CN114770803A - Quasi-isotropic reinforcing sheet, FRP molded body, and method for producing FRP molded body - Google Patents
Quasi-isotropic reinforcing sheet, FRP molded body, and method for producing FRP molded body Download PDFInfo
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- CN114770803A CN114770803A CN202210436481.5A CN202210436481A CN114770803A CN 114770803 A CN114770803 A CN 114770803A CN 202210436481 A CN202210436481 A CN 202210436481A CN 114770803 A CN114770803 A CN 114770803A
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Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
- B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
- B29B15/10—Coating or impregnating independently of the moulding or shaping step
- B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
Abstract
The invention provides a quasi-isotropic reinforcing sheet which has excellent strength and excellent formability into various shapes, an FRP molded body which uses the quasi-isotropic reinforcing sheet as a main material and has a protrusion part which is difficult to break, and an efficient method for producing the FRP molded body. In a quasi-isotropic reinforcing sheet S comprising a reinforcing fiber material F and a thermoplastic resin M, a plurality of UD sheet pieces (P) (P) … formed by bonding and integrating continuous fibers in a state of being aligned in one direction are bonded in a state of randomly orienting the fiber direction of each sheet piece and in a state of being stacked and arranged in layers between the sheet pieces to form a sheet main body, and as the UD sheet pieces P.P …, a sheet having a width of 2mm to 20mm, a length of 5mm to 70mm, and a ratio of width to length of 1: 1-1: 6 in the form of a square sheet.
Description
The present application is a divisional application based on chinese patent application having application number 201810264447.8, application date 2018, 3/28, entitled "method for producing quasi-isotropic reinforcing sheet, FRP molded body, and FRP molded body".
Technical Field
The present invention relates to an improvement in prepreg sheets, and more particularly to a quasi-isotropic reinforcing sheet excellent in strength and formability, an FRP molded body having a slender protrusion using the quasi-isotropic reinforcing sheet as a main material, and an efficient method for producing the FRP molded body.
Background
In recent years, Fiber Reinforced Plastics (FRP) composed of a matrix resin and a reinforcing fiber material such as carbon fibers or glass fibers have been used in various applications because of their excellent functionality. As FRP, FRP in which continuous fibers as a reinforcing fiber material are oriented in a longitudinal direction and FRP in which a matrix resin is impregnated into a product in which continuous fibers are woven in a flat manner are also known.
However, when the above conventional FRP using continuous fibers is formed into a desired shape by hot press working, the long continuous fibers extending over the entire sheet become a factor of hindering the following property to the press mold, and this causes a deterioration in the shaping property, resulting in a drawback that the shape to be formed is limited.
In addition, in the case of using the above-described conventional prepreg sheet, in order to form the elongated protrusion portion in a stripe shape (rib arch shape), it is necessary to thermally fuse or bond the protrusion piece and the main body portion which are separately molded, and if this method is adopted, the reinforcing fibers of the protrusion portion and the reinforcing fibers of the main body portion are cut at the base portion of the protrusion portion, and therefore, there is a problem that the base portion of the protrusion portion is easily broken.
On the other hand, there has been developed a prepreg sheet in which a UD sheet having continuous fibers aligned in one direction is finely cut, the resultant is aligned in a two-dimensional direction and integrated with a matrix resin (see patent document 1), and there is no mention in document 1 of a technique for producing an FRP molded body having elongated protrusions using such a prepreg sheet.
Documents of the prior art
Patent document
Patent document 1: japanese patent laid-open publication No. 2016-27956
Disclosure of Invention
Problems to be solved by the invention
The present invention has been made in view of the above problems, and an object of the present invention is to provide a quasi-isotropic reinforcing sheet excellent in strength and in formability into various shapes, an FRP molded body having a hard-to-break protrusion portion using the quasi-isotropic reinforcing sheet as a main material, and an efficient method for producing the FRP molded body.
Means for solving the problems
Means employed by the present inventors to solve the above problems will be described below with reference to the drawings.
That is, the present invention is characterized in that: in a quasi-isotropic reinforcing sheet material S composed of a reinforcing fiber material F and a thermoplastic resin M, a plurality of UD sheet material sheets P & P … formed by bonding and integrating continuous fibers in a state of being arranged in one direction are bonded in a state of randomly orienting the fiber direction of each sheet material sheet and in a state of being arranged in layers in a manner of overlapping each sheet material sheet, and a sheet material main body is formed by bonding, as the UD sheet material sheet P & P …, a sheet material: 1-1: 6 in the form of a square sheet.
In the present invention, a quasi-isotropic reinforcing sheet having excellent formability and ductility can be formed by using carbon fibers as the reinforcing fiber material F, using a polyamide resin, polypropylene, a fluororesin, or polyphenylene sulfide as the thermoplastic resin M, and by controlling the fiber volume content of the sheet main body to 20% to 70%, and controlling the strain at break to 1.10 to 1.75% when a plurality of sheet main bodies are laminated and integrated to have a thickness of 2.0 mm.
On the other hand, in the present invention, in the FRP molded body mainly composed of the laminate of the quasi-isotropic reinforcing sheets S, the strip-shaped protrusions 12 having a width of 0.5mm or more and a height of 5mm or more (preferably 20mm or more, and more preferably 50mm or more) are formed on the surface, and the reinforcing fiber material F is present in the base portions B of the protrusions 12 so as to connect the main body 11 and the protrusions 12, whereby the protrusions having a small width and a large height can be formed so as to be hardly broken with respect to the main body.
Further, the portion 12a on the tip side and the portion 12b on the base side of the projection 12 are formed to have the same width, and the bending strength of the portion 12b on the base side is set to a value of-10% to + 30% with respect to the bending strength of the portion 12a on the tip side, whereby the projection 12 having a small strength difference depending on the portion can be formed.
In the present invention, when producing the FRP molded product, the following production method can be employed: the laminate of isotropic reinforcing sheets S is hot-press molded by a mold, and stripe-shaped protrusions 12 having a width of 0.5mm or more and a height of 5mm or more are formed on the surface of the body 11 of the molded body.
ADVANTAGEOUS EFFECTS OF INVENTION
In the present invention, a plurality of UD sheet pieces are bonded to each other in a state where the fiber directions of the sheet pieces are randomly oriented and in a state where the sheet pieces are arranged in layers so as to overlap each other, thereby forming a quasi-isotropic reinforcing sheet, and a rectangular sheet piece having a predetermined size is used as the UD sheet piece, whereby the shaping property of the prepreg sheet can be improved.
Further, if the quasi-isotropic reinforcing sheet is laminated and hot-press molded, the elongated stripe-shaped protrusion can be easily formed on the surface of the main body of the FRP molded body, and the reinforcing fiber material is disposed in the base of the formed protrusion so as to connect the main body and the protrusion.
Therefore, according to the present invention, it is possible to provide a quasi-isotropic reinforcing sheet which can be molded into various shapes by hot press molding, and an FRP molded body having protrusions which is excellent in durability and has the quasi-isotropic reinforcing sheet as a main material.
Drawings
Fig. 1 is an enlarged plan view showing a quasi-isotropic reinforcing sheet according to a first embodiment of the present invention.
Fig. 2 is a cross-sectional explanatory view showing a cross-sectional structure of a quasi-isotropic reinforcing sheet according to a first embodiment of the present invention.
Fig. 3 is an overall perspective view showing a UD sheet according to a first embodiment of the present invention.
Fig. 4 is an overall perspective view showing an FPR molded body according to a second embodiment of the present invention.
Fig. 5 is an explanatory view of an X-X' cross section showing a cross-sectional structure of an FPR molded body according to a second embodiment of the present invention.
Fig. 6 is an explanatory view of a method of a verification test for the effect of the specification.
Description of the reference numerals
1 FRP molded body
11 main body part
12 projecting part
12a on the tip side
12b on the bottom end side
S-quasi-isotropic reinforcing sheet
Pud sheet
F reinforced fiber material
M thermoplastic resin
B base
Detailed Description
First embodiment
A first embodiment of the present invention will be described with reference to fig. 1 to 3. In the figure, a quasi-isotropic reinforcing sheet is denoted by reference numeral S, and a UD sheet is denoted by reference numeral P. Further, a reinforcing fiber material is denoted by reference numeral F, and a thermoplastic resin is denoted by reference numeral M.
Construction of quasi-isotropic reinforcing sheet
[1] Basic constitution of quasi-isotropic reinforcing sheet
First, a basic structure of the quasi-isotropic reinforcing sheet S will be described. In the present embodiment, as shown in fig. 1, the plurality of UD sheet pieces P · P … are bonded in a state in which the fiber directions of the sheet pieces are randomly oriented (arranged such that the fiber directions of the sheet pieces are not aligned), and the sheet pieces are layered (arranged in two-dimensional directions) so as to overlap each other, thereby forming the quasi-isotropic reinforcing sheet S.
The quasi-isotropic reinforcing sheet S is configured such that a reinforcing fiber material F is impregnated with a thermoplastic resin M as a matrix resin as shown in fig. 2, and each UD sheet P constituting the quasi-isotropic reinforcing sheet S is formed by bonding and integrating continuous fibers (carbon fibers in the present embodiment) in a state in which the continuous fibers are aligned in one direction as shown in fig. 3. This makes it possible to form a quasi-isotropic reinforcing sheet S having excellent strength and formability.
[2] About reinforced fiber material
Next, each constituent element of the quasi-isotropic reinforcing sheet S will be explained. First, although carbon fibers are used in the present embodiment as the reinforcing fiber material F, fibers other than carbon fibers, for example, inorganic fibers such as glass fibers, aramid fibers, ceramic fibers, and metal fibers, organic fibers such as polyarylate fibers and PBO fibers, and the like can be used as long as they are high-strength fiber materials.
[3] Concerning the fiber volume fraction (Vf)
In addition, regarding the fiber volume content (Vf) of the reinforcing fiber material in the quasi-isotropic reinforcing sheet S, if the content of the reinforcing fibers is too low, sufficient strength cannot be obtained, and if the content of the reinforcing fibers is too high, the proportion of the resin becomes small, and sufficient formability becomes difficult to obtain, so it is preferable to adjust the fiber volume content within a range of Vf 20% to 70%.
[4] About thermoplastic resin
In addition, although a polyamide resin (nylon resin) is used in the present embodiment as the thermoplastic resin M, any other thermoplastic resin (acrylic resin, PET, polyethylene, polystyrene, polycarbonate, ABS resin, polyetherimide, fluorine resin, polyphenylene sulfide, or the like) can be used as long as it has impregnability for the reinforcing fiber material, and among them, a polyamide resin, polypropylene, fluorine resin, or polyphenylene sulfide is preferably used.
[5] Method for impregnating thermoplastic resins
In the present embodiment, the thermoplastic resin M is impregnated into the reinforcing fiber material F by laminating the thermoplastic resin M in a film form on the UD sheet P · P … arranged in a layer form and hot-pressing the thermoplastic resin M and the UD sheet P · P …, but the thermoplastic resin M in a granular form or a short fiber form may be laminated and impregnated on the UD sheet P · P …. The impregnation rate of the thermoplastic resin M is not necessarily required to be completely impregnated into all the reinforcing fibers F of the UD sheet P, and may be only sufficient to bond the UD sheet P · P ….
[6] Impregnation of thermoplastic resins
In the case of using a method of laminating films on the UD sheet P · P … and hot-pressing the laminated films in the method of impregnating the thermoplastic resin M, a polyamide resin is preferably used, and a resin having a low viscosity is more preferably used. Although the impregnation property is inferior to that of the polyamide resin, polypropylene or ETFE (a copolymer of tetrafluoroethylene and ethylene) can be used. The test results of the impregnation property of the thermoplastic resin are shown in the following table 1 for reference.
[ TABLE 1]
| Thermoplastic resin | Film thickness [ mu ] m] | UD sheet thickness [ mu ] m] | Melting Point [. degree.C. ]] | Processing temperature of [ deg.C ]] | Evaluation of impregnation Property |
| PET | 25 | 60 | 255 | 280 | × |
| PEN | 25 | 60 | 264 | 280 | × |
| ETFE | 25 | 60 | 225 | 280 | △ |
| PEI | 25 | 60 | 215 | 330 | × |
| PPS | 25 | 60 | 278 | 300 | △ |
| PEEK | 25 | 60 | 340 | 380 | × |
| PP | 20 | 50 | 160 | 200 | △ |
| PA6 | 20 | 50 | 225 | 270 | ○ |
[7] Regarding the shape of the UD sheet
In the UD sheet P shown in fig. 3, a sheet having a width W5mm × a length L20mm is used in the present embodiment, and a rectangular sheet having a width W2mm to 20mm (preferably 5mm to 10mm), a length L5mm to 70mm (preferably 10mm to 30mm), and a ratio of the width W to the length L of 1: 1 to 1: 6 can be used in consideration of strength and shaping properties. In the present specification, a direction parallel to the longitudinal direction of the reinforcing fiber material is defined as the longitudinal direction of the UD sheet P, and a direction perpendicular thereto is defined as the width direction.
[8] Thickness of quasi-isotropic reinforcing sheet and UD sheet
The thickness of the quasi-isotropic reinforcing sheet S is preferably set to a range of 0.3mm to 1.0mm, and the thickness of the UD sheet P is preferably set to a range of 40 μm to 100 μm. The average number of UD sheet pieces P · P … stacked in the quasi-isotropic reinforcing sheet S in the thickness direction is designed to be in the range of 5.0 sheets to 8.0 sheets in the present embodiment, but is preferably designed to be in the range of 2.0 sheets to 15.0 sheets in consideration of strength and impregnation property of the resin.
[9] Physical Properties of quasi-Isotropic Reinforcement sheet
The quasi-isotropic reinforcing sheet S is preferably designed so that the strain at break when the thickness is 2.0mm is 1.10 to 1.75%. Further, as a result of performing a fracture strain test when a plurality of sheets are laminated and integrated to have a thickness of 2.0mm, the quasi-isotropic reinforcing sheet S of the present embodiment was 0.71% in a conventional sheet laminate in which plain-woven sheets of carbon fibers were laminated and impregnated with a resin, and 1.53% in the sheet laminate of the present embodiment. The comparison of other physical property values is shown in table 2 below. In the table, the numerical values of "strain at break", "tensile strength" and "tensile modulus" were calculated according to JIS K7164, the numerical values of "flexural breaking strength" and "flexural modulus" were calculated according to JIS K7074, and the numerical values of "compressive strength" were calculated according to JIS K7076. The number n of test pieces in each laminate was 6, and the average value is shown in the table.
[ TABLE 2]
Second embodiment
Constitution of FPR molded body
[1] Basic constitution of FPR molded body
Next, a second embodiment of the present invention will be described with reference to fig. 4 to 5. In the present embodiment, as shown in fig. 4, an FRP molded body 1 having a laminate of quasi-isotropic reinforcing sheets S (except for the conditions the same as those in the first embodiment) using Vf 54% of UD sheet pieces having a width W5mm × a length L20mm as main materials was configured to have stripe-shaped protrusions 12 on the surface of a main body portion 11.
The stripe-shaped protrusion 12 may be designed to have a width of 0.5mm or more and a height of 5mm or more (preferably 20mm or more, and more preferably 50mm or more). In addition, as shown in fig. 5, a bent reinforcing fiber material F is made to exist at the base portion B of the above-described protrusion portion 12 to connect the main body portion 11 with the protrusion portion 12. This makes it possible to form the elongated rib-like projecting portion 12 more resistant to breaking than in the conventional case.
[2] Regarding the shape of the projection
In addition, as for the above-described projecting part 12, in the present embodiment, as shown in fig. 5, the portion 12a on the tip end side and the portion 12b on the base end side of the projecting part 12 are formed with the same width and in such a manner that the fiber volume content ratio (Vf) is not greatly different. Thereby, the bending strength of the portion 12b on the base end side is set to a value of-10% to + 30% with respect to the bending strength of the portion 12a on the tip end side, and the protrusion 12 having a small strength difference depending on the portion is formed.
Method for producing FPR molded body
In addition, when the FRP molded body 1 of the present embodiment is manufactured, the strip-shaped protrusion 12 having a width of 1.0mm to 6.0mm and a height of 20mm or more can be easily formed on the surface of the body 11 of the molded body by hot press molding the laminate of the isotropic reinforcing sheet S with a mold. In addition, by adopting this manufacturing method, it becomes possible to make the reinforcing fiber material F connecting the main body portion 11 and the protrusion portion 12 exist at the base portion B of the protrusion portion 12.
[ examples ] A
[ test (i) for verifying Effect ]
Next, a verification test (i) of the effect of the present invention will be described. First, in this test, the type of quasi-isotropic reinforcing sheet serving as the main material of the FRP molded body and the size of the linear protrusions formed in the FRP molded body were changed, hot press molding was performed, and the formability was evaluated from the molding results.
Example 1
The same quasi-isotropic reinforcing sheet material (reinforcing fiber material: carbon fiber, thermoplastic resin: polyamide resin, dimensions of UD sheet material: 5mm in width × 20mm in length, fiber content: Vf 54%) as that used for the FRP molded body of the second embodiment was used, and a laminate of the sheet materials was hot-press molded using a mold having a concave portion 0.5mm in width and 45mm in depth. As a result, an FRP molded body having a protrusion with a width of 0.5mm and a height of 45mm on the surface of the body can be molded.
Example 2
The same quasi-isotropic reinforcing sheet (reinforcing fiber material: carbon fiber, thermoplastic resin: polyamide resin, dimensions of the UD sheet: 5mm in width × 20mm in length, fiber content: Vf 54%) as that used for the FRP molded body of the second embodiment was used, and a laminate of the sheets was hot-press molded using a mold having a concave portion 1.0mm in width and 45mm in depth. As a result, an FRP molded body having a protrusion with a width of 1.0mm and a height of 45mm on the surface of the body can be molded.
Example 3
The same quasi-isotropic reinforcing sheet material (reinforcing fiber material: carbon fiber, thermoplastic resin: polyamide resin, dimensions of UD sheet material: 5mm in width × 20mm in length, fiber content: Vf 54%) as that used for the FRP molded body of the second embodiment was used, and a laminate of the sheet materials was hot-press molded using a die having a concave portion 2.0mm in width and 45mm in depth. As a result, an FRP molded body having a protrusion with a width of 2.0mm and a height of 45mm on the surface of the body can be molded.
Example 4
The same quasi-isotropic reinforcing sheet (reinforcing fiber material: carbon fiber, thermoplastic resin: polyamide resin, dimensions of the UD sheet: 5mm in width × 20mm in length, fiber content: Vf 54%) as that used for the FRP molded body of the second embodiment was used, and a laminate of the sheets was hot-press molded using a mold having a concave portion 3.0mm in width and 45mm in depth. As a result, an FRP molded body having protrusions of 3.0mm in width and 45mm in height on the surface of the body can be molded.
Example 5
The same quasi-isotropic reinforcing sheet material (reinforcing fiber material: carbon fiber, thermoplastic resin: polyamide resin, dimensions of UD sheet material: 5mm in width × 20mm in length, fiber content: Vf 54%) as that used for the FRP molded body of the second embodiment was used, and a laminate of the sheet materials was hot-press molded using a mold having a concave portion 5.0mm in width and 45mm in depth. As a result, an FRP molded body having a protrusion with a width of 5.0mm and a height of 45mm on the surface of the body can be molded.
Comparative example 1
A quasi-isotropic reinforcing sheet material (reinforcing fiber material: carbon fiber, thermoplastic resin: polyamide resin, fiber content: Vf 45%) obtained by laminating flat woven sheets of a reinforcing fiber material and impregnating the sheet material with a resin was used, and the laminate of the sheet materials was hot-press molded using a mold having a concave portion with a width of 1.0mm and a depth of 45 mm. As a result, only the projections having a height of 3mm or less are formed on the surface of the body.
Comparative example 2
A quasi-isotropic reinforcing sheet material (reinforcing fiber material: carbon fiber, thermoplastic resin: polyamide resin, fiber content: Vf 45%) obtained by laminating flat woven sheets of a reinforcing fiber material and impregnating the sheet material with a resin was used, and the laminate of the sheet materials was hot-press molded using a mold having a concave portion 2.0mm wide and 45mm deep. As a result, only the projections having a height of 3mm or less are formed on the surface of the main body.
Comparative example 3
A quasi-isotropic reinforcing sheet material (reinforcing fiber material: carbon fiber, thermoplastic resin: polyamide resin, fiber content: Vf 45%) obtained by laminating flat woven sheets of a reinforcing fiber material and impregnating the sheet material with a resin was used, and the laminate of the sheet materials was hot-press molded using a mold having a concave portion 3.0mm wide and 45mm deep. As a result, only the projections having a height of 3mm or less are formed on the surface of the main body.
Comparative example 4
A quasi-isotropic reinforcing sheet material (reinforcing fiber material: carbon fiber, thermoplastic resin: polyamide resin, fiber content: Vf 45%) obtained by laminating flat woven sheets of a reinforcing fiber material and impregnating the sheet material with a resin was used, and the laminate of the sheet materials was hot-press molded using a mold having a concave portion with a width of 5.0mm and a depth of 45 mm. As a result, only the projections having a height of 3mm or less are formed on the surface of the body.
Comparative example 5
The same quasi-isotropic reinforcing sheet (reinforcing fiber material: carbon fiber, thermoplastic resin: polyamide resin, dimensions of the UD sheet: 5mm in width × 20mm in length, fiber content: Vf 54%) as that used for the FRP molded body of the second embodiment was used, and a laminate of the sheets was hot-press molded using a mold having a concave portion 0.1mm in width and 45mm in depth. As a result, the projections cannot be formed neatly on the surface of the body.
< summary of test results >
From the results of examples 1 to 5, it was confirmed that: by hot press molding using the quasi-isotropic reinforcing sheet of the present invention, it is possible to form a stripe-shaped protrusion having a width of 0.5mm to 5.0mm and a height of 45mm without any problem. From the results of comparative examples 1 to 4, it was confirmed that: it is difficult to form a stripe-shaped protrusion having a width of 1.0mm to 5.0mm and a height of 45mm from a conventional quasi-isotropic reinforcing sheet. From the results of comparative example 5, it was confirmed that: even in the hot press molding using the quasi-isotropic reinforcing sheet of the present invention, it is difficult to form a projection having a width of 0.1mm or less.
[ test (ii) for verifying the Effect ]
Next, a verification test (ii) of the effect of the present invention will be described. In this test, a quasi-isotropic reinforcing sheet (reinforcing fiber material: carbon fiber, thermoplastic resin: polyamide resin, and UD sheet material: 5mm in width × 20mm in length, and Vf54 in fiber content) similar to that used for the FRP molded body of the second embodiment was used, and a laminate of the sheets was hot-press molded using a mold having a recessed portion 2.0mm in width and 60mm in depth, to prepare an FRP molded body having a protruding portion 2.0mm in width and 60mm in height on the surface of the main body portion as shown in FIG. 6.
Then, 3 test pieces (9 pieces in total, where n is 3) were prepared for each part having a length of 100mm by cutting out a sheet-like test piece (dimensions: width 15 mm. times. length 120 mm. times. thickness 2mm) from each part on the tip side, center part, and base end side of the protrusion of the FRP molded body, and subjected to a 4-point bending test in accordance with JIS K7074 to calculate an average value. As shown in fig. 6, the test pieces on the top end side and the bottom end side were cut out with a gap of 5.5mm from the edge portions of the top end and the bottom end of the protrusion, and the test pieces on each part were cut out with a gap of 2.0mm between the test pieces.
< test results >
As a result of performing a 4-point bending test on each of the test pieces on the top end side, the center portion, and the bottom end side, it was confirmed that the numerical value of the bending failure strength of each portion varied within ± 10%, no large difference was observed between the test pieces, and the UD sheet pieces were uniformly dispersed in the protrusions without being biased. From this, it is understood that the molding method of the present invention is effective not only for molding a flat plate shape but also for molding a three-dimensional shape. Table 3, which summarizes the data of this test, is shown below.
TABLE 3
Claims (9)
1. A method of making a quasi-isotropic reinforcing sheet, comprising: a step of laminating a film-like thermoplastic resin (M) after a plurality of UD sheet pieces (P) (P) …, which are formed by bonding and integrating continuous reinforcing fibers in a state of being arranged in one direction, are arranged in layers in a state of randomly orienting fiber directions of the sheet pieces and in a manner of overlapping the sheet pieces in a thickness direction,
impregnating the thermoplastic resin M into a reinforcing fiber material (F) by hot-pressing the thermoplastic resin M and the plurality of UD sheet pieces (P) …;
the UD sheet piece P is 40-60 mu m thick, 2-20 mm wide, 5-70 mm long and 1: 1-1: 6, the laminated UD sheet (P) … has an average number in the thickness direction of 2.0 to 15.0 sheets, the thermoplastic resin M has a thickness of 20 to 25 μ M, and the whole UD sheet P is not completely impregnated in the reinforcing fibers by hot pressing.
2. The method of manufacturing a quasi-isotropic reinforcing sheet according to claim 1, wherein the continuous reinforcing fibers are carbon fibers, the thermoplastic resin (M) is polyamide resin, polycarbonate, polypropylene, fluororesin, or polyphenylene sulfide, the fiber volume content of the sheet main body is 20% to 70%, and the strain at break when the sheet main body is formed by laminating and integrating a plurality of the sheet main bodies to have a thickness of 2.0mm is 1.10 to 1.75%.
An FRP molded body comprising, as a main material, a laminate of quasi-isotropic reinforcing sheets produced by the method for producing a quasi-isotropic reinforcing sheet according to claim 1 or 2, wherein stripe-shaped protrusions (12) having a width of 0.5mm or more and a height of 5mm or more are formed on the surface of the main body (11), and the reinforcing fibers are present in the base portions (B) of the protrusions (12) so as to connect the main body (11) and the protrusions (12).
4. The FRP formed body as claimed in claim 3, wherein the tip end side portion (12a) and the base end side portion (12b) of the protrusion (12) are formed to have the same width, and the bending strength of the base end side portion (12b) is set to a value of-10% to + 30% with respect to the bending strength of the tip end side portion (12 a).
5. The method for producing an FRP molded body as claimed in claim 3 or 4, wherein the laminate of quasi-isotropic reinforcing sheets is hot-press molded by using a mold, and stripe-shaped protrusions (12) having a width of 0.5mm or more and a height of 5mm or more are formed on the surface of the body (11) of the molded body.
An FPR molded body which is an FRP molded body comprising a laminate of quasi-isotropic reinforcing sheets (S) as a main material, characterized in that strip-shaped protrusions (12) having a width of 0.5mm or more and a height of 5mm or more are formed on the surface of a main body (11), and a reinforcing fiber material (F) is present at the base (B) of the protrusions (12) to connect the main body (11) and the protrusions (12),
in the laminated body of the quasi-isotropic reinforcing sheet material (S), the quasi-isotropic reinforcing sheet material is composed of a reinforcing fiber material (F) and a thermoplastic resin (M), wherein, the sheet material main body is formed by bonding a plurality of UD sheet material sheets (P) (P) … under the state of randomly orienting the fiber direction of each sheet material sheet and under the state of overlapping and arranging layer by layer, the UD sheet material sheets (P) (P) … is formed by bonding and integrating continuous fibers under the state of arranging in one direction, furthermore, as the UD sheet material sheets (P), the UD sheet material sheets with the thickness of 40-60 μ M, the width of 2-20 mm, the length of 5-70 mm and the ratio of 1: 1-1: 6, wherein the average number of the UD sheet pieces (P) (P) … stacked in the quasi-isotropic reinforcing sheet in the thickness direction is 2.0 to 15.0 sheets.
7. The FPR molded body according to claim 6, wherein the reinforcing fiber material (F) is carbon fiber, the thermoplastic resin (M) is polyamide resin, polypropylene, fluorine resin or polyphenylene sulfide, the fiber volume content of the sheet main body is 20% to 70%, and the breaking strain when the sheet main body is formed by laminating and integrating a plurality of the sheet main bodies to have a thickness of 2.0mm is 1.10 to 1.75%.
8. The FRP formed body as claimed in claim 6 or 7, wherein the tip end side portion (12a) and the base end side portion (12b) of the protrusion (12) are formed to have the same width, and the bending strength of the base end side portion (12b) is set to a magnitude of-10% to + 30% with respect to the bending strength of the tip end side portion (12 a).
9. A method for producing an FRP molded body according to any one of claims 6 to 8, characterized in that the laminate of quasi-isotropic reinforcing sheets (S) is hot-press molded using a mold, and stripe-shaped protrusions (12) having a width of 0.5mm or more and a height of 5mm or more are formed on the surface of the body part (11) of the molded body.
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| CN202210436481.5A CN114770803A (en) | 2018-03-28 | 2018-03-28 | Quasi-isotropic reinforcing sheet, FRP molded body, and method for producing FRP molded body |
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Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5164255A (en) * | 1989-08-31 | 1992-11-17 | E. I. Du Pont De Nemours And Company | Nonwoven preform sheets of fiber reinforced resin chips |
| US20100215887A1 (en) * | 2006-11-22 | 2010-08-26 | Fukui Prefectural Government | Reinforced thermoplastic-resin multilayer sheet material, process for producing the same, and method of forming molded thermoplastic-resin composite material |
| CN104781065A (en) * | 2012-12-26 | 2015-07-15 | 东丽株式会社 | Molded product having hollow structure and process for producing same |
| CN107428043A (en) * | 2015-04-16 | 2017-12-01 | 三菱瓦斯化学株式会社 | Pass through the compressing manufacture method for being manufactured body of thermoplastic resin sheet or film |
-
2018
- 2018-03-28 CN CN202210436481.5A patent/CN114770803A/en active Pending
- 2018-03-28 CN CN201810264447.8A patent/CN110315660B/en active Active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5164255A (en) * | 1989-08-31 | 1992-11-17 | E. I. Du Pont De Nemours And Company | Nonwoven preform sheets of fiber reinforced resin chips |
| US20100215887A1 (en) * | 2006-11-22 | 2010-08-26 | Fukui Prefectural Government | Reinforced thermoplastic-resin multilayer sheet material, process for producing the same, and method of forming molded thermoplastic-resin composite material |
| CN104781065A (en) * | 2012-12-26 | 2015-07-15 | 东丽株式会社 | Molded product having hollow structure and process for producing same |
| CN107428043A (en) * | 2015-04-16 | 2017-12-01 | 三菱瓦斯化学株式会社 | Pass through the compressing manufacture method for being manufactured body of thermoplastic resin sheet or film |
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| CN110315660B (en) | 2022-06-10 |
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