JP2016199008A - Method for producing integrated laminated product and method for producing molded body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing an integrated laminated product capable of producing an integrated laminated product which is excellent in moldability and handleability in stamping moldability with a small number of steps while reducing a production cost, and to provide a method for producing a molded body.SOLUTION: There is provided a method for producing an integrated laminated product by working a laminated substrate in which a plurality of prepregs containing reinforced fibers and thermoplastic resins are laminated, including the following step (1) and step (2); and a method for producing a molded body including a step of producing an integrated laminated product by the method for producing the same and a step of stamping molding the obtained integrated laminated product. The step (1) is a lamination step of laminating a plurality of prepregs to obtain a laminated substrate. The step (2) is a cut fusion step of fusing a cut surface by heat generated by cutting while cutting the laminated substrate.SELECTED DRAWING: None

Description

  The present invention relates to a method for producing an integrated laminate suitably used for stamping molding, and a method for producing a molded body.

  As a method for molding fiber reinforced thermoplastics, a laminated base material obtained by laminating a plurality of prepregs impregnated with thermoplastic resin into continuous reinforcing fibers is cut into a desired shape and then preheated and heated with a press machine etc. Stamping molding is generally performed in which a desired shape is formed by applying pressure. The resulting fiber-reinforced thermoplastic has excellent mechanical properties because it uses continuous reinforcing fibers. Moreover, it is possible to design the required mechanical properties by arranging the continuous reinforcing fibers regularly.

However, the prepreg constituting the laminated base material is less sticky in a normal temperature environment than a thermosetting prepreg in which a reinforcing fiber is impregnated with a thermosetting resin, and is very handling in stamping molding. It became complicated and the moldability and handleability were apt to decrease.
Therefore, it is necessary to fuse and integrate all or part of the laminated base material after the prepreg is laminated so that the reinforcing fibers are regularly arranged to form a laminated base material before cutting the laminated base material. there were.

For example, Patent Document 1 discloses a laminated base material obtained by laminating a plurality of fiber reinforced resin sheets obtained by impregnating a thermoplastic resin into a reinforcing fiber or woven fabric such as glass fiber or carbon fiber, at a desired temperature. The method of heating and pressurizing and integrating is disclosed. According to Patent Document 1, handling properties are improved by heating and pressurizing and laminating a laminated base material.
Further, in Patent Document 2, a sheet-like laminated base material obtained by laminating a plurality of prepregs composed of a thermoplastic resin and a reinforcing fiber is point-fused by penetrating the laminated base material using a heated needle. A method for integrating them is disclosed.

JP 07-214714 A JP 2007-262360 A

However, in the case of the method described in Patent Document 1, a continuous fusing method using a large apparatus such as a belt press or a heating roll, a combination of a heating press machine, an infrared heater and a cooling press, or a multistage heating / cooling press It is necessary to fuse and integrate the laminated base material by a method with low productivity such as a batch-type fusion method such as using a batch, and the manufacturing cost is likely to increase. In addition, since the step of fusing and integrating is performed before the laminated base material is cut, the number of steps is increased.
As in the method described in Patent Document 2, it is very cumbersome to make point fusion by penetrating a laminated base material of various thicknesses in the thickness direction. It was difficult to integrate.

  The present invention has been made in view of the above circumstances, and an integrated laminate manufacturing method capable of manufacturing an integrated laminate excellent in formability and handleability during stamping molding with a reduced number of steps while reducing manufacturing costs. It is an object of the present invention to provide a method for producing a molded body.

  As a result of intensive studies, the present inventors have found that the problem can be solved by fusing the cut surface with heat generated when cutting the laminated base material, and have completed the present invention.

That is, this invention has the following aspects.
[1] A method of manufacturing an integrated laminate by processing a laminated base material in which a plurality of prepregs containing reinforcing fibers and a thermoplastic resin are laminated, and includes the following steps (1) and (2) Method for manufacturing a laminated laminate.
Step (1): A lamination step in which a plurality of prepregs are laminated to obtain a laminated substrate.
Step (2): A cutting and fusing step of fusing the cut surface with heat generated by cutting while cutting the laminated base material.
[2] The method for producing an integrated laminate according to [1], wherein the cutting and fusion are performed using a rotary blade.
[3] The method for producing an integrated laminate according to [1], wherein the cutting and fusion are performed by ultrasonic cutting.
[4] The method for producing an integrated laminate according to [1], wherein the cutting and fusion are performed by laser cutting.
[5] The method for producing an integrated laminate according to [1], wherein the cutting and fusing are performed using a blade whose temperature is adjusted by heating.
[6] The method for producing an integrated laminate according to any one of [1] to [5], wherein the following step (3) is performed at least one of before and after the step (2).
Step (3): A point fusion step in which the surface other than the end portion of the laminated base material is point-fused at 1 to 100 points per 100 cm ² of surface area.
[7] The method for producing an integrated laminate according to any one of [1] to [6], wherein the prepreg is obtained by impregnating a reinforced fiber oriented in one direction with a thermoplastic resin.
[8] The prepreg is obtained by impregnating a reinforced fiber oriented in one direction with a thermoplastic resin, and has a notch penetrating from the front surface to the back surface of the prepreg so as to cut the reinforcing fiber. 6] The method for producing an integrated laminate according to any one of [6].
[9] The prepreg is formed in a sheet form so that a plurality of small prepregs obtained by cutting a prepreg in which a reinforced fiber oriented in one direction is impregnated with a thermoplastic resin is random in the fiber direction of the reinforcing fibers of each small prepreg. The method for producing an integrated laminate according to any one of [1] to [6] [10], wherein in the step (1), a plurality of the prepregs and a thermoplastic resin or The manufacturing method of the integrated laminated body as described in any one of [1]-[9] which laminates | stacks the sheet | seat or film (however, except the said prepreg) which consists of a filler containing thermoplastic resin.
[11] The method for producing an integrated laminate according to [10], wherein the filler is carbon fiber.
[12] The method for producing an integrated laminate according to [10], wherein the filler is a glass composition.
[13] The method for producing an integrated laminate according to [10], wherein the filler is a recycled material.
[14] The method for producing an integrated laminate according to any one of [1] to [13], wherein the reinforcing fibers are carbon fibers.
[15] A step of producing an integrated laminate by the method for producing an integrated laminate according to any one of [1] to [14], and a step of stamping molding using the obtained integrated laminate The manufacturing method of a molded object containing these.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the integrated laminated body which can manufacture the integrated laminated body excellent in the moldability at the time of stamping shaping | molding, and a handleability with few processes, reducing a manufacturing cost, and the manufacturing method of a molded object Can provide.

It is a top view which shows an example of the prepreg which has a notch. It is a top view which shows the other example of the prepreg which has a notch.

"Production method of integrated laminate"
The present invention is a method for producing an integrated laminate by processing a laminated substrate obtained by laminating a plurality of prepregs containing reinforcing fibers and a thermoplastic resin, and includes the following steps (1) and (2). Moreover, it is preferable to perform the following process (3) at least one before and after the process (2).
Step (1): A lamination step in which a plurality of prepregs are laminated to obtain a laminated substrate.
Step (2): A cutting and fusing step of fusing the cut surface with heat generated by cutting while cutting the laminated base material.
Step (3): A point fusion step in which the surface other than the end portion of the laminated base material is point-fused at 1 to 100 points per 100 cm ² of surface area.

<Prepreg>
The prepreg used in the present invention contains reinforcing fibers and a thermoplastic resin.
The reinforcing fiber used for the prepreg is not particularly limited, and inorganic fiber, organic fiber, metal fiber, or a hybrid fiber having a combination of these can be used.
Examples of the inorganic fiber include carbon fiber, graphite fiber, silicon carbide fiber, alumina fiber, tungsten carbide fiber, boron fiber, and glass fiber.
Examples of organic fibers include aramid fibers, high density polyethylene fibers, nylon fibers, and polyester fibers.
Examples of metal fibers include stainless steel and iron fibers. Further, carbon fibers coated with metal can also be used.
These reinforcing fibers may be used alone or in combination of two or more.
1-50 micrometers is preferable and, as for the average fiber diameter of a reinforced fiber, 4-20 micrometers is more preferable.

Among the above-described reinforcing fibers, mechanical properties such as strength of a molded body (hereinafter simply referred to as “molded body”) formed by stamping the integrated laminate manufactured according to the present invention and the mass of the molded body are considered. Then, carbon fiber is preferable.
The carbon fiber is not particularly limited, and any carbon fiber derived from any raw material such as polyacrylonitrile (PAN), petroleum / coal pitch, rayon, and lignin can be used. Among these, PAN-based carbon fibers using PAN as a raw material are particularly preferable in terms of excellent productivity and mechanical properties on an industrial scale.
In addition, since petroleum / coal pitch-based carbon fibers are known to have high elasticity, PAN-based carbon fibers may be used in combination.
These carbon fibers can be obtained as commercial products.

The fineness of the carbon fiber bundle is preferably 200 to 7000 tex. The number of filaments is preferably 1,000 to 100,000, more preferably 3,000 to 60,000. Moreover, 1-10 GPa is preferable and, as for the intensity | strength as a carbon fiber bundle, 5-8 GPa is more preferable. The elastic modulus is preferably 100 to 1,000 GPa, more preferably 200 to 600 GPa.
In addition, the intensity | strength and elastic modulus of a carbon fiber bundle are each measured based on JISR7608.

  The single fiber fineness of the carbon fiber is preferably 0.5 to 2.4 dtex. When the single fiber fineness is less than 0.5 dtex, when the carbon fibers are closely packed during prepreg production, the space between the fibers is reduced and the resin impregnation may be difficult or insufficient. On the other hand, if the single fiber fineness exceeds 2.4 dtex, it takes time to transfer heat to the center of the fiber when manufacturing such a carbon fiber, which increases the cost of the carbon fiber and the associated increase in the cost of the prepreg. May cause.

Examples of the thermoplastic resin used in the prepreg include polyamide (polyamide 6, polyamide 66, etc.), polyolefin (polyethylene, polypropylene, etc.), modified polyolefin, polyester (polyethylene terephthalate, polybutylene terephthalate, etc.), polycarbonate, polyamideimide, polyphenylene oxide, Examples include polysulfone, polyethersulfone, polyetheretherketone, polyetherimide, polystyrene, ABS, polyphenylene sulfide, liquid crystal polyester, and a copolymer of acrylonitrile and styrene. Further, a copolymer such as a nylon copolymerized with polyamide 6 and polyamide 66 may be used.
These thermoplastic resins may be used individually by 1 type, and may use 2 or more types together.

  Depending on the properties required for the molded product, prepregs include flame retardants, weather resistance improvers, antioxidants, heat stabilizers, UV absorbers, plasticizers, lubricants, colorants, compatibilizers, and conductive fillers. Etc. may be contained.

The prepreg is obtained by impregnating a reinforcing fiber with a thermoplastic resin. The form of the prepreg is preferably a sheet form, a tape form, or a film form. In particular, a prepreg obtained by impregnating a reinforced fiber in which reinforced fibers are oriented in one direction with a thermoplastic resin (hereinafter also referred to as “unidirectional material”). ) Is preferably used from the viewpoint of control of mechanical properties and high mechanical properties.
When the prepreg contains an additive, it is preferable to add the additive to the thermoplastic resin in advance.

The prepreg is obtained, for example, by preparing two resin films made of a thermoplastic resin, sandwiching a reinforcing fiber sheet in which reinforcing fibers are arranged in a sheet, and performing heating and pressing. More specifically, each first supply is performed using an apparatus including a first supply roll having two systems for feeding a resin film made of a thermoplastic resin and a second supply roll for feeding a reinforcing fiber sheet. The resin films are individually fed from the rolls, and the reinforcing fiber sheet fed from the second supply roll is sandwiched between two resin films, and then heated and pressurized to obtain a prepreg.
One type of thermoplastic resin which comprises a resin film may be sufficient, and 2 or more types may be sufficient as it. Further, a plurality of resin films made of different types of thermoplastic resins may be supplied in piles. Moreover, you may send out two resin films from the supply roll of another system | strain, and may pinch a reinforcing fiber sheet.

As the means for heating and pressurizing, known means can be used. For example, a multi-step process such as using two or more heat rolls or using a plurality of upper and lower pairs of preheating devices and heat rolls is required. It may be a thing.
Although the conditions at the time of heating and pressurization depend on the kind of the thermoplastic resin, the heating temperature is usually preferably 100 to 400 ° C., and the pressure at the time of pressurization is preferably 0.1 to 10 MPa. If the heating temperature and the pressure during heating are within the above ranges, the thermoplastic resin can be sufficiently impregnated between the reinforcing fibers contained in the prepreg.
In addition, a commercial item can also be used as a prepreg.

For example, as shown in FIG. 1, the prepreg used in the present invention preferably has a notch 12 penetrating from the front surface to the back surface of the prepreg 10 so as to cut the reinforcing fiber 11. If the prepreg 10 has the notches 12, that is, if the reinforcing fibers 11 are cut to a certain length, the fluidity at the time of stamping molding is improved, and the molding metal having a complicated three-dimensional shape such as ribs and bosses. Even when molding is performed using a mold, a laminated base material capable of following the shape of the molding die is obtained.
Here, the front surface to the back surface of the prepreg is a pair of surfaces having the largest area of the prepreg. Since the cut penetrates from the front surface to the back surface of the prepreg, the reinforcing fibers located inside the prepreg are also cut, and the fluidity during stamping molding is further improved.

The fiber length L of the reinforcing fiber 11 cut by cutting is preferably 5 to 100 mm from the viewpoint of mechanical properties and fluidity. In particular, the fiber length L is more preferably 10 to 100 mm in order to achieve both sufficient mechanical properties and flow to a thin portion such as a rib during stamping molding.
The fiber lengths L of the reinforcing fibers 11 in the prepreg 10 are not necessarily the same, and reinforcing fibers 11 having different fiber lengths L may be ubiquitous in the prepreg 10. These are matters that should be appropriately designed according to the mechanical properties, fluidity, and flow behavior required for the compact.

From the viewpoint of stamping molding, an angle formed by the reinforcing fiber 11 and the cut 12 (that is, an angle at which a line segment (straight line) connecting the start point and the end point of the cut 12 intersects the fiber direction of the reinforcing fiber 11) θ. The larger the value is, the smaller the shearing force between the fibers becomes, so that the fluidity tends to increase. In addition, the larger the total length (hereinafter referred to as “la”) of the lengths (cut lengths) 1 of the notches 12 per 1 m ^{2 of the} prepreg 10, the greater the number of cut portions in the prepreg 10, and thus the better the fluidity. It is in.
In the case of flat plate stamping, the angle θ is preferably 25 ° or more, and la is preferably 10 m or more. Further, in the case of stamping molding having a complicated shape such as a rib, the angle θ is preferably 30 ° or more, and la is preferably 20 m or more.

  On the other hand, mechanical properties such as bending properties depend on the angles θ and la. It is known that the smaller the angle θ is, the higher the mechanical properties are, and the smaller la is, the smaller the number of cut parts in the prepreg 10, the higher the mechanical properties tend to be obtained. For example, in order to use the molded body for a semi-structure member of an automobile, the angle θ is preferably 70 ° or less, and la is preferably 200 m or less. Further, in order to use the molded body for a structural member that requires higher mechanical strength, the angle θ is preferably 60 ° or less, and la is preferably 150 m or less.

Although the shape of the notch 12 shown in FIG. 1 is linear, the shape of the notch 12 is not particularly limited, and may be, for example, a curved shape as shown in FIG. If the shape of the cut 12 is curved, la becomes larger than the straight cut having the same angle θ and fiber length L, and the stamping formability tends to be improved while maintaining high mechanical properties. These are matters that should be appropriately designed according to the mechanical properties, fluidity, and flow behavior required for the molded body.
In FIG. 2, the same components as those in FIG.

The method for forming the cut in the prepreg is not particularly limited, and it can be processed using a laser marker, a cutting plotter, a cutting die or the like. If a laser marker is used, a complicated shape such as a curve or a zigzag line can be formed in a short time. If a cutting plotter is used, a cut can be formed in a large prepreg (for example, the length in the longitudinal direction is 2 m or more). If the die is used, the cut can be formed in a short time.
In the cutting process, depending on the processing method, an ear part in which the reinforcing fiber at the end of the prepreg is not cut may be generated. This ear portion may be removed after the prepreg is cut, or may be removed before or after the step (1) described later. Further, a part of the ear portion may be removed, all may be removed, or all may be left.

The prepreg used in the present invention is a sheet in which a plurality of small prepregs obtained by cutting a prepreg in which thermoplastic fibers are impregnated with reinforced fibers oriented in one direction are random so that the fiber directions of the reinforcing fibers of each small prepreg are random. It may be integrated into a shape. When such a prepreg is used, for example, the unidirectional material exhibits excellent characteristics with respect to the fiber direction, whereas the prepreg can be used as an isotropic material because the fiber direction is random. In addition, when the production size of the laminated base material is larger than the width of the unidirectional material, it is necessary to perform splicing, and depending on the laminated configuration of the laminated base material, material loss may occur when obtaining a prepreg with a specific cutting angle. May occur. On the other hand, a small piece of prepreg can be obtained by manufacturing a narrow-width unidirectional material and then cutting it, making it possible to reduce the size of the manufacturing equipment and reducing the loss depending on the cutting angle. There is a tendency. In addition, small pieces of prepreg can be obtained by cutting appropriately from the loss part that occurs when a prepreg with a specific cutting angle is obtained from a unidirectional material, reducing the total cost with minimal material loss. It is possible to realize.
The prepregs of small pieces may overlap at least partially or may not overlap.

  The length of the reinforcing fiber contained in the prepreg of the small piece is preferably 5 to 100 mm from the viewpoint of mechanical properties and fluidity. In particular, in order to achieve both sufficient mechanical properties and flow to thin portions such as ribs at the time of stamping molding, the length of the reinforcing fibers contained in the small prepreg is more preferably 10 to 100 mm. Note that the lengths of the reinforcing fibers contained in the prepreg of the small pieces are not necessarily the same, and reinforcing fibers having different lengths may be ubiquitous. These are matters designed in consideration of mechanical properties, fluidity, and variations thereof.

The prepreg used in the present invention preferably has a fiber volume content (Vf) of 60% or less, which is the volume ratio of reinforcing fibers in the prepreg volume. When the fiber volume content (Vf) is 60% or less, the balance between mechanical properties, fluidity, and workability is improved. When the fiber volume content (Vf) exceeds 60%, there is a concern that the production cost increases in order to produce such a prepreg with high quality. Moreover, since the binding by the resin tends to be weak at the time of processing, there is a concern that the end accuracy is lowered at the time of processing.
If the fiber volume content (Vf) is too low, it may be difficult to obtain sufficient mechanical properties as a structural material. Therefore, the fiber volume content (Vf) is more preferably 20 to 60%, further preferably 20 to 55%.
The fiber volume content (Vf) is measured according to JIS K 7075.

If the thickness of the prepreg is too thick, it tends to be difficult for the thermoplastic resin to be sufficiently impregnated into the reinforcing fiber during the production of the prepreg, or it takes time to impregnate. In addition, when the prepreg has a cut, the thicker the prepreg having the reinforcing fibers cut by the cut, the thicker the layer of the cut reinforcing fibers in the same direction, so that the mechanical properties tend to decrease. is there. In consideration of the impregnation property of the resin during prepreg production and the application of the molded body to the structural material, the thickness of the prepreg is preferably 200 μm or less.
On the other hand, if the thickness of the prepreg is too thin, the handleability of the prepreg tends to deteriorate, or the number of prepregs laminated to form a laminated base material tends to increase, leading to a reduction in productivity. In consideration of the handleability and productivity of the prepreg, the thickness of the prepreg is preferably 50 μm or more.

<Step (1)>
Step (1) is a lamination step in which a plurality of prepregs are laminated to obtain a laminated substrate.
The number of prepregs to be laminated and the way of lamination may be determined according to the purpose in consideration of the mechanical properties, fluidity, flow behavior and the like necessary for the obtained integrated laminate or molded article.
For example, when it is desired to reinforce an integrated laminate or a molded body in one specific direction, it is preferable to laminate a plurality of prepregs so that the fiber directions of the reinforcing fibers are in the same direction.
Moreover, when it is desired to reinforce an integrated laminate or a molded body, it is preferable to laminate a plurality of prepregs so that the fiber directions of the reinforcing fibers are pseudo-isotropic. By laminating in this way, flow anisotropy during pressing can be reduced. In addition, the anisotropy of mechanical properties can be reduced.
Moreover, a prepreg whose fiber direction of reinforcing fiber is 0 ° and a prepreg whose angle is 90 °, which is intermediate between one direction and pseudo-isotropic, may be alternately laminated in the laminating direction, or the fiber direction of reinforcing fiber is 60 °. The prepreg may be laminated in the laminating direction so as to be shifted every time.
Moreover, as a point common to lamination | stacking, it is preferable that the surface and the back surface of a laminated base material are object structure at the point which reduces the twist and curvature of an integrated laminated body and a molded object.
Although the thickness of a laminated base material is not specifically limited, 50-10000 micrometers is preferable.

In the step (1), a plurality of prepregs and a sheet or film made of a thermoplastic resin or a filler-containing thermoplastic resin (excluding the prepreg, hereinafter collectively referred to as “resin layer”). Are preferably laminated. That is, the laminated base material preferably includes a resin layer. If the laminated base material is provided with a resin layer, it is possible to reduce the content of reinforced fibers, which is expensive, so that a large cost reduction can be realized. Moreover, it is possible to improve fluidity and uniformity during flow by appropriately designing the position and thickness of the resin layer.
From a different point of view, hybrid molding has been proposed in which long fiber reinforced material is used for the main surface of the molded product, and short fiber reinforced material is used for injection molding and other parts such as buttocks and ribs and bosses. When using a material provided with a resin layer for such hybrid molding, it is designed so that the prepreg layer is located on the main surface of the molded product, and the resin layer has higher fluidity than the long fiber reinforced material. By using the points, it is also possible to form peripheral ridges, ribs, bosses, and other parts, and it is also possible to reduce the number of processes compared to widening the width of the processed shape or normal hybrid molding.

When the laminated base material includes a resin layer, the laminated structure is not particularly limited, but is preferably symmetrical with respect to the neutral axis of the laminated base material. If it is symmetrical with respect to the neutral axis, warping is less likely to occur after molding.
As a laminated structure, for example, a structure in which the prepreg is unevenly distributed on at least one of the front surface and the back surface side of the laminated base material, and a resin layer is unevenly distributed in the center of the laminated base material, the prepreg and the resin layer are alternately arranged in the stacking direction. Examples include the arrangement. Among these, a configuration in which mechanical properties such as specific strength are enhanced and lamination is simple, and the prepreg is unevenly distributed on the front and back sides, and the resin layer is unevenly distributed in the center of the laminated base material (sandwich configuration). Is preferred.

  When the laminated base material is provided with a resin layer, the ratio of the total thickness of the prepreg and the total thickness of the resin layer (total thickness of the resin layer / total thickness of the prepreg) constituting the laminated base material is 0.2 to 3. Is preferred. When the ratio is less than 0.2, the complexity at the time of lamination increases with respect to the improvement in specific strength and specific rigidity, and the productivity may decrease. On the other hand, when the ratio exceeds 3, the specific strength and specific rigidity of the obtained integrated laminate and molded product tend to be improved, but the absolute values of strength and elastic modulus may be lowered, and the molded product is used. Depending on the various members used, there is a concern that the mechanical properties are insufficient.

As a thermoplastic resin which comprises a resin layer, the thermoplastic resin illustrated previously in description of a prepreg is mentioned.
The thermoplastic resin used for the prepreg and the thermoplastic resin used for the resin layer may be of the same type or different types.

Examples of the filler contained in the filler-containing thermoplastic resin composition include reinforcing fibers and carbon black.
As the filler, carbon black is preferable from the viewpoint of antistatic properties and coloring, and reinforcing fiber is preferable from the viewpoint of mechanical properties and fluidity.

Examples of the reinforcing fibers include the reinforcing fibers exemplified above in the description of the prepreg. Among these, carbon fiber and glass fiber are preferable. When reinforcing fibers are used as the filler, the fiber length can be appropriately adjusted and used.
A new fiber may be used as the reinforcing fiber, or a recycled material may be used. Recycled materials include recycled fibers that remove the resin components from used prepregs, which are impregnated with thermoplastic resin or thermosetting resin in reinforced fibers, and collect the remaining reinforced fibers; impregnated with reinforced fibers with thermoplastic resin Examples thereof include a melt-kneaded product obtained by charging a used prepreg into an extruder or the like and melt-kneading. Further, a melt-kneaded product obtained by melting and kneading a material obtained by pulverizing a material in which a reinforcing fiber is impregnated with a thermosetting resin and a thermoplastic resin into an extruder or the like is also included.
Moreover, you may use a glass composition as a filler. Examples of the shape of the glass composition include a fiber shape, a balloon shape, a scale shape, and a particle shape.
A filler may be used individually by 1 type and may use 2 or more types together.

When reinforcing fibers are used as the filler, those satisfying the following conditions (A) or (B) are preferable.
Condition (A): The fiber length of the reinforcing fibers is 0.001 mm or more and less than 5 mm, and the fiber volume content (Vf), which is the volume ratio of the filler as reinforcing fibers in the resin layer, is 0.1. What is ~ 55%.
Examples of such materials include recycled materials obtained by directly kneading the prepreg used in the present invention, and resin layers obtained from generally known reinforcing fiber pellets. The fiber length of the reinforcing fibers contained in the resin layer is Because it is short, it is possible to provide high fluidity.

Condition (B): The fiber length of the reinforcing fibers is 5 mm or more, and the fiber volume content (Vf), which is the volume ratio of the filler as reinforcing fibers in the resin layer, is 0.5% or more and 20%. What is less than.
Examples of such a material include a resin layer obtained from a material in which a conventionally known continuous fiber is impregnated with a resin. Since the fiber volume content is low, high fluidity can be provided. In addition, as an example of the material which impregnated resin to the continuous fiber, QUADRANT PLASTIC COMPOSITES JAPAN LTD. Examples thereof include unisheets manufactured by the company and materials obtained by direct LFT.

<Step (2)>
Step (2) is a cutting and fusing step of fusing the cut surface with heat generated by cutting while cutting the laminated base material.
The laminated substrate is cut into a size corresponding to a molding die used for stamping molding.

  Laminated substrate cutting methods include a method using a band saw, shearing (shearing machine), a method using a rotary blade (chip saw, diamond saw, SL cutter), ultrasonic cutting (ultrasonic cutter), laser cutting. Conventionally known cutting methods such as a method using a fiber laser, a carbon dioxide laser, a YAG laser, or the like, or a heating-controlled blade (cutting die) can be employed. However, in band saws and shearing machines, the amount of heat generated during cutting tends to be weak, the prepreg breaks and the surface accuracy of the cut surface decreases, and the prepregs constituting the laminated base material are misaligned during cutting. , Etc. may occur. Therefore, from the viewpoint of causing strong heat generation at the time of cutting, high processing speed, hardly damaging the prepreg, and hardly causing deviation between prepregs constituting the laminated base material, a cutting method is a method using a rotary blade, ultrasonic cutting A method using a blade cut by laser cutting or heating temperature is preferable. In particular, a method using a rotary blade is more preferable from the viewpoint of excellent processing flexibility in addition to processing speed, versatility of equipment, and ease of enlargement. In addition, if the machining shape is determined even if the machining dimension and the degree of machining freedom are low, a method using ultrasonic cutting or a blade whose temperature is adjusted is also a useful means. Laser cutting limits the size of the equipment, but it can handle not only straight lines but also curved lines, and it is excellent in that it can suppress deterioration due to aging and use of equipment unlike the method of physical processing. ing.

(Rotating blade)
The rotary blade can be used by being attached to a conventionally known facility. Examples of the rotary blade used include a tip saw having a tip at the tip of a wheel, a diamond saw having a diamond particle, a grindstone, a tip having a tip and diamond particles. Among these, a tip saw type having at least a tip at the tip of the wheel is preferably used. If it is a rotary blade which has a chip | tip, there are many quantities currently distribute | circulated and it can reduce a processing machine cost. Moreover, since maintenance is very simple, time loss derived from maintenance can be reduced.
Examples of rotary blades that do not have a tip include diamond saws and grindstones with diamond particles, but these are mechanisms that cut while cutting the cut surface during cutting, so the amount of heat generated can be extremely large in some cases. There is sex. Therefore, depending on the type of thermoplastic resin used for the prepreg, the processing condition range may be narrowed, or the diamond resin on the rotary blade may be covered with the thermoplastic resin, which tends to cause a decrease in productivity due to maintenance. It is in.

The operating conditions of the rotary blade include the peripheral speed and feed rate of the blade.
The peripheral speed largely depends on the material of the laminated base material to be cut, but is preferably 1000 to 6000 m / min. When the peripheral speed is less than 1000 m / min, there is a tendency that the cutting feed speed cannot be increased, and the production speed tends to decrease. On the other hand, when the peripheral speed exceeds 6000 m / min, the rotary blade may be deformed at the time of cutting in consideration of the material of the rotary blade at such a high speed rotation, which may lead to a reduction in the life of the rotary blade or equipment.
The feed speed is preferably 1 to 20 m / min. Although it depends on the peripheral speed, if the feed speed is 1 m / min or less, the processing speed tends to be slow and the productivity tends to decrease. On the other hand, when the feed rate exceeds 20 m / min, in order to cut at such a high speed, a large load is applied to the laminated base material, and thus the physical properties of the laminated base material may be deteriorated and the cut surface may be distorted.

When a tip saw is used as the rotary blade, the number of chips is preferably 50 or more and less than 500, more preferably 80 to 450, with respect to the rotary blade having a diameter of 305 mm. If the number of chips is less than 50, the number of blades that cut into almost the same layer of the laminated base material is reduced, so that the cut surface tends to become rough and the processing speed cannot be increased. On the other hand, it is technically difficult to manufacture a chip saw having more than 500 chips. If the number of chips is within the above range, a conventionally known rotary blade can be used, and defects on the cut surface when the laminated base material is cut and fused can be reduced.
Further, the squeeze angle of the tip provided on the rotary blade is preferably -30 to 30 °, more preferably -20 to 15 °. If the squeeze angle of the chip is less than −30 °, the cutting amount per chip tends to be too small, and the processing time tends to be excessively long. On the other hand, if the squeeze angle of the tip exceeds 30 °, the tip is likely to be chipped during cutting, and thus the feed rate of the rotary blade tends to be unable to be increased, causing a reduction in the processing speed and increasing the production cost. There is a case. In addition, when the squeeze angle of the chip is within the above range, it is possible to suppress a decrease in the fusion accuracy of the end face at the time of cutting, and the cut surface can be more sufficiently fused by heat generated by the cutting.

  The tip of the rotary blade need not be symmetrical, and may be asymmetric. When using an asymmetrical tip, make sure that the tip is not unevenly distributed so that the tip does not become unevenly distributed, for example, the tips of different shapes are arranged alternately or in units of several. Is preferred.

  The thickness of the rotary blade is preferably 0.8 to 10 mm. If the thickness of the rotary blade is less than 0.8 mm, the loss of the laminated base material is minimized along with the cutting, but chattering occurs during cutting and the cutting becomes unstable, and the life of the rotary blade is shortened. Production costs tend to increase. On the other hand, when the thickness of the rotary blade exceeds 10 mm, the cutting becomes very stable and the life of the rotary blade becomes longer, but the loss of the laminated base material accompanying the cutting tends to increase and the production loss tends to increase.

When cutting a laminated substrate with a rotary blade, the cutting is performed with respect to the relationship between the direction of the reinforcing fiber of the outermost layer of the laminated substrate and the cutting direction, the number of tips of the rotary blade, the squeeze angle and rotational direction of the tip, the cutting machine It tends to depend on various factors such as feed rate. Therefore, it is preferable to provide a sheet-like or film-like protective plate on at least one surface of the laminated base material and cut the whole protective plate. This is a useful technique because it can minimize the dependence of rotating blades and cutters.
Moreover, it is known that the site | part where the rotary blade of a cutter operates will spread gradually with aged deterioration according to operation time. When the laminated base material is cut with a cutter in which the movable part spreads with such deterioration, the laminated base material tends to be insufficiently pressed. Therefore, it can be said that the method of cutting together with the protective plate is a useful technique even when using a cutter in which the movable part of the rotary blade has spread due to deterioration.

As the protection plate, a protection plate made of a conventionally known material can be used as long as it is in the form of a sheet or film. However, depending on the material of the protection plate, the protection plate dissolves due to heat generated during processing, and thus the laminated base material is used. Since there is also a concern of adhering, it is preferable to select and use it appropriately. Further, the protective plate preferably has flame retardancy, self-digestibility and the like.
Further, the protective plate can be appropriately set according to the thickness of the laminated base material to be cut, the rotary blade to be used and the operating conditions, but the thickness of the protective plate tends to increase as the thickness increases, and the function as the protective plate decreases as the thickness decreases. It tends to decrease. If it functions as a protective plate even if it is thin, use a protective plate with adhesive on one side, fix the protective plate on the workbench with adhesive, and place the laminated substrate on this protective plate. A method of cutting is also a useful means.

(Ultrasonic)
As the ultrasonic cutter used for the ultrasonic cutting, a conventionally known ultrasonic cutter including a vibrator and an oscillator that oscillates the ultrasonic vibration of the vibrator can be used.
As for the amplitude of an ultrasonic wave, 10-100 micrometers is preferable. If the amplitude is less than 10 μm, it is necessary to generate a very high frequency in order to generate the necessary energy at such an amplitude, and the equipment tends to be costly. On the other hand, when the amplitude exceeds 100 μm, the roughness of the cut surface due to the amplitude being too large tends to be noticeable.
The frequency of ultrasonic waves is preferably 10 to 50 kHz. If the frequency is less than 10 kHz, it is necessary to increase the amplitude, and the cut surface tends to be rough. On the other hand, when the frequency exceeds 50 kHz, the amplitude can be reduced, but such high-speed movement may shorten the life of the equipment.

(laser)
Examples of the laser used for laser cutting include a gas laser such as a carbon dioxide laser and an excimer laser, a solid laser such as a YAG laser and a YVO4 laser, and a fiber laser. Among these, a solid laser such as a YAG laser and a YVO4 laser, and a fiber laser are preferable in that the laminated base material can be cut and fused satisfactorily by irradiation for a short time.
Laser output, oscillation mode, scanning speed, pulse width, pulse frequency, air blow flow rate, gas type, and processing sequence, etc., include thermoplastic resin used in the prepreg and fiber volume of the prepreg constituting the laminated substrate What is necessary is just to set according to the precision calculated | required by the rate (Vf) and the required end surface at the time of the cutting | disconnection.

(Heated temperature-controlled blade)
Examples of the blade whose temperature has been adjusted include conventionally known processing tools such as a cutting blade (cutting die) and a Thomson blade that have been heated and adjusted.
The heating temperature is likely to depend on the thermoplastic resin used in the prepreg, and is preferably set as appropriate according to the type of the thermoplastic resin. Usually, it is about 80-400 degreeC. When the heating temperature is less than 80 ° C., even if cutting is possible at such a temperature, there is a possibility that the types of thermoplastic resins that can fuse the cut surface are limited and lack of versatility. . On the other hand, if the heating temperature exceeds 400 ° C., even if cutting and fusion are possible, a large amount of electric power is consumed to maintain such a temperature, which may increase the production cost. There is.
Depending on the cutting conditions, the thickness of the laminated base material, and the material constituting the laminated base material, the thermoplastic resin may adhere to the processing tool during the cutting. In such a case, although there is a concern that the facilities will be large, a blade whose temperature is adjusted may be used in combination with fine vibration caused by ultrasonic waves.

<Step (3)>
Step (3) is a point fusion step in which the surface other than the end portion of the laminated base material is point-fused at 1 to 100 points per 100 cm ² of surface area.
By performing point fusion on the surface other than the end portion of the laminated base material, the laminated base material is fused and integrated even at a location other than the cut surface, so that the moldability is further improved.
Step (3) may be performed before step (2) described above, may be performed after step (2), or may be performed before and after step (2).
When step (3) is performed before step (2), the target of point fusion is the laminated base material before cutting and fusion, and step (3) is performed after step (2). In this case, the target for point fusion is the laminated base material after cutting and fusion.

As a method of point fusion, a conventionally known method can be used, and examples thereof include a method using a heated probe or a probe that generates ultrasonic waves. Among these, spot fusion with ultrasonic waves is preferable from the viewpoint of facility versatility and high degree of processing freedom.
Moreover, as a probe, the probe whose cross section of a fusion point becomes circular or a needle shape is preferable. Among these, it is preferable to use a probe in which the cross section of the fusion point is circular in that separation after fusion is less likely to occur.
Further, the point fusion is not limited to the approach from the front surface of the laminated base material, but may be an approach from the back surface or may be approached from both surfaces. If the thickness of the laminated base material is not too large, it may be possible to perform point fusion sufficiently from an approach from only one side.However, if the thickness of the laminated base material is large, only the approach from one side can be used to point all the thickness directions. It may be difficult to fuse. In such a case, point fusion from both sides is a useful means. However, in such a case, it is necessary to fuse | melt the thickness more than half of the thickness of a laminated base material in each point.

The number of fusion points is preferably 1 to 100 per 100 cm ² . When the number of fusion points exceeds 100, even if a large number of needle-like fusion tools are spread and used, the facility is close to the limit and the production cost of the facility tends to increase dramatically.

<Effect>
As described above, when a molded body such as a fiber reinforced thermoplastic is conventionally produced, before the laminated base material obtained by laminating the prepreg is cut into a size corresponding to a stamping molding mold, It was necessary to fuse and integrate all or part of the material.
However, in the method for producing an integrated laminate according to the present invention, the cut surface is fused using heat generated when the laminated substrate is cut. The cutting step can be performed in one step. Therefore, according to the method for producing an integrated laminate of the present invention, an integrated laminate excellent in moldability and handling at the time of stamping can be produced with a small number of steps while reducing the production cost.

"Method of manufacturing molded body"
The manufacturing method of the molded body of the present invention uses a process of manufacturing an integrated laminate by the above-described manufacturing method of an integrated laminate of the present invention (processing step of a laminated base material) and the obtained integrated laminate. A stamping molding step (stamping step).
Moreover, it is preferable to perform the preheating process demonstrated below between a process process and a stamping process.
Hereinafter, the integrated laminate produced by the method for producing an integrated laminate of the present invention is also referred to as “molding material”.

<Preheating process>
In the preheating step, the integrated laminate is preheated using a conventionally known facility. Examples of the preheating method include a hot air drying method, a steam drying method, an induction heating method, an infrared heater method, a hot plate heating method, and the like. Among these, an infrared heater method with high uniform irradiation and a high temperature rising effect is preferable. Moreover, you may use combining the method of the preheating mentioned above according to the thickness etc. of an integrated laminated body.

  Although the preheating temperature in the preheating step depends on the thermoplastic resin used for the prepreg, the lower limit temperature is preferably 150 ° C or higher, more preferably 180 ° C or higher, and the upper limit temperature is preferably 400 ° C or lower, more preferably 350 ° C or lower. Increasing the preheating temperature improves followability to complex shapes during stamping molding, but may cause degradation depending on the type of thermoplastic resin used in the prepreg. Therefore, it is preferable to preheat in an appropriate temperature range according to the kind of thermoplastic resin. On the other hand, if the preheating temperature is set too high, excessive overheating may occur, resulting in lowering of handling properties and various physical properties of the thermoplastic resin, and coloring in addition to improvement of moldability.

  Among the thermoplastic resins, there is a thermoplastic resin in which thermal decomposition is easily promoted in the air, but thermal decomposition is reduced by blocking air. When such a thermoplastic resin is used for the prepreg, the pre-heating step may be performed by appropriately covering the integrated laminate with a heat-resistant film or sheet. Further, the preheating step may be performed in an oxygen-free / low oxygen concentration environment such as an inert gas.

  When a plurality of integrated laminates are used, the total thickness is preferably 0.5 to 10 mm from the viewpoint of handling properties and electrothermal behavior. If the total thickness of the plurality of integrated laminates is less than 0.5 mm, such a thin material has a heat capacity that is too low, and therefore heat is dissipated before the mold is charged in stamping molding. There is a tendency. On the other hand, if the total thickness exceeds 10 mm, it tends to take too much time to reach the target temperature during preheating.

  At the time of transition from the preheating process to the stamping process, from the stage of the preheating process, an integrated laminate is placed on the metal mesh, preheated, transported to the molding die, peeled off from the metal mesh, and charged. It is convenient and advantageous for small molding. In addition, there is a method in which a needle-like, sucker-like, or arm-like unit is provided at the tip of the carrying robot arm for carrying. With such means, it is possible to carry it quickly and without loss. In addition, there is a technique in which a metal frame is provided and the integrated laminate is connected with an elastic body such as a spring from the frame to apply tension to the integrated laminate and suspend it, and then preheat the metal frame and perform stamping molding. . In this method, the integrated laminate is always suspended by an elastic body before and after preheating. Therefore, even when charged to the mold, the upper and lower molds can be moved simultaneously without contacting the lower mold and being cooled. Since it can adjust so that it may contact, it is preferable from a viewpoint of the improvement of a moldability or a molded external appearance.

<Stamping process>
The mold temperature during stamping depends on the thermoplastic resin used for the prepreg, but the lower limit temperature is preferably 30 ° C or higher, more preferably 50 ° C or higher, and the upper limit temperature is preferably 300 ° C or lower, more preferably 200 ° C or lower. preferable. If the mold temperature is too low, the mold is rapidly cooled when charged on the mold, and the ability to follow the complex shape of the ribs and bosses may be reduced. On the other hand, if the mold temperature is too high, the followability to the complex shape of the ribs and bosses is excellent, but depending on the thermoplastic resin used, the crystallization time becomes too long and the appearance of the molded body deteriorates. May cause uncured. Moreover, when manufacturing the molded object of an asymmetrical shape, the molded object obtained may warp.

The charge rate during stamping molding is preferably 20 to 150%. The charge rate is a calculated value when the opening area of the mold is the denominator and the area of the integrated laminate to be charged is the numerator.
The optimum range of the charge rate depends on whether the mold shape is cut or not, and whether the mold shape is a planar shape, but as one index, the charge rate is less than 20%. In order to achieve a high charge rate, it is necessary to use a plurality of integrated laminates to pile up in bulk. For this reason, when preheating is performed in a pre-stacked state, the rate of temperature increase is slow, and when preheating is performed individually, it is very complicated to perform such an operation so as not to dissipate heat during the stacking. However, in the case of a non-cutting die, there is a balance with material loss, but by making the charge rate more than 100%, the uniformity of the appearance of the molded body can be improved.
Similarly, the upper limit value of the charge rate also depends greatly on the shape of the mold, but as one index, in the case of a cut-off mold and a flat mold, the charge rate may be 95% or less. preferable. When the charge rate exceeds 95%, it becomes difficult to charge the preheated integrated laminate to the mold, which may cause a charge mistake. Even in the case of a cutting die, if it is deviated from the planar shape, the charge rate is preferably 150% or less in consideration of the surface area of the lower part of the molded body. If the charge rate is 150% or less, the uniformity of the appearance of the molded body can be improved. In addition, there is a tendency that it is difficult for the integrated laminates to come into contact with each other in the mold.

<Effect>
Since the above-described method for producing a molded article of the present invention uses the integrated laminate manufactured by the above-described integrated laminate manufacturing method of the present invention, it is excellent in moldability and handleability during stamping molding.

As described above, conventionally, when a molded body is manufactured, the whole or a part of the laminated base material is melted before cutting the laminated base material obtained by laminating the prepreg into a size corresponding to a stamping molding die. It was necessary to make them wear together.
However, if it is the manufacturing method of the molded object of this invention, the fusion | fusion integrated process of a laminated base material which is a pre-process of stamping shaping | molding, and a cutting process can be implemented by one process. Therefore, it is possible to manufacture the molded body with a smaller number of steps while reducing the manufacturing cost as compared with the conventional manufacturing method of the molded body.

  EXAMPLES Hereinafter, although an Example demonstrates this invention concretely, this invention is not limited at all by these Examples.

<Evaluation method>
(Evaluation of formability)
Integrated lamination with a heater temperature set at 360 ° C and cut into 200 mm width and 100 mm depth using a far-infrared heater type heating device (product name: H7GS-71289, manufactured by NGK Kiln Tech Co., Ltd.) with a mesh stage. The object was heated for 6 minutes and preheated. A mold projection area having a mold having a rib with a cylindrical portion for an ejector pin having a width of 70 mm to 60 mm, a height of 60 mm, a thickness of 3 mm to 2 mm, and a diameter of 6 mm in the center in the width direction on the back surface is 140. Using a 300 ton press machine (manufactured by Kawasaki Yoko Co., Ltd.) using a 240 mm molding die, the pre-heated integrated laminate is placed in a stacked state on the lower die, and the charging time is 25 seconds. Then, press molding was performed at a mold temperature of 145 ° C., a molding pressure of 18 MPa, and a molding time of 1 minute to obtain a molded body.
About the obtained molded object, the moldability was evaluated according to the following evaluation criteria.
A: Rib filling rate is 100%.
○: The rib filling rate is 80% or more and less than 100%.
Δ: The rib filling rate is 50% or more and less than 80%.
X: The rib filling rate is less than 50%.
In addition, the rib filling rate was calculated | required from the following formula.
Rib filling (%) = (total volume of rib part of molded article / total volume of rib part calculated from mold shape) × 100

(Evaluation of handleability)
Molded bodies were produced in the same manner as the moldability evaluation, and the handleability was evaluated according to the following evaluation criteria.
A: The handling property at the time of molding was good, which is not inferior to the conventionally known laminated base material.
(Triangle | delta): Although it is inferior to a conventionally well-known laminated base material, the handleability at the time of shaping | molding was favorable.
X: Although it is inferior to a conventionally well-known laminated base material, the handleability at the time of shaping | molding was unsatisfactory.
In addition, “a conventionally known laminated base material” refers to a laminated base material that has been fused, in which the entire surface is fused and integrated using a hot press or the like before cutting.

[Manufacture of prepreg]
<Production Example 1>
Carbon fiber sheets (made by Mitsubishi Rayon Co., Ltd., product name: TR50S15L, 12,000 fibers, density 1.82 g / cm ² ) are arranged in a unidirectional plane so that the basis weight is 72.0 g / m ^2. It was. A resin film (polyamide 6 (PA6), manufactured by Ube Industries, product name: UBE1013B) having a basis weight of 45.6 g / m ² was laminated on both surfaces of this carbon fiber sheet to obtain a laminate. This laminate was passed through a calender roll heated to 200 to 280 ° C. multiple times, and a resin film was melt impregnated into a carbon fiber sheet to obtain a prepreg 1.
The thickness of the obtained prepreg 1 was 120 μm, the basis weight was 145.0 g / m ² , and the fiber volume content (Vf) was 33%.

<Production Example 2>
Carbon fiber sheet in which carbon fibers (manufactured by Mitsubishi Rayon Co., Ltd., product name: TR50S15L, 12,000 fibers, density 1.82 g / cm ² ) are arranged in a unidirectional plane so that the basis weight is 72.0 g / m ² It was. A resin film (acid-modified polypropylene (acid-modified PP), manufactured by Mitsubishi Chemical Corporation, product name: Modic P958) having a basis weight of 36.4 g / m ² was laminated on both surfaces of the carbon fiber sheet to obtain a laminate. This laminate was passed through a calender roll heated to 200 to 220 ° C. multiple times, and a resin film was melt impregnated into a carbon fiber sheet to obtain a prepreg 2.
The thickness of the obtained prepreg 2 was 120 μm, the basis weight was 145.0 g / m ² , and the fiber volume content (Vf) was 33%.

<Production Example 3>
The prepreg 1 obtained in Production Example 1 is cut into 1240 mm × 940 mm, and using a cutting plotter (manufactured by Rezac Co., Ltd., product name: L-2500), linear incisions are made at regular intervals as shown in FIG. A prepreg 3 having an incision was obtained. At that time, the fiber length L of the reinforcing fiber is constant at 25.0 mm, excluding the portion from the end of the sheet to 10 mm, the angle θ = 45 ° between the cut for cutting the fiber and the reinforcing fiber, and the cut length l = 42 Cutting was performed so as to be 4 mm. The total la of the cutting length l per 1 m ² was 56.6 m.

<Production Example 4>
Except that the prepreg 2 obtained in Production Example 2 was used, cutting was performed in the same manner as in Production Example 3 to obtain a prepreg 4 having a cut.

[Manufacture of laminated substrates]
<Production Example 5>
16 layers of the prepreg 3 having notches produced in Production Example 3, the fiber axis direction is [0/45/90 / −45] s2, and the incision direction is [−45/0/45/90]. The laminated base material 1 having a thickness of 1.92 mm was obtained by laminating so as to be s2.

<Production Example 6>
A laminated base material 2 having a thickness of 1.92 mm was obtained in the same manner as in Production Example 5 except that the prepreg 4 having notches produced in Production Example 4 was used.

[Example 1]
Using a panel saw (manufactured by Shinx Corporation, product name: HP1-2100GI) equipped with a tip saw (manufactured by Tenryu Saw Co., Ltd., product name: LAQIV series (ABA10), diameter 305 mm), a peripheral speed of 3500 rpm and a feed speed of 10 m / Under the condition of min, the laminated substrate 1 was cut and fused to 100 mm × 200 mm so that the long side and the fiber direction of the outermost reinforcing fiber were parallel to obtain an integrated laminate.
The moldability and handleability of the obtained integrated laminate were evaluated. The results are shown in Table 1.

[Example 2]
Except that the laminated substrate 2 was used, cutting and fusing were performed in the same manner as in Example 1 to obtain an integrated laminate.
The moldability and handleability of the obtained integrated laminate were evaluated. The results are shown in Table 1.

[Example 3]
Before cutting and fusing the laminated base material 1, an ultrasonic welder (product name: 2000LPt, manufactured by Nippon Emerson Co., Ltd.) is used to apply a surface other than the end of the laminated base material 1 to a surface area of 1 to 100 cm ² . An integrated laminate was obtained in the same manner as in Example 1 except that point fusion was performed at two locations.
The moldability and handleability of the obtained integrated laminate were evaluated. The results are shown in Table 1.

[Example 4]
Before using the laminated base material 2 and cutting and fusing the laminated base material 2, using an ultrasonic welding machine (manufactured by Emerson Japan Ltd., product name: 2000LPt), other than the end of the laminated base material 2 An integrated laminate was obtained in the same manner as in Example 1 except that the surface was subjected to point fusion at 1 to 2 points per 100 cm ^{2 of} surface area.
The moldability and handleability of the obtained integrated laminate were evaluated. The results are shown in Table 1.

[Example 5]
Before cutting and fusing the laminated base material 1, an ultrasonic welder (product name: 2000LPt, manufactured by Nippon Emerson Co., Ltd.) is used to apply a surface other than the end of the laminated base material 1 to a surface area of 1 to 100 cm ² . Integrated laminating in the same manner as in Example 1, except that the laminated base material 1 was spot-fused at two places and point-fused using a resin sheet (Acrysandy Corporation, Sunday Sheet). I got a thing.
The moldability and handleability of the obtained integrated laminate were evaluated. The results are shown in Table 1.

[Example 6]
Before using the laminated base material 2 and cutting and fusing the laminated base material 2, using an ultrasonic welding machine (manufactured by Emerson Japan Ltd., product name: 2000LPt), the surface other than the end of the laminated base material 2 Example 1 except that 1 to 2 points per 100 cm ² of surface area were point-fused and cut and welded by sandwiching the laminated base material 2 that was point-fused using a resin sheet (Acrysandy Corporation, Sunday Sheet). In the same manner, an integrated laminate was obtained.
The moldability and handleability of the obtained integrated laminate were evaluated. The results are shown in Table 1.

[Comparative Example 1]
Using an ultrasonic welding machine (product name: 2000LPt, manufactured by Nippon Emerson Co., Ltd.), the surface other than the end of the laminated base material 1 is spot-welded at 1 to 2 locations per 100 cm ² of surface area to cause prepreg misalignment. After that, it was placed in the stamping die and the heating panel was put into a multi-stage press machine preheated to 250 ° C., heated and pressurized at a pressure of 0.3 MPa for 10 minutes, and subsequently at a pressure of 1.0 MPa. A cooling / pressing press was performed for 2 minutes to obtain a laminated base material that had been fused.
Except for using the obtained laminated base material having been fused, cutting and fusion were performed in the same manner as in Example 1 to obtain an integrated laminate.
The moldability and handleability of the obtained integrated laminate were evaluated. The results are shown in Table 1.

[Comparative Example 2]
A laminated base material having been fused was obtained in the same manner as in Comparative Example 1 except that the laminated base material 2 was used and the temperature of the heating plate was changed to 200 ° C.
Except for using the obtained laminated base material having been fused, cutting and fusion were performed in the same manner as in Example 1 to obtain an integrated laminate.
The moldability and handleability of the obtained integrated laminate were evaluated. The results are shown in Table 1.

In the case of Examples 1 and 2, the rib tip of the molded body was slightly missing, but the moldability was sufficiently excellent. Moreover, the handleability was not inferior to a conventionally known laminated base material, and the workability of the molding operation was good.
In Examples 3 to 6, the moldability was excellent, the handleability was not inferior to that of a conventionally known laminated base material, and the workability of the molding operation was good.
In Comparative Examples 1 and 2, the moldability was excellent, the handleability was good, and the workability of the molding work was good. However, the number of steps from lamination of the prepreg to molding increased, resulting in poor mass productivity.

10 Prepreg 11 Reinforcing fiber 12 Notch

Claims (15)

A method for producing an integrated laminate by processing a laminated substrate in which a plurality of prepregs containing reinforcing fibers and a thermoplastic resin are laminated,
The manufacturing method of an integrated laminated body including the following process (1) and process (2).
Step (1): A lamination step in which a plurality of prepregs are laminated to obtain a laminated substrate.
Step (2): A cutting and fusing step of fusing the cut surface with heat generated by cutting while cutting the laminated base material.   The manufacturing method of the integrated laminated body of Claim 1 which performs the said cutting | disconnection and melt | fusion using a rotary blade.   The manufacturing method of the integrated laminated body of Claim 1 which performs the said cutting | disconnection and melt | fusion by ultrasonic cutting.   The method for producing an integrated laminate according to claim 1, wherein the cutting and fusion are performed by laser cutting.   The manufacturing method of the integrated laminated body of Claim 1 performed using the blade which heated and controlled the said cutting | disconnection and melt | fusion. The manufacturing method of the integrated laminated body as described in any one of Claims 1-5 which performs the following process (3) at least one before and after the said process (2).
Step (3): A point fusion step in which the surface other than the end portion of the laminated base material is point-fused at 1 to 100 points per 100 cm ² of surface area.   The said prepreg is a manufacturing method of the integrated laminated body as described in any one of Claims 1-6 with which the thermoplastic resin impregnated the reinforced fiber oriented in one direction.   The prepreg is obtained by impregnating a reinforced fiber oriented in one direction with a thermoplastic resin, and has a notch penetrating from the front surface to the back surface of the prepreg so as to cut the reinforcing fiber. A method for producing an integrated laminate according to one item.   The prepreg is formed by integrating a plurality of small prepregs obtained by cutting a prepreg in which a reinforced fiber oriented in one direction is impregnated with a thermoplastic resin into a sheet shape so that the fiber directions of the reinforcing fibers of each small prepreg are random. The manufacturing method of the integrated laminated body as described in any one of Claims 1-6 which is what was.   In the step (1), a plurality of the prepregs and a sheet or a film (excluding the prepreg) made of a thermoplastic resin or a filler-containing thermoplastic resin are laminated. The manufacturing method of the integrated laminated body as described in a term.   The method for producing an integrated laminate according to claim 10, wherein the filler is carbon fiber.   The method for producing an integrated laminate according to claim 10, wherein the filler is a glass composition.   The method for producing an integrated laminate according to claim 10, wherein the filler is a recycled material.   The method for producing an integrated laminate according to any one of claims 1 to 13, wherein the reinforcing fibers are carbon fibers.   Molding including a step of manufacturing an integrated laminate by the method for manufacturing an integrated laminate according to any one of claims 1 to 14, and a step of stamping molding using the obtained integrated laminate. Body manufacturing method.

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