[0013] There are no particular restrictions on the type of resin component contained in the molded article; for example, any necessary type can be appropriately selected and used from among resin components known to be moldable. For example, the resin component may include a thermoplastic polymer. The types of thermoplastic polymers applicable in this process include various crystalline or amorphous polymers, and examples include, but are not limited to, polyolefin polymers such as PP (polypropylene) and PE (polyethylene), polyalkylene oxide polymers such as mPPO (Modified PPO (Polyethylene oxide)), polyamide polymers such as PA (polyamide), acetal polymers such as POM (polyoxymethylene), polyester polymers such as PC (polycarbonate), PBT (polybutylene terephthalate), or PET (polyethylene terephthalate), acrylic polymers such as PMMA (poly(methyl methacrylate)), and polystyrene polymers such as PS (polystyrene) and ABS (Acrylonitrile butadiene styrene).

[0014] The resin component may have an inherent glass transition temperature (Tg) depending on its type. Although not particularly limited, the lower limit of the glass transition temperature of the resin component applied in this application may be around 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 around 500°C, 450°C, 400°C, 350°C, 300°C, 250°C, 200°C, or 150°C. The glass transition temperature of the resin component may be greater than or greater than any of the lower limits mentioned above, less than or less than any of the upper limits mentioned above, or greater than or greater than any of the lower limits mentioned above, while remaining within the range of less than or less than any of the upper limits mentioned above.

[0015] There are no particular restrictions on the proportion of the resin component within the molded body, and it may be adjusted to an appropriate proportion depending on the purpose. For example, the lower limit of the proportion of the resin component within the molded body may be around 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 around 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 proportion of the resin component may be greater than or exceeding any of the lower limits mentioned above, less than or equal to any of the upper limits mentioned above, or greater than or exceeding any of the lower limits mentioned above, while being less than or equal to any of the upper limits mentioned above.

[0016] The molded article may also contain a filler component as an additional component. Such a filler component may be included, for example, as a reinforcing material.

[0017] There are no particular limitations on the examples of applicable filler components; for example, organic fillers such as glass fillers, carbon fillers and / or silica fillers, or inorganic fillers or mixed-inorganic fillers may be used.

[0018] There are no particular restrictions on the shape of the filler; for example, the filler may be a particulate filler (spherical, angular, irregular, or other shaped particulate filler), a plate-shaped filler, or a fibrous filler.

[0019] The lower limit of the filler size described above may be, for example, around 1 μm, 5 μm, or 10 μm, and the upper limit may be around 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 filler size may be greater than or greater than any of the lower limits mentioned above, or less than or less than any of the upper limits mentioned above, or greater than or greater than any of the lower limits mentioned above, while being within the range of less than or less than any of the upper limits mentioned above.

[0020] The size of the filler may be the average diameter of the filler (or median diameter if the filler is D50 particle size) if the filler is particulate, 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-like, or the diameter of the cross-section of the filler if the filler is fibrous.

[0021] In one example, the filler may be a fibrous filler. In the case of a fibrous filler, because it has a large aspect ratio, it exhibits orientation during the manufacturing process of the molded article, and as a result, the physical properties of the molded article may become more easily non-uniform depending on the pressure applied. However, by applying the method of this application, it is possible to manufacture a molded article with uniform physical properties even in the case of a fibrous filler.

[0022] In the case of a fibrous filler, the lower limit of the aspect ratio of the filler may be approximately 3, 5, 7, 9, 10, 12, 14, 16, 18, 20, 22, or 24, and the upper limit may be approximately 60, 55, 50, 45, 40, 35, 30, or 25. The aspect ratio may be greater than or exceeding any of the lower limits mentioned above, less than or equal to any of the upper limits mentioned above, or greater than or exceeding any of the lower limits mentioned above, while remaining within the range of less than or equal to any of the upper limits mentioned above. The aspect ratio of a fibrous filler is the value obtained by dividing the length of the filler by the diameter of the cross-section of the filler.

[0023] In the case of fibrous fillers, the lower limit of the diameter of the filler's cross-section may be, for example, around 1 μm, 5 μm, or 10 μm, and the upper limit may be around 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 diameter of the cross-section of the fibrous filler may be greater than or greater than any of the lower limits mentioned above, or less than or less than any of the upper limits mentioned above, or greater than or greater than any of the lower limits mentioned above, while being within the range of less than or less than any of the upper limits mentioned above.

[0024] In the molded body, the lower limit of the weight ratio of the filler component to 100 parts by weight of the resin component may be approximately 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 approximately 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 greater than or greater than any of the lower limits mentioned above, or less than or less than any of the upper limits mentioned above, or greater than or greater than any of the lower limits mentioned above, while being less than or less than any of the upper limits mentioned above. Furthermore, the weight ratio of the filler component may be changed to be outside or outside the ranges mentioned above, taking into consideration the desired physical properties.

[0025] The molded article of this application containing the above-mentioned components may be a plate-shaped molded article, or it may be a molded article having an uneven shape formed by including embossed portions and incised portions.

[0026] When a molded body having an uneven shape as described above is manufactured using a conventional molding method, differences in physical properties easily occur between the incised and embossed portions of the molded body, and if the molded body contains reinforcing materials such as filler components, the difference becomes even larger.

[0027] There are no particular restrictions on the specific form of the aforementioned uneven shape, such as the depth or height of the incised or raised shapes, the area, the shape, and / or the number of them. An appropriate form of uneven shape may be applied considering the intended use of the molded article.

[0028] However, this application makes it possible to provide a molded article that exhibits equivalent physical properties in the incised and embossed areas through a molding method described later.

[0029] For example, in the molded body, the absolute value of the difference between the tensile breaking strength of the engraved portion and the tensile breaking strength of the embossed portion may be adjusted to be within a predetermined range.

[0030] In this specification, the method for measuring tensile breaking strength is summarized in the examples. The tensile breaking strength may be measured at room temperature (approximately 25°C) using a UTM (Universal Testing Machine) equipped with a specimen cut to a length of approximately 45 mm horizontally and approximately 12.5 mm vertically.

[0031] The side of the specimen may be parallel to the MD (Machine Direction) or TD (Transverse Direction) of the raw material. In the above, MD and TD refer to the MD and TD directions of the raw material, which will be described later, and these refer to the MD and TD directions in the extrusion process used to manufacture the raw material.

[0032] The specimen is fixed to the aforementioned equipment at both lateral ends by approximately 8 mm each, and while the specimen is pulled in the lateral direction at a speed of approximately 50 mm / sec, the strength at the point of fracture is measured, and this strength is defined as the tensile fracture strength.

[0033] The difference between the tensile breaking strength of the incised portion and the tensile breaking strength of the raised portion is the difference between the tensile breaking strength of the incised portion and S M The tensile breaking strength of the embossed area is set to S P When this is done, 100 × (S P -S M ) / S M It is a value calculated using a formula, and its unit is %.

[0034] The upper limit of the absolute difference in tensile breaking strength between the embossed portion and the incised portion may be approximately 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, or 1%, and the lower limit may be approximately 0%, 0.5%, 1%, 1.5%, 2%, 2.5%, 3%, or 3.5%. The absolute difference in tensile breaking strength between the embossed portion and the incised portion may be less than or equal to any of the upper limits mentioned above, or greater than or equal to any of the lower limits mentioned above, while remaining within the range of less than or equal to any of the upper limits mentioned above.

[0035] The molded body of the present application may be further manufactured to have physical properties similar to those of the base material. In the above, the base material means a film or sheet-like material applied to manufacture the molded body having the concavo-convex shape. That is, the process of manufacturing the molded body of the present application may include applying a material containing the resin component and the filler component to an extrusion process to manufacture a plate material (sheet or film), and a molding stage of forming concavo-convex portions on the plate material. When a large number of 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 be different from those of the previous plate material. However, when the method of the present application is applied, the molded body can be manufactured while minimizing or eliminating the change in the physical properties of the base material.

[0036] For example, the change rate of the tensile breaking strength of the molded body with respect to the base material may be within a predetermined range or more. In the above, the change rate of the tensile breaking strength with respect to the base material is the tensile breaking strength of the base material as S R and the tensile breaking strength of the molded body as S S When it is, it is a value calculated by 100×S S / S R and its unit is %. Also, in the above, the tensile breaking strength S S of the molded body may be the tensile breaking strength of the recessed portion or the protruded portion of the molded body, or may be the arithmetic mean of the tensile breaking strengths of the recessed portion and the protruded portion.

[0037] In the molded body, the lower limit of the change rate of the tensile breaking strength may be about 70%, 72%, 74%, 76%, 78%, 80%, 82%, 84%, 86%, 88%, 90%, 92%, 94%, 96% or 98%, and the upper limit may be about 100%, 98%, 96%, 94%, 92%, 90%, 88%, 86%, 84% or 82%. The change rate of the tensile breaking strength may be in the range exceeding or being equal to any one of the lower limits described above, or being in the range exceeding or being equal to any one of the lower limits described above and less than or equal to any one of the upper limits described above.

[0038] In the molded body, the engraved portion or embossed portion may have a certain level of tensile breaking strength.

[0039] For example, the lower limit of the tensile breaking strength of the incised or embossed portion of the molded body may be around 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 may be around 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 breaking strength may be greater than or equal to any of the lower limits mentioned above, or it may be greater than or equal to any of the lower limits mentioned above, while being less than or equal to any of the upper limits mentioned above.

[0040] The molded article of this application can have uniform physical properties as a whole. That is, during the manufacturing process of a molded article, different levels of pressure may be applied to the recessed and raised shapes, and even with the same recessed or raised shape, different pressures may be applied to different parts, which can cause variations in physical properties. However, when the method of this application is applied, the molded article can have uniform physical properties as a whole.

[0041] For example, if the plate-shaped molded body of this application has a side formed in a first direction, the standard deviation of the tensile fracture strength of the upper, middle, and lower sections obtained by dividing the molded body into three equal parts in a direction perpendicular to the side in the first direction may be controlled to be below a certain level.

[0042] The first direction is a direction parallel to any side of the molded body that can be observed when the plate-shaped molded body is viewed along the thickness direction of the molded body. For example, referring to Figure 1, if the molded body is rectangular as shown in Figure 1, the direction of the horizontal side 100 or the vertical side 200 of the rectangle may be the first direction. In Figure 1, the vertical side 200 is taken as the first direction, and the molded body is divided into three equal parts perpendicular to the side of the first direction, with the upper section U, middle section M, and lower section L defined by dotted lines. In some cases, if the side of the molded body is not straight, the direction of a virtual straight line connecting the two ends of the side (2001 and 2002 in Figure 1) can be taken as the first direction.

[0043] In the above, dividing the molded body into three equal parts along the first direction means dividing the molded body such that the upper section U, the middle section M, and the lower section L have equal areas.

[0044] On the other hand, the standard deviation is calculated by S, where S is the tensile breaking strength of the upper, middle, and lower sections, respectively. U、 S M、 S L Let A be the arithmetic mean of {[(S U -A) 2 +(S M -A) 2 +(S L -A) 2 ] / 3} 0.5 This is the value calculated using [the formula / method].

[0045] In appropriate examples, the upper limit of the standard deviation of the tensile breaking strength of the upper, middle, and lower sections may be approximately 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, or 15, and the lower limit may be approximately 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 greater than or equal to any of the lower limits mentioned above, while being within the range of less than or equal to any of the upper limits mentioned above.

[0046] The molded article of this application may have any two physical properties selected from the rate of change of tensile fracture strength, the tensile fracture strength, the absolute value of the difference between the tensile fracture strength of the embossed portion and the incised portion, and the standard deviation of the tensile fracture strength of the upper, middle, and lower portions, and in some cases may satisfy all of the above physical properties.

[0047] The thickness of the molded body described above may be adjusted to an appropriate level depending on the purpose, and is not significantly limited thereto. For example, the lower limit of the thickness of the molded body may be around 100 μm, 500 μm, 1,000 μm, 1,500 μm, or 2,000 μm, and the upper limit may be around 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 mentioned above, less than or equal to any of the upper limits mentioned above, or greater than or equal to any of the lower limits mentioned above, while being less than or equal to any of the upper limits mentioned above.

[0048] The molded bodies described above can be used for a variety of purposes, one example being a so-called heat sink. As is well known, a heat sink is a component that can absorb or dissipate heat from another object through direct or indirect thermal contact. Since such heat sinks benefit from having as large a surface area as possible, molded bodies with an uneven shape as described above can be advantageously used as heat sinks.

[0049] The heat sink may include at least the plate-shaped molded body described above. The heat sink may consist solely of the plate-shaped molded body, or it may include the plate-shaped molded body and other necessary materials simultaneously.

[0050] The contents of the plate-shaped molded body included in the heat sink, such as the contents of the resin component and filler component, the absolute value of the difference in tensile breaking strength between the engraved portion and the embossed portion, the rate of change in tensile breaking strength relative to the original material, the standard deviation of the tensile breaking strength of the upper, middle, and lower portions obtained by dividing the body into three equal parts, and the contents of the thickness of the plate-shaped molded body may be similarly applied to the contents described above.

[0051] This application further relates to a method for manufacturing the aforementioned molded articles.

[0052] The manufacturing method of this application may include the step of molding a sheet or film containing the resin component and the filler component to produce a molded body having an uneven shape including the incised portion and the raised portion.

[0053] The sheet or film containing the resin component and filler component described above may be the raw material described above. Such a raw material may be manufactured by applying the material containing the resin component and filler component to a known molding process, such as an extrusion process. The specific types of resin component and filler component used in the manufacture of the raw material and their mixing ratios are the same as those described for the molded article.

[0054] Such raw materials may be in the form of sheets or films, as mentioned above.

[0055] In such cases, the thickness of the raw material can be adjusted to an appropriate level depending on the purpose, and is not significantly limited thereto. For example, the lower limit of the thickness of the raw material may be around 100 μm, 500 μm, 1,000 μm, 1,500 μm, or 2,000 μm, and the upper limit may be around 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 mentioned above, less than or equal to any of the upper limits mentioned above, or greater than or equal to any of the lower limits mentioned above, while being within the range of less than or equal to any of the upper limits mentioned above.

[0056] In this application, a molding step is performed to form the uneven shape using the raw material.

[0057] In the molding stage, as shown in Figure 2, a mold 3000 having an incision corresponding to a desired uneven shape is used. The incision shape of the mold can be determined according to the uneven shape.

[0058] In the molding stage, the raw material 1000 may be placed on top of the mold 3000, and the raw material may be sucked from the bottom of the mold 3000 (a suction force is applied in the L direction in Figure 2). Pressure is applied to the raw material 1000 by the suction force applied in this process.

[0059] In the molding stage, in addition to applying suction as described above, pressure can be applied from the top of the raw material (in the U direction in Figure 2).

[0060] By performing the molding process while applying force from both the top and bottom of the raw material roll 1000 in this manner, the desired molded product can be effectively manufactured.

[0061] In the foregoing, there are no particular restrictions on the method of applying force from the top of the raw material 1000, but it may be done using either of the following two methods.

[0062] For example, as shown in Figures 3 and 4, the application of pressure from above may be carried out using an additional mold 4000 (hereinafter sometimes referred to as the second mold). That is, a second mold 4000 having a raised shape corresponding to the incised shape of the mold having an incised shape corresponding to the uneven shape is prepared, and the pressure can be applied by moving the second mold 4000 toward the raw material 1000 and pressing the raw material 1000, as shown in Figures 3 and 4.

[0063] In other examples, for instance, the application of pressure from above may be carried out by injecting gas from the top of the raw material.

[0064] Such an example is shown in Figure 5. As shown in Figure 5, after covering with a lid 5000 or the like to form a sealed space, the pressure can be applied from above via a gas U such as air.

[0065] During the molding stage, the temperature of the raw material, for example, the surface temperature of the raw material, may be adjusted. Specifically, the temperature of the raw material may be adjusted so that the absolute value of ΔT according to the following formula 1 falls within a predetermined range.

[0066] [Formula 1] △T = 100 × (Ts - Tg) / Tg

[0067] In Equation 1, Ts is the surface temperature of the raw material during the molding stage, and Tg is the glass transition temperature of the resin component.

[0068] For example, the upper limit of the absolute value of ΔT may be around 50%, 48%, 46%, 44%, 42%, 40%, 38%, 36%, 34%, 32%, 30%, 28%, 26%, 24%, or 22%, and its lower limit may be around 0%, 5%, 10%, 15%, or 20%. In Equation 1, ΔT may be greater than or exceeding any of the lower limits mentioned above, or less than or equal to any of the upper limits mentioned above, or greater than or exceeding any of the lower limits mentioned above, while being within the range of less than or equal to any of the upper limits mentioned above.

[0069] The surface temperature (Ts) of the raw material can be higher or lower than the glass transition temperature of the resin component, as long as it satisfies the range of the absolute value of ΔT in Equation 1.

[0070] There are no particular limitations on the method for adjusting the surface temperature of the raw material; for example, known heaters such as ceramic heaters or coil heaters may be used for adjustment.

[0071] Furthermore, the relationship between the suction force applied from the bottom of the raw material and the pressure applied from the top of the raw material may also be adjusted during the process described above.

[0072] For example, the suction from the bottom and the application of pressure from the top may be controlled so that the absolute value of △P in the following equation 2 falls within a predetermined range.

[0073] [Formula 2] △P = 100 × (P U- P L ) / P L

[0074] In Equation 2, P U P is the pressure applied to the raw material by the pressure applied from above the raw material during the molding stage, L This is the pressure applied to the raw material by suction from the lower part of the raw material.

[0075] For example, the upper limit of the absolute value of △P in Equation 2 may be around 100%, 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 5%, and its lower limit may be around 0%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, or 60%. △P in Equation 2 may be greater than or exceeding any of the lower limits mentioned above, or less than or equal to any of the upper limits mentioned above, or greater than or exceeding any of the lower limits mentioned above, while remaining within the range of less than or equal to any of the upper limits mentioned above.

[0076] In Equation 2, force P U This refers to the instantaneous load applied to the raw material when only the aforementioned suction force is applied, and P L This refers to the instantaneous load applied to the raw material when only the aforementioned pressure is applied.

[0077] In equation 2, △P may be a positive or negative number, as long as its absolute value satisfies the range mentioned above.

[0078] In the above, the pressure applied to the raw material by suction applied from the lower part of the raw material (P in Equation 2) L The lower limit of ) is 100 gf / cm³. 2 , 150 gf / cm³ 2 , 200 gf / cm 2 , 250 gf / cm³ 2 300 gf / cm³ 2 350 gf / cm³ 2 , 400 gf / cm³ 2 450 gf / cm³ 2 500 gf / cm³ 2 550 gf / cm³ 2 600 gf / cm³ 2 or 650 gf / cm³ 2 It may be as low as 2000 gf / cm³, with an upper limit of 2000 gf / cm³. 2 , 1900 gf / cm³ 2 , 1800 gf / cm³2 , 1700 gf / cm³ 2 , 1600 gf / cm³ 2 , 1500 gf / cm² 2 , 1400 gf / cm² 2 , 1300 gf / cm³ 2 , 1200 gf / cm² 2 , 1100 gf / cm³ 2 , 1000 gf / cm² 2 950 gf / cm³ 2 900 gf / cm³ 2 850 gf / cm² 2 800 gf / cm³ 2 750 gf / cm³ 2 or 700 gf / cm³ 2 It may be to a certain extent. The force may be greater than or exceeding any of the lower limits mentioned above, less than or equal to any of the upper limits mentioned above, or greater than or exceeding any of the lower limits mentioned above, while remaining within the range of less than or equal to any of the upper limits mentioned above.

[0079] The molded article of this application may be manufactured by the above-mentioned steps. The method of this application may further include any additional steps necessary in the above-mentioned steps. For example, the method may further include a step of fixing the molded shape through a cooling step or the like after the molding step. [Effects of the Invention]

[0080] This application may provide a molded article, a method for manufacturing the same, and applications for the molded article. This application may provide a molded article having an indented portion and an embossed portion, wherein the physical properties of the indented portion and the embossed portion are uniform, a method for manufacturing the molded article, and applications for the molded article. This application may provide a molded article having an indented portion and an embossed portion, wherein the physical properties of the raw material for manufacturing the molded article are stably maintained, a method for manufacturing the molded article, and applications for the molded article. [Brief explanation of the drawing]

[0081] [Figure 1] Figure 1 is a diagram illustrating a method for dividing a molded body into three equal parts. [Figure 2] Figure 2 is a diagram illustrating the manufacturing method of the molded article of this application. [Figure 2] Figure 3 is a diagram illustrating the manufacturing method of the molded article of this application. [Figure 2] Figure 4 is a diagram illustrating the manufacturing method of the molded article of this application. [Figure 2] Figure 5 is a diagram illustrating the manufacturing method of the molded article of this application. [Figure 6] Figure 6 is a photograph of a molded product manufactured in the example. [Figure 7] Figure 7 is an SEM image of the molded body produced in the example. [Figure 7] Figure 8 shows an SEM image of the molded body produced in the example. [Figure 9] Figure 9 shows an SEM image of the molded product manufactured in the comparative example. [Figure 10] Figure 10 is a photograph illustrating the sampling site for measuring tensile fracture strength. [Modes for carrying out the invention]

[0082] The present application will be described in detail below through the examples provided, but the scope of this application is not limited by the examples described below. [Examples]

[0083] Example 1. As shown in Figure 6, a molded body having an uneven shape formed by an incised shape 100 and a raised shape 200 was manufactured by the following method. The molded body in Figure 1 is a rectangular plate with a width of approximately 608 mm, a length of approximately 308 mm, and a thickness of approximately 2 mm, and may be used as a heat sink.

[0084] First, the raw material was manufactured. The raw material was produced by applying an extrusion process to a material with a thickness of approximately 2 mm, which was a mixture of the resin component mPPO (Modified PPO (Polyethylene oxide)) and the filler component glass fiber in a weight ratio of 8:2 (mPPO: filler component).

[0085] The aforementioned resin component, mPPO, has a glass transition temperature of approximately 145°C, and the glass fibers have a cross-sectional diameter of approximately 12.5 μm and an aspect ratio of approximately 24.

[0086] The molded body shown in Figure 6 was manufactured using the aforementioned raw material in the following manner. As shown in Figure 3, the raw material 1000 was placed on a first mold 3000, which had intaglios formed thereon corresponding to the uneven shape of the molded body. A second mold 4000, which had embossed shapes formed thereon corresponding to the uneven shape, was then placed on the raw material 1000.

[0087] Next, a ceramic heater was used to maintain the surface temperature of the raw material at approximately 195°C. The ceramic heater was placed inside the heating equipment, and with the ceramic heater positioned above the raw material, the temperature was raised to the desired level through the temperature control of a PLC (Programmable Logic Controller) system. Whether the surface temperature of the raw material was controlled to the desired level was confirmed using a non-contact infrared thermometer.

[0088] Next, while maintaining the temperature, suction (L) was performed at the bottom of the first mold 3000 as shown in Figure 3, and at the same time, the second mold 4000 was moved to the bottom to apply pressure to the raw material in the configuration shown in Figure 4.

[0089] The aforementioned suction (L) was performed with the equipment's gauge fully open. In this case, the vacuum flow, based on the rate, was approximately 1 atmosphere, and the pressure applied to the raw material was approximately 690.2 gf / cm². 2(Applied load is approximately 1500 kg level). Furthermore, the applied pressure of the second mold 4000 is approximately 548.7 gf / cm² to the molded body formed through the suction. 2 The system was designed to apply pressure at a level of approximately 1000 kg.

[0090] The state of the first mold 3000 and the second mold 4000 as shown in Figure 4 was maintained for about 10 seconds, and the temperature of the molded body (raw material) 1000 was reduced to about 40°C to perform a cooling process.

[0091] After the cooling process, the first and second molds 3000 and 4000 were separated, and the molded bodies were recovered.

[0092] Example 2. A molded body was manufactured using the same method as in Example 1. However, in Example 2, the raw material was heated using a coil heater, and the surface temperature of the raw material was maintained at approximately 175°C. The coil heater was placed inside the heating equipment, and with the heater positioned above the raw material, the temperature was raised to the desired level through temperature control of a PLC (Programmable Logic Controller) system. Whether or not the surface temperature of the raw material was controlled to the desired level was confirmed using a non-contact infrared thermometer.

[0093] Except for the above, the molded article was manufactured in the same manner as in Example 1.

[0094] Comparative Example 1. The molded body was manufactured using the same method as in Example 1, but without applying pressure using the second mold 4000.

[0095] Test Example 1. Evaluation of Molding Condition The moldability of the molded bodies of the examples or comparative examples was evaluated by photographing the cross-sections with a Scanning Electron Microscope (SEM) (JEOL, JSM-7800F model). The molded bodies were cross-sectionally treated with a TXP pretreatment device and then photographed with the SEM. During the photography, the BED-C observation mode was applied, and the magnification, working distance, and acceleration voltage were set to 100x, 15 mm (Working Distance), and 15.0 kV, respectively. Figures 7 and 8 show the results for Examples 1 and 2, respectively, and Figure 9 shows the results for Comparative Example 1.

[0096] Through a comparison of Figures 7-9, it was found that in Examples 1 and 2, no pores were generated internally and good molding was achieved. However, in the case of the molded body of Comparative Example 1, numerous pores were observed internally, and the desired uneven shape of the molded body was not properly formed.

[0097] Test Example 2. Evaluation of Tensile Breaking Strength The tensile strength of the engraved and embossed portions of the plate-shaped molded bodies produced in the examples or comparative examples was evaluated. As shown in Figure 10, specimens were prepared by cutting the engraved portions (rectangles filled with dots in Figure 10) and embossed portions (rectangles filled with shaded areas in Figure 10) of the molded bodies, respectively. The specimens were cut to have a horizontal length of approximately 45 mm and a vertical length of approximately 12.5 mm. As shown in the figure, 32 specimens were taken from each engraved portion and 17 specimens were taken from each embossed portion. The tensile strengths described below are the average values ​​of the tensile strengths measured in these specimens.

[0098] The tensile breaking strength was measured at room temperature (approximately 25°C) using a Universal Testing Machine (UTM) system. The specimen was fixed to the system at both ends in the lateral direction, approximately 8 mm apart, and the strength at which the specimen fractured while being pulled in the lateral direction was measured and defined as the tensile breaking strength. The pulling was performed at a constant speed of approximately 50 mm / sec.

[0099] The measurement results mentioned above are summarized in Table 1 below.

[0100] In Table 1, the deviation represents the tensile fracture strength of the incised area, S. M And the tensile breaking strength is S P When this is done, 100 × (S P -S M ) / S M This is the value calculated using [the formula / method].

[0101] [Table 1]

[0102] Test Example 3. Evaluation of Tensile Breaking Strength The plate-shaped molded body produced in the example or comparative example was cut into three equal parts with lengths equal to the length in the longitudinal direction (direction of the arrow in Figure 10) to produce upper, middle, and lower sections as test specimens. The tensile breaking strength of each section was then evaluated in the same manner as in Test Example 2.

[0103] At this time, the specimens were cut using a water jet process to prevent cracks and other damage to the edges.

[0104] As shown in Figure 10, specimens were obtained from the incised area (the rectangle filled with dots in Figure 10) and the raised area (the rectangle filled with diagonal lines in Figure 10) of the molded body, and specimens were obtained from the upper, middle, and lower sections in the same manner as described above. When cutting the specimens, the specimens were cut so that the TD (Transverse direction) of the molded body was the transverse direction. The TD direction is the direction based on the extrusion process used to manufacture the raw material. Using the above method, four specimens each (a total of eight specimens) were taken from the incised area and the raised area of ​​the upper section, and specimens were similarly taken from the middle and lower sections.

[0105] The tensile breaking strength of the aforementioned specimens was evaluated in the same manner as in Test Example 2, and the results are summarized in Table 2.

[0106] In Table 2 below, the strength in MPa represents the tensile breaking strength, which is the average value of the tensile breaking strengths measured for specimens taken from the upper, middle, and lower sections, respectively.

[0107] Furthermore, in Table 2 below, the deviation is the ratio of the average value to the tensile breaking strength of the raw material, where S is the tensile breaking strength of the raw material. R Let the above average value be S S In that case, 100 × S S / S R This is the value calculated using [the formula / method].

[0108] [Table 2]

Claims

1. A plate-shaped molded article containing a resin component and a filler component, The plate-shaped molded body has an uneven shape formed thereon, including raised and recessed areas. The absolute value of the difference in tensile breaking strength between the embossed portion and the incised portion is 10% or less. The tensile breaking strength of the engraved portion is 50 MPa or more, or the rate of change in tensile breaking strength relative to the original roll is 80% or more. The aforementioned filler component includes a fibrous filler. The resin component is a plate-shaped molded body having a glass transition temperature of 145°C or higher.

2. A plate-shaped molded article containing a resin component and a filler component, The plate-shaped molded body has an uneven shape formed thereon, including raised and recessed areas. The plate-shaped molded body has sides formed in a first direction, The standard deviation of the tensile breaking strength of the upper, middle, and lower sections obtained by dividing the plate-shaped molded body into three equal parts in a direction perpendicular to the first side is 100 MPa or less. The aforementioned filler component includes a fibrous filler. The resin component is a plate-shaped molded body having a glass transition temperature of 145°C or higher.

3. The plate-shaped molded article according to claim 2, wherein the tensile breaking strength of the engraved portion is 50 MPa or more, or the rate of change in tensile breaking strength relative to the original roll is 80% or more.

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

5. The plate-shaped molded article according to claim 1, wherein the fibrous filler has an aspect ratio in the range of 3 to 60.

6. The plate-shaped molded article according to claim 5, wherein the fibrous filler has a cross-sectional diameter in the range of 1 μm to 100 μm.

7. The plate-shaped molded body according to claim 1 or 2, wherein the plate-shaped molded body contains 1 to 100 parts by weight of a filler component per 100 parts by weight of the resin component.

8. A plate-shaped molded body according to claim 1 or 2, wherein the thickness is in the range of 100 μm to 100 mm.

9. A method for producing a plate-shaped molded body having an uneven shape including incised and raised areas by molding a raw material containing resin components and filler components, The molding step includes placing the raw material on the corresponding incision of a mold having incisions corresponding to the aforementioned uneven shape, and applying pressure from the top of the raw material while sucking the raw material from the bottom of the mold, A method for maintaining the temperature of the raw material in the molding step such that the absolute value of ΔT, calculated using the following formula 1, is 50% or less. [Formula 1] △T=100×(Ts-Tg) / Tg In Equation 1, Ts is the surface temperature of the raw material during the molding stage, and Tg is the glass transition temperature of the resin component.

10. The method according to claim 9, wherein pressure is applied by injecting gas from the top of the raw material.

11. The method according to claim 9, wherein the pressure is applied by pressing the raw material onto the raised shape of a second mold having a raised shape corresponding to the incision of the mold.

12. The method according to claim 9, wherein the surface temperature of the raw material is controlled by a ceramic heater or a coil heater.

13. The method according to claim 9, wherein suction from the bottom of the raw material and pressure application from the top are performed such that the absolute value of ΔP in the following formula 2 is within 100%. [Formula 2] △P=100×(P Ｕ－ P Ｌ ) / P Ｌ In Equation 2, P Ｕ P is the pressure applied to the raw material by the pressure applied from above, Ｌ This is the pressure applied to the raw material by suction at the bottom of the raw material.

14. The pressure applied to the raw material by suction at the bottom of the raw material is 100 gf / cm². ２ ~2,000gf / cm ２ The method according to claim 13, which is within the range.

15. The plate-shaped molded body includes resin components and filler components, The aforementioned plate-shaped molded body has an uneven surface formed thereon, including raised and recessed areas. The absolute value of the difference between the tensile breaking strength of the embossed portion and the tensile breaking strength of the incised portion is 10% or less. The tensile breaking strength of the engraved portion is 50 MPa or more, or the rate of change in tensile breaking strength relative to the original roll is 80% or more. The aforementioned filler component includes a fibrous filler. The aforementioned resin component is a heat sink having a glass transition temperature of 145°C or higher.

16. The plate-shaped molded body includes resin components and filler components, The aforementioned plate-shaped molded body has an uneven surface formed thereon, including raised and recessed areas. The plate-shaped molded body has sides formed in a first direction, The standard deviation of the tensile breaking strength of the upper, middle, and lower sections obtained by dividing the plate-shaped molded body into three equal parts in a direction perpendicular to the first side is 100 MPa or less. The aforementioned filler component includes a fibrous filler. The aforementioned resin component is a heat sink having a glass transition temperature of 145°C or higher.

Images