CN115038569A - 含纤维的片材的制造方法及含纤维的片材 - Google Patents

含纤维的片材的制造方法及含纤维的片材 Download PDF

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CN115038569A
CN115038569A CN202180011983.7A CN202180011983A CN115038569A CN 115038569 A CN115038569 A CN 115038569A CN 202180011983 A CN202180011983 A CN 202180011983A CN 115038569 A CN115038569 A CN 115038569A
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resin
core layer
fiber
die
skin layers
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藤冈修司
小崎修司
铃川正纮
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Hitachi Zosen Corp
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Hitachi Zosen Corp
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Abstract

本发明提供一种含纤维的片材的制造方法。该制造方法中，在使用T型模具将树脂挤出成型为片状时，以层叠了用于形成芯层的第一树脂和用于形成位于芯层的两表面上的两皮层的第二树脂的状态，进行由T型模具挤出的挤出成型。此时，将包含纤维材料的树脂用作第一树脂，且将不包含纤维材料的树脂用作第二树脂。

Description

含纤维的片材的制造方法及含纤维的片材
技术领域
本发明涉及含纤维的片材的制造方法及含纤维的片材。
背景技术
在将树脂中包含碳纤维或玻璃纤维等纤维材料的塑料复合材料进行了成型时，其纤维有时会沿成型体的纵向(MD)取向。该取向的产生尤其是在使用了T型模具的片状挤出成型品中较为突出。由于沿MD取向，其所成型的片材的沿MD的方向的强度升高。这种使用T型模具将包含纤维材料的塑料复合材料成型的技术，例如记载于JPH08-269210A中。
发明内容
本发明要解决的技术问题
然而，对于利用这种方法成型且沿MD取向的片材，如上所述，一方面虽其沿MD的方向的强度变高，但另一方面，却存在其垂直于MD的方向(TD)的强度显著降低的倾向。
作为对策，通过将沿MD取向的多个片材一边彼此变换角度一边堆积，并利用热压加工进行一体化，从而得到在整个方向具有强度的片材。然而，对于这种手法而言，需要所需的特殊技术、所需的成型时间及所需的成本。
因此，本发明的目的在于解决这种技术问题，使可轻松且确切地得到取向得以抑制的含纤维的片材成为可能。
解决技术问题的技术手段
为了实现该目的，本发明的含纤维的片材的制造方法的特征在于，在使用T型模具将树脂挤出成型为片状时，以层叠了用于形成芯层的第一树脂和用于形成位于芯层的两表面的两皮层的第二树脂的状态，进行由T型模具挤出的挤出成型，此时，将包含纤维材料的树脂用作第一树脂，且将不包含纤维材料的树脂用作第二树脂。
即，本发明基于以下见解而完成：在树脂中含有纤维的复合材料中树脂中的纤维发生取向的原因在于，熔融状态的树脂与纤维以混合状态流入T型模具内，并最终在T型模具内扩展为片状时，纤维因流路的壁面的阻力朝向沿MD的方向而发生取向。根据本发明，由于在进行使用了T型模具的挤出成型时，在芯层的两表面配置皮层，并且芯层利用包含纤维材料的树脂而成型，而两皮层利用不包含纤维材料的树脂而成型，因此，使得芯层的包含纤维材料的树脂以不与T型模具的流路的壁面接触的方式由T型模具挤出，因而，会在纤维的取向得以抑制的状态下成型为片状。
根据本发明的含纤维的片材的制造方法，优选将芯层的第一树脂与两皮层的第二树脂以彼此可剥离的状态成型为一体。由此，通过在成型后使皮层从芯层上剥离，可得到表面露出了取向得以抑制的含纤维的树脂的片材。
根据本发明的含纤维的片材的制造方法，为了使芯层的第一树脂与两皮层的第二树脂良好地剥离，优选：作为用于成型为芯层的第一树脂和用于成型为皮层的第二树脂，使用彼此不具有相容性的树脂。
根据本发明的含纤维的片材的制造方法，可通过使至少一个皮层从以一体的层叠状态获得的成型体中剥离，轻松地得到表面露出了取向得以抑制的含纤维的树脂的片材。
根据本发明的含纤维的片材的制造方法，也优选：将芯层的第一树脂与两皮层的第二树脂以彼此不可剥离的状态成型为一体。由此，可无需经过剥离工序而简便地得到取向得以抑制的含纤维的片材。
根据本发明的含纤维的片材的制造方法，也优选：作为用于成型为芯层的第一树脂和用于成型为皮层的第二树脂，使用彼此具有相容性的树脂。由此，能够易于将芯层的第一树脂与两皮层的第二树脂以彼此不可剥离的状态成型为一体。
本发明的含纤维的片材的特征在于，具有包含纤维材料的第一树脂制的芯层、和配置在该芯层的两表面的不包含纤维材料的第二树脂制的皮层，皮层可从芯层上剥离。
本发明的另一含纤维的片材的特征在于，包含纤维材料的第一树脂制的芯层、和配置在该芯层的两表面的不包含纤维材料的第二树脂制的皮层被成型为一体。
发明效果
根据本发明，可轻松且确切地得到取向得以抑制的含纤维的片材。
附图说明
图1为示出本发明的实施方案的含纤维的片材的关键部件的剖面结构的图。
图2为示出可用于本发明的实施方案的含纤维的片材的制造方法中的T型模具的结构例的图。
图3为示出实施例2中的芯层的表面的放大图像与比较例1的成型体的表面的放大图像的对比的图。
具体实施方式
对图2所示的T型模具的详细结构进行说明。图示的T型模具11通过模具(die)12与进料块(feed block)13彼此接合并一体化而成。
进料块13中设置有供给用于芯层的熔融状态的含纤维的树脂材料的第一路径14、和供给用于皮层的熔融状态的树脂材料的一对第二路径15、15。16为合流部，来自各路径14、15、15的熔融状态的树脂材料在此得以合流。此时，来自第二路径15的用于皮层的熔融状态的树脂材料分别供给至来自第一路径14的用于芯层的熔融状态的含纤维的树脂材料的两侧。结果这些熔融状态的树脂材料以3层的状态运送至模具12。
模具12具有窄喷嘴18，且以通过使该喷嘴18在垂直于图2的纸面的方向上形成为长条，从而能够将树脂以片状由模具12挤出而得到片状的成型体的方式构成。19为用于由进料块13运送出的树脂的引导路，20为歧管(manifold)。歧管20以使用于来自引导路19的熔融状态的树脂材料的流路在垂直于图2的纸面的方向上展开从而能够在上述垂直于图2的纸面的方向上对长条的喷嘴18供给充足的量的树脂的方式构成。
图示的T型模具11中，树脂材料在到达至合流部16之前会在垂直于图2的纸面的方向展开一次(例如宽100mm左右)，并在合流部16进行层叠之后，在模具12的歧管20处再次展开。通过采用这种结构，能够防止芯层以形成得较薄的状态与树脂流路的壁面接触，因此能够在后述的取向抑制效果的基础上进一步抑制取向。
本发明的制造方法中，作为T型模具11，并不仅限于上述结构，只要能够将在芯层的两表面上配置有皮层的层叠结构的片材挤出，则可以使用任意结构的T型模具。
例如，图2中虽未示出，但在第一路径14与第二路径15、15处使树脂材料分别展开至制品宽度后再进行层叠的T型模具，也可实施本发明的制造方法，其并非图2所示的在上述2个阶段展开的成型。此时，可以紧跟着歧管20设置扩展宽度后的树脂材料的合流部。使用这种T型模具实施了本发明的方法时，虽然片材的取向性些许变差，但能够在以良好的精度控制了厚度的状态下制造片材。
根据本发明，使用图2所示的结构的T型模具11，将用于芯层的熔融状态的含纤维的树脂材料从系统外部送入进料块13中的第一路径14，并且将用于皮层的熔融状态的树脂材料从系统外部送入一对第二路径15、15。由此，这些树脂材料以上述方式由T型模具11的喷嘴18以层叠状态的片状而挤出。
图1示出由T型模具11挤出的树脂在此之后通过冷却固化而形成的片状的成型体的关键部件的剖面结构。25为芯层。26、26为皮层，并以与芯层25的两表面接触的状态而分别形成。
芯层25为树脂27中包含纤维材料28的结构。而皮层26、26为树脂中不包含纤维材料的结构。
作为形成芯层25的树脂，能够以熔融状态由T型模具11挤出即可，可适当使用任意的热塑性树脂。例如，可列举出聚乙烯或聚丙烯等聚烯烃、聚酰胺、聚酯、聚碳酸酯、聚苯乙烯、聚乳酸、聚氯乙烯、液晶聚合物、聚苯硫醚、聚醚醚酮、聚醚酰亚胺等。纤维材料28为主要用于强化树脂27而添加的成分，只要能够实现该目的，则可适当使用任意的纤维材料。例如，可列举出碳纤维、玻璃纤维、硼纤维、高强度的树脂纤维、纤维素纤维等。
如上所述，皮层26、26以与芯层25的两表面接触的状态而分别形成，作为构成皮层26、26的树脂，可列举出与构成芯层25的树脂不具有相容性的树脂、或者与构成芯层25的树脂具有相容性的树脂。当构成皮层26、26的树脂为与构成芯层25的树脂不具有相容性的树脂时，如图1中虚线所示，能够使至少一个皮层26、26从所制造的片状的成型体的表面上剥离，而仅由芯层25构成该成型体。而当构成皮层26、26的树脂为与构成芯层25的树脂具有相容性的树脂时，如图1中实线所示，能够制成芯层25与皮层26、26以不可剥离的方式一体化而成的结构的成型体。
作为具有相容性的树脂的组合的实例，例如可列举出构成芯层25的树脂与构成皮层26、26的树脂均为聚丙烯的这种两者为同种树脂的情况。作为不具有相容性的树脂的组合，例如可列举出构成芯层25的树脂为聚丙烯，而构成皮层26、26的树脂为高密度聚乙烯的情况；或者，构成芯层25的树脂为聚丙烯，而构成皮层26、26的树脂为聚碳酸酯的情况等。
成型为图1所示的成型体时，在图2所示的T型模具11中，在构成皮层26、26的树脂彼此之间夹入有构成芯层25的树脂的基础上，将这些树脂由该T型模具11挤出而进行成型。因此，会以虽构成皮层26、26的树脂会与T型模具11中的树脂流路的壁面接触，但构成芯层25的树脂不会与T型模具11中的树脂流路的壁面接触的方式，由该T型模具11挤出。因此，构成芯层25的树脂不会受到树脂流路的壁面的阻力，因而，能够在抑制了在芯层25的表面及其附近处纤维材料28产生取向的状态下，形成作为成型体的芯层25。
皮层26、26为防止构成芯层25的树脂在以熔融状态沿T型模具11中的树脂流路流动时与树脂流路的壁面接触的层。因此，只要具备用以发挥该功能而所需的最小限的厚度即足矣。例如，只要皮层26的厚度为10μm以上，就可以称得上发挥效果，但当其厚度在10～50μm之间时，存在产生层间错乱(流痕)的问题或纤维材料28的取向未得以抑制的问题。因此，皮层的厚度最好为50μm以上。对于芯层25与一对皮层26、26的合计厚度，可结合成型品的用途而适当设定。
如上所述，皮层26、26只要为防止构成芯层25的树脂在以熔融状态沿T型模具11中的树脂流路流动时与树脂流路的壁面接触的层即足矣。因此，虽然原则上皮层26、26中不包含纤维材料，但只要能够防止在芯层25中纤维材料产生取向，则即使皮层26、26中含有些许纤维材料也是可以的。在本发明中，皮层26、26在树脂中不包含纤维材料是指广泛地包括此类情况在内。
实施例
对于以下的实施例、比较例，以如下方式进行各物性的测定。
(1)取向的程度
将由芯层用挤出机与皮层用挤出机这两台挤出机(Hitachi Zosen Corporation制造：HMT57、SHT65)吐出的熔融树脂在进料块(Hitachi Zosen Corporation制造：FB3)内层叠，并在T型模具(Hitachi Zosen Corporation制造：TFS102F)内扩展为宽1020mm后，利用片材成型机(Hitachi Zosen Corporation制造：GOMP120.3)的辊进行挟压并固化，由此进行成型。将该成型的片材裁切成长1m，并利用光学显微镜(KEYENCE CORPORATION制造：VHX-900)对由该片材切取的30mm见方的断片的表面进行观察，通过肉眼确认取向。
(2)芯层与皮层的剥离性
用美工刀等锋利的刀具对皮层的一部分切入切口，借助于此用手抓住一侧的皮层的部分与另一侧的皮层的部分，将两者沿不同的方向拉伸从而进行剥离，利用该手法确认剥离性。
(实施例1)
作为用于构成芯层的材料，使用含有30质量％碳纤维的聚丙烯树脂(MitsubishiChemical Corporation制造，产品名称/产品编号：PYROFIL PP-C-30)，此外，作为用于构成两皮层的材料，使用聚丙烯树脂(Japan Polypropylene Corporation制造，产品编号：EA9)。然后，使用图2所示的结构的T型模具，利用挤出成型法制造厚0.7mm、宽1002mm的片状的成型体。两皮层与芯层的厚度之比为皮层:芯层:皮层＝1:6:1。
所得到的成型体中，芯层与皮层牢固地一体化，未能通过上述手法使两者剥离。从皮层的表面上方对芯层的表面进行显微镜观察，结果未对碳纤维的取向确认到明显的方向性，可认为碳纤维随机取向。
对于实施例1，将制造条件与物性的测定结果示于表1。
Figure BDA0003773373180000081
(实施例2～4)
与实施例1相比，将制造条件变更为表1所示。除此以外，与实施例1相同。
对于实施例2～4，将制造条件与物性的测定结果示于表1。
(实施例5)
与实施例4相比，将用于构成皮层的材料变更为与用于构成芯层的树脂不具有相容性的高密度聚乙烯(Japan Polypropylene Corporation制造，产品编号：HF313)。并且，除此以外，与实施例4相同。
对于实施例5，将制造条件与物性的测定结果示于表1。
(实施例6)
与实施例3相比，将用于构成皮层的材料变更为如下材料。即，将上述聚丙烯与高密度聚乙烯以质量比计为聚丙烯:高密度聚乙烯＝2:1的方式进行掺合而成的材料，用作用于构成皮层的材料。并且，除此以外，与实施例3相同。
对于实施例6，将制造条件与物性的测定结果示于表1。
(实施例7)
与实施例3相比，将用于构成皮层的材料变更为聚碳酸酯树脂(MitsubishiEngineering-Plastics Corporation制造，产品编号：E-2000)。并且，除此以外，与实施例3相同。
对于实施例7，将制造条件与物性的测定结果示于表1。
(比较例1)
仅使用实施例1中使用的用于构成芯层的材料，得到不具备皮层的片状的成型体。
对于比较例1，将制造条件与物性的测定结果示于表1。
如表1所示，对于实施例1～7的片状的成型体，均未对碳纤维的取向确认到明显的方向性，碳纤维随机取向。而对于比较例1，由于未使用用于构成皮层的材料而进行了成型，成型体中的树脂中的碳纤维在沿MD的方向上强烈地取向。图3示出实施例2与比较例1的芯层的表面的放大图像。图中，上侧为实施例2的图像，下侧为比较例1的图像。由该图像可确认到：比较例1中碳纤维具有明显的方向性，而实施例2中碳纤维不具有明显的方向性而是随机取向。
对于实施例1～4、6，用于构成芯层的材料与用于构成皮层的材料为同种材料，彼此具有相容性，因此皮层与芯层牢固地一体化。然而，对于实施例5及7，用于构成芯层的材料与用于构成皮层的材料为不同种的材料，彼此不具有相容性，因此可在成型后轻松地将皮层从芯层上剥离。由此，能够仅由树脂中含有纤维材料的材料构成片状的成型体。

Claims (8)

1.一种含纤维的片材的制造方法，其特征在于，在使用T型模具将树脂挤出成型为片状时，以层叠了用于形成芯层的第一树脂和用于形成位于芯层的两表面上的两皮层的第二树脂的状态，进行由T型模具挤出的挤出成型，此时，将包含纤维材料的树脂用作第一树脂，且将不包含纤维材料的树脂用作第二树脂。
2.根据权利要求1所述的含纤维的片材的制造方法，其特征在于，将芯层的第一树脂与两皮层的第二树脂以彼此可剥离的状态成型为一体。
3.根据权利要求2所述的含纤维的片材的制造方法，其特征在于，作为用于成型为芯层的第一树脂和用于成型为皮层的第二树脂，使用彼此不具有相容性的树脂。
4.根据权利要求2或3所述的含纤维的片材的制造方法，其特征在于，使至少一个皮层从以一体的层叠状态获得的成型体中剥离。
5.根据权利要求1所述的含纤维的片材的制造方法，其特征在于，将芯层的第一树脂与两皮层的第二树脂以彼此不可剥离的状态成型为一体。
6.根据权利要求5所述的含纤维的片材的制造方法，其特征在于，作为用于成型为芯层的第一树脂和用于成型为皮层的第二树脂，使用彼此具有相容性的树脂。
7.一种含纤维的片材，其特征在于，具有包含纤维材料的第一树脂制的芯层、和配置在该芯层的两表面的不包含纤维材料的第二树脂制的皮层，皮层可从芯层上剥离。
8.一种含纤维的片材，其特征在于，包含纤维材料的第一树脂制的芯层、和配置在该芯层的两表面的不包含纤维材料的第二树脂制的皮层被成型为一体。
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