JP2009019201A - Molding material, preform and fiber-reinforced resin - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molding material that exhibits excellent handleability, resin impregnability and shaping properties and productively affords FRP excellent in mechanical properties and qualities, an to provide a preform and FRP obtained by using the same. <P>SOLUTION: The molding material 1 is produced by integrating a laminate constituted of two or more layers of sheets, prepared by parallelly arranging a large number of reinforcing fiber threads 2 and laminated so that the reinforcing resin threads intersect with one another, where (i) a fabric 3, composed of a first thermoplastic resin constituting a matrix of a composite material, is arranged at least between the sheets; (ii) the laminates are integrated by a stitch yarn 4 comprising a second thermoplastic resin or by the fabric comprising the first thermoplastic resin; and (iii) slits in the direction traversing the reinforcing fiber threads are arranged all over the surface of the sheet and at least (100-100/n)% of the reinforcing fiber threads, constituting the laminate where the reinforcing fiber threads are orientated towards n axis directions, are cut in a fiber length La of 10-300 mm. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a molding material having excellent handling properties, resin impregnation properties, and formability, and in producing a fiber reinforced resin (hereinafter referred to as FRP) having excellent mechanical properties and quality. The present invention relates to a suitably used molding material, preform, and FRP comprising the same.

  Conventionally, FRP using carbon fiber or glass fiber as reinforced fiber is superior in specific strength and specific elastic modulus. Therefore, FRP is widely used for aircraft and general industries, such as sports equipment and leisure goods that have a large weight reduction effect. It is used.

  As a method of molding such FRP, a prepreg in which a reinforcing fiber base material is impregnated with a matrix resin in advance is used, this is set in a mold, covered with a bag film, heated and pressurized in an autoclave, and the thermosetting resin is cured. In general, there are widely used autoclave molding methods and vacuum injection molding methods in which a reinforced fiber base material in a dry state is set in a mold, and a liquid thermosetting resin is injected under a reduced pressure (vacuum state) in the mold Are known. However, in the autoclave molding method and the vacuum injection molding method, it is necessary to laminate the base materials, and it is necessary to cover with a bag film and reduce the pressure to a vacuum. In particular, in the vacuum injection molding, it is necessary to inject a thermosetting resin. Further, in these methods, since the molding time (cycle time) per process including the above-described steps becomes relatively long, it is difficult to adapt to, for example, automobile members having a large number of production.

  To solve this problem, as a means for omitting the lamination process when molding FRP, a multiaxial stitch base material in which reinforcing fiber layers in which reinforcing fiber yarns are oriented in multiple directions is laminated and integrated by stitch yarns is provided. Proposed. However, with such a technique, the reinforcing fiber layer is constrained by stitch yarns, and thus it is difficult to form a curved surface having a cylindrical or hemispherical shape called a single contour shape or a double contour shape. That is, when trying to place this multi-axis stitch base material in the mold, it cannot be formed into the desired shape by stretching it at the curved surface, or the material will be restored to its original shape with an accurate shape. There was a problem that wrinkles would occur even if it could not be held or if it could be shaped.

  As means for improving this problem, it has been proposed to form a stitch yarn with a low melting point polymer (for example, Patent Document 1). However, in this method, since the stitch yarn is composed of a low melting point polymer, it is possible to improve the apparent formability by heating and melting the stitch yarn at the time of shaping, but the stitch yarn is completely When melted, there is a problem that the reinforcing fiber yarns are not restrained, the reinforcing fiber layers are separated, and the shape cannot be maintained and cannot be handled.

  In addition, it has been proposed to form a free end in the surface by making a cut in the prepreg to improve the shapeability (for example, Patent Document 2). However, this method has a problem that wrinkles easily occur unless the resin is impregnated with a resin such as a prepreg because the deformation behavior at the time of shaping differs between the cut and the periphery of the cut.

  On the other hand, as a means of omitting the resin injection / curing step, a molding material (for example, a multi-axis stitch base material obtained by previously integrating fibers made of a thermoplastic resin that becomes a matrix after melt-impregnating reinforcing fiber yarns) And a molding material (for example, Patent Document 4) in which a film made of a thermoplastic resin that becomes a matrix after being melt-impregnated between layers of the multiaxial stitch base material is proposed.

  In the method described in Patent Document 3, the resin impregnating property is inferior because the resin is made of thermoplastic resin fibers serving as a matrix in the reinforcing fiber layer of the multiaxial stitch base material. There is a problem that high pressure is required for impregnation. Further, when the reinforcing fiber is impregnated with the thermoplastic resin serving as a matrix, the air present at the location to be impregnated can be efficiently released to the outside of the system, that is, a path of air to the outside of the system can be formed. Importantly, because the fiber made of thermoplastic resin is pre-integrated with the reinforcing fiber, the path to the outside of the system is narrow and easily blocked during pressurization and heating. As a result, in the FRP There is a problem that it tends to remain as a void. Furthermore, since it is necessary to integrate the synthetic resin fiber with the reinforcing fiber in advance, there is a problem that the cost increases due to an increase in the number of steps.

  Further, in the method described in Patent Document 4, since each of the reinforcing fiber layers is thick and has a large basis weight, it is difficult to completely impregnate in the thickness direction after melting the thermoplastic resin film as a matrix. There was a problem.

  In addition, for the problem in the case of using the resin film made of the thermoplastic resin, a molding material in a prepreg or semi-preg state in which a reinforcing fiber sheet and a nonwoven fabric of a thermoplastic resin are laminated and heated and pressurized is also proposed. (For example, patent document 5 etc.). However, if the reinforcing fiber is impregnated into the prepreg or semi-preg state over the entire surface of the molding material in the plane direction, there is a problem that the handling property and the shapeability of the molding material are significantly lowered.

That is, in the conventional techniques including Patent Documents 1 to 5, a molding material that has excellent handling properties, resin impregnation properties, and shapeability, and can obtain FRP excellent in mechanical properties and quality with high productivity. Preforms and FRPs composed of them have not been found and such techniques are craved.
JP 2002-227066 A JP-A 63-267523 Japanese Patent Application Laid-Open No. 2001-073241 JP 2004-346175 A JP 2003-165851 A

  Accordingly, the object of the present invention is to solve the above-mentioned problems of the prior art, and to obtain an FRP having excellent handling characteristics, resin impregnation properties and formability, and excellent mechanical properties and quality with high productivity. It is in providing a molding material, a preform, and FRP using them.

In order to achieve the above object, the present invention adopts the following configuration. That is,
(1) A molding material in which a plurality of layers of sheets in which a large number of reinforcing fiber yarns are arranged in parallel is laminated to form a laminated body, and the laminated body is integrated. A molding material characterized by satisfying the requirements of (d).
(A) A textile body comprising as a component a first thermoplastic resin constituting a matrix of a composite material is disposed at least between the sheets,
(B) The laminated body is integrated by a stitch yarn having the second thermoplastic resin as a component and / or a textile body having the first thermoplastic resin as a component,
(C) A sheet in which the reinforcing fibers constituting the laminate are aligned in parallel, and a cut in a direction across the reinforcing fiber yarn is arranged on the entire surface of the sheet, and the reinforcing fiber yarn constituting the laminate. Including a sheet in which the fiber length La is cut at a finite length of 10 to 300 mm,
(D) At least 50% or more of the reinforcing fiber yarns constituting the laminate have a finite length in which the fiber length La of the reinforcing fiber yarns constituting the laminate is 10 to 300 mm.
(2)
Each of the sheets constituting the laminate is laminated in a multiaxial orientation so that the reinforcing fiber yarns intersect to constitute a laminate, the number of axes to be oriented is n-axis, and the fiber length La is 10 The molding material according to (1), wherein n and N satisfy the relationship of the following formula, where N% is a ratio in the molding material of the reinforcing fiber yarn that is cut at a finite length of ˜300 mm.
(100-100 / n) ≦ N
(3) A sheet constituting the laminate is divided into a first and second partial laminates, with a textile body having a first thermoplastic resin as a component in a thickness direction of 25 to 75% as a boundary. In this case, the first partial laminate and the second partial laminate are provided with cuts penetrating in the thickness direction in the first partial laminate and the second partial laminate, respectively, over the entire surface. 3. The molding material according to (1) or (2), wherein the notch does not overlap on the projection surface in the thickness direction.
(4) The cuts penetrating in the thickness direction for every sheet are arranged over the entire surface of all the sheets constituting the laminate, and the cuts of adjacent sheets do not overlap on the projection surface in the thickness direction (1 ) To (3).
(5) A plurality of rows composed of intermittent cuts in a direction crossing the reinforcing fiber yarns are arranged in parallel on the entire surface of the sheet, and each of the cuts has a cut length Lb. The molding material in any one of said (1)-(4) which is 1-100 mm.
(6) At an angle θ formed by the cut and the direction orthogonal to the direction in which the stitch yarn extends, the interval Wb between the stitch yarns parallel to the longitudinal direction of the molding material and the cut length Lb are | cos θ | <( Wb / Lb) and the molding material according to any one of the above (1) to (5), which does not substantially cut a stitch yarn that is continuous in the longitudinal direction of the molding material.
(7) The melting point Tm1 of the first thermoplastic resin and the melting point Tm2 of the second thermoplastic resin satisfy the relationship (Tm1-150) ≦ Tm2 ≦ (Tm1-20). The molding material according to any one of 6).
(8) The melting point Tm1 of the first thermoplastic resin and the melting point Tm2 of the second thermoplastic resin satisfy the relationship of (Tm2-150) ≦ Tm1 ≦ (Tm2-20). (6) The molding material in any one of.
(9) The melting points Tm1 of the first thermoplastic resin and the melting points Tm2 of the second thermoplastic resin satisfy the relationship of (Tm2-20) <Tm1 <(Tm2 + 20) (1) to (6 ) The molding material according to any one of
(10) Any of the above (1) to (9), wherein the basis weight of the reinforcing fiber in the sheet is in the range of 50 to 350 g / m ² and the basis weight of the fabric body is in the range of 15 to 250 g / m ^2. Molding material according to crab.
(11) A preform characterized in that one or a plurality of molding materials according to any one of (1) to (10) are laminated and formed into a single contour shape or a double contour shape.
(12) The length Lc of the arc and the fiber length La in the respective sections in the reinforcing fiber yarn direction of each sheet constituting the molding material are Lc> La at the portion formed into the single contour shape or the double contour shape. The preform according to (11) above.
(13) A fiber reinforced resin formed using the molding material or preform according to any one of (1) to (11).

According to the molding material of the present invention, a laminated body is configured by arranging a fabric body composed of a thermoplastic resin as a matrix between sheets composed of reinforcing fiber yarns, and the laminated body is stitched yarn and / or Since the first thermoplastic resin is used as a component, the body is integrated, so there is no need to laminate the base material or inject a matrix resin in the preform or FRP molding operation, making the molding operation easy. Therefore, it can be performed in a short time and with high accuracy.
In addition, since the fabric body arranged between the layers of the laminated body is melted, it becomes a mode in which shear deformation easily occurs between the layers of the laminated body, and the reinforcing fiber yarns are cut into a predetermined length by cutting, so that It becomes an aspect which is easy to progress and deform | transform in the surface of each sheet | seat of a body, and can show the outstanding shaping property in shaping | molding of a preform or FRP.

The molding material of the present invention is a molding material in which a plurality of layers of sheets in which a large number of reinforcing fiber yarns are aligned in parallel are laminated to form a laminate, and the laminate is integrated, The following requirements (a) to (d) are satisfied.
(A) A textile body comprising as a component a first thermoplastic resin constituting a matrix of a composite material is disposed at least between the sheets,
(B) The laminated body is integrated by a stitch yarn having the second thermoplastic resin as a component and / or a textile body having the first thermoplastic resin as a component,
(C) A sheet in which the reinforcing fiber yarns constituting the laminate are aligned in parallel, and a cut in a direction crossing the reinforcing fiber yarns is arranged on the entire surface of the sheet, and the reinforcing fibers constituting the laminate Including a sheet in which the fiber length La of the yarn is cut at a finite length of 10 to 300 mm,
(D) At least 50% or more of the reinforcing fiber yarns constituting the laminate have a finite length in which the fiber length La of the reinforcing fiber yarns constituting the laminate is 10 to 300 mm.

  The sheet constituting the molding material of the present invention includes a group of reinforcing fiber yarns formed by aligning a large number of reinforcing fiber yarns in parallel. Such a sheet is not limited to one in which each of the reinforcing fiber yarn groups is bonded and bonded to each other and can be handled as a single sheet, and only a plurality of reinforcing fiber yarns are arranged in parallel. It may be an apparent sheet, or each of the reinforcing fiber yarn groups arranged in parallel or a part thereof may have a gap.

  Here, aligning in parallel means arranging adjacent reinforcing fiber yarns side by side so as not to substantially intersect or cross each other. More preferably, adjacent reinforcing fiber yarns are continuously arranged at a constant interval of 20 to 200% of the reinforcing fiber yarn width, or are arranged so as to overlap by a certain width within a range not exceeding the reinforcing fiber yarn width. That is. It should be noted that substantially not intersecting or crossing means that even if the reinforcing fiber yarns meander and overlap in the width direction, the width of the narrower one of the adjacent reinforcing fiber yarns is reduced. If it does not overlap, it is not included. Further, the term “constant” here means that the width and interval are within a range of ± 50% from the average value. More preferably, when two adjacent reinforcing fiber yarns are approximated to a straight line within a length range of 100 mm, the angle formed by the approximated straight line is arranged to be 5 ° or less, more preferably It is arranged so as to be 2 °. In addition, approximating a thread | yarn to a straight line is connecting the starting point and end point of the range of a length of 100 mm, and forming a straight line.

  As a means for forming a sheet that satisfies such an aspect, for example, the reinforcing fiber yarns may be drawn directly from the bobbin around which the reinforcing fiber yarns are wound and arranged in parallel, or simultaneously from a plurality of bobbins. It may be arranged by pulling out and arranging, or a plurality of reinforcing fiber yarns that have been pre-aligned and processed into a tape shape or a sheet shape may be separately arranged. It may be formed by the same means, and each layer may be formed by the above different means.

  The laminate constituting the molding material of the present invention is formed by laminating a plurality of layers of the sheet, that is, at least two layers, and the number of layers and the lamination angle are not particularly limited. As a structure of such a laminated body, for example, [0 °] n, [0 ° / 90 °], [+ 45 ° / −45 °], [0 ° / ± 60 °], [−45 ° / 0 ° / + 45]. However, when emphasis is placed on shapeability, biaxially oriented laminates in which the orientations of the reinforcing fiber yarns are orthogonal to each other (for example, [0 ° / 90 °], [+ 45 ° / −45 °]) is preferable, and in such a configuration, excellent shear deformation can be expressed in the plane of the laminate, and when it is desired to reduce the anisotropy of the FRP to be obtained, many reinforcing fiber yarns are used. By orienting in the direction (for example, [0 ° / + 45 ° / 90 ° / −45 ° /...]), It is possible to make the FRP quasi-isotropic, so that a preform or FRP can be produced with high productivity. If you want to obtain it, you can contribute to labor saving in the lamination process by laminating in more layers.

  Here, although the laminated body of this invention is classified into a unidirectional laminated body and a crossing laminated body, it defines as follows, respectively. The unidirectional laminate is a laminate in which the sheets constituting the laminate are laminated so that the reinforcing fiber directions are the same (for example, [0 °] n, [90 °] n, etc.) The angle formed by the reinforcing fiber direction of each sheet is within ± 5 °. The cross laminate is a laminate in which the sheets constituting the laminate are laminated so that the reinforcing fiber directions intersect (for example, [0 ° / 90 °], [+ 45 ° / −45 °]). , Etc.). In the present invention, that the reinforcing fiber directions intersect each other means that the angle formed by the reinforcing fiber directions of adjacent sheets is ± 5 ° or more, and preferably within a range of 30 ° to 60 °. Here, when the number of orientation directions of the reinforcing fiber layers included in the laminate is n, it is expressed as n-axis orientation. That is, the cross laminate is a laminate having biaxial orientation or more. Furthermore, isotropic lamination such as [−45 / 0 / + 45/90] and [0 / ± 60] is preferable, and more preferable is [−45 / 0 / + 45/90] s and [0 / ± 60] s. Symmetrical lamination. By setting it as this aspect, FRP can be made into a uniform physical property and generation | occurrence | production of the curvature by a thermal stress can be suppressed. In the symmetric lamination, the fiber directions are the same in the two layers at the center in the lamination thickness direction that are turned back, but the two layers in this case are exceptions to the above definition. With regard to (a) above, the resin body having the first thermoplastic resin constituting the matrix of the composite material at least as a component between the sheets is disposed, so that the resin impregnating property of the molding material and the first Shapeability can be expressed. In this requirement, “the thermoplastic resin constituting the matrix of the composite material” refers to a thermoplastic resin that becomes the matrix after being molded into a composite material. When molding the molding material, in order to impregnate the reinforcing fiber yarn with the melt of the thermoplastic resin as the matrix, it is important to efficiently release the air present in the molding material out of the system. Therefore, it is important to form a path to the outside of the system. If such a path cannot be formed, air (void) remains in the obtained FRP, which causes the quality and mechanical properties of the FRP to deteriorate. In the above aspect (a), the gap between the single yarns of the reinforcing fiber yarns in the sheet and / or the sheet extending over the entire surface in the plane direction of the molding material is removed by disposing at least the textile body between the sheets. By adopting the route to, it is possible to avoid closing the route to the outside of the air system during molding. In other words, the present invention satisfies the above-mentioned aspect (a), so that it is possible to easily impregnate the thermoplastic resin melt as a matrix even at a low pressure, and to form FRP without voids.

  Moreover, said (a) brings the 1st shaping property to a molding material. The first formability is that, when the FRP is formed by heating the molding material, a space is formed between the layers by melting the fabric body arranged between the layers, and adjacent sheets are sheared between the layers. This means that it is easy to deform. Specifically, when the FRP is molded by heating the molding material, the fabric body arranged between the layers melts, so that the restraint due to stitches described later is relaxed, or even the stitch yarn is melted. The deformation resistance between the respective layers is reduced, and it can be easily deformed by applying a slight external force. That is, the first formability is a shear deformation between layers of the molding material and indicates the shapeability in the thickness direction of the molding material. By having the first formability, particularly in a single contour shape such as a cylinder or a U shape, the inner and outer peripheral length difference generated in the thickness direction of the molding material is absorbed by the shear deformation between layers, and the reinforcing fiber yarn It is possible to form a good-quality FRP along the curved surface portion by suppressing the occurrence of tension and wrinkles. This works more effectively as the thickness of the molding material increases. The single contour shape as used in the present invention refers to the kind of curved surface shape, and when the surface of the laminate is taken out as a quadric surface, assuming a tangential plane in contact with the quadric surface, the tangential plane and the A quadratic surface having a single tangent and a tangent to the quadratic surface (that is, a surface having a curvature change only in one axial direction within the surface: a surface called a developable surface in terms of differential geometry) Specifically, a conical shape, a cylindrical shape, or a part of them is applicable.

  In addition, if the textile body here can be handled as one sheet, the form will not be restrict | limited in particular, It selects from various forms, such as a nonwoven fabric, a film, a mat | matte, a mesh, a woven fabric, and a knitted fabric. be able to. Especially when it is in the form of a non-woven fabric, it is inexpensive as a material, has moderate deformability, has excellent needle permeability in the manufacturing process of molding material, has low anisotropy and has excellent handleability, and stitches This is preferable because the load on the needle can be reduced.

  Regarding (b) above, in the molding material of the present invention, the laminate is integrated by a stitch yarn comprising the second thermoplastic resin as a component and / or a textile body comprising the first thermoplastic resin as a component. Thus, excellent handling property of the molding material and excellent impregnation property when molding the FRP are brought about.

  A sheet in which a large number of reinforcing fiber yarns used in each layer of the molding material of the present invention are arranged in parallel has no woven-like structure formed. The components are easily separated. The function is performed by the textile body containing the first thermoplastic resin as a component and / or the stitch yarn containing the second thermoplastic resin as a component. This enables handling as a molding material and minimizes the effects of disturbances in handling such as misalignment, bending, and bending of reinforcing fiber yarns caused by external interference. it can.

  Moreover, when the molding material of this invention takes the aspect integrated by the stitch thread | yarn in said (b), the resin impregnation property excellent in shape | molding FRP is brought about. Such resin impregnation property is different from that in the above (a) and is as described in detail below. Since the stitch yarn penetrates in the thickness direction of the laminate, a through-hole is formed in the thickness direction of the molding material, which functions as a resin flow path when the thermoplastic resin as a matrix is impregnated. Provides excellent resin impregnation. Such a through hole functions more effectively as the basis weight of reinforcing fibers per layer increases, that is, the longer the impregnation distance in the thickness direction, the more suitable this aspect.

  Further, in the case where the molding material of the present invention is laminated in multiple axes, the straightness of the reinforcing fiber yarn that is excellent when molding FRP by taking the form integrated by the stitch yarn in (b) above Bring sex. When FRP is formed by heating and pressurizing a multiaxial molding material, the laminate is constrained by stitch yarns, so that the orientation and straightness of the reinforcing fiber yarn in the multiaxial molding material can be obtained in the obtained FRP. Is also maintained. The loop formed by the stitch yarn has the function of physically restricting the reinforcing fiber yarn in the multiaxial molding material, so that the disturbance of the reinforcing fiber yarn induced by molding pressure and resin flow during FRP molding is suppressed. be able to.

  In the integration by the stitch yarn, it is preferable that the through holes are regularly arranged within a range of 4 to 25 rows / 25 mm in each of the longitudinal direction and the width direction of the molding material. More preferably, it is in the range of 5 to 13 rows / 25 mm in each direction. If the through hole is arranged within such a range, the stitch yarn restrains the reinforcing fiber yarn to maintain its orientation direction (angle) and straightness, and minimizes damage to the reinforcing fiber yarn. In particular, it is preferable because the uniform shapeability in molding into FRP can be expressed, and furthermore, the above-described resin impregnation properties can be combined and considered in a balanced manner. In addition, it is not necessary to arrange the through holes at the same interval in the longitudinal direction and the width direction. If you dislike shapeability, resin impregnation anisotropy, and non-uniformity when molding FRP, keep the same interval. It is preferable to arrange.

Moreover, it is preferable that the through hole has a density in the plane direction of the molding material in the range of 30,000 to 250,000 locations / m ² . More preferably, it is in the range of 60,000 to 200,000 locations / m ² , and more preferably in the range of 65,000 to 150,000 locations / m ² . When the through holes are less than 4 rows / 25 mm or less than 30,000 locations / m ² , the restraint of the reinforcing fiber yarn becomes loose, so that the handleability is inferior. Inducing bending or bending of reinforcing fiber yarns. In addition, the through-hole functions as a resin impregnation channel in the thickness direction of the molding material, and therefore the resin impregnation property may be inferior when the number thereof is reduced. On the other hand, if the through hole exceeds 25 rows / 25 mm or exceeds 250,000 locations / m ² , the resin impregnation property is excellent, but the probability that the reinforcing fiber yarn is damaged by the needle is increased. Since the amount of stitch yarn contained in the FRP increases, the mechanical properties are inferior, the effect of reducing the weight of the FRP is impaired, and the reinforcement of the reinforcing fiber yarn becomes too strong and the shapeability is inferior. There is a case.

Here, the density of the through-holes refers to a material obtained by proportionally converting the number of through-holes through which the stitch yarn penetrates in the thickness direction from a molding material cut into a square of 100 mm × 100 mm per 1 m ^2. It is easily obtained by counting the number of. The number of rows of through holes per 25 mm in the longitudinal direction or width direction of the molding material is a row in which through holes are regularly arranged in the longitudinal direction or width direction from the molding material cut into a square of 100 mm × 100 mm. Is represented to one digit after the decimal point. In order to determine whether or not the through holes are regularly arranged, the distance between the 25 through holes that are adjacent to each other in the direction of the molding material is obtained, and each distance is individually determined with respect to the average value. If the value is within ± 10%, it shall be judged as regular. Note that the distances between adjacent through holes do not have to be the same.

  With regard to the above (b), the molding material of the present invention may be integrated in either a textile body containing the first thermoplastic resin as a component or a stitch yarn containing the second thermoplastic resin as a component. From the viewpoint of mechanical properties and smoothness in the FRP, it is preferable that the fiber body is composed of the first thermoplastic resin as a component from the viewpoint that damage to the reinforcing fiber yarn can be minimized. From the viewpoints of material handling properties, form stability, and FRP moldability, it is preferable that they are integrated with stitch yarns containing the second thermoplastic resin as a component.

  As an embodiment in which the first thermoplastic resin is integrated from the fabric body as a component, the fabric body including the first thermoplastic resin component disposed between the sheets is heat-sealed or mechanically entangled. Although the mode of making it adhere | attach by a means is mentioned, From the viewpoint of the surface quality of FRP obtained and a mechanical characteristic, the former is preferable. The range of integration is not particularly limited. However, when handling is considered, it is preferable that the sheet is adhered over the entire surface, and as a minimum condition, the shape as a molding material can be maintained (in carrying) Extent to which the orientation of the reinforcing fiber yarn can be maintained). Examples of such integration means include a method in which a molding material containing a textile body is subjected to pressure heat treatment with a hot roller, a heating press, or the like, and a method using a hot roller that can be intermittently processed is preferable from the viewpoint of productivity. .

  Examples of an embodiment in which the second thermoplastic resin is integrated by the stitch yarn include warp knitting, weft knitting, tufting, and the like, and warp knitting is preferable from the viewpoints of both handleability and productivity.

  In addition, a molding material that is particularly excellent in shape stability when it is integrated by both the textile body having the first thermoplastic resin as a component and the stitch yarn having the second thermoplastic resin as a component. It can be. Specifically, this mode is a combination of the above-described means. For example, when needles are pierced in knitting, the sheet and the fabric body in the laminated body are mechanically bound by entanglement, and at the same time, the stitch yarns are combined. Examples thereof include a method of organizing, and a method of fusing the laminated body with a hot roller and then integrating with a stitch yarn. In particular, the former that can simplify the process is preferable from the viewpoint of productivity.

  With regard to (c), the sheet in which the reinforcing fiber yarns constituting the laminate are aligned in parallel is provided with cuts in the direction across the reinforcing fiber yarns arranged on the entire surface of the sheet. The 2nd shaping property in the molding material of invention can be expressed. Here, the second formability means that when the molding material is shaped into a predetermined shape by the notch disposed on the entire surface of the sheet, the notch is opened, and the planar direction of the sheet It is that it is in an aspect that is easily deformed or deformed.

  Such progress deformation is a deformation of the reinforcing fiber yarn itself that occurs when the cut end of the reinforcing fiber yarn moves (opening, skidding, crossing, etc.) at the cut portion of the sheet, resulting from this. This corresponds to deformation of the molding material. Carbon fibers and glass fibers can be mentioned as reinforcing fibers suitably used for FRP, but these reinforcing fibers have a low elongation, so when trying to shape them into a single contour shape or a double contour shape, reinforcing fiber yarns Will be stretched and cannot follow the desired shape, or wrinkles will occur. If it is a single contour shape, it is possible to alleviate this problem due to the development of the first formability described above. However, when it becomes a double contour shape, it will be shaped only by the shapeability in the thickness direction of the molding material. Therefore, deformation of the molding material in the plane direction is required. Even if shear deformation is caused in the plane direction of the molding material, there is a limit to this, and the amount of deformation is limited as the orientation axis of the reinforcing fiber yarn increases, so that the effect cannot be expected in a multiaxially oriented material. . On the other hand, since the reinforcing fiber yarn is cut when it is a molding material that takes the form of (c) above, even when trying to shape it into a double contour shape, the cut portion is opened to reinforce There is no worry that the fiber yarns are stretched, and even if they are multiaxially oriented, each of the reinforcing fiber yarns has a free end, so that there is no restriction in the orientation direction of the reinforcing fiber yarns, so that shear deformation is likely to occur. It can be said that this is an aspect.

  Here, the double contour shape referred to in the present invention is a point on the quadric surface when the surface of the laminate is taken out as a quadric surface, and any plane passing through the point can be referred to. , A curved surface shape including at least a portion where the intersection line passing through the point becomes a curve among the intersection lines of the plane and the quadric surface. Specifically, a saddle shape, a hemispherical shape, a flat plate having an uneven portion, and the like are applicable, but a flat plate without an uneven portion, a conical shape, and a cylindrical shape are not applicable.

  Moreover, said (c) is that the fiber length La of the reinforcing fiber yarn which comprises the said laminated body includes what is cut | disconnected by the finite length of 10-300 mm. More preferably, it includes what is cut at a finite length within the range of 30 to 100 mm. By including what has the reinforced fiber yarn cut at such a finite length, it is possible to achieve both handleability and shapeability of the molding material. When the length of the reinforcing fiber yarn is less than 10 mm, each of the reinforcing fiber yarn cut pieces becomes too fine, and the cut pieces easily fall off the molding material when handling the molding material. In addition, even if a slight force is applied, the deformation is induced, so that it is difficult to handle it as a molding material. On the other hand, when the length of the reinforcing fiber yarns includes only more than 300 mm, the cut ends of the reinforcing fiber yarns are reduced, so that the cut pieces will not fall off, but in the plane direction of the molding material Since the density of the free ends becomes small, when trying to shape in any shape, the distance between each is too large and the reinforcing fiber yarn does not move at the desired location, making shaping difficult, If the shape is extremely strict, there is no free end at such a location, and the above-described second shaping property does not appear. In addition, when FRP molding is performed, the fragmented reinforcing fiber yarns flow into the openings generated by the second formability to compensate, but this also leads to a decrease in the fluidity. .

  In addition, although it is the fiber length La of the cut reinforcing fiber yarn, since it is difficult to distinguish the individual reinforcing fiber yarns after drawing the reinforcing fiber yarns in parallel to form a sheet, strictly speaking, It is that of the single yarn constituting the reinforcing fiber yarn, and in this specification, the term “reinforcing fiber yarn” includes such meaning.

  Regarding (d), at least 50% or more of the reinforcing fiber yarns constituting the laminated body have a finite length in which the fiber length La of the reinforcing fiber yarns constituting the laminated body is 10 to 300 mm.

  By cutting the reinforcing fiber yarn in such a ratio, it is possible to effectively draw the shaping property in the molding material.

  As described above, the shapeability of the molding material of the present invention is a synergistic effect between the shear deformation between the layers which is the first shapeability and the progress deformation within the layer which is the second shapeability, Regarding the shapeability in the in-plane direction, the contribution of the second shapeability is large.

  However, a molding material composed of continuous fibers does not have no formability in the plane. As an example, it is a bi-directional woven fabric, and when the woven fabric is stretched in the non-fiber direction, the phenomenon that the structure is deformed from a square to a rhombus. In this specification, this phenomenon is called in-plane shear deformation.

  Such in-plane shear deformation is a change in the shape of the components in the plane, and brings about shaping by absorbing strain by converging reinforcing fiber bundles, closing gaps, and densifying tissues. In addition, there is a limit to deformation, and the space is dense (there is no room for deformation in the plane). Theoretically, the reinforcing fiber bundles converge in a perfect circle and close It is in a state of being. In other words, the more room for deformation in the plane, the larger the deformation amount and the better the shapeability.

  That is, the essence of the above (d) is that in the state where the continuous fiber bundle and the non-continuous fiber bundle coexist, the non-continuous fiber bundle having no order in the reinforcing fiber direction exists as a room for deformation in the plane. It is to improve the in-plane shear deformation characteristics. In the present invention, as a result of intensive studies, it has been found that at least 50% or more of the reinforcing fiber yarns constituting the laminated body are discontinuous fiber bundles, so that the above effect can be sufficiently exhibited.

  Here, as a method of providing a cut in the molding material, a method of inserting a cut by a manual operation or an automatic cutting machine using a cutter (a method), a method of punching with a punching blade having a blade at a predetermined position (b method), And a method of continuously inserting cuts (rotation method c) through a rotary roller having a blade at a predetermined position. In any method, there is no change in inserting a notch so that the molding material in which the sheets are laminated and integrated in advance is penetrated in the thickness direction of the molding material. When the cutting pattern is complicated or when it is desired to strictly control the position of the cutting, the method a is preferable, and the method b is preferable when manufacturing in large quantities considering production efficiency, more preferably The method c.

  In the molding material of the present invention, each of the sheets constituting the laminate is laminated in a multiaxial orientation such that the reinforcing fiber yarns intersect to constitute a laminate, and the number of axes to be oriented is n When the weight ratio in the molding material of the reinforcing fiber yarn that is cut at a finite length of 10 to 300 mm in the shaft and fiber length La is N%, it is preferable that n and N satisfy the relationship of the following formula: .

(100-100 / n) ≦ N (1)
By satisfying the formula (1), it is possible to control the shapeability and mechanical properties of the molding material with a good balance. As specific modes satisfying the formula (1), there are the following two modes. The effects that can be expected in each aspect will be described in detail below, but may be properly used depending on the shape and design of the target molded body. As a first aspect satisfying the expression (1), a reinforcing fiber yarn is inserted into the molding material in which the reinforcing fiber yarn is oriented at (0 ° / 90 °) along the 0 ° direction, and the reinforcing fiber of the 90 ° sheet is obtained. An example is one in which the entire length of the yarn is cut to a finite length with a fiber length La of 10 to 300 mm. In this case, n is biaxial and N ≧ 50. That is, when the cut is inserted in the 0 ° direction, the reinforcing fiber yarn of the 0 ° sheet is not substantially cut, and only the 90 ° sheet is cut. In such a case, when the weight per unit area of each sheet of 0 ° and 90 ° is equal, N = 50, and the weight per unit area of the 90 ° sheet to be cut (the total) is cut. If it is greater than the weight per unit area of the 0 ° sheet that is not applied, 50 <N.

  The molding material obtained from this is because only the reinforcing fiber yarns of the 90 ° sheet are cut, so the second formability is also given only to the 90 ° sheet. If the shape requires a curvature only in the 90 ° direction, shaping is possible, and in the 0 ° direction, the same strength expression as that of the continuous fiber can be expected. This is the same even when the fiber orientation axis is increased, and can be obtained by inserting a cut parallel to the reinforcing fiber direction of the sheet having a specific orientation in the laminate. That is, all the sheets except the sheet with a specific orientation in the laminate are selectively provided with anisotropy in the formability of the molding material because the cuts in the direction crossing the reinforcing fiber yarns are arranged on the entire surface. And the mechanical properties of FRP can be maximized.

The second satisfying the above formula (1) is one in which cuts are inserted along the 45 ° direction of the molding material in which the reinforcing fiber yarns are oriented at (0 ° / 90 °). Also in this case, n is biaxial and N ≧ 50, but since the cut is inserted in the 45 ° direction, both the reinforcing fiber yarns of the 0 ° sheet and the 90 ° sheet are cut. Also in the second aspect, it is preferable that the weight ratio N of the reinforcing fiber yarns that are cut with a finite length of 10 to 300 mm satisfies the expression (1).
Such a molding material has some notches in all sheets constituting the laminate, and exhibits some second shapeability in all sheets. Alternatively, even if the effect of the second shapeability is not sufficient, the presence of the reinforcing fiber yarn having a free end in the vicinity causes the above-described shear deformation in the layer, so that shaping as a molding material Sex is sufficiently secured. In addition, since the ratio of remaining continuous fibers or fiber length La can be controlled for each sheet with a restriction, it is possible to take a prescription taking into account the anisotropy of physical properties in FRP. That is, the physical properties of the molding material can be made uniform and anisotropy can be imparted, but in particular, this is a preferred embodiment in view of the balance of all sheets of the molding material. Therefore, preferably, the ratio of the reinforcing fiber yarns cut at a finite length of 10 to 300 mm in fiber length La is the same for each sheet at N% or more, and the molding material obtained therefrom is homogeneous. Excellent.

  The molding material of the present invention is the first partial lamination of the sheet constituting the laminated body, with a specific one layer of the textile body including the first thermoplastic resin in the thickness direction of 25 to 75% as a boundary. And a second partial laminate, the first partial laminate and the second partial laminate are provided with cuts penetrating in the thickness direction over the entire surface. It is preferable that the cuts in the second partial laminate do not overlap on the projection surface in the thickness direction.

  The thickness direction of the molding material is the stacking direction of the sheets for molding the molding material.

  Each of the first partial laminate and the second partial laminate is provided with a notch penetrating in the thickness direction over the entire surface, and the first partial laminate and the second partial laminate are cut. Does not overlap on the projection surface in the thickness direction. To penetrate the partial laminate in the thickness direction means that the cuts inserted at a time penetrate the partial laminate, and the cuts are made in all the sheets constituting the partial laminate. At this time, the cutout may or may not be inserted in the fabric body at the boundary, but when emphasizing the formability in the molding material, it is an inserted mode and the handleability in the molding material. In the case where importance is attached, it is not inserted.

  The cuts in the first partial laminate and the second partial laminate do not overlap on the projection surface in the thickness direction. Here, not overlapping on the projection surface in the thickness direction means that, when the cuts do not overlap at all, the cuts in the intersecting direction overlap at points, and the cuts in the parallel direction are 10% of the cut length Lb. The case where it overlaps below.

  Such a molding material can disperse the cuts in the thickness direction of the molding material, and has the effect of homogenizing the second shapeability of the molding material in the thickness direction. The second formability is the opening at the cut end of the reinforcing fiber, and the fact that it is dispersed in the thickness direction means that the opening is not concentrated at one point, and an improvement in surface quality in FRP is expected. From another viewpoint, since formation of a resin spot, stress concentration at the cut end of the reinforcing fiber, and propagation of damage at the portion can be suppressed, it is advantageous in improving the mechanical characteristics of the FRP.

  From such an effect, the cloth body serving as the boundary is preferably located in the thickness direction at 40 to 60%, more preferably 50%.

  Here, the means for obtaining the molding material of this aspect is basically the same as the method a, b, and c, and the blade can remove the molding material at once by the clearance and pressing between the blade and the board surface. It is controlled so as not to penetrate. Preferably, in the above-mentioned methods b and c, in these methods, after a cut is inserted into one of the first and second partial laminates from one side, the other side is applied to the first and second partial laminates. This is a method of inserting a cut. With such a method, it is possible to continuously insert incisions, and since the production stability is excellent, it is suitable for industrial production. In the molding material of the present invention, since the fabric body is arranged at least between the sheets, when cutting the reinforcing fiber yarn, the thickness of the adjacent fabric body becomes a grace thickness, and the cut is deeper than the sheet thickness. It can be inserted, and unintentional uncut residue of the reinforcing fiber can be suppressed to a slight extent. From this, the molding material of the present invention has a suitable configuration in controlling the depth of cut, that is, it is easy to control the depth of cut.

  In the molding material of the present invention, all sheets constituting the laminate are provided with notches penetrating in the thickness direction for each sheet over the entire surface, and the notches of adjacent sheets overlap on the projection surface in the thickness direction. It is preferable not to be.

  In such an aspect, the cuts penetrating in the thickness direction for each sheet are arranged over the entire surface, whereby the physical properties can be controlled for each sheet, and a molding material having desired physical properties is obtained in a tailor-made manner. be able to. The degree of freedom is high and the obtained effect is further enhanced as compared with the aspect of the partial laminate unit described above.

  Here, the means for obtaining the molding material of this mode is basically the same as the method of cutting the partial laminate, and requires some application depending on the configuration of the molding material.

  For example, when considering a biaxial laminate (uniaxial orientation, biaxial orientation), after inserting a notch penetrating one layer of the sheet from one side of the molding material, from the other side in the thickness direction of the other sheet It is obtained by inserting a notch that penetrates.

  As an alternative method 1, when considering a biaxially oriented multi-layer laminate (however, it is limited to those laminated alternately), a notch parallel to the direction of one of the biaxial reinforcing fibers is formed into the thickness of the molding material. By inserting through the direction, it is possible to cut the reinforcing fiber yarn substantially only in one direction. Furthermore, the other orientation remains by inserting a cut through the thickness direction so that it does not overlap with the previously inserted cut at an angle that intersects the other uncut fiber direction. The reinforcing fiber yarn can be cut, and the desired molding material can be obtained.

  As an alternative method 2, when a four-layer oriented four-layer laminate is considered, the first partial laminate, with a fabric body sandwiched between the second-layer sheet and the third-layer sheet of the four-layer stack, Consider the second partial laminate. At this time, each of the first partial laminate and the second laminate is a biaxially oriented two-layer laminate, and the thickness of each sheet is the same as that of the biaxially oriented multilayer laminate. It is possible to obtain a partial laminate including a notch penetrating in the direction. The molding material obtained from this is inevitably a molding material with notches penetrating in the thickness direction for each sheet.

The means for producing the molding material of the above aspect is as described above. As a configuration to be applied, a biaxially oriented multilayer laminate, a triaxially oriented three or four layer laminate, and a four-axis oriented four-layer laminate are used. In addition, in the case of a biaxial multilayer laminate and a four-axis four-layer laminate, it is necessary to laminate so that the reinforcing fiber orientations of adjacent sheets intersect.
In the molding material according to the present invention, it is preferable that the cuts have the same cut angle with respect to the orientation direction of the reinforcing fiber yarn in each sheet in each of the sheets constituting the molding material.

  The expression of the shapeability in the molding material is as described above. Among them, the second shapeability is a progress deformation due to the opening of the notch, and the aspect of the notch greatly contributes to the deformation behavior. That is, different cuts in each layer in the laminate mean that the deformation behavior in each layer is different, which leads to an interlayer disparity in progress deformation. In addition, there is a difference in fluidity in FRP molding. Therefore, it is preferable that the cutting angle in each sheet is inserted at the same angle with respect to the reinforcing fiber yarn. More preferably, the cut length and the interval are the same (the cut mode will be described in detail later). As a result, the shapeability and fluidity of each sheet can be made substantially uniform, and the openings can be distributed almost uniformly in the FRP. Improvement of characteristics is also expected.

  Here, the same cut angle with respect to the orientation direction of the reinforcing fiber yarns in each sheet means that the cuts between the sheets are within a range of ± 2 °, respectively. Consider the same angle.

  Moreover, it is preferable that the absolute value of the angle formed by the notch and the reinforcing fiber direction is in the range of 2 to 25 °.

  When the angle formed by the cut and the reinforcing fiber direction is reduced, the amount of reinforcing fiber that is actually cut is smaller than the predetermined cut length. In other words, the cut length is shorter than the target cut length. Is effective in stably inserting the cut. However, when the angle formed by the cut and the reinforcing fiber direction is smaller than 2 °, it becomes difficult to control the cut, that is, the reinforcing fiber easily escapes from the blade when making the cut, and the reinforcing fiber is not intended in the molding material. Since uncut parts increase, production stability may be lacking. On the other hand, when the angle formed by the incision and the reinforcing fiber direction is larger than 25 °, it is necessary to apply a large force to cut the reinforcing fiber at a stroke when inserting the incision, resulting in the durability of the blade. May decrease.

  From another viewpoint, as the cut angle becomes smaller, the absolute amount of reinforcing fibers cut by one cut can be reduced. The reinforcing fiber bundle end portion generated by the cutting inhibits stress transmission and is highly likely to break due to a decrease in elastic modulus or stress concentration. Expected. On the other hand, the fact that the angle of cut becomes small means that it is necessary to set the interval between the cuts closely in order to obtain the desired fiber length La, which also reduces the handling of the molding material. It is. Therefore, in view of the productivity of the molding material, the handleability, and the mechanical properties of the FRP, it is preferably within the range of the cut angle, and more preferably within the range of 10 to 20 °.

  Hereinafter, the molding material of the present invention will be described in detail with reference to the drawings.

  FIG. 1 is a schematic perspective view showing one embodiment of the molding material of the present invention.

  As shown in FIG. 1, the molding material 1 is composed of a plurality of layers of a sheet in which a large number of reinforcing fiber yarns 2 are aligned in parallel, and is formed of a sheet in which the reinforcing fiber yarns 2 are aligned in parallel at 0 °. A first layer, a second layer composed of a sheet in which the reinforcing fiber yarns 2 are aligned in parallel at 90 °, a third layer composed of a sheet in which the reinforcing fiber yarns 2 are aligned in parallel at α °, and a reinforcement A total of four layers including a fourth layer (outermost layer) made of sheets in which the fiber yarns 2 are aligned in parallel with -α ° are laminated, and a textile body (nonwoven fabric) 3 is arranged between each layer. The laminated body is constituted and integrated by stitch yarns 4 that penetrate through the laminated body in the thickness direction. Each of the first to fourth layers constituting the molding material 1 is provided with cuts (not shown) on the entire surface of the sheet, and the reinforcing fiber yarns constituting each sheet are cut. The stitch yarn structure in FIG. 1 is an irregular 1/1 tricot knitting in which a chain knitting and a 1/1 tricot knitting are combined. However, a chain knitting or a 1/1 tricot knitting may be used. If it can penetrate and be integrated, a desired tissue can be obtained. As shown in FIG. 1, when the reinforcing fiber yarns are oriented at 0 ° in the first layer (outermost layer), a structure having stitch yarns in the direction intersecting with the longitudinal direction of the molding material such as tricot knitting. By doing, it is preferable because it can prevent the reinforcing fiber yarn from falling off the surface. Here, the reinforcing fiber yarn direction (0 ° direction) 5 in the first layer, the direction 6 in which the stitch yarn 4 extends, and the longitudinal direction 7 of the molding material are the same direction, and any direction below. Shall also accompany this.

  Here, in the molding material of the present invention, a plurality of rows composed of intermittent cuts in the direction crossing the reinforcing fiber yarns are arranged in parallel on the entire surface of the sheet, and the individual cuts are as follows. The cut length Lb is 1 to 300 mm.

  This aspect will be described in more detail with reference to FIG.

  FIG. 2 is a schematic plan view showing one embodiment of the molding material of the present invention.

  In FIG. 2, the molding material 8 includes a first layer composed of a sheet in which reinforcing fiber yarns 9 are aligned in parallel at −45 °, and a first layer composed of a sheet in which reinforcing fiber yarns 9 are aligned in parallel at + 45 °. A total of two layers, two layers, are laminated, and a textile body (not shown) is arranged between the first layer and the second layer, and is integrated by stitch yarns 10 organized by chain stitch. A cut 11 in the 90 ° direction is provided on the entire surface of the first and second layer sheets constituting the molding material 8.

  In the incision 11 of the present invention, a plurality of rows 12 are arranged in parallel, each of which is composed of intermittent incisions in a direction crossing the reinforcing fiber yarns. Further, each of the cuts 11 preferably has a cut length Lb in the range of 1 to 100 mm.

  If the cut length Lb is too short, the cut pieces of the reinforcing fiber yarns are too fine, so that the reinforcing fiber yarns can easily fall off from the molding material, or it can be difficult to handle as the molding material. From the viewpoint of production stability of molding materials, it becomes difficult to control the cutting, and unintentional uncutting may increase, and it will be necessary to insert a huge amount of cutting in the manufacturing process. There is also a concern that requires. On the other hand, if the cutting length Lb is too long, the cut pieces of the reinforcing fiber yarns are too large, and when trying to shape into any shape, the formability is uniformly expressed in the plane direction of the molding material. In some cases, the opening becomes extremely large, and the surface quality when FRP is reduced, and the mechanical properties are deteriorated due to the stress concentration in the opening and the formation of resin rich. That is, since the cut length Lb coexists within such a range, it is possible to balance the handling and shaping of the molding material without impairing each other, and also in the productivity of the molding material. It can be excellent. From this viewpoint, more preferably, the cut length Lb is in the range of 3 to 10 mm.

  In FIG. 2, the notches 11 form rows 12 that are intermittently arranged at a constant interval in the 90 ° direction, and these rows are arranged in parallel at a constant interval in the 0 ° direction. In addition, the cuts of the rows 13 and 14 adjacent to the row 12 are arranged alternately with the row 12 so that the cuts partially overlap each other.

  In the present invention, the arrangement pattern of the cuts and the columns formed by the cuts is not particularly limited, but is preferably the above-described embodiment. In such a mode, all of the reinforcing fiber yarns constituting the sheet can be surely cut, and in the multiaxially oriented material, the reinforcing fiber yarns of each layer are cut by cutting in one direction. Moreover, since it can cut | disconnect efficiently, it can be said that it is a preferable aspect.

  Further, in the molding material of the present invention, the stitch thread interval Wb parallel to the longitudinal direction of the molding material and the notch length Lb are | at an angle θ formed by the notch and the direction orthogonal to the direction in which the stitch thread extends. It is preferable that cos θ | <(Wb / Lb) and that the stitch yarn extending in the longitudinal direction of the molding material is not substantially cut. Here, the angle θ is a value obtained by converting the degree unit into the radian unit.

  This aspect will be described in detail below with reference to FIG.

  FIG. 3 is a schematic plan view showing another embodiment of the molding material of the present invention.

  In FIG. 3, the molding material 18 includes a first layer composed of a sheet in which the reinforcing fiber yarns 19 are aligned in parallel at 0 °, and a second layer composed of a sheet in which the reinforcing fiber yarns 19 are aligned in parallel at 90 °. A total of two layers are laminated, and a textile body (not shown) is arranged between the first layer and the second layer, and is integrated by stitch yarns 20 organized by 1/1 tricot knitting. Yes. The stitch yarns are parallel to the longitudinal direction 21 of the molding material 18 at the interval Wb22, and a cut 23 in a 45 ° direction is arranged between the parallel stitch yarns. The reinforcing fiber yarn 19 is cut over the entire length.

According to FIG. 3, since the angle formed by the notch 23 and the orthogonal direction 24 of the direction in which the stitch yarn extends is 45 °, the angle θ is π / 4 radians, and | cos θ | is calculated as 0.71. . Therefore, (Wb / Lb) is 0.71 or less, and the interval Wb22 between the stitch yarns is fixed by the molding material, so Lb is Wb / 0.71 or less. Here, when the stitch thread interval Wb22 is 5 mm, the notch length Lb25 is 7.1 mm, and the notch length Lb25 is the length Lb ₁ 26 in the direction in which the stitch thread extends and the stitch thread is When divided into the length Lb ₂ 27 in the orthogonal direction of the extending direction, Lb ₁ = 5.0 mm and Lb ₂ = 5.0 mm. That is, since Wb> Lb ₂ , it is possible to arrange the cut between the stitch yarns parallel to the longitudinal direction of the molding material, that is, the stitch yarn 28 extending in the longitudinal direction of the molding material. It can be set as the aspect which is not cut | disconnected substantially. Here, in the case of θ = 0 (0 °) to π (180 °), | cos θ | = 1, and in the case of θ = π / 2 (90 °) to 3π / 2 (270 °), almost | cos θ Since | = 0, | cos θ | is defined within a range of 0 to 1, and within such a range, by satisfying | cos θ | <(Wb / Lb), stitches can be cut at any angle. Can fit within the thread spacing. Note that when | cos θ | = 0, Lb is assumed to be infinitely large. Therefore, Lb is selectively determined within a range of 2 to 50 mm as an exception only in this case. In addition, when the surface of the molding material is projected, the stitch yarn 28 extending in the longitudinal direction of the molding material and the notch 23 do not intersect with each other when the surface of the molding material is projected. It does not mean that it is not cut including the stitch yarns (29, 30 in FIG. 3) arranged at an angle crossing the longitudinal direction of the molding material.

  Although it is as above-mentioned that the stitch thread improves the handleability of a molding material, it is as above-mentioned that a shaping property improves by arranging a notch in a molding material. That is, these handleability and formability are in a trade-off relationship, and the above aspect is a preferable aspect for satisfying these two characteristics.

  In such an aspect, since the stitch yarn extending in the longitudinal direction of the molding material is not substantially cut, a decrease in handleability in the molding material can be minimized. Of the stitch yarns contained in the molding material, stitch yarns that extend in the longitudinal direction of the molding material are integrated into the longitudinal direction by forming a loop that penetrates in the thickness direction of the molding material and forms a loop. The reinforcing fiber yarns are constrained in the plane direction of the molding material by being continuously parallel. On the other hand, the stitch yarn arranged at an angle intersecting with the longitudinal direction of the molding material strengthens the entanglement in the weft direction (width direction of the molding material) in the knitted structure, or the reinforcing fiber yarn located on the surface of the laminate in the molding material Covering the strips, it is responsible for handling the molding material in the plane direction. In other words, by cutting only the stitch yarn arranged at an angle intersecting the longitudinal direction of the molding material, not only the shapeability of the molding material in the plane direction is improved, but also the handleability in the thickness direction of the molding material is improved. Since the main stitch yarn to be held remains, a decrease in handleability can be minimized. With regard to formability, the stitch yarn extending in the longitudinal direction of the molding material remains substantially continuously, so that the deformation at the time of shaping is transmitted through the stitch yarn, so the notch This embodiment is also preferable because the shapeability can be expressed uniformly in the plane direction of the molding material without locally opening.

  In this aspect, the stitch yarn is disconnected in the transverse direction of the molding material, but it is not necessary to cut all of the stitch yarns arranged at an angle intersecting with the longitudinal direction of the molding material. In the case where the outermost reinforcing fiber yarn direction is 0 ° or when it is formed into an extremely deep drawing shape or the like, it is preferable to leave a part of it in view of handling and shaping.

In the molding material of the present invention, the melting point Tm1 of the first thermoplastic resin and the melting point Tm2 of the second thermoplastic resin satisfy the following relationships (e) to (g): In the molding of FRP and the obtained FRP, excellent effects are brought about respectively.
(E) The melting point Tm1 of the first thermoplastic resin and the melting point Tm2 of the second thermoplastic resin are (Tm1-150) ≦ Tm2 ≦ (Tm1-20).
(F) The melting point Tm1 of the first thermoplastic resin and the melting point Tm2 of the second thermoplastic resin are ((Tm2-150) ≦ Tm1 ≦ (Tm2-20).
(G) The melting point Tm1 of the first thermoplastic resin and the melting point Tm2 of the second thermoplastic resin are (Tm2-20) <Tm1 <(Tm2 + 20).
When the melting points of the first thermoplastic resin and the second thermoplastic resin are in the relationship (e), the stitch yarn can be melted first when molding the FRP. Before impregnation into the fiber yarn layer, the stitch yarn is restrained in the thickness direction of the molding material, so that it is particularly easy to shear between the layers. In the relationship of (e), the function of the stitch yarn is not lost at all, but the stitch yarn that has been melted first changes its form and remains in the thickness direction and the plane direction of the molding material. It is possible to prevent the yarns from cracking in the plane direction and to suppress the bending of the reinforcing fiber yarns from being significantly bent. Therefore, even when shaping into a complicated shape, it can be shaped while suppressing wrinkles generated in the molding material. That is, it can be said that the molding material satisfying the relationship (e) is an aspect specialized for shear deformation between layers of the molding material, and has such a feature, and thus has a single contour shape (for example, cylindrical shape, U Shape). In the relationship of (e), when a plurality of molding materials are laminated, the molding material is integrated by partially melting the stitch yarn containing the second thermoplastic resin without melting the textile body. Therefore, it can be said to be a preferred embodiment in the present invention.

  As a specific combination satisfying the relationship (e), for example, the first thermoplastic resin is polyamide 6 or polyamide 66, and the second thermoplastic resin is polyamide 11, polyamide 12 or copolymer polyamide ( For example, polyamide 6/66/12, polyamide 610/12, polyamide 6/66/610/12, polyamide 6/66/612/12, and the like, and the first thermoplastic resin is polyamide 66, The combination in which the second thermoplastic resin is polyamide 6, the first thermoplastic resin is polyester, the second thermoplastic resin is a copolymerized polyester, and the first thermoplastic resin is polyethylene or polypropylene A combination in which the second thermoplastic resin is a copolymerized polyolefin, and the first thermoplastic resin is polypropylene. , And the second thermoplastic resins are combinations is ethylene. In the case of the above combination, the first thermoplastic resin and the second thermoplastic resin are composed of resins having a similar molecular structure, so that both are excellent in compatibility and exhibit excellent mechanical properties in FRP. Can do.

  In addition, when the first thermoplastic resin is polyphenylene sulfide and the second thermoplastic resin is a combination of polyamide, the difference in melting point between the first thermoplastic resin and the second thermoplastic resin is increased. It has the advantage that it is particularly excellent in formability.

  When the melting points of the first thermoplastic resin and the second thermoplastic resin are in the relation (f), when the FRP is molded by heating the molding material, the textile body that is the first thermoplastic resin is While the first thermoplastic resin is impregnated in the reinforcing fiber yarn layer in order to melt first, each layer constituted by the reinforcing fiber yarn is formed by the stitch yarn which is the second thermoplastic resin. Since it is restrained, the orientation of the reinforcing fiber yarn can be particularly restricted. Further, since the stitch yarn penetrates in the thickness direction of the molding material, the through hole becomes an impregnation flow path for the resin, and there is also an effect of remarkably improving the impregnation property of the melted first thermoplastic resin. . In addition, the improvement of the impregnation property by the through hole is achieved regardless of whether or not the stitch yarn is melted, and also in the relationship of the above (e) and the later (g) in which the stitch yarn is melted. Since the melted stitch yarn changes its form and exists in the through hole, the through hole remains and functions as an impregnation channel. In this embodiment (f) in which the stitch yarn is not melted, the shape of the through hole is completely maintained by the presence of the stitch yarn as a yarn, and the function as the impregnation channel is more efficiently performed. In this embodiment, the effect is particularly greatly manifested.

  In addition, in relation to (f), the fabric body (nonwoven fabric) 35 is inserted as shown in FIGS. 5 and 6 in order to melt the fabric body first and impregnate each layer with a thermoplastic resin as a matrix. Since the thickness between the layers is reduced and the constraint of the stitch yarn 36 is loosened, and the frictional resistance between the layers is reduced, it becomes a mode in which shear deformation easily occurs between the layers. For this reason, the generation of wrinkles is suppressed even in the formation of a curved surface, and the orientation of the reinforcing fiber yarn is maintained by the presence of the stitch yarn, so that a high-quality FRP that can exhibit excellent mechanical properties is obtained. be able to. That is, it can be said that the molding material satisfying the relationship (ii) is an aspect in which both the ease of shear deformation between the layers of the molding material and the restraint of the reinforcing fiber yarn by the stitch yarn are compatible. Therefore, it is preferably shaped into a double contour shape (for example, a hat shape) having a relatively gentle curved surface or a large area and a thin shape. In the relationship (v), when the textile body containing the first thermoplastic resin as the component is disposed on at least one of the outermost layers of the molding material, the stitch yarn is not melted when the plurality of molding materials are laminated. Since the outermost layer body is partially melted and the molding materials can be integrated (for example, a form of a preform), it can be said to be a preferable aspect in the present invention. FIG. 6 is a schematic view for easy understanding of the state in which the stitch yarn 36 is loosened. When the fabric body is actually melted, the stitch yarn is in a loose state. Also, it is immersed in a thermoplastic resin as a matrix.

  As a specific combination satisfying the relationship (v), for example, the first thermoplastic resin is polyamide 11, polyamide 12 or copolymer polyamide (for example, polyamide 6/66/12, polyamide 610/12, polyamide). 6/66/610/12, etc.), and the second thermoplastic resin is polyamide 6 or polyamide 66, or the first thermoplastic resin is polyamide 6 and the second thermoplastic resin is polyamide 66. A combination in which the first thermoplastic resin is a copolymerized polyester, a second thermoplastic resin is a polyester, the first thermoplastic resin is a copolymerized polyolefin, and the second thermoplastic resin is polyethylene. Or a combination that is polypropylene, the first thermoplastic resin is polyethylene, and the second thermoplastic resin is polypropylene. Combinations pyrene and the like. In the case of the above combination, when a resin similar to the first thermoplastic resin and the second thermoplastic resin is used, the adhesiveness between the two is excellent, and thus excellent mechanical properties can be expressed. In addition, when the first thermoplastic resin is a polyolefin and the second thermoplastic resin is a combination of polyester, the difference in melting point between the first thermoplastic resin and the second thermoplastic resin can be increased. Since it can be easily impregnated, there is an advantage of excellent moldability.

  From another point of view, if the melting points of the first thermoplastic resin and the second thermoplastic resin are in the relationship (g), the stitch yarn and the fabric body are melted almost simultaneously when the FRP is formed. Can do. The molding material of this aspect has intermediate characteristics between the above (e) and (f), and as a particularly excellent point, heating during molding can be performed in one step, and the molding cycle can be shortened. . Moreover, it can shape | mold so that most traces of a stitch thread | yarn may not be left by heating of 1 step, and FRP excellent in surface smoothness can be obtained. Furthermore, since the first thermoplastic resin and the second thermoplastic resin can be made of the same resin, they are excellent in compatibility and can exhibit particularly excellent mechanical properties in FRP.

  As described above, the molding material of the present invention may be arbitrarily selected in a mode that satisfies any one of the relationships (e) to (g) according to the desired FRP form.

  Here, melting | fusing point refers to the value measured by DSC (differential scanning calorimeter) based on JISK7121 (1987) at the temperature increase rate of 20 degrees C / min in the absolutely dry state. In the present invention, the glass transition temperature + 100 ° C. obtained by the above measuring method is simply regarded as the melting point for those that do not exhibit a melting point (for example, an amorphous polymer).

Here, the basis weight of the reinforcing fibers in each sheet constituting the molding material of the present invention is preferably in the range of 50 to 350 g / m ² .

When the basis weight of the reinforcing fiber is within such a range, an excellent surface product and formability are exhibited in the molding material. When the basis weight of the reinforcing fiber in each layer is less than 50 g / m ² , a gap (gap) is formed between adjacent reinforcing fiber yarns, resulting in inferior quality when FRP is used, and deterioration in mechanical properties. There are concerns such as. On the other hand, if the basis weight of the reinforcing fibers in each layer is larger than 350 g / m ² , a portion where adjacent reinforcing fiber yarns overlap with each other is generated. This may increase the shapeability and impregnation properties. Regarding the impregnation property, excessive pressure is required to melt and completely impregnate the sheet of thermoplastic resin in each sheet, and the excessive pressure induces bending of the reinforcing fiber yarn. There is a case.

Moreover, it is preferable that each fabric weight of the textile body arrange | positioned between the said sheets is the range of 15-250 g / m < ² >. More preferably, it is 35-150 g / m < ² >, More preferably, it is 40-100 g / m < ² >.

If the fabric weight is less than 15 g / m ² , the amount of the thermoplastic resin is relatively insufficient with respect to the amount of the reinforcing fiber yarn, so that it cannot be sufficiently impregnated, and the fabric body becomes too thin. Problems such as tearing or deformation in the manufacturing process of the molding material are likely to occur, and the handleability of the fabric body is significantly reduced. From the same viewpoint, it is more preferably 35 g / m ² or more, further preferably 40 g / m ² or more. In order to avoid this problem, if the basis weight of the reinforcing fiber in each sheet is lowered beyond the range of the present invention, a gap is formed between the reinforcing fiber yarns, so that not only the strength when FRP is reduced but also the quality. May get worse. On the other hand, if the basis weight of the textile body exceeds 250 g / m ^2, the content of reinforcing fibers is relatively reduced, and sufficient strength cannot be expressed when FRP is used. In order to avoid this problem, if the basis weight of the reinforcing fiber of each sheet is increased beyond the scope of the present invention, the reinforcing fiber yarns overlap each other, resulting in unevenness on the surface, not only inferior formability and quality, When impregnating the resin, an excessive external pressure is required, and the reinforcing fiber yarn may be bent.

  In addition, the basis weight of the reinforcing fiber yarn and the fabric body of each sheet is cut out in accordance with JIS R7602 (1989) 5.5, the local material is released, the molding material is disassembled, and each sheet is disassembled. It is set as the value measured about the reinforcing fiber and fabric body.

  Examples of the reinforcing fiber yarn used in the present invention include carbon fibers, graphite fibers, glass fibers, and organic fibers such as aramid, paraphenylenebenzobisoxazole, polyvinyl alcohol, polyethylene, polyarylate and polyimide, These 1 type (s) or 2 or more types can be used together. Among these, carbon fibers are preferably used because they are excellent in specific strength and specific elastic modulus and effective in reducing the weight of the FRP molded product. As the carbon fiber, the tensile strength of the yarn is preferably 4 GPa or more and 7 GPa or less, more preferably 4.5 GPa or more and 6.5 GPa or less, and the tensile elastic modulus is 200 GPa or more and 500 GPa or less, particularly suitable for a structural material. . The tensile strength of the yarn can be determined according to a tensile test method specified in JIS R-7601 after impregnating a carbon fiber yarn with a resin having the following composition and curing at 130 ° C. for 35 minutes. The resin composition is alicyclic epoxy resin (3,4-epoxycyclohexylmethyl-3,4-epoxy-cyclohexyl-carboxylate): 100 parts by weight, boron trifluoride monoethylamine: 3 parts by weight, acetone: 4 weights Part. Further, the tensile elastic modulus of the yarn can be obtained from a slope of a load-elongation curve by performing a tensile test in the same manner as the above-described tensile strength measuring method.

  The reinforcing fiber yarn is preferably attached with 0.2 to 2.5% by weight of a sizing agent from the viewpoint of handleability and resistance to needle abrasion during knitting. Generation | occurrence | production of fluff can be suppressed because the sizing agent adheres in the said range.

The reinforcing fiber yarns may be either untwisted yarns or twisted yarns, but are preferably substantially untwisted (less than 1 turn / m) from the viewpoint of mechanical properties such as tensile strength and compressive strength. From this point of view, in the production of the molding material of the present invention, the reinforcing fiber yarn may be warped and untwisted to mix the untwisting twist, but the twisting and untwisting will not cause untwisting. The reinforcing fiber yarn is preferably present in the molding material in a substantially untwisted state (less than 1 turn / m). With this weft removal, not only a high-quality sheet can be easily obtained in the reinforcing fiber basis weight within the scope of the present invention, but also the reinforcing fiber volume ratio (Vf) and mechanical properties can be improved as FRP. . In particular, when the basis weight of the sheet is 190 g / m ² or less, a gap (gap) between the reinforcing fiber yarns is easily formed in the sheet, and the sheet quality may be inferior. The above effect is more markedly manifested when the fineness of the reinforcing fiber yarn is within the following range. The fineness of the reinforcing fiber yarn is preferably 500 to 7,000 tex, more preferably 1,000 to 2,000 tex. If the fineness is too small, the effect of the present invention may not be exhibited because there is almost no influence due to the mixing of the twist, the fiber yarn becomes expensive, and a large number of fine fiber yarns with fineness are used. Therefore, the multiaxial base material itself becomes expensive. On the other hand, when the fineness is too large, for example, when obtaining a molding material having a low basis weight of reinforced fiber yarns per layer of 100 g / m ² or less, the yarn width is likely to fluctuate with a slight force and is stable. It may be difficult to maintain the yarn width.

  The molding material of the present invention can exhibit its excellent formability to the maximum by forming a preform in which one or more of the molding materials are laminated and formed into a single contour shape or a double contour shape. .

  FIG. 4 is a schematic cross-sectional view of a preform obtained by shaping the molding material of the present invention into an arch shape.

  As shown in FIG. 4, the molding material 31 of the present invention is shaped into a mold (not shown) having an arch shape, and the molding material 31 is located on the surface of the mold by shear deformation in the thickness direction. The difference between the inner and outer peripheral lengths from the inner peripheral portion to the outer peripheral portion is alleviated, and the generation of wrinkles is suppressed. Further, when attention is paid to the respective sheets 32 constituting the molding material, it can be seen that the reinforcing fiber yarns have openings 33 in the respective sheets. Such an opening 33 corresponds to a cut portion in the molding material, and the deformation in the planar direction of the molding material is released by inducing a progressing deformation at the free end of the reinforcing fiber yarn, and is shaped along the mold. ing. That is, due to the mutual synergistic effect of the first shapeability and the second shapeability in the molding material, even in the double contour shape or the double contour shape, the wrinkles and the reinforcing fiber yarns are not stretched. A preform along a desired shape can be obtained.

  In addition, in a portion where the molding material is shaped into a single contour shape or a double contour shape, the arc length Lc and the fiber length La in each cross section in the reinforcing fiber yarn direction of each sheet constituting the molding material are Lc>. La is preferred. Here, each cross section in the reinforcing fiber yarn direction of each sheet constituting the molding material is cut out along the direction in which the reinforcing fiber yarns are aligned in parallel in each sheet forming the molding material The length Lc of the arc is the length of a line segment in contact with the molding material in the shape of the cross section, and the fiber length La is a reinforcing fiber that is aligned in the same direction as the cross section. The fiber length of the yarn. In addition, since there are an infinite number of cross sections in the shape, it is only necessary to satisfy the above aspect for an arc that is within 1/10 of the length Lc of the largest arc in the shape to be shaped.

  In such an embodiment, since the reinforcing fiber yarn is cut at a distance shorter than at least the arc, the free end of the reinforcing fiber yarn is always disposed on the mold to be shaped. It is possible to develop the second formability in the molding material without stretching. That is, in this aspect, it is possible to express the shaping property of the molding material described above without being influenced by the shape to be shaped. For this reason, Lc> La. Since La is in the range of 10 to 300 mm as described above, the lower limit value is La = 10 mm, and when Lc <10 mm, there is a slight change in shape, which is caused by the free ends of the nearby reinforcing fiber yarns. Since it is relaxed, there is no particular problem even if it is outside the range of Lc> La.

  The FRP of the present invention is formed by using the above-mentioned molding material or preform, and is a matrix resin obtained by melting and solidifying at least the first thermoplastic resin constituting the fabric body. is there.

  In the case of the molding material or preform of the present invention integrated with the thermoplastic resin as the matrix in advance, the step of injecting the matrix resin like RTM can be omitted, so the molding cycle can be shortened and the production of FRP can be shortened. Excellent in properties. In addition, when the molding material or preform of the present invention is used, it can be shaped into a single contour shape or a double contour shape while suppressing the generation of wrinkles, and an FRP in which the disturbance of the orientation of the reinforcing fiber yarn is suppressed is molded. can do.

  In the case of using the fabric body and stitch yarn composed of the thermoplastic resin described in (e) above, the FRP is obtained by first melting the stitch yarn containing the second thermoplastic resin as a component and then the first heat. Since the textile body composed of the plastic resin is melted and solidified to form a matrix, the FRP has no trace of stitch yarn. And as above-mentioned, even if it is a complicated shape, it can shape | mold while suppressing wrinkles, As a result, it can be set as FRP excellent in surface smoothness and a mechanical characteristic. Further, when forming and forming a preform by laminating a plurality of molding materials, the molding materials can be integrated in advance, so that the molding cycle is short and the productivity is excellent.

  In addition, when a fabric body composed of the above-mentioned thermoplastic resin and stitch yarn are used, the fabric body containing the first thermoplastic resin as a component melts and solidifies to form a matrix, The stitch yarn containing the thermoplastic resin of 2 as an ingredient becomes an FRP that substantially maintains its form, and as described above, the disorder of the orientation of the reinforcing fiber yarn is suppressed by the stitch yarn that is not melted, The FRP can exhibit excellent mechanical properties.

  Furthermore, when the textile body comprised from the thermoplastic resin of the said aspect (g) and the stitch thread | yarn are used, the textile body which uses the 1st thermoplastic resin as a component, and 2nd thermoplastic resin as a component The stitch yarn and FRP are simultaneously melted and solidified to form a matrix. Thereby, as above-mentioned, a shaping | molding cycle can be shortened and it can be set as FRP excellent in surface smoothness and a mechanical characteristic.

  In the production of such FRP, means for heating and pressurizing the molding material is not particularly limited, but it is preferable to use an autoclave, a combination of an oven and atmospheric pressure, a press machine, etc. A press is more preferable because of its speed.

The following were used as raw materials in the examples and comparative examples.
<Reinforcing fiber yarn>
PAN-based carbon fiber yarn, 12,000 filaments, fineness 800 tex, tensile strength 4,900 MPa, tensile elastic modulus 240 GPa, 0 turns / m.
<Stitch yarn>
Stitch yarn A: Copolyamide (“Elder” (registered trademark), manufactured by Toray Industries, Inc.), 10 filaments, fineness 56 dtex, melting point 115 ° C.
Stitch yarn B: Polyamide 66, 10 filament, fineness 33 dtex, melting point 255 ° C.
<Textile body>
Nonwoven fabric A: Polyamide 6, basis weight 80 g / m ² , melting point 220 ° C.
Nonwoven fabric B: copolymerized polyamide (manufactured by Toray Industries, Inc., “Elder” (registered trademark)), basis weight 80 g / m ² , melting point 115 ° C.
<Molding material>
Thereafter, a molding material having a width of 1.27 m was produced by the procedures (1) to (6).

First, the laminated body which has the nonwoven fabric A between each sheet | seat comprised with the reinforced fiber yarn and any outermost layer was formed.
(1) The nonwoven fabric A arranged in the outermost layer was continuously supplied so that the longitudinal directions of the nonwoven fabric A and the belt conveyor were parallel. The belt conveyor continues to move in the longitudinal direction (0 ° direction) at a constant speed of 1 m / min during the subsequent lamination of the reinforcing fiber yarn layer and the nonwoven fabric, and continuously to the adhesive means described later. It is to be transported.
(2) On the nonwoven fabric A, the reinforcing fiber yarns that have been weaved and unwound so as not to mix the untwisted strands are aligned in parallel to the longitudinal direction (0 ° direction) at −45 °, and A -45 ° sheet was formed by arranging so that the basis weight of the reinforcing fibers per layer was 150 g / m ² . The arrangement of the reinforcing fiber yarns of the −45 ° sheet was performed by a carriage device. The carriage device in this process reciprocates in the -45 ° direction, and is a device that arranges reinforcing fiber yarns on the belt conveyor during the forward movement (or backward movement), and the belt conveyor is longitudinal. The reinforcing fiber yarns are controlled so as to be adjacent to each other in parallel without being overlapped with each other in synchronization with the speed of conveyance in the direction.
(3) The second nonwoven fabric A is placed on the −45 ° sheet, and the reinforcing fiber yarns are parallel to the longitudinal direction at + 90 ° with respect to the longitudinal direction in the same manner as in the −45 ° sheet formation. And a + 90 ° sheet was formed so as to be 150 g / m ² .
(4) A third non-woven fabric A is placed on the + 90 ° sheet, and the reinforcing fiber yarns are parallel to the longitudinal direction at + 45 ° in the same manner as in the −45 ° sheet formation. And it arranged so that it might become 150 g / m < ² >, and the +45 degree sheet | seat was formed.
(5) The 4th nonwoven fabric A is arrange | positioned on the said +45 degree sheet | seat, and in the same method as -45 degree sheet | seat formation on it, a reinforcement fiber thread is parallel to 0 degree with respect to a longitudinal direction. And 0 ° sheet was formed by arranging so as to be 150 g / m ² .
(6) The 5th nonwoven fabric A was arrange | positioned on the said 0 degree sheet | seat, and the laminated body was formed.
Subsequently, the laminate on the belt conveyor formed as described above was integrated by stitching with the stitch yarn A. In such stitches, the stitch yarn A was unwound by an unwinding device and knitted while allowing the needle to penetrate the laminate. The knitting structure of the stitch yarn is an irregular 1/1 tricot knitting composed of chain knitting and 1/1 tricot knitting, and the through holes by the stitch yarn are 8.3 rows / 25 mm in the longitudinal direction of the molding material and 5 rows in the width direction. / 25 mm (Wb = 5.0 mm) was regularly arranged. The density of the through holes was 66,666 places / m ² . Nonwoven fabric A was excellent in needle penetrability, and the fibers of the nonwoven fabric were not entangled with the needle. The molding material integrated with the stitch yarn A was wound as a blank by a winding device.

(Example 1)
Cuts were inserted in the direction of 90 ° with respect to the longitudinal direction of the molding material on the entire surface of the molding material (blank) sheet produced by the procedures of (1) to (6). In addition, each of the cuts has a cut length Lb of 25.0 mm and is arranged on a straight line so as to have an interval of 12.5 mm in the 90 ° direction, and the cut rows are arranged in parallel. Thus, molding material A was obtained. Adjacent cut rows were alternately shifted by 18.75 mm in the 90 ° direction, and both ends of the cuts of the adjacent rows were arranged to overlap each other by 6.25 mm in the 0 ° direction. In the molding material A, 75% of the reinforcing fiber yarns are cut, and the fiber length La of each sheet is 35.3 mm, 50% is 106.1 mm, and + 45% in the −45 ° sheet. Of the 0 sheet, 50% was 35.5 mm, 50% was 106.1 mm, and 50% of the 0 sheet was 25.0 mm and 50% was 50.0 mm. The insertion of the cut was performed off-line from the manufacturing process of the molding material (blank) using an automatic cutting device.

  The obtained molding material A had a level in which the reinforcing fiber yarns were restrained moderately by the stitch yarn, and was sufficiently handled as the molding material.

  The obtained molding material A was placed on a hemispherical female mold having a radius of curvature of 300 mm at the maximum diameter, and pressed from above with a female mold of the same shape having a radius of curvature of 305 mm, and the preform was pressed. Obtained.

  The resulting preform was a good preform without the occurrence of wrinkles by releasing the in-plane distortion of the molding material by opening the free ends of the reinforcing fiber yarns at the incision points. Since the stitch yarn was partially cut, some unevenness was confirmed in the distribution of the openings.

  Further, the obtained preform was placed again on the mold, and once heated to 150 ° C., the stitch yarn A was allowed to follow the mold while being melted, and pressed (pressed) at 25 MPa for 180 seconds. While being pressurized, the mold temperature was raised to 250 ° C. and held for 180 seconds, the mold temperature was cooled to 50 ° C., and then the pressure was released and demolded to obtain FRP.

  When the cross section cut out from the obtained FRP so as to have a width of 2 cm is observed with an optical microscope, the resin is impregnated into the inside of the reinforcing fiber yarn, and the observation surface of the void is slightly seen near the outermost layer 96% of the resin was impregnated with resin. Further, since the stitch yarn continuous in the longitudinal direction was partially cut, the fiber orientation was disordered and the surface irregularities were slightly generated, but no wrinkles were observed.

(Example 2)
Cuts were inserted in the 0 ° direction with respect to the longitudinal direction of the blank on the entire surface of the blank sheet produced by the procedures (1) to (6). In addition, each of the cuts has a cut length Lb of 25.0 mm and is arranged on a straight line so as to have an interval of 12.5 mm in the 0 ° direction, and the cut rows are arranged in parallel. Thus, molding material B was obtained. All of these notches were arranged between the stitch yarns parallel to the longitudinal direction of the molding material B, and all the stitch yarns extending in the longitudinal direction of the molding material B were not cut.
In the molding material B, 75% of the reinforcing fiber yarn is cut, and the fiber length La of each sheet is 35.5 mm for 75%, 106.1 mm for 25%, and 90% for the -45 ° sheet. Of the sheet, 50% was 25.0 mm, 50% was 50.0 mm, and among the +45 sheet, 75% was 35.5 mm and 25% was 106.1 mm.

  Since the obtained molding material B had continuous stitch yarns remaining, it could be stably handled as a molding material as compared with Example 1.

  The obtained molding material B is placed on a hemispherical female mold having a radius of curvature of 300 mm at the maximum diameter, and pressed from above with a female mold of the same shape with a radius of curvature of 305 mm, and a preform is pressed. Obtained.

  The resulting preform opens the free ends of the reinforcing fiber yarns at the incisions to release distortion in the surface of the molding material, without wrinkling, and with continuous stitch yarns. Since it remained, it was a good preform with a uniform opening distribution.

  Further, the obtained preform was placed again on the mold, and once heated to 150 ° C., the stitch yarn A was allowed to follow the mold while being melted, and pressed (pressed) at 25 MPa for 180 seconds. While being pressurized, the mold temperature was raised to 250 ° C. and held for 180 seconds, the mold temperature was cooled to 50 ° C., and then the pressure was released and demolded to obtain FRP.

  When the cross section cut out from the obtained FRP so as to have a width of 2 cm is observed with an optical microscope, the resin is impregnated into the inside of the reinforcing fiber yarn, and the observation surface of the void is slightly seen near the outermost layer 96% of the resin was impregnated with resin. In addition, disorder of fiber orientation and slight irregularities on the surface occurred, but no wrinkles were observed.

(Example 3)
A molding material C was obtained with the same specifications as in Example 1 except that the stitch yarn A used was changed to the stitch yarn B.

  The obtained molding material C was at a level at which the reinforcing fiber yarns were restrained moderately by the stitch yarns and could be sufficiently handled as the molding material.

  The obtained molding material C was placed on a hemispherical female mold having a radius of curvature of 300 mm at the maximum diameter, and pressed from above with a female mold of the same shape having a radius of curvature of 305 mm, and the preform was pressed. Obtained.

  The resulting preform was a good preform without the occurrence of wrinkles by releasing the in-plane distortion of the molding material by opening the free ends of the reinforcing fiber yarns at the incision points. Since the stitch yarn was partially cut, some unevenness was confirmed in the distribution of the openings.

  Further, the obtained preform is placed again on the mold, and the nonwoven fabric A is allowed to follow the mold while being heated to 230 ° C., and is pressed (pressed) at 25 MPa for 240 seconds. After cooling the mold temperature to 50 ° C., the pressure was released and demolded to obtain FRP.

  The obtained FRP is excellent in resin impregnation property during molding because the stitch yarn remains, and the resin is impregnated even inside the reinforcing fiber yarn, and 99% of the observation surface is impregnated with the resin. It was. Further, since the fibers were constrained by the stitch yarn, the fiber orientation was not disturbed and wrinkles were not observed at all, and the surface unevenness was slightly generated.

Example 4
Except that the nonwoven fabric A to be used was replaced with the nonwoven fabric B, a molding material D was obtained with the same specifications as in Example 1.

  The obtained molding material D was at a level where the reinforcing fiber yarns were restrained moderately by the stitch yarns and could be sufficiently handled as the molding material.

  The obtained molding material D is placed on a hemispherical female mold having a radius of curvature of 300 mm at the maximum diameter, and pressed from above with a female mold of the same shape with a radius of curvature of 305 mm to press the preform. Obtained.

  The resulting preform was a good preform without the occurrence of wrinkles by releasing the in-plane distortion of the molding material by opening the free ends of the reinforcing fiber yarns at the incision points. Since the stitch yarn was partially cut, some unevenness was confirmed in the distribution of the openings.

  Furthermore, the obtained preform is placed again on the mold, and while being heated to 150 ° C., the wrinkles generated while melting the nonwoven fabric B and the stitch yarn A are stretched to follow the mold and pressurized at 25 MPa for 180 seconds. (Pressing), the mold temperature was cooled to 50 ° C. while being pressurized, and then released and released from the mold to obtain FRP.

  In the obtained FRP, the resin was impregnated to the inside of the reinforcing fiber yarn, and although a void was slightly seen in the vicinity of the outermost layer, 96% of the observation surface was impregnated with the resin. In addition, there was almost no trace of stitch yarn, but there was almost no disorder of fiber orientation or wrinkles, and the surface quality was excellent.

(Example 5)
About the blank sheet | seat produced in the procedure of said (1)-(6), the notch of 0 degree direction which penetrates -45 degree sheet | seat and 90 degree sheet | seat from the one surface of the sheet | seat was inserted in the whole surface of the sheet | seat. Further, a 90 ° cut formed through the 0 ° sheet and the + 45 ° sheet from the other surface was inserted into the entire surface of the sheet. At this time, each cut was cut in the thickness direction so that the nonwoven fabric A sandwiched between the 90 ° sheet and the + 45 ° sheet was a boundary.

  Each of the cuts in the 0 ° direction has a cut length Lb of 25.0 mm, and is arranged on a straight line so as to have an interval of 12.5 mm in the 0 ° direction, and the cut rows are parallel. Arranged. Adjacent cut rows were alternately shifted by 18.75 mm in the 0 ° direction, and both ends of the cuts in the adjacent rows were arranged to overlap each other by 6.25 mm in the 90 ° direction.

  Each of the cuts in the 90 ° direction has a cut length Lb of 25.0 mm, and is arranged in a straight line so as to have an interval of 12.5 mm in the 90 ° direction, and the cut rows are parallel. Arranged. Adjacent cut rows were alternately shifted by 18.75 mm in the 90 ° direction, and both ends of the cuts of the adjacent rows were arranged to overlap each other by 6.25 mm in the 0 ° direction.

  In addition, each notch | incision was arrange | positioned so that it might cross | intersect at the midpoint of each incision on the projection surface of the thickness direction. Thereby, the molding material I was obtained.

  In the molding material I, 100% of the reinforcing fiber yarns are cut, and the fiber length La of each sheet is 75% of the −45 ° sheet, 35.5 mm, 25% 106.1 mm, 90%. ° 50% of the sheet is 25.0 mm, 50% is 50.0 mm, + 45 ° of the sheet, 75% is 35.5 mm, 25% is 106.1 mm, 50% of the 0 ° sheet is 25.0 mm, 50% was 50.0 mm.

  Here, each cut was made so as not to cut through the nonwoven fabric A sandwiched between the 90 ° sheet and the + 45 ° sheet. In addition, the insertion of the incision is the same method as the above-described (Example 1) to (Example 4) except that the insertion thickness of the blade of the automatic cutting device is adjusted so that the blade does not penetrate in the thickness direction of the molding material. I went there.

  The obtained molding material I was excellent in handleability because the reinforcing fiber yarns were restrained moderately by the stitch yarns and the nonwoven fabric corresponding to the intermediate layer of the molding material was continuously present.

  The obtained molding material I was placed on a hemispherical female mold having a radius of curvature of 300 mm at the maximum diameter, and pressed from above with a female mold of the same shape with a radius of curvature of 305 mm, and the preform was pressed. Obtained.

  The obtained preform was cut at 100% of the reinforcing fiber yarn while releasing the in-plane distortion of the molding material by opening the free end of the reinforcing fiber yarn at the incision. It was a good preform without wrinkles. Moreover, compared with Examples 1-4, since the notch was disperse | distributed to the thickness direction of the molding material, the nonuniformity of opening was also slight.

  Further, the obtained preform was placed again on the mold, and once heated to 150 ° C., the stitch yarn A was allowed to follow the mold while being melted, and pressed (pressed) at 25 MPa for 180 seconds. While being pressurized, the mold temperature was raised to 250 ° C. and held for 180 seconds, the mold temperature was cooled to 50 ° C., and then the pressure was released and demolded to obtain FRP.

  When the cross section cut out from the obtained FRP so as to have a width of 2 cm is observed with an optical microscope, the resin is impregnated into the inside of the reinforcing fiber yarn, and the observation surface of the void is slightly seen near the outermost layer 96% of the resin was impregnated with resin. Further, since the stitch yarn continuous in the longitudinal direction was partially cut, the fiber orientation was disordered and the surface irregularities were slightly generated, but no wrinkles were observed. Furthermore, since the openings were dispersed in the thickness direction, local large openings were not seen, and the surface quality was excellent.

(Example 6)
About the blank sheet produced by the procedure of (1) to (6), after inserting a cut in the −45 ° direction penetrating the −45 ° sheet and the 90 ° sheet from one surface of the sheet into the entire surface of the sheet. A cut in the 90 ° direction penetrating only the −45 ° sheet was inserted into the entire surface of the sheet. Furthermore, after inserting a 0 ° cut through the 0 ° sheet and the + 45 ° sheet from the other surface into the entire surface of the sheet, insert a + 45 ° cut through only the 0 ° sheet into the entire sheet. did. Thereby, it was set as the aspect which distribute | arranged the cut of +45 degree direction with respect to the reinforcing fiber direction for every sheet | seat.

  Each of the cuts in the −45 ° direction has a cut length Lb of 25.0 mm, and is arranged on a straight line so as to have an interval of 25.0 mm in the 45 ° direction. Arranged in parallel.

  Each of the cuts in the 90 ° direction has a cut length Lb of 25.0 mm and is arranged on a straight line so as to have an interval of 25.0 mm in the 90 ° direction, and the cut rows are parallel. Arranged.

  Each of the cuts in the 0 ° direction has a cut length Lb of 25.0 mm, and is arranged on a straight line so as to have an interval of 25.0 mm in the 0 ° direction, and the cut rows are parallel. Arranged.

  Each of the cuts in the + 45 ° direction has a cut length Lb of 25.0 mm and is arranged on a straight line so as to have an interval of 25.0 mm in the 0 ° direction, and the cut rows are parallel. Arranged.

  Note that the cuts of each sheet were arranged so as to intersect at the midpoint of each cut on the projection surface in the thickness direction. Thereby, the molding material J was obtained.

  In the molding material J, 100% of the reinforcing fiber yarn is cut, and the fiber length La of each sheet is 25.0 mm for 100% of the −45 ° sheet, and 100% of the 90 ° sheet. Of the 25.0 mm, + 45 ° sheets, 100% was 25.0 mm, and 100% of the 0 ° sheets was 25.0 mm.

  Here, each cut was made so as not to cut through the nonwoven fabric A sandwiched between the 90 ° sheet and the + 45 ° sheet. The insertion of the cut was performed in the same manner as in Example 5.

  The obtained molding material J was excellent in handleability because the reinforcing fiber yarns were restrained moderately by the stitch yarns and the nonwoven fabric corresponding to the intermediate layer of the molding material was continuously present.

  The obtained molding material J is placed on a hemispherical female mold having a radius of curvature of 300 mm at the maximum diameter, and pressed from above with a female mold of the same shape with a radius of curvature of 305 mm, and a preform is pressed. Obtained.

  The obtained preform was cut at 100% of the reinforcing fiber yarn while releasing the in-plane distortion of the molding material by opening the free end of the reinforcing fiber yarn at the incision. It was a good preform without wrinkles. Further, compared to Example 5, the fiber lengths La were all the same length, and the cuts were dispersed in the thickness direction of the molding material, so that the openings were uniform in the preform and unevenness was also generated. There wasn't.

  Further, the obtained preform was placed again on the mold, and once heated to 150 ° C., the stitch yarn A was allowed to follow the mold while being melted, and pressed (pressed) at 25 MPa for 180 seconds. While being pressurized, the mold temperature was raised to 250 ° C. and held for 180 seconds, the mold temperature was cooled to 50 ° C., and then the pressure was released and demolded to obtain FRP.

  When the cross section cut out from the obtained FRP so as to have a width of 2 cm is observed with an optical microscope, the resin is impregnated into the inside of the reinforcing fiber yarn, and the observation surface of the void is slightly seen near the outermost layer 96% of the resin was impregnated with resin. Further, since the stitch yarn continuous in the longitudinal direction was partially cut, the fiber orientation was disordered and the surface irregularities were slightly generated, but no wrinkles were observed. Furthermore, since the openings were dispersed in the thickness direction, local large openings were not seen, and the surface quality was particularly excellent.

(Comparative Example 1)
The molding material (blank) obtained by the procedure of (1) to (6) was used as the molding material E in a state where no cut was inserted. In the molding material E, 100% of the reinforcing fiber yarns remained in a continuous state.

  The obtained molding material E was excellent in handling property as a molding material because the reinforcing fiber yarn was completely held by the stitch yarn.

  A preform and FRP were produced in the same manner as in Example 1 using the obtained molding material E.

  Since the obtained preform has all the reinforcing fiber yarns continuously, the reinforcing fiber yarns are stretched at the time of shaping and cannot be made to follow a hemisphere. As a result, sputum occurred frequently.

  Furthermore, when a cross section cut out from the obtained FRP so as to have a width of 2 cm is observed with an optical microscope, the resin is impregnated into the inside of the reinforcing fiber yarn, and a void is slightly seen in the vicinity of the outermost layer. 96% of the observation surface was impregnated with resin. In addition, since the stitch yarn A and the nonwoven fabric A are melted, the degree of freedom of deformation is generated, so the wrinkles in the preform are somewhat relieved, but the surface irregularities and fiber orientation disturbance remain in the FRP, and the quality is improved. It was quite inferior.

(Comparative Example 2)
Cuts were inserted in the direction of 90 ° with respect to the longitudinal direction of the molding material on the entire surface of the molding material (blank) sheet produced by the procedures of (1) to (6). In addition, each of the cuts has a cut length Lb of 25.0 mm and is arranged on a straight line so as to have an interval of 75.0 mm in the 90 ° direction, and the cut rows are arranged in parallel. Thus, molding material F was obtained. In the molding material F, 25% of the reinforcing fiber yarns are cut, and the fiber length La of each sheet is 35.4 mm for 25% of the −45 ° sheets and 35% for 25% of the + 45 ° sheets. 4%, 50% of the 0 ° sheet was 50.0 mm.

  Since the obtained molding material F had many continuous reinforcing fiber yarns remaining, it could be handled stably as a molding material.

  Using the obtained molding material F, a preform and FRP were produced in the same manner as in Example 1.

  Since the obtained preform had many continuous reinforcing fiber yarns remaining, the reinforcing fiber yarns were stretched during shaping and could not follow a hemispherical shape, although slightly better than Comparative Example 1. , As well as a lot of sputum.

  Furthermore, when a cross section cut out from the obtained FRP so as to have a width of 2 cm is observed with an optical microscope, the resin is impregnated into the inside of the reinforcing fiber yarn, and a void is slightly seen in the vicinity of the outermost layer. 96% of the observation surface was impregnated with resin. In addition, since the stitch yarn A and the nonwoven fabric A are melted, a degree of freedom of deformation is generated, so that the wrinkles in the preform are somewhat relieved, but the surface irregularities and fiber orientation disturbance remain in the FRP and are inferior in quality. It was a thing.

(Comparative Example 3)
Cuts were inserted in the direction of 90 ° with respect to the longitudinal direction of the molding material on the entire surface of the molding material (blank) sheet produced by the procedures of (1) to (6). In addition, each of the cuts has a cut length Lb of 2.5 mm and is arranged in a straight line so as to have an interval of 1.25 mm in the 90 ° direction, and the cut rows are arranged in parallel. Thus, a molding material G was obtained. Adjacent cut rows were alternately shifted by 1.875 mm in the 90 ° direction, and both ends of the cuts in the adjacent row were arranged to overlap each other by 0.625 mm in the 0 ° direction. In the molding material G, 75% of the reinforcing fiber yarns are cut, and the fiber length La of each sheet has a fiber length La of −45 °, 50% is 3.5 mm, 50% is 10.6 mm, +45 Among the 0 sheets, 50% was 3.5 mm, 50% was 10.6 mm, and 0% sheets were 50% 2.5 mm and 50% 5.0 mm.

  Using the obtained molding material G, a preform and FRP were produced in the same manner as in Example 1.

  In the obtained molding material G, the reinforcing fiber yarn was finely cut, and even the stitch yarn did not exist almost continuously. I couldn't even handle it.

(Comparative Example 4)
Cuts were inserted in the direction of 90 ° with respect to the longitudinal direction of the molding material on the entire surface of the molding material (blank) sheet produced by the procedures of (1) to (6). In addition, each of the cuts has a cut length Lb of 400 mm and is arranged on a straight line so as to form an interval of 200 mm in the 90 ° direction, and the cut rows are arranged in parallel to form a molding material. H was obtained. Adjacent cut rows were alternately displaced by 300 mm in the 90 ° direction, and both ends of the cuts in the adjacent rows were arranged to overlap each other by 100 mm in the 0 ° direction. In the molding material H, 75% of the reinforcing fiber yarns are cut, and the fiber length La of each sheet is such that, among the −45 ° sheets, 50% is 565.7 mm, 50% is 1697.1 mm, +45 Of the 0 sheet, 50% was 565.7 mm, 50% was 1697.1 mm, and 50% of the 0 sheet was 400.0 mm and 50% was 800.0 mm.

  The obtained molding material H was excellent in handleability as a molding material because both the stitch yarn and the reinforcing fiber yarn remained for a long time.

  Using the obtained molding material H, a preform and FRP were produced in the same manner as in Example 1.

  Although the obtained preform had a long fiber length of the reinforcing fiber yarn, it was able to be shaped without hesitation in a hemispherical shape, but the openings at the cuts were concentrated locally, resulting in holes in the preform. .

  Furthermore, when a cross section cut out from the obtained FRP so as to have a width of 2 cm is observed with an optical microscope, the resin is impregnated into the inside of the reinforcing fiber yarn, and a void is slightly seen in the vicinity of the outermost layer. 96% of the observation surface was impregnated with resin. In addition, a large opening in the preform remained in the FRP, and the quality was out of the question.

  Table 1 shows the results of the above examples and comparative examples.

  As shown in Tables 1 and 2, in the sheet in which the reinforcing fibers constituting the laminate are aligned in parallel, the cut in the direction crossing the reinforcing fiber yarn is arranged on the entire surface of the sheet to constitute the laminate. Reinforcing fiber that includes a sheet in which the fiber length La of the reinforcing fiber yarn is cut at a finite length of 10 to 300 mm, and at least 50% of the reinforcing fiber yarn that constitutes the laminated body constitutes the laminated body It was confirmed that when the yarn fiber length La is a finite length of 10 to 300 mm, the yarn is at a level that can be handled as a molding material and has an excellent shape forming property. Among these, the embodiments of Examples 2, 5, and 6 are preferable because they are excellent in terms of both the handleability and the formability of the molding material.

  Further, in the molding of FRP, excellent characteristics are shown in each of Examples 1, 3, and 4, and when pursuing the excellent mechanical properties of FRP, pursuing the excellent design characteristics of Example 3 and FRP In Example 4, and in consideration of these balances, it was Example 1.

  Among them, Examples 5 and 6 are balanced at a high level in all the characteristics, and can be said to be a preferable aspect in a member having a complicated structure and requiring design properties and mechanical characteristics.

  According to the molding material of the present invention, the handling property is excellent, and in the molding of FRP having a complicated shape, it is possible to suppress wrinkles and disorder of the orientation of the reinforcing fiber yarn. Therefore, a high-quality FRP can be obtained with high productivity. Such a molding material can be suitably used for a structural member of a transportation device such as an automobile, an aircraft, and a ship, a building member, and the like.

It is a schematic perspective view which shows one embodiment of the molding material of this invention. It is a schematic plan view which shows one embodiment of the molding material of this invention. It is a schematic plan view which shows another embodiment of the molding material of this invention. It is a schematic sectional drawing of the preform which shape | molded the molding material of this invention in the arch shape. It is a schematic sectional drawing which shows one embodiment of the molding material before the textile body (nonwoven fabric) in this invention fuse | melts. It is a schematic sectional drawing which shows one embodiment of the molding material of the state by which the textile body (nonwoven fabric) in this invention was fuse | melted.

Explanation of symbols

1, 8, 18, 31, 34: Molding material 2, 9, 19: Reinforcing fiber yarn 3, 35: Textile body (nonwoven fabric)
4, 10, 20, 36: Stitch yarn 5: Reinforcing fiber yarn direction (0 ° direction)
6: Direction in which the stitch yarn extends 7, 21: Longitudinal direction of the molding material 11, 23: Incision 12, 13, 14: Row of intermittent incisions 15: Direction orthogonal to the incision direction 17, 25: Length of the incision (Lb)
22: Stitch thread spacing (Wb)
24: orthogonal direction of the direction in which the stitch yarn extends 26: cut length in the direction in which the stitch yarn extends (Lb1)
27: Cut length in the direction perpendicular to the direction in which the stitch yarn extends (Lb2)
28: Stitch yarns extending in the longitudinal direction of the molding material 29, 30: Stitch yarns arranged at an angle intersecting with the longitudinal direction of the molding material 32: Sheet 33 constituting the molding material 33: Opening

Claims (13)

A plurality of layers of sheets in which a large number of reinforcing fiber yarns are arranged in parallel are laminated to form a laminate, and the molding is an integrated molding material comprising the following (i) to (d) The molding material characterized by satisfying the requirement of
(A) A textile body comprising as a component a first thermoplastic resin constituting a matrix of a composite material is disposed at least between the sheets,
(B) The laminated body is integrated by a stitch yarn having the second thermoplastic resin as a component and / or a textile body having the first thermoplastic resin as a component,
(C) A sheet in which the reinforcing fibers constituting the laminate are aligned in parallel, and a cut in a direction across the reinforcing fiber yarn is arranged on the entire surface of the sheet, and the reinforcing fiber yarn constituting the laminate. Including a sheet in which the fiber length La is cut at a finite length of 10 to 300 mm,
(D) At least 50% or more of the reinforcing fiber yarns constituting the laminate have a finite length in which the fiber length La of the reinforcing fiber yarns constituting the laminate is 10 to 300 mm. Each of the sheets constituting the laminate is laminated in a multiaxial orientation so that the reinforcing fiber yarns intersect to constitute a laminate, the number of axes to be oriented is n-axis, and the fiber length La is 10 The molding material according to claim 1, wherein n and N satisfy the relationship of the following formula, where N% is a ratio of the reinforcing fiber yarn cut at a finite length of ˜300 mm in the molding material.
(100-100 / n) ≦ N When the sheet constituting the laminated body is a first partial laminated body and a second partial laminated body, with the textile body containing the first thermoplastic resin in the thickness direction of 25 to 75% as a component, The first partial laminated body and the second partial laminated body are each provided with cuts penetrating in the thickness direction over the entire surface, and the first partial laminated body and the second partial laminated body are notched. The molding material according to claim 1, wherein the molding material does not overlap on the projection surface in the thickness direction. The cuts penetrating in the thickness direction for every sheet are arranged over the entire surface of all the sheets constituting the laminate, and the cuts of adjacent sheets do not overlap on the projection surface in the thickness direction. The molding material in any one. A plurality of rows composed of intermittent cuts in the direction crossing the reinforcing fiber yarns are arranged in parallel on the entire surface of the sheet, and each of the cuts has a cut length Lb of 1 to 100 mm. The molding material according to any one of claims 1 to 4. At an angle θ formed by the cut and the direction orthogonal to the direction in which the stitch yarn extends, the interval Wb between the stitch yarn parallel to the longitudinal direction of the molding material and the cut length Lb are | cos θ | <(Wb / Lb The molding material according to any one of claims 1 to 5, which does not substantially cut a stitch yarn that is continuous in the longitudinal direction of the molding material. The melting point Tm1 of the first thermoplastic resin and the melting point Tm2 of the second thermoplastic resin satisfy a relationship of (Tm1-150) ≦ Tm2 ≦ (Tm1-20). The molding material as described. The melting point Tm1 of the first thermoplastic resin and the melting point Tm2 of the second thermoplastic resin satisfy a relationship of (Tm2-150) ≦ Tm1 ≦ (Tm2-20). The molding material as described in 2. The melting point Tm1 of the first thermoplastic resin and the melting point Tm2 of the second thermoplastic resin satisfy a relationship of (Tm2-20) <Tm1 <(Tm2 + 20). Molding material. 10. The molding material according to claim 1, wherein the basis weight of the reinforcing fibers in the sheet is in the range of 50 to 350 g / m ² , and the basis weight of the fabric body is in the range of 15 to 250 g / m ^2. . A preform characterized in that one or a plurality of molding materials according to any one of claims 1 to 10 are laminated and formed into a single contour shape or a double contour shape. The length Lc and the fiber length La of the arc in each cross section in the reinforcing fiber yarn direction of each sheet constituting the molding material in a portion formed into a single contour shape or a double contour shape are Lc> La. 11. The preform according to 11. A fiber-reinforced resin formed using the molding material or preform according to any one of claims 1 to 11.

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