JP2005330605A - Reinforced sheet and method for producing the same - Google Patents

Reinforced sheet and method for producing the same Download PDF

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JP2005330605A
JP2005330605A JP2004148045A JP2004148045A JP2005330605A JP 2005330605 A JP2005330605 A JP 2005330605A JP 2004148045 A JP2004148045 A JP 2004148045A JP 2004148045 A JP2004148045 A JP 2004148045A JP 2005330605 A JP2005330605 A JP 2005330605A
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resin
fiber
reinforcing
sheet
fibers
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Nobuyasu Suematsu
伸康 末松
Toshio Ohashi
利男 大橋
Toshiharu Watanabe
年春 渡辺
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Marelli Corp
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Calsonic Kansei Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a reinforced sheet which can sufficiently obtain the reinforcing effect of reinforcing fibers contained therein, and to provide a method for producing the same. <P>SOLUTION: This reinforced sheet 12 is characterized by thermally melting a woven sheet 1 formed by weaving thermoplastic resin fibers 2 with non-resin material reinforcing fibers 3 having a higher strength than that of the resin fibers 2, thus adhering the resin fibers 2 to the reinforcing fibers. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、補強シートおよびその製造方法に関するものである。   The present invention relates to a reinforcing sheet and a manufacturing method thereof.

例えば自動車部品等の分野において、成形の容易性或いは補強繊維の添加による強度調整の容易性から、熱可塑性樹脂の中に補強繊維を含ませた樹脂パネルが広く用いられている。補強繊維としては、一般にカーボンファイバー繊維やグラスファイバー繊維が用いられている。   For example, in the field of automobile parts and the like, a resin panel in which a reinforcing fiber is included in a thermoplastic resin is widely used from the viewpoint of easy molding or easy strength adjustment by adding a reinforcing fiber. In general, carbon fiber fiber or glass fiber fiber is used as the reinforcing fiber.

このような補強繊維は、それが含有される樹脂成分との密着性が良くないと、本来の補強効果が得られないため、補強繊維の表面には、予め熱可塑性樹脂による樹脂コーティングが施されている。そして、その樹脂コーティングが成形時の熱により溶けて、周辺の樹脂成分と融合するため、この樹脂コーティングがバインダーとなって、補強繊維と周辺樹脂との密着性が向上する仕組みになっている(例えば、特許文献1。)。
特開2002−59477号公報
Such a reinforcing fiber cannot have its original reinforcing effect unless it has good adhesion to the resin component in which it is contained. Therefore, the surface of the reinforcing fiber is pre-coated with a thermoplastic resin. ing. And since the resin coating melts by the heat at the time of molding and fuses with the surrounding resin components, this resin coating serves as a binder, and the adhesiveness between the reinforcing fiber and the surrounding resin is improved ( For example, Patent Document 1).
JP 2002-59477 A

しかしながら、このような従来の技術にあっては、表面に樹脂コーティングを施した補強繊維を製造するために、特殊な製造装置が必要となり、コストの面において不利である。また、表面に施された樹脂コーティング成分だけでは、バインダーとしての樹脂量が不十分で、補強繊維と周辺樹脂との密着性を十分に高めることができず、得られる補強効果にも限りがあった。   However, such a conventional technique is disadvantageous in terms of cost because a special manufacturing apparatus is required to manufacture a reinforcing fiber having a resin coating on the surface. In addition, the resin coating component applied to the surface alone does not provide sufficient amount of resin as a binder, and the adhesion between the reinforcing fiber and the peripheral resin cannot be sufficiently increased, and the resulting reinforcing effect is limited. It was.

本発明は、このような従来の技術に着目してなされたものであり、補強繊維の含有による補強効果を十分に得ることができる補強シートおよびその製造方法を提供するものである。   The present invention has been made by paying attention to such a conventional technique, and provides a reinforcing sheet that can sufficiently obtain a reinforcing effect due to the inclusion of reinforcing fibers, and a method for manufacturing the same.

請求項1記載の発明は、熱可塑性樹脂材料製の樹脂繊維と、樹脂繊維より高強度な非樹脂材料製の補強繊維とにより織製された織物シートを加熱したことにより溶融させることで、前記樹脂繊維と前記補強繊維とを密着させて形成させてなることを特徴とする。   The invention according to claim 1 is a method in which a fabric sheet woven by a resin fiber made of a thermoplastic resin material and a reinforcing fiber made of a non-resin material having a higher strength than the resin fiber is melted by heating. The resin fibers and the reinforcing fibers are formed in close contact with each other.

請求項2記載の発明は、請求項1記載の補強シートであって、織物シートにおいて、樹脂繊維の方が補強繊維よりも太いことを特徴とする。   The invention according to claim 2 is the reinforcing sheet according to claim 1, wherein the resin fiber is thicker than the reinforcing fiber in the woven sheet.

請求項3記載の発明は、請求項1又は請求項2記載の補強シートであって、補強繊維が、カーボンファイバー繊維又はグラスファイバー繊維であることを特徴とする。   The invention according to claim 3 is the reinforcing sheet according to claim 1 or 2, wherein the reinforcing fibers are carbon fiber fibers or glass fiber fibers.

請求項4記載の発明は、熱可塑性樹脂材料製の樹脂繊維と、樹脂繊維より高強度な非樹脂材料製の補強繊維により織製された織物シートに、ホットプレス加工を加えて、互いに融合した樹脂繊維成分内に補強繊維が含有された状態の所定厚さで且つ所定形状を有することを特徴とする。   In the invention according to claim 4, hot pressing is applied to a woven sheet made of a resin fiber made of a thermoplastic resin material and a reinforcing fiber made of a non-resin material having a strength higher than that of the resin fiber, and then fused together. The resin fiber component has a predetermined thickness and a predetermined shape in which reinforcing fibers are contained.

請求項1記載の発明によれば、樹脂繊維と補強繊維とを織り込んで形成した織物シートを加熱したことにより溶融させることで樹脂繊維と補強繊維とを密着した補強シートを形成したため、溶けた樹脂繊維の成分が十分な量のバインダーとなって、補強繊維に密着させ、補強繊維による補強効果が確実に高まる。また、織物シートは、補強繊維に対して樹脂繊維を織り込むだけなので、通常の織物製造装置を利用することができ、コストの面でも有利である。   According to the first aspect of the present invention, since the woven sheet formed by weaving the resin fibers and the reinforcing fibers is heated and melted to form the reinforcing sheet in which the resin fibers and the reinforcing fibers are in close contact, the molten resin The component of the fiber becomes a sufficient amount of the binder and is brought into close contact with the reinforcing fiber, so that the reinforcing effect by the reinforcing fiber is reliably increased. In addition, since the woven sheet only includes resin fibers woven into the reinforcing fibers, a normal woven fabric manufacturing apparatus can be used, which is advantageous in terms of cost.

請求項2記載の発明によれば、織物シートにおいて、樹脂繊維の方を補強繊維よりも太くしたため、樹脂繊維が溶けた際に十分な量の樹脂成分が得られ、補強繊維と周辺の樹脂シートとの密着性を高めることができる。   According to the invention described in claim 2, since the resin fiber is thicker than the reinforcing fiber in the woven sheet, a sufficient amount of the resin component is obtained when the resin fiber is melted, and the reinforcing fiber and the surrounding resin sheet are obtained. Adhesion can be improved.

請求項3記載の発明によれば、補強繊維が、カーボンファイバー繊維又はグラスファイバー繊維であるため、軽量化を図ることができる。   According to invention of Claim 3, since a reinforcement fiber is a carbon fiber fiber or a glass fiber fiber, weight reduction can be achieved.

請求項4記載の発明によれば、織物シートをホットプレス加工により樹脂繊維成分内に補強繊維が含まれた補強シートに成形できるため、その補強シートを樹脂で覆わなくても十分強度を有する自動車部品等とすることができる。   According to the invention of claim 4, since the woven sheet can be formed into a reinforcing sheet in which the reinforcing fiber is contained in the resin fiber component by hot pressing, the automobile has sufficient strength without covering the reinforcing sheet with the resin. It can be a part or the like.

補強繊維の含有による補強効果を十分に得ることができる補強シートおよびその製造方法を提供する、という目的を、熱可塑性樹脂材料製の樹脂繊維と、樹脂繊維より高強度な非樹脂材料製の補強繊維とにより織製された織物シートを加熱したことにより溶融させることで、前記樹脂繊維と前記補強繊維とを密着させて形成させてなることにより、実現した。以下、本発明の実施形態を図面に基づいて説明する。ものである。   For the purpose of providing a reinforcing sheet and a method for producing the same, which can sufficiently obtain a reinforcing effect due to the inclusion of the reinforcing fiber, the reinforcement is made of a resin fiber made of a thermoplastic resin material and a non-resin material having higher strength than the resin fiber. This was realized by forming the woven fabric sheet woven with the fibers by heating them so that the resin fibers and the reinforcing fibers were brought into close contact with each other. Hereinafter, embodiments of the present invention will be described with reference to the drawings. Is.

図1〜図7は、本発明の第1実施例を示す図である。図1及び図2に示す織物シート1は、熱可塑性樹脂材料製の樹脂繊維2と、樹脂繊維2よりも高強度な非樹脂材料製の補強繊維3とを交互に織製した構造になっている。   1 to 7 are views showing a first embodiment of the present invention. The fabric sheet 1 shown in FIGS. 1 and 2 has a structure in which resin fibers 2 made of a thermoplastic resin material and reinforcing fibers 3 made of a non-resin material having higher strength than the resin fibers 2 are woven alternately. Yes.

樹脂繊維2を構成する熱可塑性樹脂としては、例えばポリ塩化ビニル、ポリスチレン、ポリプロピレン、ポリカーボネート、ポリアミドなど何でも良い。補強繊維3を構成する高強度な非樹脂材料としては、軽量なカーボンファイバー繊維やグラスファイバー繊維などが好適である。樹脂繊維2の方が補強繊維3よりも太く形成されている。織物シート1は、補強繊維3に対して樹脂繊維2を織り込むだけなので、通常の織物製造装置を利用することができ、コストの面でも有利である。   As a thermoplastic resin which comprises the resin fiber 2, anything, such as a polyvinyl chloride, a polystyrene, a polypropylene, a polycarbonate, polyamide, may be sufficient, for example. As the high-strength non-resin material constituting the reinforcing fiber 3, lightweight carbon fiber fiber or glass fiber fiber is suitable. The resin fiber 2 is formed thicker than the reinforcing fiber 3. Since the woven fabric sheet 1 only includes the resin fibers 2 woven into the reinforcing fibers 3, a normal woven fabric manufacturing apparatus can be used, which is advantageous in terms of cost.

織物シート1を一対のホットプレス10、11の間に挿入して、織物シート1の表裏両面をホットプレス10、11により加熱すると共に加圧させ、溶けた樹脂繊維2内に補強繊維3が含有された状態の補強シート12を形成する。補強シート12は均一な厚さを有する硬い板状で、表面は樹脂繊維2の樹脂成分で形成され、内部に補強繊維3が含まれた状態になっている。   The woven fabric sheet 1 is inserted between a pair of hot presses 10 and 11, and both the front and back surfaces of the woven fabric sheet 1 are heated and pressurized by the hot presses 10 and 11, and reinforcing fibers 3 are contained in the melted resin fibers 2. The reinforcing sheet 12 in the finished state is formed. The reinforcing sheet 12 is a hard plate having a uniform thickness, the surface is formed of the resin component of the resin fiber 2, and the reinforcing fiber 3 is included inside.

この第1実施例によれば、織物シート1をホットプレス10,11により固い補強シート12に成形するため、その補強シート12を樹脂で覆わなくても十分強度を有する自動車部品等とすることができる。また、その補強シート12を後加工の際にセットしやすくなり、原価が低減できる。   According to the first embodiment, the fabric sheet 1 is formed into the hard reinforcing sheet 12 by the hot presses 10 and 11, so that the reinforcing sheet 12 can be made an automobile part having sufficient strength without being covered with resin. it can. Moreover, it becomes easy to set the reinforcing sheet 12 during post-processing, and the cost can be reduced.

かかる補強シート12を、図5に示すように、一対の金型4、5により形成されたキャビティ空間C内にセットした際には、図示せぬ支持手段により、テンションを付与された状態で支持されるが、補強シート12の状態が安定しているので、補強シート12の表裏両面側に所定厚さの樹脂シート14、15を正確に形成することができる。そして、このキャビティ空間C内に加熱軟化された熱可塑性樹脂6が射出される(図6参照)。熱可塑性樹脂6は、樹脂繊維2と同じ種類の方が好ましいが、別の種類であっても良い。   When the reinforcing sheet 12 is set in a cavity space C formed by a pair of molds 4 and 5 as shown in FIG. 5, it is supported in a tensioned state by a support means (not shown). However, since the state of the reinforcing sheet 12 is stable, the resin sheets 14 and 15 having a predetermined thickness can be accurately formed on both the front and back sides of the reinforcing sheet 12. Then, the heat-softened thermoplastic resin 6 is injected into the cavity space C (see FIG. 6). The thermoplastic resin 6 is preferably the same type as the resin fiber 2, but may be another type.

射出された熱可塑性樹脂6の熱により、補強シート12の樹脂繊維2が射出された熱可塑性樹脂6と融合して一体化する。熱可塑性樹脂6の固化後、金型4,5を開いて成形された樹脂パネル7を取り出す(図7参照)ことで、樹脂パネル7が成形される。樹脂パネル7は、溶融した樹脂繊維2により補強繊維3を包んだ状態となった補強シート12が、更に2枚の熱可塑性樹脂製の樹脂シート8,9の間に含まれた状態となっている。2枚の熱可塑性樹脂製の樹脂シート8、9の周縁部同士は結合された状態になっている。   Due to the heat of the injected thermoplastic resin 6, the resin fibers 2 of the reinforcing sheet 12 are fused and integrated with the injected thermoplastic resin 6. After the thermoplastic resin 6 is solidified, the resin panel 7 is molded by opening the molds 4 and 5 and taking out the molded resin panel 7 (see FIG. 7). The resin panel 7 is in a state in which the reinforcing sheet 12 in which the reinforcing fiber 3 is wrapped with the molten resin fiber 2 is further included between the two resin sheets 8 and 9 made of thermoplastic resin. Yes. The peripheral portions of the two resin sheets 8 and 9 made of thermoplastic resin are in a coupled state.

従って、補強シート12を2枚の樹脂シート8、9の間に含ませ、補強シート12の樹脂繊維2と樹脂シート8、9とを互いに熱により融合させた状態にしたため、溶けた樹脂繊維2の成分が十分な量のバインダーとなって、補強繊維3と周辺の樹脂シート8、9とを密着させ、補強繊維3による補強効果が確実に高まる。特に、この実施例では、織物シート1における樹脂繊維2の方を補強繊維3よりも太くしたため、樹脂繊維2が溶けた際に十分な量の樹脂成分となり、補強繊維3と周辺の樹脂シート8、9との密着性がより高められた状態になっている。   Therefore, since the reinforcing sheet 12 is included between the two resin sheets 8 and 9 and the resin fibers 2 of the reinforcing sheet 12 and the resin sheets 8 and 9 are fused with each other by heat, the melted resin fibers 2 This component becomes a sufficient amount of the binder to bring the reinforcing fiber 3 and the surrounding resin sheets 8 and 9 into close contact with each other, and the reinforcing effect by the reinforcing fiber 3 is reliably increased. In particular, in this embodiment, since the resin fiber 2 in the woven fabric sheet 1 is thicker than the reinforcing fiber 3, a sufficient amount of the resin component is obtained when the resin fiber 2 is melted, and the reinforcing fiber 3 and the surrounding resin sheet 8. , 9 is in a more improved state of adhesion.

図8〜図11は、本発明の第2実施例を示す図である。尚、第1実施例と共通する部分には同一の符号を付し、重複する説明は省略する。この第2実施例では、織物シート16を、図3に示すホットプレス10,11とは形状の異なるホットプレス加工によりコ字状の補強シート17に成形し(図9参照)、それをコ字状のキャビティ空間Cを有する金型18、19内にセットした。補強シート17は、図示せぬ支持手段により、キャビティ空間Cの厚さの中央位置に支持される。そして、先の実施例同様に、キャビティ空間C内に加熱軟化された熱可塑性樹脂6を射出し(図10参照)、コ字状の補強シート17を、同じくコ字状の樹脂シート20、21の間に含んだ状態の樹脂パネル22を得た(図11参照)。   8 to 11 are views showing a second embodiment of the present invention. In addition, the same code | symbol is attached | subjected to the part which is common in 1st Example, and the overlapping description is abbreviate | omitted. In this second embodiment, the woven fabric sheet 16 is formed into a U-shaped reinforcing sheet 17 by hot press processing having a shape different from that of the hot presses 10 and 11 shown in FIG. 3 (see FIG. 9). Were set in the dies 18 and 19 having a hollow cavity space C. The reinforcing sheet 17 is supported at a central position of the thickness of the cavity space C by a support means (not shown). As in the previous embodiment, the heat-softened thermoplastic resin 6 is injected into the cavity space C (see FIG. 10), and the U-shaped reinforcing sheet 17 is replaced with the U-shaped resin sheets 20, 21. The resin panel 22 in a state of being included in between was obtained (see FIG. 11).

第2実施例によれば、補強シート17を樹脂パネル22に相応した形状に予め成形することにより、複雑な形状の樹脂パネル22を形成する際も、補強シート17を含む2枚の樹脂シート20、21の厚さを正確に形成することができる。   According to the second embodiment, the two resin sheets 20 including the reinforcing sheet 17 are formed even when the resin panel 22 having a complicated shape is formed by previously forming the reinforcing sheet 17 into a shape corresponding to the resin panel 22. , 21 can be formed accurately.

以上の実施例では、樹脂繊維と補強繊維とを交互に織った織物シートを例にしたが、織り方はどのようなものでも良い。また、織物シートや補強シートを挟む(含む)2枚の樹脂シートの成形方法も、射出成形に限定されず、加熱軟化した2枚の樹脂シートを、織物シートや補強シートと一緒に金型内にセットし、金型内で圧力を掛けながら挟み込む成形方法でも良い。   In the above embodiment, a woven fabric sheet in which resin fibers and reinforcing fibers are alternately woven is taken as an example, but any weaving method may be used. In addition, the method of forming two resin sheets (including) a woven sheet or a reinforcing sheet is not limited to injection molding, and the two heat-softened resin sheets are placed in the mold together with the woven sheet and the reinforcing sheet. It is also possible to use a molding method in which the sheet is sandwiched while being pressed in a mold.

この発明の第1実施例の織物シートを示す平面図。The top view which shows the textile sheet of 1st Example of this invention. 図1中矢示SA−SA線に沿う断面図。Sectional drawing which follows the arrow SA-SA line in FIG. 図2の織物シートをホットプレス内にセットした状態を示す模式的断面図。The typical sectional view showing the state where the textile sheet of Drawing 2 was set in the hot press. 図3により成形した補強シート単体を示す模式的断面図。FIG. 4 is a schematic cross-sectional view showing a single reinforcing sheet formed according to FIG. 3. 図4の補強シートを金型内にセットした状態を示す模式的断面図。示す模式的断面図。The typical sectional view showing the state where the reinforcement sheet of Drawing 4 was set up in the metallic mold. FIG. 図5に示す金型内に熱可塑性樹脂を射出した状態を示す模式的断面図。FIG. 6 is a schematic cross-sectional view showing a state in which a thermoplastic resin is injected into the mold shown in FIG. 5. 図6により成形した樹脂パネル単体を示す模式的断面図。FIG. 7 is a schematic cross-sectional view showing a single resin panel molded according to FIG. 6. この発明の第2実施例の織物シートを示す模式的断面図。The typical sectional view showing the textile sheet of the 2nd example of this invention. 図8の織物シートによる補強シート単体を示す模式的断面図。FIG. 9 is a schematic cross-sectional view showing a single reinforcing sheet by the fabric sheet of FIG. 8. 図9の補強シート単体を金型内にセットして熱可塑性樹脂を射出した状態を示す模式的断面図。FIG. 10 is a schematic cross-sectional view showing a state in which a single reinforcing sheet of FIG. 9 is set in a mold and a thermoplastic resin is injected. 図10により成形された樹脂パネル単体を示す模式的断面図。FIG. 11 is a schematic cross-sectional view showing a single resin panel molded according to FIG. 10.

符号の説明Explanation of symbols

1、16 織物シート
2 樹脂繊維
3 補強繊維
4、5、18,19 金型
6 熱可塑性樹脂
7、22 樹脂パネル
8、9、20,21 樹脂シート
10、11 ホットプレス
12、17 補強シート
C キャビティ空間
DESCRIPTION OF SYMBOLS 1,16 Textile sheet 2 Resin fiber 3 Reinforcement fiber 4, 5, 18, 19 Mold 6 Thermoplastic resin 7, 22 Resin panel 8, 9, 20, 21 Resin sheet 10, 11 Hot press 12, 17 Reinforcement sheet C Cavity space

Claims (4)

熱可塑性樹脂材料製の樹脂繊維(2)と、樹脂繊維(2)より高強度な非樹脂材料製の補強繊維(3)とにより織製された織物シート(1、16)を加熱したことにより溶融させることで、前記樹脂繊維(2)と前記補強繊維(3)とを密着させて形成させてなることを特徴とする補強シート。   By heating the woven sheet (1, 16) woven with the resin fiber (2) made of thermoplastic resin material and the reinforcing fiber (3) made of non-resin material having higher strength than the resin fiber (2). A reinforcing sheet formed by melting the resin fiber (2) and the reinforcing fiber (3) in close contact with each other. 請求項1記載の補強シートであって、
織物シート(1)において、樹脂繊維(2)の方が補強繊維(3)よりも太いことを特徴とする補強シート。
The reinforcing sheet according to claim 1,
In the woven fabric sheet (1), the resin fiber (2) is thicker than the reinforcing fiber (3).
請求項1又は請求項2記載の補強シートであって、
補強繊維(3)が、カーボンファイバー繊維又はグラスファイバー繊維であることを特徴とする補強シート。
The reinforcing sheet according to claim 1 or 2,
The reinforcing sheet, wherein the reinforcing fiber (3) is a carbon fiber fiber or a glass fiber fiber.
熱可塑性樹脂材料製の樹脂繊維(2)と、樹脂繊維(2)より高強度な非樹脂材料製の補強繊維(3)により織製された織物シート(1、16)に、ホットプレス加工を加えて、互いに融合した樹脂繊維(2)成分内に補強繊維(3)が含有された状態の所定厚さで且つ所定形状を有することを特徴とする補強シートの製造方法。   Hot pressing is performed on the woven sheets (1, 16) woven by the resin fibers (2) made of thermoplastic resin material and the reinforcing fibers (3) made of non-resin material having higher strength than the resin fibers (2). In addition, a method for producing a reinforcing sheet, which has a predetermined thickness and a predetermined shape in a state in which the reinforcing fibers (3) are contained in the resin fiber (2) components fused together.
JP2004148045A 2004-05-18 2004-05-18 Reinforced sheet and method for producing the same Pending JP2005330605A (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1908581A1 (en) * 2006-10-05 2008-04-09 Novameer B.V. Process for producing fabrics comprising unidirectionally arranged polymeric tapes
JP2020075384A (en) * 2018-11-06 2020-05-21 三菱瓦斯化学株式会社 Manufacturing method of fiber-reinforced resin molded product

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1908581A1 (en) * 2006-10-05 2008-04-09 Novameer B.V. Process for producing fabrics comprising unidirectionally arranged polymeric tapes
WO2008040510A1 (en) * 2006-10-05 2008-04-10 Novameer B.V. Process for producing fabrics comprising unidirectionally arranged polymeric tapes
AU2007304495B2 (en) * 2006-10-05 2011-09-15 Novameer B.V. Process for producing fabrics comprising unidirectionally arranged polymeric tapes
US8349112B2 (en) 2006-10-05 2013-01-08 Novameer B.V. Process for producing fabrics comprising unidirectionally arranged polymeric tapes
CN101522406B (en) * 2006-10-05 2013-04-17 诺瓦摩尔有限公司 Process for producing fabrics comprising unidirectionally arranged polymeric tapes
JP2020075384A (en) * 2018-11-06 2020-05-21 三菱瓦斯化学株式会社 Manufacturing method of fiber-reinforced resin molded product
JP7219053B2 (en) 2018-11-06 2023-02-07 三菱瓦斯化学株式会社 METHOD FOR MANUFACTURING FIBER REINFORCED RESIN MOLDED PRODUCT

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