JP2018030986A - プリプレグ、成形体、成形体の製造方法、プリプレグの製造方法、積層成形体の製造方法及び二次加工成形体の製造方法 - Google Patents
プリプレグ、成形体、成形体の製造方法、プリプレグの製造方法、積層成形体の製造方法及び二次加工成形体の製造方法 Download PDFInfo
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- 238000004804 winding Methods 0.000 description 1
Abstract
Description
水溶性熱可塑性PVA系樹脂を海成分とし、イソフタル酸変性度6モル%のPETを島成分とし、繊維1本あたりの島数が25島で、海成分/島成分が25/75(重量比)となるような溶融複合紡糸用口金を用い、260℃で海島型のフィラメントを口金より吐出した。そして、紡糸速度が3700m/minとなるようにエジェクター圧力を調整し、2.1dtexの海島型複合長繊維をネット上に捕集した。そしてネット上に捕集された海島型複合長繊維を表面温度42℃の金属ロールで軽く押さえることにより表面の毛羽立ちを抑えてネットから剥離し、さらに、表面温度75℃の格子柄の金属ロールとバックロールとの間を通過させて熱プレスすることにより、表面の極細繊維が仮融着した目付31g/m2の長繊維ウェブを得た。
実施例1で得られたプリプレグを2枚重ねて積重体を形成した。そして、1枚のプリプレグに代えて、2枚重ねた積重体を用いた以外は実施例1と同様にスマートフォンの筐体形状の成形体を得た。得られた成形体は、厚さ0.98mm、見掛け密度1.021g/cm3であった。得られた成形体の厚み方向断面のSEM写真(倍率100倍)を図2に示す。また、別途作成した2枚重ねた積重体を用いて成形した厚さ1.021mmの平板の成形体から25mm幅、長さ200mmの長方形の試験片を切り出し、実施例1と同様にして応力−歪み曲線を求め、破断強力を求めた。結果を表1に示す。
実施例1で得られたプリプレグを4枚重ねて積重体を形成した。そして、1枚のプリプレグに代えて、4枚重ねた積重体を用いた以外は実施例1と同様にスマートフォンの筐体形状の成形体を得た。得られた成形体は、厚さ1.19mm、見掛け密度1.300g/cm3であった。得られた成形体の厚み方向断面のSEM写真(倍率100倍)を図3に示す。また、別途作成した2枚重ねた積重体を用いて成形した厚さ1.19mmの平板の成形体から25mm幅、長さ200mmの長方形の試験片を切り出し、実施例1と同様にして応力−歪み曲線を求め、破断強力を求めた。結果を表1に示す。
繊度0.1dtexの極細長繊維を含む不織布の代わりに、繊度3.5dtexのPET長繊維を含む見かけ密度0.15g/cm3、目付300g/m2、厚み2.00mmの不織布を用いた以外は、実施例1〜3と同様にしてプリプレグ及び成形体を成形し、評価した。結果を表1に示す。
熱可塑性エポキシ樹脂の液状樹脂原料に代えて、熱硬化性のエポキシ樹脂(jER(三菱化学))を用いた以外は、実施例2と同様にしてプリプレグ及び成形体を成形し、評価した。結果を表1に示す。
Claims (15)
- 熱可塑性樹脂からなる繊維構造体と、前記繊維構造体に含浸付与された熱可塑性を有する硬化樹脂の半硬化物と、を含むことを特徴とするプリプレグ。
- 前記熱可塑性を有する硬化樹脂が熱可塑性エポキシ樹脂である請求項1に記載のプリプレグ。
- 前記繊維構造体は0.01〜1dtexの極細繊維の不織布である請求項1に記載のプリプレグ。
- 熱可塑性樹脂からなる繊維構造体と前記繊維構造体に含浸付与された熱可塑性を有する硬化樹脂とを含むことを特徴とする成形体。
- 前記熱可塑性を有する硬化樹脂が熱可塑性エポキシ樹脂である請求項4に記載の成形体。
- 前記繊維構造体は0.01〜1dtexの極細繊維の不織布である請求項4または5に記載の成形体。
- 前記成形体は、前記繊維構造体と前記熱可塑性を有する硬化樹脂とを含む繊維樹脂複合層を少なくとも2層有する積層成形体である請求項4〜6の何れか1項に記載の成形体。
- 各前記繊維樹脂複合層の接合面の少なくとも一つに、導電体層又は繊維層が介在する請求項7に記載の成形体。
- 表層にさらに加飾層が積層されている請求項4〜8の何れか1項に記載の成形体。
- 熱可塑性樹脂からなる繊維構造体に熱可塑性を有する硬化樹脂の液状樹脂原料を含浸させる工程と、
前記繊維構造体に含浸させた前記液状樹脂原料を加熱乾燥させる工程と、を含むことを特徴とするプリプレグの製造方法。 - 前記熱可塑性を有する硬化樹脂が、熱可塑性エポキシ樹脂である請求項10に記載のプリプレグの製造方法。
- 請求項1または2に記載のプリプレグを金型内に収容する工程と、金型内に収容された前記プリプレグを熱プレス成形する工程と、を備えることを特徴とする成形体の製造方法。
- 請求項1〜3の何れか1項に記載のプリプレグを少なくとも2枚積層した積重体を形成する工程と、
前記積重体を熱プレスすることにより少なくとも2枚の前記プリプレグを一体化させる工程と、を含むことを特徴とする積層成形体の製造方法。 - 2枚の前記プリプレグの間に導電体層又は繊維層を介在させる請求項13に記載の積層成形体の製造方法。
- 請求項4〜9の何れか1項に記載の成形体を加熱する工程と、加熱した状態で前記成形体を加工する工程と、を備えることを特徴とする二次加工成形体の製造方法。
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